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A Guide to Applying Powder Coatings: Your Secret Weapon to Create High-Quality Finishes and Happy Customers

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A Guide to Applying Powder Coatings: Your Secret Weapon to Create High-Quality Finishes and Happy Customers A GUIDE TO APPLYING POWDER COATINGS: YOUR SECRET WEAPON TO CREATE HIGH-QUALITY FINISHES AND HAPPY CUSTOMERS www.ifscoatings.com TABLE OF CONTENTS The Different Types of Powder Coatings 01 QC Testing For Your Powder Coating Line 02 The Different Types of Pretreatments for Powder Coatings 05 How to Apply a Two Coat System 06 Spraying Metallics with Powder Coatings: What you Need to Know 08 Special Effect Powder Coatings and How To Apply Them 10 Appearance Issues: When Powder Coating Jobs Go Wrong 15 Powder Coating Application Issues, Problems & Fixes 18 Fluidization and Fluidizing Bed Issues - Powder Coatings 24 Cured Film Properties - Issues, Causes and Solutions 26 The Trials and Tribulations of Hoses and Pumps 29 The Little Things: Keeping Order in Your Job Shop 30 A GUIDE TO APPLYING POWDER COATINGS www.ifscoatings.com The Different Types of Powder Coatings Whether you’re new to powder coatings or an experienced pro, you’re probably well aware that powder coating is a fantastic painting method that creates a tough, durable and beautiful finish. No matter whether you’re using a single gun and small oven or a large fully automated line, the process is basically the same. A powder spray gun is used, which when triggered gives an electrostatic charge to the powder particles passing through it. As the parts to be coated are grounded, the powder is attracted towards the part via the electrostatic process. Once the powder is applied the parts are cured in an oven, which melts and cross-links the powder over the surface of the part and creates a tough, scratch resistant and beautiful finish. There are literally thousands of different applications for powder coatings. Powder coating is used mainly on metals, so is perfect for industrial parts, medical devices, architectural applications, automotive refinishing, bicycle parts, household appliances, furniture, enclosures, trailers, lighting…the list goes on! There are many different types of powders used, each with their own characteristics and applications, so making sure you have the right type of powder, and THEN choose the color is very A GUIDE TO APPLYING POWDER COATINGS 01 www.ifscoatings.com important for a successful application. Check out the different and hardness than traditional liquid paints, but let’s take a look types of powder and the benefits they will bring to the parts. at some of the different powders used that help achieve these characteristics. There are so many advantages to using powder coatings – too many to cover in this blog post – but some of the obvious Epoxies ones include lack of solvents. This means no volatile organic Epoxies were the first widely used powders. They are very compounds (VOCs) are released, a great advantage especially durable, offer excellent hardness and have arguably the best when compared to traditional liquid paints. This makes them safer chemical and corrosion resistance of all available powders. to work with, dispose of and transport and brings unbeatable Another plus of this type of powder is its ease of use and a wide environmental advantages to you and your customer. range of cure schedules. Epoxies adhere to metals extremely well, with various pretreatments of the metal providing excellent Powder coating allows for much thicker coatings than liquid paint, adhesion, including phosphate coating and sandblasting. without running or sagging. With liquid paint, horizontal and vertical painted surfaces often have differences in appearances, The drawback of epoxy powders is that they do not weather but powder coating typically provides a uniform visual appearance well. Exterior exposure can cause them to fade and chalk in the regardless of orientation. sun. They weather poorly and will often start to degrade on the surface after a few months. This makes epoxies better suited to Powder coating allows for much thicker coatings than liquid paint indoor applications. without running or sagging. With liquid paint, horizontal and vertical painted surfaces often have differences in appearances, A final note on epoxies is that many primers are epoxies due but powder coating typically provides a uniform visual appearance to their adhesion strength and corrosion resistance. Since they regardless of orientation. do not handle the sun well, their use as a pre-coat underneath another paint type utilizes their strengths while covering their Powder coating also offers a wide range of specialty effects that weaknesses. are hard to achieve through traditional methods. The list goes on, and we could get into better scratch resistance, toughness, A GUIDE TO APPLYING POWDER COATINGS 02 www.ifscoatings.com Polyesters pieces that will be permanently outside and therefore need good wearability and durability, then consider the super durable Polyesters are the most commonly used powders and offer great polyester instead. Limited exterior durability is a standard value for money. The two most widely used types of polyester