Metal CoatingsMetal Coatings

POWDER COATINGPOWDER COATING

Why Powder Coat?Why Powder Coat?

Elimination of VOCs - Elimination of VOCs - VOCVOC is short for is short for volatile volatile organic compoundsorganic compounds, ,

VOCsVOCs that escape into the air contribute to air that escape into the air contribute to air pollution outdoors and inside our homes. pollution outdoors and inside our homes. ......• • Elimination of HAPs –Hazardous Air Pollutants.Elimination of HAPs –Hazardous Air Pollutants.• • Reduction of ESOH Concerns ( Environmental Reduction of ESOH Concerns ( Environmental Safety & Occupational Health)Safety & Occupational Health)• • Reduction of Hazardous WasteReduction of Hazardous Waste

Why Powder Coat - continuedWhy Powder Coat - continued

Single component, solvent free material Single component, solvent free material life limitations - goodlife limitations - good• • Process EfficiencyProcess Efficiency– – Quick cure timeQuick cure time– – Quick equipment prep and clean-upQuick equipment prep and clean-up

Powder CoatingPowder CoatingOne of the most One of the most common methods common methods of finishing metal of finishing metal surfaces.surfaces. Many items used Many items used everyday are everyday are powderpowder coated. coated.

Examples of Powder CoatingExamples of Powder Coating

Everyday items such Everyday items such as mailboxes, chairs, as mailboxes, chairs, appliances, appliances, automotive parts, automotive parts, tools, and tools, and construction construction materials. materials.

The ProcessThe Process

A simple process, involving “spray A simple process, involving “spray painting” a fine plastic powder paint onto a painting” a fine plastic powder paint onto a metal surface. metal surface. Typically the surface is steel, aluminum or Typically the surface is steel, aluminum or iron. iron. Most any surfaces can be coated, Most any surfaces can be coated, however, they must be able to withstand however, they must be able to withstand the high temperatures of the baking oven. the high temperatures of the baking oven.

Walk in ovenWalk in oven

Before coating the part, the surface must be Before coating the part, the surface must be cleaned. Often a sand blaster is used for cleaned. Often a sand blaster is used for this purpose. Parts must be totally free of this purpose. Parts must be totally free of contaminants that might effect the process contaminants that might effect the process such as grease, rust, oils, etc. such as grease, rust, oils, etc. As the powder leaves the gun it is charged As the powder leaves the gun it is charged with static electricity. This charge then with static electricity. This charge then attracts the powder to the surface that is attracts the powder to the surface that is being coated. being coated. After the parts are coated, they are then After the parts are coated, they are then baked in an oven at about 400 degrees baked in an oven at about 400 degrees Fahrenheit for 10 to 45 minutes depending Fahrenheit for 10 to 45 minutes depending on the part. The actual part itself must on the part. The actual part itself must reach these temperatures in order for curing reach these temperatures in order for curing to occur properly. to occur properly. While in the oven, the powder melts and While in the oven, the powder melts and flows into a smooth finish. Curing time is flows into a smooth finish. Curing time is critical, because under curing will cause loss critical, because under curing will cause loss of adhesion, and over curing will cause the of adhesion, and over curing will cause the strength characteristics of the powder to strength characteristics of the powder to decrease. decrease.

Unlike painting, there are no runs or drips with Unlike painting, there are no runs or drips with powder coating, and due to the static charge, powder coating, and due to the static charge, there is no need for primers. there is no need for primers.

Additional clear coating and primers can be Additional clear coating and primers can be added to improve protection and depth. added to improve protection and depth.

If a mistake is made before baking, the powder If a mistake is made before baking, the powder can simply be blown off with an air nozzle and can simply be blown off with an air nozzle and reapplied. If the mistake is realized after baking, reapplied. If the mistake is realized after baking, the part must be sandblasted or the coating the part must be sandblasted or the coating must be burned off.must be burned off.

Types of PowdersTypes of PowdersThere are two main There are two main types of powders used types of powders used for different for different applications. applications.

Both types outperform Both types outperform most wet paint finishes most wet paint finishes and they both come in and they both come in many varieties of many varieties of colors, textures, and colors, textures, and glosses. glosses.

