Powder coating is becoming an increasingly popular choice for industrial and commercial applications due to its superior durability. The powder coating process produces a high-quality finish that is both more durable and aesthetically pleasing than traditional liquid paint. It is resistant to wear and tear, extreme temperatures, sunlight and corrosion, making it an ideal finishing option for various industries.
Read more
Powder Coating Definition and how does it work?
The powder coating process involves electrostatic guns that apply an even layer of colored dry powder over the surface in need of coating. It then goes through a curing process at high temperatures, where the charged particles are bonded together creating a strong, long-lasting coating. The dry powder coating process is an efficient and cost-effective way to create thicker coatings than liquid paint.
Powder coating is particularly great for metal surfaces because it is heat-resistant and can be used to give the surface a protective and aesthetic finish. This makes it an an ideal choice for products such as outdoor furniture and car parts that are exposed to changing temperatures and need to be protected from damage.
Composition of Powder Coating
The polymer resin is the basis of any powder coating and can be composed of many different materials. The most common are thermosetting epoxy, polyester, and acrylic resins. Each has its own associated benefits, allowing for a wide range of possible applications. These include uses in automotive finishes, outdoor furniture, decorative items, and more.
Powder coatings are applied to surfaces through an electrostatic process. The powder particles of the coating attract themselves to the grounded surface of the object, forming a smooth and even layer over it. This layer is then cured in an oven at a high temperature, which evaporates any solvents and bonds the ingredients together into a uniform finish. Additionally, powder coatings are available in many different colors and finishes so they can be customized to suit any aesthetic need.
Powder Coating Colors
The Nordson Color-On-Demand System is the perfect solution for powder coating operations requiring a wide range of custom colors in small batches. Our system is equipped with Nordson HDLV Technology and can hold up to 28 different powder coating colors at one time, ensuring faster color changes that occur within 20 seconds or less. This makes it easier and quicker to apply precise finishes - no matter what type of product you are working on, from rims to intricate parts requiring precision powder coating.
Types of Powder Coating
Thermoplastic powder coatings offer excellent flexibility and impact strength, as well as excellent chemical resistance. It is also very resistant to UV light and other environmental factors. However, thermoplastic coatings have a limited range of colors, and they are not as durable as thermoset coatings.
Thermoset powder coatings are cured using heat and pressure. This type of coating is more durable than thermoplastic coatings, and it has a much wider range of colors available. It also provides excellent corrosion protection, as well as good electrical insulation. However, thermoset powder coatings are not as flexible or impact resistant as thermoplastic coatings. They can also be more difficult to apply.
Both types of powder coating can provide long-lasting protection and a great finish. The type of coating chosen depends on the needs of the particular application.
What Is Powder Coating Used For?
Powder coatings are used in various applications in manufacturing industry, architectural industry, agriculture industry, appliance industry, energy industry, aerospace industry, automotive industry and other industries that require durable finishes for products.
Thermoplastic coatings offer a range of benefits to products that use them, including increased durability and protection from the elements. They are also an environment-friendly choice as they contain fewer VOCs (Volatile Organic Compounds) than other coating options. They are used in a variety of applications including playground furniture, light poles and pipes.
Thermoset powder coatings are known for providing a durable finish to whatever surface they are applied on. They have excellent corrosion and weather resistance, meaning that they can stand up to the elements no matter where they are used. This makes them ideal for outdoor products or surfaces exposed to the elements. This makes them perfect for products that get frequent use, such as lawn mowers, furniture, and fencing. They are also available in a wide range of colors and textures to suit any aesthetic need.
Powder Coating vs Paint
The powder coating process provides an advantage over conventional liquid coatings or conventional paint, in that the powder particles stick to the substrate much more easily and evenly, resulting in a thicker coating. Unlike paint, this helps create a smoother finish and greater protection from impacts, scratches, and other damage for your finished product.
Powder coated finishes also produce thicker coatings than traditional liquid finishes. The powder is also less likely to chip or peel off compared to traditional paint because of its superior adhesion. It also provides a tough, weather-resistant layer of protection against UV radiation and other environmental elements.
The Coating Process
The coating process consists of multiple steps like blasting, surface preparation, pretreatment, masking, coating, curing, quality control and final inspection:
1. Blasting, remove inorganic contaminants
Blasting is a critical step in the process, as it helps to ensure that the surface of the substrate is properly prepared for optimal coating. Blasting removes any dirt, oils or contaminants from the surface of the work piece, making it ready for powder adhesion. It also creates a textured surface with small indentations, which help powder particles to adhere better.
