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PRETREATMENT
What is Pretreatment?
2
2
Why Pretreatment?
3
3
Selection of Pretreatment Process
4
4
Soil Types
5
Inorganics
Rust
Heat scale
Particulate
Laser Scale
Organics
Petroleum oils and grease
Polymers
Soaps
Laser Scale Formation - O2 Assist
6
6
Why remove Laser Scale?
7
7
Mechanical Cleaning Options
8
Grinding
Blasting
8
Mechanical Cleaning
9
9
Mechanical Cleaning
10
10
Hand Grinding
11
11
Manual Pressure Blast
12
12
Automated Blast Cabinet
13
13
Automated In-line Wheel Blast
14
Blast Cleaning Standards
15
White metal, highly corrosive environments all visible rust, mill scale,
paint, foreign matter
Near white, harsh environments 95% removal of all visible residue
Commercial blast, non-corrosive environments two-thirds of all visible
residue is removed
Brush-off blast, long-term coating life is not required remove all but
tightly adherent scale
16
Types of Blast Media
17
17
Chemical Pretreatment Process
18
18
Chemical Cleaning
19
Acidic Cleaners
Alkaline Cleaners
19
Defining a Clean Surface
20
Laboratory Development
Alcohol drop test
P.A.T. cleanliness
Surface carbon
In Plant
Visual inspection
Visual Inspection
Mechanical
20
The Importance of Water Rinsing
21
21
Rinse Water Preferences
22
Well water
Recycled water
City water
Reverse osmosis
De-ionized
22
Conversion Coatings
23
23
Conversion Coating Helps Inhibit Corrosion
24
Surface Preparation Chemistries
25
Steel
Aluminum
Zinc coated steel
Other non-ferrous metals
Conversion Coatings Selection Chart
26
New Non-
Iron Zinc Chrome Chrome
Conversion Chrome
Phosphate Phosphate Phosphate Oxide
Substrate Coatings Coatings
Iron/Steel X X X
Galvanized X X X X X X
Aluminum X X X X X X
Galvanneal X X X
Magnesium X X X X X
Iron & Zinc Phosphates
27
Iron Zinc
Process Process
Single to multiple stages Multiple stages
Clean/phosphate in one Requires conditioning step
stage
Performance
Performance Good physical adhesion
Excellent physical adhesion Excellent corrosion
Good corrosion resistance resistance
New Conversion Coatings
28
New Conversion Coating Solution~90% Efficient in the use of the bath
Soluble by-products
No Solid Waste
Coating
Me+2 + Reaction Bi-Products
Components
Conversion Coating
Metal Substrate
New Conversion Coatings
29
Little or no heat
Very little or no phosphorous
Almost no sludge
Easier maintenance
Non-regulated materials
Excellent for multi-metal applications
Environmental Protection Agency Discharge Limits
30
Wisconsin: 1 mg/l
Toronto: 10 mg/l
Chromate
Chrome Oxide
Non-Chrome
Aluminum Conversion Coatings
33
Reactive
Post treatments will react with the substrate and the coating
resulting in a passivation of the surface
Non-Reactive
Post Treatments will lay down a protective coating passivating
the surface. These typically are considered dry-in-place
The Pretreatment Process
37
Advantages
Simple to maintain with few mechanical parts
Relatively low capital cost needed (batch)
Prolonged chemical contact time
Full wetting of complex shapes
Batch Pretreatment
Immersion Systems
44
Disadvantages
Less mechanical/physical force to remove soils
Increased process control: contact time, chemical
solution temperature, & concentrations
More suited to batch processing vs. continuous
production flows unless conveyorized
44
Conveyorized Systems
45