Most indoor powders are Most indoor powders are made of epoxy. Epoxy is made of epoxy. Epoxy is the most durable the most durable powder, but it will chalk powder, but it will chalk and dull from the sun’s and dull from the sun’s ultraviolet rays.ultraviolet rays.

Polyester powders are not as durable, but Polyester powders are not as durable, but since they are unaffected by the sun, they since they are unaffected by the sun, they should be used for most outdoor should be used for most outdoor applications.applications.

Equipment UsedEquipment UsedObviously the most important and expensive Obviously the most important and expensive item to purchase is the oven. item to purchase is the oven.

The oven must be able to heat a part to around The oven must be able to heat a part to around 400 degrees Fahrenheit for at least 10 minutes, 400 degrees Fahrenheit for at least 10 minutes, sometimes more depending on the part. sometimes more depending on the part.

The size of the oven depends on the sizes of The size of the oven depends on the sizes of parts the consumer wishes to coat. Obviously parts the consumer wishes to coat. Obviously the larger the oven, the larger the part that can the larger the oven, the larger the part that can be coated. be coated.

With a larger oven, several parts can be baked With a larger oven, several parts can be baked at one time. at one time.

Ovens vary in style Ovens vary in style and price. and price. – A small 6’x 8’x 10’ A small 6’x 8’x 10’

walk in gas oven is walk in gas oven is priced around priced around $30,000. $30,000.

– A 100’ oven with a A 100’ oven with a pass through pass through conveyer can be as conveyer can be as much as $100,000. much as $100,000. Small walk in oven

There are three main types of ovens; There are three main types of ovens; gas, electric, and infrared. Infrared gas, electric, and infrared. Infrared ovens work well if designed properly, ovens work well if designed properly, however gas and electric tend to be however gas and electric tend to be more dependable. Electric ovens more dependable. Electric ovens take longer to heat up, thus delaying take longer to heat up, thus delaying the coating process. Obviously, the the coating process. Obviously, the faster the oven heats, the faster the faster the oven heats, the faster the product will be coated.product will be coated.

Spray GunsSpray Guns

There are two types of spray guns, There are two types of spray guns,

– Corona and a Corona and a

–Tribomatic spray gun. Tribomatic spray gun.

Corona Gun MethodCorona Gun MethodPowder is applied using hand-held gun featuring aPowder is applied using hand-held gun featuring ahigh-voltage electrode at the front end.high-voltage electrode at the front end.Theelectrode creates ions, which impart a charge to theTheelectrode creates ions, which impart a charge to the

powder particles exiting the gun, and the chargedpowder particles exiting the gun, and the chargedparticles are attracted to the electrically grounded target part.particles are attracted to the electrically grounded target part.BenefitsBenefits

– – Low film thickness possible (1.5 - 5 mils)Low film thickness possible (1.5 - 5 mils) LimitationsLimitations

– – Difficult to cover recessed areas and tight cornersDifficult to cover recessed areas and tight cornersdue to Faraday Cage Effectdue to Faraday Cage Effect

Tribomatic Gun MethodTribomatic Gun MethodPowder is applied using hand-held gun designed to impart an Powder is applied using hand-held gun designed to impart an electrostatic charge through friction between powder particles and electrostatic charge through friction between powder particles and gun internal material.gun internal material.BenefitsBenefits– – Even layer depositionEven layer deposition– – Improved deposition into recessesImproved deposition into recesses– – Gun does not produce the Faraday Cage EffectGun does not produce the Faraday Cage Effect– – Typically consumes 20% less powder than Corona GunTypically consumes 20% less powder than Corona Gun

LimitationsLimitations– – Coats at half the speed of corona gunCoats at half the speed of corona gun– – Electron donor/acceptor tendency between powder andElectron donor/acceptor tendency between powder andgun material must be great enough for adequategun material must be great enough for adequatecharging of the powdercharging of the powder

Other equipment needed:Other equipment needed:

the powder supplies the powder supplies an air operated vacuum cleaner to an air operated vacuum cleaner to retrieve any overspray retrieve any overspray

a spray booth. a spray booth.

