Powder coating is a type of coating that is applied as a free-flowing, dry powder. Unlike conventional liquid paint, which is delivered via an evaporating solvent, powder coating is typically applied electrostatically and then cured under heat or with ultraviolet light. The powder may be a thermoplastic or a thermosetting polymer. It is usually used to create a thick, tough finish that is more durable than conventional paint. Powder coating is mainly used for coating of metal objects, particularly those subject to rough use. Advancements in powder coating technology like UV-curable powder coatings allow for other materials such as plastics, composites, carbon fiber, medium-density fibreboard (MDF), and solid wood to be powder coated, as little heat or oven dwell time is required to process them.
History, properties, and uses of powder coating
The powder coating process was invented around 1945 by Daniel Gustin and received US Patent 2538562 in 1945. This process coats an object electrostatically and then cures it with heat, creating a finish harder and tougher than conventional paint. Originally used on metal manufactures, such as household appliances, aluminium extrusions, drum hardware, automobile parts, and bicycle frames, the practice of powder coating has been expanded to allow finishing of other materials.
Because powder coating does not have a liquid carrier, it can produce thicker coatings than conventional liquid coatings without running or sagging, and powder coating produces minimal appearance differences between horizontally coated surfaces and vertically coated surfaces. Further, because no carrier fluid evaporates away, the coating process emits few volatile organic compounds (VOC). Finally, several powder colors can be applied before all are cured together, allowing color blending and special bleed effects in a single layer.
While it is relatively easy to apply thick coatings that cure to smooth, texture-free coating, it is not as easy to apply smooth thin films. As the film thickness is reduced, the film becomes more and more orange peeled in texture because of the particle size and glass transition temperature (Tg) of the powder.
Most powder coatings have a particle size in the range of 2 to 50 μm, a softening temperature Tg around 80 °C, and a melting temperature around 150 °C, and are cured at around 200 °C for a minimum of 10 minutes to 15 minutes (exact temperatures and times may depend on the thickness of the item being coated). For such powder coatings, film build-ups of greater than 50 μm may be required to obtain an acceptably smooth film. The surface texture which is considered desirable or acceptable depends on the end product. Many manufacturers prefer to have a certain degree of orange peel since it helps to hide metal defects that have occurred during manufacture, and the resulting coating is less prone to showing fingerprints.
There are very specialized operations that apply powder coatings of less than 30 μm or with a Tg below 40 °C in order to produce smooth thin films. One variation of the dry powder coating process, the Powder Slurry process, combines the advantages of powder coatings and liquid coatings by dispersing very fine powders of 1–5 μm sized particles into water, which then allows very smooth, low-film-thickness coatings to be produced.
For small-scale jobs, "rattle can" spray paint is less expensive and complex than powder coating. At the professional scale, the capital expense and time required for a powder coat gun, booth and oven are similar to those for a spray gun system. Powder coatings do have a major advantage in that the overspray can be recycled. However, if multiple colors are being sprayed in a single spray booth, this may limit the ability to recycle the overspray.
Advantages over other coating processes Powder coatings contain no solvents and release little or no amount of volatile organic compounds (VOC) into the atmosphere. Thus, there is no need for finishers to buy costly pollution control equipment. Companies can comply more easily and economically with environmental regulations, such as those issued by the U.S. Environmental Protection Agency. Powder coatings can produce much thicker coatings than conventional liquid coatings without running or sagging. Powder coated items generally have fewer appearance differences than liquid coated items between horizontally coated surfaces and vertically coated surfaces. A wide range of speciality effects are easily accomplished using powder coatings that would be impossible to achieve with other coating processes. Curing time is significantly faster with powder coatings compared to liquid coatings especially when using ultraviolet cured powder coatings or advanced low bake thermosetting powders.
Types of powder coating There are three main categories of powder coatings: thermosets, thermoplastics, and UV curable powder coatings. Thermoset powder coatings incorporate a cross-linker into the formulation.
Most common cross-linkers are solid epoxy resins in so-called hybrid powders in mixing ratios of 50/50, 60/40 and 70/30 (polyester resin/ epoxy resin) for indoor applications and triglycidyl isocyanurate (TGIC) in a ratio of 93/7 and β-hydroxy alkylamide (HAA) hardener in 95/5 ratio for outdoor applications. When the powder is baked, it reacts with other chemical groups in the powder to polymerize, improving the performance properties. The chemical cross-linking for hybrids and TGIC powders—representing the major part of the global powder coating market—is based on the reaction of organic acid groups with an epoxy functionality; this carboxy–epoxy reaction is thoroughly investigated and well understood, by addition of catalysts the conversion can be accelerated and curing schedule can be triggered in time and/or temperature. In the powder coating industry it is common to use catalyst masterbatches where 10–15% of the active ingredient is introduced into a polyester carrier resin as matrix. This approach provides the best possible even dispersion of a small amount of a catalyst over the bulk of the powder. Concerning the cross-linking of the TGIC-free alternative based on HAA hardeners, there is no known catalyst available.