Conveyorized Pretreatment
Spray Washers
46
Advantages
Efficient
high volume throughput
cleaning and conversion coating
Shortened process times
Reduced temperatures
Chemical concentrations can be minimized
46
Three-Stage Washer
47
Stage 1 D Stage 2 D
Stage 3
R R
Clean & A Rinse A
I I Post
Phosphate Treatment
N N
(Seal Rinse)
Five-Stage Washer
48
Stage 1 D Stage 2 D D D
Stage 3 Stage 4 Stage 5
R R R R
A A A A
Clean I Rinse I Phosphate I Rinse I Post
N N N N Treatment
Cost Drivers
49
Part profile/drag-out
Part condition & soils
Cleaner Process Cost Savings
50
Oil removal
Improves Performance
use as rinse make-up water through spray nozzles
use as cleaner make-up water
Poor Adhesion
Blisters
Surface Defects
Dusty Coatings
Incomplete Coatings
POWDER APPLICATION
RODGER TALBERT
TALBERT CONSULTING
Powder Application System
Application Gun
Control Unit
Feed Hopper
Compressed
Air Supply
Fluidizing Plate
2
Application System Components
3
Delivery System
Feed hopper or box
Pump
Hose
Gun barrel & nozzle
Pneumatic controls
Charging System
Generator
Cable
Electrode
Voltage & micro-amp control
Powder Delivery
4
Powder Fluidization
5
Powder Pump
Fan
Final Filter Hopper Vent
Pick-up Tube
Fluidizing Plate
5
Fluidization
6
6
Excess Fluidization
Excessive Fluidization
Surging - inconsistent spray
7
Insufficient Fluidization
Spray pulsing
Higher pump pressure settings
required
Increased wear on parts
8
Proper Fluidization
9
Contaminated or Damaged Fluid Plate
Oil Scratched
10
Box Feed Unit
11
Vibratory Box Feeder
12
12
Venturi Powder Pump Operation
13
Pump
Feed/Delivery Air
13
Dense Phase Transport Pump
14
Stirrer or Gravity Hopper
15
Bulk Feed Systems
16
Powder Feed Hose
Polyethylene
Conductive polyethylene
EVA plasticized
PVC
Isoprene rubber
Natural gum rubber
Polyurethane
Polyester
And others..
17
Corona Charging Process
o Gun-to-part distance
Charging Time - o Powder velocity
o Electrode/Nozzle configuration
Particle Size -
o Powder particles; larger particles
hold more cumulative charge
19
Application Goals
20
Control Factors for Deposition
21
Powder Particle Size Distribution
% of Total
Best TE
Range
12
10
8
Differential
Volume, % 6
0
210 125 75 45 25 15 10 5 3 2 1
Microns
Virgin Reclaim
Powder Material Cyclone Recovery
25
14
12
10
8
Differential
Volume, % 6
0
210 125 75 45 25 15 10 5 3 2 1
Microns
Virgin Reclaim
Particle Size & Film Build
Insufficient
Q Attraction
Strong Mirror
Q Image Attraction
26
Ohms Law
50
V is the potential difference
8"
measured across the conductor in
units of volts
50
3"
27
Target Distance (Electrostatics)
kV 10
Target distance affects the resistance as
the gun gets closer to the grounded
100 6 surface
Gun Voltage
85
3 Optimizing the application requires a
balance of the load & control the free ions
63
in the process
mA
20 50 75 160
Gun Current
28
Current Limiting
29
Conventional Current Limited
10 10
kV kV
100 6 100
Gun Voltage
Gun Voltage
85
3 85
63
58
3
45
40
mA mA
20 50 75 160 20
Gun Current Gun Current
Faraday Cage Effect
30
Powder pattern
Charge
Air flow
31
Faraday Cage (Aerodynamics)
32
Forces that affect a Charged Particle
33
Particle is attracted to part because of electrostatic charge
Attraction is influenced by aerodynamic interference
Electric Force
Air Resistance
Weight
Powder particles are easily influenced by competing airflow.