Fluidized Bed MethodFluidized Bed MethodParts are pre-heated and Parts are pre-heated and suspended in ansuspended in anairborne cloud of powder airborne cloud of powder coating material.coating material.• • Benefits:Benefits:– – SimplicitySimplicity– – Less waste, lowerLess waste, lowercostcost• • Limitations:Limitations:– – Only coatings 10-Only coatings 10-100 mil are possible100 mil are possible– – Coating thicknessCoating thicknesscontrol is difficultcontrol is difficult

Electrostatic Fluidized Bed Electrostatic Fluidized Bed MethodMethod

Similar to standard fluidized bed system, but powderSimilar to standard fluidized bed system, but powderis electrostatically charged and part is grounded sois electrostatically charged and part is grounded sothat particles are attracted to part surface.that particles are attracted to part surface.• • BenefitsBenefits

– – Preheating of part not requiredPreheating of part not required– – 4-10 mil thickness of coating is possible4-10 mil thickness of coating is possible– – Small parts coated uniformly, quicklySmall parts coated uniformly, quickly

LimitationsLimitations– – Inside corners tend to receive low film thickness due to Inside corners tend to receive low film thickness due to Faraday Cage EffectFaraday Cage Effect– – Part size is limited by container sizePart size is limited by container size

Drawbacks to powder coatingDrawbacks to powder coating

The major drawback is the initial investment to The major drawback is the initial investment to begin the operation. begin the operation. Powder coating does not have the strength or Powder coating does not have the strength or hardness characteristics that some other coating hardness characteristics that some other coating processes such as chrome or zinc have. processes such as chrome or zinc have. Chipping is another main problem with powder Chipping is another main problem with powder coating. This often results because the part was coating. This often results because the part was not baked long enough or kept at the proper not baked long enough or kept at the proper cure temperature.cure temperature.

Benefits of Powder CoatingBenefits of Powder Coating

The biggest benefit of powder coating is that The biggest benefit of powder coating is that it is environmentally friendly. it is environmentally friendly. – There are no solvents as in paints, and thus no There are no solvents as in paints, and thus no

harmful air pollution. There is absolutely no harmful air pollution. There is absolutely no hazardous waste created with this process. hazardous waste created with this process.

EconomicEconomic– Overspray can be air vacuumed and reused, Overspray can be air vacuumed and reused,

thus reducing the amount of waste produced as thus reducing the amount of waste produced as well as saving cost. well as saving cost.

AnalysisAnalysis

As can be seen for certain applications, As can be seen for certain applications, powder coating is the most durable powder coating is the most durable decorative finish available at this time. decorative finish available at this time. A variety of different textures, colors, and A variety of different textures, colors, and glosses can be used. glosses can be used. The process is fairly simple and the cost is The process is fairly simple and the cost is much less than other processes like much less than other processes like chroming or zinc plating. chroming or zinc plating. Also the initial investment is minimal Also the initial investment is minimal compared to other processes. compared to other processes.

ConclusionConclusion

With all the benefits of powder With all the benefits of powder coating, it can be seen why it is such coating, it can be seen why it is such a widely applied technique. a widely applied technique. Obviously, if a person has the Obviously, if a person has the resources and demand for the resources and demand for the procedure, they should think seriously procedure, they should think seriously about investing in the operation.about investing in the operation.

SUMMARYSUMMARYA powder coating A powder coating material that will allowmaterial that will allowus to overcome us to overcome previous limitations of previous limitations of thethepowder coating powder coating process resulting in:process resulting in:• • VOC, HAP and VOC, HAP and solvent free coatingsolvent free coating• • reduced labour hoursreduced labour hours• • lower costslower costs

Tin plating Tin plating Tin plating is primarily for "functional" Tin plating is primarily for "functional" purposes such as providing a level of purposes such as providing a level of protection or corrosion resistance to a protection or corrosion resistance to a range of range of Tin Plating Tin Plating is a lower cost alternative is a lower cost alternative than some protective coatings. Tin also than some protective coatings. Tin also has a good level of conductivity has a good level of conductivity enhancement properties (as opposed to enhancement properties (as opposed to silver which has higher conductivity) silver which has higher conductivity) which may be of benefit to manufacturers which may be of benefit to manufacturers seeking to enhance this property seeking to enhance this property somewhat without adding too much to the somewhat without adding too much to the price. price. Tin has good solderability and is therefore Tin has good solderability and is therefore a coating of choice where later soldering a coating of choice where later soldering of components is required especially in of components is required especially in the electronic fields.the electronic fields.Colour & Aesthetics:Colour & Aesthetics: Tin plating has a 'whitish Tin plating has a 'whitish grey' hue and is usually applied without the grey' hue and is usually applied without the layer of bright nickel used in decorative coatings layer of bright nickel used in decorative coatings - as such tin has a dull, or matt appearance.- as such tin has a dull, or matt appearance.commonly is used on lower value substrates commonly is used on lower value substrates such as mild steel or copper alloys.such as mild steel or copper alloys.