For special applications like coil coatings or clear coats it is common to use glycidylesters as hardener component; their cross-linking is based on the carboxy–epoxy chemistry too. A different chemical reaction is used in so-called polyurethane powders, where the binder resin carries hydroxyl functional groups that react with isocyanate groups of the hardener component. The isocyanate group is usually introduced into the powder in blocked form where the isocyanate functionality is pre-reacted with ε-caprolactame as blocking agent or in form of uretdiones, at elevated temperatures (deblocking temperature) the free isocyanate groups are released and available for the cross-linking reaction with hydroxyl functionality.
In general all thermosetting powder formulations contain next to the binder resin and cross-linker additives to support flow out and levelling and for degassing. Common is the use of flow promoter where the active ingredient—a polyacrylate—is absorbed on silica as carrier or as masterbatch dispersed in a polyester resin as matrix. Vast majority of powders contain benzoin as degassing agent to avoid pinholes in final powder coating film.
The thermoplastic variety does not undergo any additional actions during the baking process as it flows to form the final coating. UV-curable powder coatings are photopolymerisable materials containing a chemical photoinitiator that instantly responds to UV light energy by initiating the reaction that leads to crosslinking or cure. The differentiating factor of this process from others is the separation of the melt stage before the cure stage. UV-cured powder will melt in 60 to 120 seconds when reaching a temperature 110 °C and 130 °C. Once the melted coating is in this temperature window, it is instantly cured when exposed to UV light. UV powder coatings are processed in the fastest time and uses the least amount of energy compared to other powder coating technologies
The most common polymers used are polyester, polyurethane, polyester-epoxy (known as hybrid), straight epoxy (fusion bonded epoxy) and acrylics.
Production The polymer granules are mixed with hardener, pigments and other powder ingredients in an industrial mixer, such as a turbomixer The mixture is heated in an extruder The extruded mixture is rolled flat, cooled and broken into small chips The chips are milled and sieved to make a fine powder
Methodology The powder coating process involves three basic steps: part preparation or the pre-treatment, the powder application, and curing.
Part preparation processes and equipment Removal of oil, dirt, lubrication greases, metal oxides, welding scale etc. is essential prior to the powder coating process. It can be done by a variety of chemical and mechanical methods. The selection of the method depends on the size and the material of the part to be powder coated, the type of impurities to be removed and the performance requirement of the finished product. Some heat-sensitive plastics and composites have low surface tensions and plasma treating can be necessary to improve powder adhesion.
Chemical pre-treatments involve the use of phosphates or chromates in submersion or spray application. These often occur in multiple stages and consist of degreasing, etching, de-smutting, various rinses and the final phosphating or chromating of the substrate and new nanotechnology chemical bonding. The pre-treatment process both cleans and improves bonding of the powder to the metal. Recent additional processes have been developed that avoid the use of chromates, as these can be toxic to the environment. Titanium, zirconium and silanes offer similar performance against corrosion and adhesion of the powder.
In many high end applications, the part is electrocoated following the pretreatment process, and subsequent to the powder coating application. This has been particularly useful in automotive and other applications requiring high end performance characteristics.
Another method of preparing the surface prior to coating is known as abrasive blasting or sandblasting and shot blasting. Blast media and blasting abrasives are used to provide surface texturing and preparation, etching, finishing, and degreasing for products made of wood, plastic, or glass. The most important properties to consider are chemical composition and density; particle shape and size; and impact resistance.
Silicon carbide grit blast medium is brittle, sharp, and suitable for grinding metals and low-tensile strength, non-metallic materials. Plastic media blast equipment uses plastic abrasives that are sensitive to substrates such as aluminum, but still suitable for de-coating and surface finishing. Sand blast medium uses high-purity crystals that have low-metal content. Glass bead blast medium contains glass beads of various sizes.
Cast steel shot or steel grit is used to clean and prepare the surface before coating. Shot blasting recycles the media and is environmentally friendly. This method of preparation is highly efficient on steel parts such as I-beams, angles, pipes, tubes and large fabricated pieces.
Different powder coating applications can require alternative methods of preparation such as abrasive blasting prior to coating. The online consumer market typically offers media blasting services coupled with their coating services at additional costs.