Charge must be strong & velocity in spray area must be low
for high transfer efficiency
Back Ionization
34
Counter-Electrode
35
Correct Distance
Too Close
Gun Position
37
Uniform spacing
Uniform, proper
target distance
Right number of
guns
Moderate flow
rates
Flow Rate & Pattern Control
38
Powder Flow Rate Control
Powder material
Avoid excess fines
39
Factors that affect Powder Delivery Rate
40
Hopper fluidization
41
Flat Spray Patterns
6 mm 4 mm 2 mm
Flat-Spray Nozzles
42
Conical Deflector Spray Patterns
43
Irregular Fan Spray Pattern
44
Irregular Conical Spray Pattern
45
Spray Technique
Uniform Application
46
Powder Application Technique
47
Powder Application Technique
Flow rate
o A small amount of powder
with high efficiency
o No flooding with powder; concentrate on
gun settings
Application efficiency:
o Optimize gun-to-part distance & gun
current; 4 10 for manual, 8-12" for
automatic
o Control powder spray velocity
near the part surface
o Proper nozzle selection
o Smooth, consistent spray pattern
48
Manual Gun Controllers
Automated control
Recipes
Flow rates
Standard settings
Consistency
50
Controls Capabilities
51
Part Recipe Capable
Reciprocators
o Stroke and Speed
Gun Controls
o Voltage and Current
o Powder Output
System Protection
System Functions
System Monitoring
PLC System Controls
52
Manual Fast Color Change Systems
53
Automated Fast Color Change
54
Powder Feed Center
55
Application Efficiency
Gun controls
Optimum flow rate & charging set-up
Spray technique
Consistent, smooth, accurate (training helps)
Racking
Proper density, good ground, good access to all
surfaces
56
Application Efficiency Optimization
57
Line Density
58
59
Gun Movers and Positioning Devices
Fixed guns
Fixed guns with motion
Rotary oscillator
Oscillator
Reciprocator
Multi-axis
Robots
60
Application Problems
61
Faraday areas
Light coat
Heavy coat
Inconsistent film
Hook scars
Poor Charging & Coverage
62
Check ground from conveyor rail (or rub bar when used) through
hanger to part. All contact areas must be free of powder buildup,
heavy grease and other insulating materials
Check ground resistance value
Use Meg-Ohm meter (500 V)
Resistance < 1 Meg-Ohm
(per NFPA)
If the resistance is more
than 500 ohms, clean the
conveyor hooks.
Poor Ground = More Rejects
Hook maintenance & design
o Keep rack contacts clean
o Self-masking contact point
Poor Ground & High Flow Rate Good Ground & Correct Flow Rate
64
Too Much Powder Being Sprayed
65
Orange
Peel Star
Limit Current
Increase distance from part
Less film
Pin-hole Lower voltage for recoats
Good ground
Forrest Paint
Powder Coating Program
1
RODGER TALBERT
TALBERT CONSULTING
Powder Booths & Recovery Systems
2
Airflow
Lighting
Space
Cleaning/color change
Application efficiency
Materials of construction
Booth Airflow
5
End Opening
8'H x 10'W = 80 sq. ft.
6
Cleaning & Color Change
9
Cyclone System
Cartridge System
Batch System
Evaluation of Collection Options
11
Number of colors
Frequency of color change
Powder cost
Labor cost
Cost of down time
Capital investment
Space
11
Application Efficiency
12
Booth Construction
Stainless Steel
Durable, rugged construction
Attracts more powder, more to clean
13
Powder Coated Walls
Bright background
Low powder attraction to walls
14
Thermoplastic Walls
15
PVC & Composite Walls
16
Lab booths
Batch booths
Walk-in batch booths
Booths for conveyor systems manual &
automatic
Batch Booth Design
18
Considerations:
Production volume
Part size
o Clearance
o Access to surfaces
Batch Booth Design
19
Material handling options
o Hanger
o Carts
o Rail system
Grounding
Operator clearance (3 guide)
Removal of powder
Reclaim vs. spray to waste
Batch System
20
Recovery Systems
21
Powder
Cartridge Cyclone
Booth
Final Filter
Drum Unloader
Transfer Pump
Feed Hopper