Applications of Tin Plating: Examples include: Low-tech electrical or electronic components such as electronic connectors or bus bars; commercial cooking equipment; parts requiring soldering; other.Substrates suited to this coating: Tin can be plated over most metal substrates .

Chrome PlatingChrome Platingis a very popular finish for many decorative is a very popular finish for many decorative applications, especially for the automotive and applications, especially for the automotive and building industries in which there are many building industries in which there are many decorative trims and components. It also has decorative trims and components. It also has industrial uses where, in conjunction with heat industrial uses where, in conjunction with heat treated base materials it can provide a harder treated base materials it can provide a harder finish (hard-chrome).finish (hard-chrome).Chrome plating is popular because it is hard Chrome plating is popular because it is hard wearing, bright and easy to clean. The nickel used wearing, bright and easy to clean. The nickel used in the coating process in conjunction with chrome in the coating process in conjunction with chrome provides high corrosion resistance. The nickel provides high corrosion resistance. The nickel type used also determines the level of brightness. type used also determines the level of brightness. TThe chrome coating itself is stain resistant and he chrome coating itself is stain resistant and abrasion resistant which is of appeal for abrasion resistant which is of appeal for decorative applications in heavier 'wear and tear' decorative applications in heavier 'wear and tear' environments. Tenvironments. There are alternative industrial uses for chrome here are alternative industrial uses for chrome plating (i.e. hard-chrome*), sometimes used for plating (i.e. hard-chrome*), sometimes used for surface maintenance on large tools or equipment.surface maintenance on large tools or equipment.

Applications of Chrome Plating: Automotive decals, door handles and trims, tap-ware, architectural fittings, racks, hubs & wheels, furniture and furniture trim, and many, many other items.

Silver platingSilver platingSilver plating is an electrolytic process. Silver plating is an electrolytic process. Its properties can be utilised for either Its properties can be utilised for either "functional" purposes such as enhanced "functional" purposes such as enhanced electronic application or corrosion electronic application or corrosion resistance, or, "decorative" purposes. resistance, or, "decorative" purposes. Silver is commonly applied over Silver is commonly applied over preliminary coatings of copper and preliminary coatings of copper and nickel though depending on the nickel though depending on the application this may vary.application this may vary.Benefits of SILVER Plating:Benefits of SILVER Plating:Functional Functional - Enhances electronic and radio - Enhances electronic and radio wave conductivity. In a "high purity" form it wave conductivity. In a "high purity" form it is possible to achieve surface silver of is possible to achieve surface silver of around 99.99% purity. around 99.99% purity. Applications of Silver Plating:Applications of Silver Plating: "Functional" coating examples include high-"Functional" coating examples include high-tech Electrical or electronic components tech Electrical or electronic components such as antennas, bus bars, connectors. such as antennas, bus bars, connectors. "Decorative" applications commonly include "Decorative" applications commonly include silverware (teapots, trays, trinkets, etc), silverware (teapots, trays, trinkets, etc), jewellery or hand crafted art pieces.jewellery or hand crafted art pieces.

