Lecture 1 Coating
Lecture 1 Coating
Lecture 1 Coating
A coating is a covering that is applied to the surface of an object, usually referred to as the
substrate. The purpose of applying the coating may be decorative, functional, or both.
Solvents (Liquids)
Pigments
Additives
Resins (Binder)
REF: Comex group ppt: PAINT BASICS AND CORROSION IN METAL AIA103 2
Prime Pigments
3
Resins
• Types: Latex, Alkyd, Epoxy, Polyurethane
• UV-resistance
• Moisture resistance
• Chemical resistance
• Stain resistance
• Fade resistance
REF: Comex group ppt: PAINT BASICS AND CORROSION IN METAL AIA103 4
Alkyd Resin Technology
ALKYD (Oil-Based)
• A synthetic resin made by reacting alcohols and fatty acids
• Benefits of alkyds:
- Abrasion resistance
- Good adhesion
- Used in rust preventative paint
Alkyd resin
REF: Comex group ppt: PAINT BASICS AND CORROSION IN METAL AIA103 5
Latex Resin Technology
LATEX (water-based)
QUALITY Latex paint benefits
Synthetic polymers include:
Main resins:
• Color retention
- 100% Acrylic • Excellent adhesion
- Styrene Acrylic • Scrub resistance
- Vinyl-Acrylic • Low odor
- Acrylic Copolymer
- Ethylene Vinyl Acetate
Acrylic acid
REF: Comex group ppt: PAINT BASICS AND CORROSION IN METAL AIA103 7
Coating Methods
Spraying
This process occurs when paint is applied to an object
through the use of an air-pressurized (compressed
gas)spray gun. The air gun has a nozzle, paint basin, and
air compressor. When the trigger is pressed the paint
mixes with the compressed air stream and is released in
a fine spray.
Marka : İzoroof
Kısa Tanım : Yerinde özel makineler ile püskürtülerek uygulanan sistemlerdir. Ek yeri
olmayan tek parça bir izolasyon elde edilir. Isı ve ses izolasyonu amacı ile
uygulanmaktadır.
http://www.chinapowdercoating.com/conventional-electrostatic-charging
Electrostatic Painting, Powder Deposition: In these deposition processes, a
powder (or sometimes a liquid) is atomized and given an electric charge. The
charged particles of powder drift toward a conductive workpiece (the item
that is being powder painted), usually with additional airflow assist from a
fan or pump. The powder is electrostatically attracted to the workpiece and
sticks to it. Then the workpiece is heated, which melts the powder so that it
forms a smooth, solid coat. Heat (or UV for a low-temperature piece) will
also polymerize the melted powder if the coating is permanently-hardening
(a thermoset). The applied voltage is usually negative, but it is positive for
nylon and some other materials, because each material has its own charging
preference. An insulator can also be electrostatically sprayed if it is very thin
and is backed by a grounded conductor.
ELEKTROSTATİK TOZ BOYAMA NEDİR ?
1) Malzemeler ilk önce yıkama-yağ alma ve durulama-fosfatlama bölümünde işlem görür. Fosfatlama işlemi sayesinde metal
yüzey üzerinde koruyucu bir tabaka oluşturulur.Bu sayede metalin hava alması engellenir ve toz boyanın malzemeyi sarması
kolaylaşır. Böylece metal üzerinde oluşacak korozyon ve paslanmanın önüne geçilir, malzemenin uzun ömürlü ve
dayanıklı olması sağlanır.
2) Daha sonra malzemelerin yüzey temizliği kontrol edilir. Eğer ki malzemelerde çapak varsa temizlenir düzeltme ve zımpara
işlemleri yapılır.
3) Malzemeler boyanmak üzere konveyör hattına asılır ve hava tabancaları ile malzemelere hava tutulur. Malzemelerin
üzerinde toz ve benzeri kalıntıların kalmadığından emin olunur.
4) Konveyör hattı ilerlemeye başlar ve malzemeler toz boya kabininin içine girer, tabanca sistemleri ile malzemeler toz boya
ile boyanırlar.
5) İlerleyen konveyör hattı üzerindeki malzemeler fırından içeriye girmeye başlarlar, malzeme kalınlıklarına göre ve boya
kürlenme derecelerine göre fırında özel ısı ve zaman ayarları yapılır.Bu sayade malzemenin kürlenmesi(pişmesi) sağlanır.
(Boya kürlenme dereceleri 180-210°C arasındadır)
6) Elektrostatik toz boya ile boyanan malzemeler fırından dışarıya çıkar ve kısa bir süre soğumaya bırakılır.
7) Böylece dayanıklı, sağlam ve estetik açıdan mükemmel bir boya elde edilmiş olur.
• In a dip-coating process, a substrate is dipped into a liquid coating solution and then is
withdrawn from the solution at a controlled speed. Coating thickness generally
increases with faster withdrawal speed. The thickness is determined by the balance of
forces at the stagnation point on the liquid surface. A faster withdrawal speed pulls
more fluid up onto the surface of the substrate before it has time to flow back down
into the solution. The thickness is primarily affected by fluid viscosity, fluid density, and
surface tension.