23
Cartridge Collection Systems
24
Multiple colors
Multiple booths
Time or gap required
Spray-to-waste
Fast color change 20 to 60 seconds
Recovery
Low color change frequency
Break even point 1-3 colors
Cyclone Recovery System
26
Cartridge module
is a secondary filter
Cyclone Recovery System Process Flow
27
Cyclone Technology
28
Manual or automatic
Reclaim or spray-to-waste
Equipment options
Number of people
Number of booths
Frequency of color change
Uptime in a single color
Factors to Reduce Color Change Time
31
Increase containment
Control Virgin/Reclaim
Use reclaim as it is generated (no stockpile)
Add virgin consistently
Materials of construction
Application considerations
Cabin size
Cleanability
Visibility
Access
Forrest Paint
Powder Coating Program
1
RODGER TALBERT
TALBERT CONSULTING
Drying
2
Angle Parts for Drainage
3
Time
Cycle enough conveyor to allow parts to cool in ambient air
Forced cooling
Install fans or a cooling tunnel to reduce temperature in less
time
10
Cooling Tunnel
11
Convection Thermal
energy delivered by air
circulation
Fan
Return Air Opening
Discharge Duct
Works well for most non-appearance parts and dark colors require
Some ovens may require higher exhaust
Clear powder coatings
Polyester urethane
High quality appearance parts
Light colors
Powder Discoloration Problems
21
Building conditions
Air supply & ventilation
Energy efficient
Does not disturb uncured powder at entrance
Requires elevated ovens
Increased capital cost
Powered Air Curtain
26
Vestibule
Entrance
Exit
Heated Zone
Batch & Conveyorized Ovens
29
Batch ovens
Flexible for size & cycle
Uniform heating
Conveyorized ovens
Larger volume from continuous movement
1 pm 1 nm 1 um 1 mm 1m 1 km
10-6 um 10-3 um 103 um 106 um 109 um
Visible
Light
Wavelengths of IR
35
Short Wavelength
2150 - 4000F Heat Source (0.8 - 2 micron wavelength)
Response time Instantaneous
Source - Electric
Color - Bright White
Medium Wavelength
845-2150F Heat Source (2-4 micron wavelength)
Response time 60 seconds
Source Gas or Electric
Color - Orange
Long Wavelength
0-845F Heat Source (4-11 micron wavelength)
Response time 5 minutes
Source Gas or Electric
Color - Dark
Zoning of Infrared Ovens
36
Z1
Z2
Z3
Product Flow
VERTICAL ZONING
Z1 Z2 Z3 Z4
Product Flow
HORIZONTAL ZONING
Zoning of IR
37
Using IR & Convection Effectively
38
44
Temperature Balance
45
Temperature Recorder
46
Measurement of Temperature in Oven
47
Use Recorded Data for Adjustment
48
c111000a
550.0 550.0
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6
500.0 500.0
450.0 450.0
400.0 U
M 400.0
L
350.0 350.0
300.0 300.0
250.0 250.0
200.0 200.0
150.0 150.0
100.0 100.0
50.0 50.0
50 100 150
0.00 160.00
(Dis tanc e Graph) Units in f eet. Ov en s peed: 8 f t/min
53
Oven Maintenance
54
Lubrication
Fan bearings
Filtration
Fresh air filter
Combustion blower
Recirculation filters
Safety checks
Gas train components
Air flow switches
Forrest Paint
Powder Coating Program
1
RODGER TALBERT
TALBERT CONSULTING
Hanger Goals
2
Hanger Attachment
Point
27 Minimum
Part
6 Part Clearance
6 Part Clearance
Hanger Considerations
6
Wires
Rods
Fixtures
Chains
Improper Racking
10
Hooks
11
Inexpensive
Flexible
Easy to maintain
Custom Made Racks
12
Accuracy
Consistency
Density
Stability
High yields
Output
Racking Cost
13
House Racks
2 pieces/rack
Special Tool
4 pieces/rack
Racking Cost
14
1,000 9.75
2,000 4.9
3,000 3.25
Custom Tooling
17
Pre-racked Parts
18
Parts Masking
19
20
Tape
21
Standard Material
Silicone Rubber
Temperature Range up to 500F
Multiple Uses
Variety of Colors
EPDM Rubber
Temperature Range up to 375F
Limited Reusability
Less Expensive Option
Limited Colors
Custom Soft Masking
Rubber Molded
Die-Cut Materials
23
Eco-Friendly Masking
24
Tubing on the rack holds the part and masks the stud.