Nickel platingNickel platingNickel provides the 'substance' of the coating Nickel provides the 'substance' of the coating as it predominantly provides the hardness and as it predominantly provides the hardness and corrosion resistance to the surface. Though corrosion resistance to the surface. Though sometimes used as a 'final finish' it is more sometimes used as a 'final finish' it is more common for nickel to be applied as the common for nickel to be applied as the "undercoat" to final finishes such as silver, gold "undercoat" to final finishes such as silver, gold or chrome. The nickel solution type used in the or chrome. The nickel solution type used in the finishing process determines the level of finishing process determines the level of brightness of the finished product. Some nickel brightness of the finished product. Some nickel solutions result in a matt or 'satin' finish.solutions result in a matt or 'satin' finish.Benefits of Decorative Nickel Plating:Benefits of Decorative Nickel Plating: Nickel Nickel plating provides the finished product with plating provides the finished product with hardness and protection from the elements hardness and protection from the elements and determines the level of brightness of the and determines the level of brightness of the product - in fact it can be extremely difficult to product - in fact it can be extremely difficult to achieve a bright finish without it.achieve a bright finish without it.Colour & Aesthetics:Colour & Aesthetics: Nickel is a silvery colour Nickel is a silvery colour with a "yellow/brown" hue. Nickel as a final with a "yellow/brown" hue. Nickel as a final finish can sometimes provide a closer match to finish can sometimes provide a closer match to some stainless steel grades - depending on some stainless steel grades - depending on the level of nickel contained in the stainless the level of nickel contained in the stainless material.material.

Applications of Decorative Nickel Plating: As an "undercoat" nickel is used for most decorative applications. It can also be used as a final finish if required. A Class's "Restoration" divison has assisted with restoration of many early model vehicle components, traditionally nickel plated.

Electroless NickelElectroless Nickel

Electroless Nickel is a chemical plating Electroless Nickel is a chemical plating process which, unlike electroplating, process which, unlike electroplating, does not require electrical current to does not require electrical current to deposit. Nickel is deposited to the deposit. Nickel is deposited to the surface metal via an 'autocatalytic' surface metal via an 'autocatalytic' process which deposits the coating in process which deposits the coating in uniform density to the surface being uniform density to the surface being plated.plated.The Electro-less Nickel plating process has The Electro-less Nickel plating process has many advantages over 'electrolytic' many advantages over 'electrolytic' processes in an engineering environment. processes in an engineering environment. The coating can be used where a hard, The coating can be used where a hard, corrosion resistant finish is required.corrosion resistant finish is required.A major advantage of the process is that it is A major advantage of the process is that it is possible to coat the whole surface of an item possible to coat the whole surface of an item EVENLY, including internals, unlike EVENLY, including internals, unlike electrolytic processes which have difficulty electrolytic processes which have difficulty depositing into recessed and internal areas depositing into recessed and internal areas and can result in excessive build-ups on and can result in excessive build-ups on points, corners, etc.points, corners, etc.

Applications of Electroless Nickel Plating: Valves, shafts, drilling equipment, rollers, dies & moulds, tooling, pumps, hardware & more. Wherever there is need to prevent corrosion, reduce wear or improve hardness and durability.

Plating grade plasticPlating grade plasticDecorative plating on plastic is Decorative plating on plastic is achieved by a metallising process achieved by a metallising process specifically engineered to enable non-specifically engineered to enable non-conductive ABS plating grade plastic conductive ABS plating grade plastic to be electroplated. to be electroplated. Why ABS Plastic?Why ABS Plastic? ABS is a specially ABS is a specially designed plastic (Acrylonitrile Butadiene designed plastic (Acrylonitrile Butadiene Styrene) with properties suited to the Styrene) with properties suited to the metallising process enabling continuous metallising process enabling continuous production of high volume components.production of high volume components.Benefits of Plating on ABS Plastic Benefits of Plating on ABS Plastic Substrates:Substrates: Moulded ABS plastic Moulded ABS plastic components are substantially cheaper to components are substantially cheaper to manufacture than metal parts. They offer manufacture than metal parts. They offer adequate strength and significant weight adequate strength and significant weight reduction is also a benefit in some reduction is also a benefit in some instances. After plating there is no instances. After plating there is no apparent difference visually between apparent difference visually between metal and plastic parts.metal and plastic parts.

Applications of Plating on ABS Plastic Substrates: Automotive decals and trim, tap- ware, furniture trim, bathroom accessories, hardware accessories, some electrical fittings and many other items.