2. Surface preparation, Pretreatment
Pretreatment is a key step and used to prepare surfaces for the application of a powder coat. This treatment helps to ensure that the coating adheres properly and provides protection from corrosion and other damage caused by exposure to moisture and other elements.
The part is sprayed or dipped in an alkaline bath that removes oils, dust and other contaminants from the surface of the part. This prepares the the part's surface for primer application to ensure better adhesion and corrosion resistance. After this, a second rinsing process ensures all traces of dirt, oil and other particulates are removed. The pretreatment typically includes degreasing, cleaning, etching and phosphating, all of which help to increase the durability and performance of the powder coat.
3. Optional: Adding the Primer
Priming surfaces before coating can be a beneficial step in the overall process of your powder coating application, depending on the intended application of the product. A primer helps form stronger bonds between powder and substrate, allowing for a more durable finish that can last up to four times longer than non-primed substrates, making them particularly useful for outdoor applications using aluminum or steel components.
4. Masking
Masking is an important part of the process, as it allows for precision application to specific areas. Various techniques can be used to mask off parts that do not need coating, including tape and paper or plastic shields, die-cuts, or polyethylene sheeting.
5. Coating Process
Manual powder equipment is used by professional finishers to spray the grounded parts with charged powder. The powder sticks to the surface of the metal through electrostatic bonds, which is created when the particles are given an electrical charge.
Automatic powder equipment is an advanced technology that speeds up the application process, and requires less manual labour. This type of coating uses automated equipment to apply a layer of charged powder on the metal parts. The advantage of this method is that it ensures consistency in results, as the exact amount of powder and pressure can be maintained at all times.
With competitive price and timely delivery, YD Powder Coating sincerely hope to be your supplier and partner.
6. Curing and Curing Time
Curing involves a chemical reaction that takes place after the coating is applied and exposed to high temperatures in a curing oven. This process makes sure that the coating adheres well to the metal surface and creates a strong, durable finish. During curing, the temperature of the substrate must remain consistent for an extended period of time to allow for maximum bonding of the particles within the powder coating. The time and temperature of curing oven will depend on the type of powder used, with some requiring temperatures as high as 180°C for up to 20 minutes. After curing, the coating can be cooled rapidly in a chill cycle to further strengthen its bond and improve its appearance.
7. Quality Control
The seventh step is quality control which involves inspecting the powder coated product to ensure that it meets all standards of quality. This may include testing for adhesion, hardness, thickness, gloss level, and more to make sure your powder coating finishes are at top quality level.
8. Final Inspection
Lastly, a final inspection is done to check for any defects or problems with the coating before delivery. This ensures that the customer receives a product that is up to their standards and expectations. With proper care and maintenance, powder coating finishes can last many years without losing its beautiful finish. It is an economical and environmentally friendly process that can be used on a variety of different materials such as metal, plastic, wood, and more!
Powder Coating Tips
Powder offers a smoother finish with a greater level of consistency than many other types of liquid coatings. Here are some powder coating tips and tricks for getting the best results:
- Pre-treat the surface: Proper surface preparation is essential for successful powder coating. Any rust, debris, oil or grease must be completely removed before beginning. Sandblasting or chemical etching may be necessary depending on the type of material being coated (metallic, wood, plastic, glass, others).
- Application Method:The main tool for applying powder coat is a powder coat gun, which is designed to evenly distribute powder onto your surface. Using a spray gun requires great care; make sure to read the instructions carefully and follow them closely. Generally, when using a powder coat gun, you should hold it at least 8 inches away from the surface and keep your motion consistent to ensure an even coverage for quality powder coating finishes, avoiding much thicker coatings.
- Coated Surfaces:Vertically coated surfaces are ideal for areas with limited space, such as walls. This type of coating is often used to protect the underlying material from water damage and other environmental factors. Horizontally coated surfaces can be used in larger spaces, like floors or decks, where there is more room to spread the coating. These coatings are great for outdoor spaces and can help protect the underlying material from sun damage, moisture, and other weather-related issues. Both vertically and horizontally coated surfaces are an important part of protecting your home or business from the elements.