polyester’s main disadvantage. powder: TGIC (tri glycidyl isocyanurate) and non-TGIC, which is also known as TGIC-free or sometimes a ‘Primid’. Both TGIC and TGIC-free polyesters offer good mechanical resistance, Super Durable Polyesters including great flexibility and impact resistance, and good Super Durable Polyesters have fast become the superhero of chemical resistance. One draw of this powder is its low cure polyester powders. As the name suggests these excellent value temperature. This low-temperature requirement makes it better powders offer superior durability when compared with a standard for sensitive items. Polyesters will also provide good overbake polyester. They are designed to hold their color and gloss to within resistance to yellowing, which makes them really easy to use and set limits for 5 to 10 years more when compared to a standard Standard Polyesters will offer 1-3 years of good UV resistance, polyester. Not only is their color and gloss protection better, so they work well for all interior and some exterior applications. A but they also provide better humidity and corrosion resistance. huge advantage of standard polyesters is the enormous choice These Super Durables have become hugely popular over the last of colors, gloss levels and special effects they’re available in. It’s few years as their increased capabilities and great value for the almost limitless! Polyesters have solid all around properties and money have made them popular for interior applications where are a common first choice for many applications. improved fade resistance is required and all manner of outdoor applications. It seems kind of obvious, but TGIC-free polyesters offer all the advantages of TGIC polyesters, without the TGIC! They can also Epoxy-Polyester Hybrids give a higher first pass transfer efficiency, but are more sensitive Epoxies and polyesters are often mixed together to form hybrids. to excess film thickness and provide less overbake resistance These hybrids remain closely related to pure epoxies but offer than TGICs. superior weather degradation properties. These hybrids can be As the workhorse of powder coatings, it’s not surprising that mixed in various ratios to emphasize the characteristics of either there aren’t that many drawbacks to polyesters. If you’re coating the epoxy or polyester. The polyester will enhance the overbake A GUIDE TO APPLYING POWDER COATINGS 03 www.ifscoatings.com resistance when compared with a straight epoxy and they also exterior performance. FEVE based Fluoropolymer metallics can create ultra-smooth, thin films. The combination of the resins also be bonded so that when applied, the metallic flake is more can also make them more economical than a pure epoxy. The evenly distributed throughout the powder for a more consistent polyester does reduce the corrosion and chemical resistance of appearance. Fluoropolymer powders are usually only available the epoxies and doesn’t really add any outdoor weatherability to to members of a Certified Applicator program, as up to 20-year the product. Hybrids are widely used on items that require good warranties are available on these products when applied by a cosmetic appeal along with good functional properties. Hybrids certified applicator to architectural aluminum. One popular brand can be used in some of the same areas that epoxies are used, of fluoropolymer is IFS 500FP, which is a high performance, but are typically found on indoor appliances and other household FEVE based Fluoropolymer and adds better abrasion resistance items like furniture, shelving, interior lighting, and power tools. to the standard fluoropolymer characteristics. IFS 500FP can be Domestic appliances like stoves, washers, and dryers are a seen on a huge range of projects from the DSNY building and the common application for hybrids. beautiful new slender skyscraper at 111 57th in Manhattan, to 9th and Lenora in Seattle and the Winstar Casino in Oklahoma. Fluoropolymers Fluoropolymers are typically used in architectural markets due Urethanes to their phenomenal weathering properties and world-class color Urethanes are chemically similar to polyesters, with a difference and gloss retention. Their corrosion resistance and excellent in curing agents. Urethanes offer a very smooth finish and weatherability make them extremely popular for exterior very good exterior durability as well as excellent chemical and architectural applications like curtain wall, windows, doors and corrosion resistance which makes them ideal for things like fuel more. The two most common types of Fluoropolymers found in tanks. Other common applications include agricultural equipment, powder coatings are FEVE and PVDF. PVDF Fluoropolymers air conditioners, car rims and doorknobs. They are used on always need a primer beneath them – whether liquid or powder door knobs, oven knobs and other such applications because and are much more difficult to bond when creating metallic fingerprints are not as visible. One drawback of urethane paint is powders. FEVE resins are the most popular within the powder that at higher mil thicknesses it can begin to outgas and become community for their superior one coat capability and incredible brittle.
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