Zinc platingZinc platingZinc plating is the most common, low Zinc plating is the most common, low cost; electroplated coating that is cost; electroplated coating that is normally applied to ferrous normally applied to ferrous components to give corrosion components to give corrosion protection. The coating can be protection. The coating can be coloured to give gold; black or olive coloured to give gold; black or olive drab coatings by post treatment. The drab coatings by post treatment. The relatively low cost, protective nature relatively low cost, protective nature and attractive appearance of zinc and attractive appearance of zinc make it a popular coating for nuts, make it a popular coating for nuts, bolts, washers, metal stampings and bolts, washers, metal stampings and automotive parts, such as interior automotive parts, such as interior components and gas filters. In components and gas filters. In addition, zinc serves as an effective addition, zinc serves as an effective undercoat for paints when high undercoat for paints when high corrosion performance is required.corrosion performance is required.

What Material Can Be Zinc Plated?What Material Can Be Zinc Plated? Near any metal can be zinc plated but Near any metal can be zinc plated but the most common are steel and iron the most common are steel and iron on which it offers sacrificial protection.on which it offers sacrificial protection.

Recommended uses for Zinc electroplating: Zinc plating is used where a clean, smooth, corrosion resistant surface is required. Commonly used on nuts, bolts, metal brackets. etc but it also makes an excellent undercoat for powdercoating or paint. Zinc electroplating can leave recesses on complex shaped components without sufficient zinc coating to provide corrosion protection. Finished Products can recommend other coatings that may overcome this effect.

Hot Dipped GalvanisingHot Dipped Galvanising

Heavy galvanizing is often referred to as Heavy galvanizing is often referred to as batch, heavy duty or after fabrication batch, heavy duty or after fabrication galvanizing. galvanizing. Light galvanizing is referred to as Light galvanizing is referred to as continuous, ILG (In-Line Galvanizing) or continuous, ILG (In-Line Galvanizing) or zinc electroplated. zinc electroplated. The Australian market has a wide variety of The Australian market has a wide variety of local and imported light galvanized products local and imported light galvanized products readily available. (See previous slide)readily available. (See previous slide)Heavy galvanizing is the only galvanize Heavy galvanizing is the only galvanize finish that gives a complete coating of finish that gives a complete coating of heavy zinc both externally and internally. heavy zinc both externally and internally. The zinc coating is typically in the range of The zinc coating is typically in the range of 85µ m² or 600 gms / m² on 6mm thick steel. 85µ m² or 600 gms / m² on 6mm thick steel. Heavy galvanizing produces the maximum Heavy galvanizing produces the maximum thickness possible relative to steel thickness possible relative to steel thickness, with long term protection its only thickness, with long term protection its only objective.objective.

ZINCALUME® ZINCALUME® steelsteel

Roof sheeting made from Roof sheeting made from ZINCALUME® steel is ZINCALUME® steel is available in a range of profiles. available in a range of profiles. The zinc/aluminium alloy The zinc/aluminium alloy coating on ZINCALUME® steelcoating on ZINCALUME® steel imparts corrosion resistance imparts corrosion resistance of up to four times the life of of up to four times the life of galvanised steel.galvanised steel.

Colorbond SteelColorbond SteelColorbond is the name Colorbond is the name given to a special grade given to a special grade of corrosion resistant high of corrosion resistant high strength steel that is strength steel that is coated with zincalume coated with zincalume and painted in a limited and painted in a limited range of colorbond range of colorbond colours. The special colours. The special corrosion resistant base corrosion resistant base metal means that any metal means that any exposed edges/surfaces exposed edges/surfaces (due to cuts and (due to cuts and scratches) do not cause scratches) do not cause premature corrosion premature corrosion failure.failure.

Zincalume is for Factories:Zincalume is for Factories: Clients thinking of the  Clients thinking of the option of using zincalume steel instead of option of using zincalume steel instead of Colorbond - thinking that there would be good Colorbond - thinking that there would be good savings.savings.Colorbond is approximately $1.40 per square metre Colorbond is approximately $1.40 per square metre more than zincalume. But over the area of an more than zincalume. But over the area of an average 120 square metre roof, it works out to be average 120 square metre roof, it works out to be ONLY $168.00! ...And for this small sum, they will ONLY $168.00! ...And for this small sum, they will get a far superior product - and with a choice of get a far superior product - and with a choice of colours too!colours too!Zincalume is really the choice for factories which Zincalume is really the choice for factories which have roofs measuring many hundreds and have roofs measuring many hundreds and thousands of square metres. And the price savings thousands of square metres. And the price savings of using the cheaper material can be substantial of using the cheaper material can be substantial here.here.