- Fluidized Bed Method:The fluidized bed should be run at the correct velocity in order to ensure that all particles are properly mixed and suspended within the bed. Ensure that you use the right particles for your application, as different particle sizes and materials can have an impact on the effectiveness of the process. Also ensure that you have adequate safety measures in place when running a fluidized bed application, such as wearing protective clothing and taking necessary precautions against dust explosions.
Following these tips and tricks should help you produce a quality finish with your powder coating projects. With regular maintenance, this protective layer can extend the life of your items and keep them looking great for years to come.
Connect With Nordson for Professional Powder Coating Equipment and Services
With Nordson powder coatings, customers can easily apply powder coatings to various substrates such as metal, aluminum, and plastic, allowing them to achieve the desired finish in less time. We examine the overall performance, quality, and cost of our powder coatings in a variety of application and environmental conditions, with case studies for powder coating providing a comprehensive overview of our results. Our facilities enables Nordson to provide its clients with the best possible experience in the powder coating industry, bringing high quality finishes and convenience together.
Founded in , the company has operations and support offices in more than 35 countries. With over 50 years of experience and expertise, we established ourselves as one of the leading suppliers of powder coatings in various regions and countries, including United States, UK, Europe, Canada, Asia, Japan, Africa, Australia and others. Additionally, we have an extensive showroom, virtual showroom and lab services, where you can see our products before purchasing them. Contact us today to find out how we can help meet your powder coating needs.
Powder Coating System - Manual
The Nordson Encore LT powder coating system, easy, and efficient solutions for any powder coating job. Even those with little to no experience can start using the system in only a few minutes. The perfect balance of a powder coating gun is crucially important for reducing the operator's fatigue. The minimum weight, ergonomic handle, and ideal balance distinguish Nordson Encore manual spray systems.
The Nordson Encore XT powder coating system and Encore HD spray systems have top-of-the-line powder coat guns for powder coating applications. Equipped with an intuitive LCD display, the gun is easy to use and offers a level of precision previously unseen in powder coating technology.
Those looking for even more productivity should go with the Encore HD powder coating system - they excel in getting the most challenging products coated quickly and accurately. With no wear parts inside the Encore HD pumps, the systems delver process control for as long as operating hours. Fully self-purging, capable of color change in less than 30 seconds without disassembly, reporting also powder savings in excess of 15% compared to ejector pump systems. Get your powder coating finishes done faster and better with Nordson’s Encore powder coating system!
Powder Coating System - Automatic
Nordson's Encore and Encore HD powder coating guns offer superior performance, a cost effective high productivity, and repeatability. With advanced technology and fast robot movement capability, the spray systems can deliver a soft spray even at high powder output.
The Nordson Encore® HD spray gun system is designed to deliver optimal powder coating results with precision. The spray gun combined with Dynamic Contouring Movers enable accurate positioning, allowing for fewer manual touch-ups and an increase in productivity.
For maximum efficiency in powder coating applications, Nordson also offers Fast Color Change Booths for quick color changes without compromising on quality. With the latest innovations in powder coating equipment from Nordson, you can expect higher yields with improved finish quality. Whether it is automatic powder application or manual operations, our wide array of products are designed to meet your specific needs.
Powder Coating Booths
Nordson’s powder coating booths and guns are designed for maximum efficiency, offering superior performance and fast color change. Our Fast Color Change Booths, like the ColorMax®2 powder coating booth improves quality, reduces downtime and maximises your production. The booth floor is made of durable Apogee® composite material, and is automatically purge-cleaned for no powder accumulation inside the booth. The advanced design of our guns allow for simple setup and operation, with multiple access points to powder recovery systems that ensure a high quality finish on each product.
With Nordson, you can be sure your powder coating processes will always be up to date with the latest technology. Whether it's manual touch-up or robot coating stations, we have a broad range of configurations available to meet all your needs. Invest in the best with Nordson powder coating solutions today!
About Nordson ICS Division
Founded in to produce and market airless spray equipment, today manufacturers rely on our equipment for the precise application and curing of powder coatings, liquid paint, ambient temperature adhesives and sealants, and food and beverage container production. Our solutions help our customers improve their manufacturing process, produce better products and become even more competitive. We do this by combining in-depth knowledge, world-leading technical expertise and precise, performance enhancing production solutions for some of the world’s most demanding and diverse manufacturing environments.
Comments
Please Join Us to post.
0