Hanger Maintenance
27
Durable construction
Keep them in good repair
Try to run full racks
Keep the contact points clean
Benefits of Hanger Cleaning
28
7.Package 1.Formulation
6.Sieve
2.Pre-mix
5.Grind 3.Extrusion
4. Chip
Production of Powder Coatings
4
Blending Weighing
Motor
Pre-Mix Operation
7
Extrusion
8
Extruder
Chipper
Chilled rollers
Cooling belt
Powder on the Cooling Belt
9
Powder Mill
10
Powder Manufacture Grinding
11
cyclone
Chip hopper
Sieve
Sieve
Grinder
Thermoset Powder Coating Systems
12
Epoxy
Urethane Polyester
TGIC Polyester
HAA (TGIC Free)
Acrylics
Hybrids
Powder Chemistry Selection
13
Urethane TGIC
Aluminum Automotive
Wheels
Brass Hardware
Aluminum Boats
Automotive Accessories
Fluoropolymer
19
Mini-Texture
Rolling Texture
26
ULB
UV
Multi-Color
Pearlescent
Fluorescent
Anti-Corrosion Primers
Sublimation
Properties & Performance of Thermoset Powder
30
1. Substrate
2. Product design
3. Pretreatment
4. Application
5. Coating selection
6. Cure
1.Variables in Substrate
32
Composition of Alloy
Soils on Surface Surface Films
Oxidation
Substrate Variables
Telegraphing
2. Product Design
39
Blisters in Coating;
No Drainage from Rail
Trapped Salt Water
Rust Bleeding From 0-T Bend Area
41
Variables in Product Design
42
Water traps
Sharp edges
Substrate condition
Castings (outgassing)
Post handling
Sharp Edges, Poor Coverage
43
3. Poor Preparation
44
Insufficient
Q Attraction
Strong Mirror
Q Image Attraction
Impact of Heavy Film
52
Impact of Particle Size
53
% of Total
TE = 70%
TE = 30% TE = 50%
55
5. Selection of Powder
56
Attribute Options
Clear-coat
Powder Top Coat Powder Top Coat Powder Top Coat Powder Top Coat
Zinc Containing Primer Powder Primer Powder Primer
Substrate
Substrate Substrate Substrate
1-layer
2- layer 2-layer 3-layer
62
Specific Gravity
63
Film Build
High Build
Thin Film
Edge coverage
Faraday penetration
Out-gassing resistance
Hardness/softness
Chemical resistance (oil, detergent, other fluids)
6. Cure
66
Yellowness
Greenness
Redness
Blueness
Color Measurement
76
Visual match
Colorimeter
Just Noticeable Difference (JND)
Units of Delta E
Color master standard
Metamerism
77
Light Source Metamerism
78
Pigment Combinations Affect Metamerism
79
Powder Storage & Handling
80
QUALITY ASSURANCE
FOR POWDER COATING
Goals
2
Improve consistency
Reduce cost
Maximize throughput
Deliver maximum volume of acceptable parts per
hour
Critical Factors
3
Alternative technologies
Your Customers
Sales & marketing; NOT purchasing agents
Determine Appearance & Performance Criteria
6
Criteria Importance
UV Resistance Critical
15
Adhesion Testing
Pencil Hardness
Salt Spray Cabinet
16
Weathering
17
EMMAQUA
Panel Farm
UV Test Cabinets
18
Light Cabinet
19
4) Written Specification
20
Scope
Surface preparation
Coating material(s)
Application
Testing & sampling
Film properties
Appearance
Gloss
Color
Film thickness
Test AAMA 2603-13 AAMA 2604-13 AAMA 2605-13
(polyester) (Superdurable (Fluoropolymer)
American Architectural Manufacturing Association polyester)
Film Thickness
Appearance Visual Comparisons
Color, Gloss, Smoothness, Texture and/or Metallic
Recording of defects
Identification of cause
Corrective adjustment
Defects
28
Adhesion Failure
Poor pretreatment
Inadequate film
Wrong coating
Back-ionization
Excess ions
Thick film
Gun too close
Defects
29
Blistering
Moisture under film
Moisture in compressed air
Chalking
Wrong powder
Incorrect cure
Defects
30
Corrosion
Poor surface preparation
Inadequate film thickness
Wrong coating
Under-cure
Craters
Silicone contamination
Oil or other liquid on surface
Defects
31
Outgassing
Casting porosity
Micro-fissure in steel
Galvanized surface
Contamination
Overbake
Excess time in oven
Excess temperature