In which:
• h: thickness
• ρ: density
• g: gravity constant
• η: viscosity
• γlv: liquid‐vapor surface tension
• v: dtagging speed
neoprene
polyurethane
Spin coating is a cheap and fast method to produce homogeneous layers. An excess
amount of the solvent is placed on the substrate, which is then rotated at high speed in
order to spread the fluid by centrifugal force. The film thickness can be adjusted by
varying the rotation speed, the rotation time, and the concentration of the used
solution. The disadvantage of this method is that it is limited by the solvent and that no
lateral resolution is possible.
Spin coating is widely used in microfabrication, where it can be used to create thin films
with thicknesses below 10 nm. It is used intensively to deposit layers of photoresist (light
sensitive materials) about 1 micrometre thick.
Spin Coating
Thickness of the layer depends on many different parameters. Equation 1 shows how these
parameters affect thickness:
In which:
• h: thickness
• ρA: density of volatile liquid
• η: viscosity of solution
• m: rate of evaporation
• ω:angular speed
A,B are constant parameters that should be calculated experimentally, but in most cases, it
has been proved that B is some where between 0.4 and 0.7.
Some technologies that depend heavily on high quality spin
coated layers are:
ADVANTAGES
•Ability to coat irregular shapes,
• Simple and inexpensive
equipment requirements,
•Process automation,
•Smooth and continuous coating
applications.
DISADVANTAGES
•Pre-heat and post-heat ovens are
required
•Minimum of 200um to be applied The Process Steps :
•Complex shapes trap excess 1. Sample pre-heated to 200-230C
powder 2. Initial deposit melts onto part
3. Film builds from residual heat
4. Coated part with desired film
Film or Sheet Coating Methods
Roll Coating
The main uses of this type of coating technique are the transfer coated polyurethane
fabrics is in up-market and the waterproof protective clothing.
Extrusion coating
In extrusion coating applications, resin is melted and formed into thin
hot film, which is coated onto a moving, flat substrate such as paper,
paperboard, metal foil or plastic film. The coated substrate then
passes between a set of counter rotating rolls that press the coating
onto the substrate to ensure complete contact and adhesion.
http://www.lyondellbasell.com/Products/ByCategory/polymers/process/ExtrusionCoating/
http://www.polynov.com/processes/heavyCoating.html
Wire Coating
http://www.mindfully.org/Plastic/VCMEmay1973-4.htm
Self-healing of a polymer
Schematic illustrations of the steps for the fabrication of the SU-8 micropillars.
Sumio Hosaka, Nanotechnology and Nanomaterials "Updates in Advanced Lithography", ISBN 978-953-51-1175-7, 2013.
This coating consists of PTFE
sub-micrometer particles and
iron oxide colloidal NPs and
they are applied by spray
deposition. Apart from their
interesting wetting properties
such type of surfaces can be
used in various applications
such as in biological scaffolds,
lab-on-a-chip devices and
aerospace vehicles. The
substrates, starting from
“sticky” hydrophobic
(uncoated patterned
surfaces), by the application
of the proper particles, can be Schematic illustrating the successive coating
converted to super steps. At first the PTFE solution is sprayed on
hydrophobic surfaces with the substrate. As a second step, the iron oxide
ultrahigh or ultralow water NPs are sprayed on top of the Si/PTFE
adhesion. micro/submicron rough pattern, thus inducing a
three-scale roughness.
Sumio Hosaka, Nanotechnology and Nanomaterials "Updates in Advanced Lithography", ISBN 978-953-51-1175-7, 2013.
Water drops that remain adhered in an iron oxide/PTFE/SU-8 patterned surface
under very high substrate inclinations (tilt angle: 122° on the left image and 173°
on the right) Such type of surfacescan be designated as “sticky superhydrophobic”
surfaces
SOL-GEL
In the solgel process, simple molecular precursors are converted into nanometer-sized particles to form
a colloidal suspension, or sol. The colloidal nanoparticles are then linked with one another in a 3D,
liquid-filled solid network. This transformation to a gel can be initiated in several ways, but the most
convenient approach is to change the pH of the reaction solution. Even the method used to remove
liquid from a solid will affect the solgel’s properties. For example, to preserve a gel’s original 3D
structure and produce low-density aerogels, chemists use a technique called supercritical drying. If,
instead, the gel is dried slowly in a fluid-evaporation process, the gel’s structural network collapses,
which creates a high-density material known as a xerogel.
Aerogel properties can be changed by adding different precursor molecules.
For example;
(a) an aluminum oxide foam prepared from aluminum nitrate has a cluster
morphology that results in (b) an opaque aerogel.
(c) Using aluminum chloride as the precursor produces an aerogel with
fibrous morphology, resulting in (d) a stronger foam that is also translucent.