User's Guide to Powder Coating, 4th Edition

✍ Scribed by Nicholas Liberto

• Publisher: Society of Manufacturing Engineers
• Year: 2003
• Tongue: English
• Leaves: 193
• Edition: 4
• Category: Library

✦ Synopsis

For nearly 20 years, 'Users Guide to Powder Coating' has been the leading hands-on guide to power coating technology. Now in its 4th edition, the book addresses recent developments which have contributed to powder coating's ever-increasing favorability over liquid coating. Since the publication of the last edition, this process has been adapted to a wider range of applications, notably for high-temperature and temperature-sensitive products. Equipment has been greatly improved, achieving faster color change, increasing transfer efficiency, and reducing overall powder usage. Environ-mental requirements have prompted many companies to switch to powder coating. 'Users Guide to Powder Coating, Fourth Edition' combines information on the latest breakthroughs in the industry (notable ultraviolet-curable materials for plastic and wood products, and improved systems) and tried-and-true guidelines from the previous edition (including factors like material selection, design considerations, surface preparation, quality control and testing, trouble shooting and safety, and more), so you can achieve superior finishes with efficiency.

✦ Table of Contents

Front Matter
About the Society of Manufacturing Engineers (SME) and AFP/SME
Preface
Table of Contents
1. Why Powder Coating?
1.1 Economic Considerations
1.1.1 Labor and Efficiency Savings
1.2 Applications
1.2.1 Powder Coating Markets
1.3 Environmental Implications
1.3.1 Non-Hazardous Powders
1.4 Powder Coating Growth
2. Powder Coating Materials
2.1 Thermoplastic Powders
2.1.1 Polyethylene
2.1.2 Polypropylene
2.1.3 Nylon
2.1.4 Polyvinyl Chloride
2.1.5 Thermoplastic Polyester
2.1.6 Ethylene Acrylic Acid Copolymer
2.1.7 Surlyn®
2.2 Thermoset Coating Powders
2.2.1 Epoxy-Resin-Based Systems
2.2.1.1 Functional Epoxies
2.2.1.2 Thin Film Coatings
2.2.2 Epoxy-Polyester Hybrids
2.2.3 Polyester
2.2.4 Hydroxyl Polyester (Urethane)
2.2.5 Carboxyl Polyester
2.2.6 Acrylics
2.2.7 Silicone and Modified-Silicone Coating Powders
2.2.8 Other Polyesters
2.3 Radiation-Cured Powders
2.4 Coating Selection
2.5 Safety
3. Economic Advantages
3.1 Cost Savings
3.1.1 Energy Savings
3.1.2 Labor-Cost Savings
3.1.3 High Operating Efficiencies
3.1.4 Capital Costs
3.1.5 Environmental Factors
3.1.6 Plant Safety
3.2 Application Evaluation
4. Surface Preparation
4.1 Mechanical Cleaning Methods
4.1.1 Airblast
4.1.2 Airless (Centrifugal-Wheel) Blast
4.1.3 Method Selection
4.1.4 Applications
4.1.5 Abrasives
4.1.6 Precautions
4.1.7 Advantages
4.1.8 Limitations
4.2 Chemical Surface Preparation
4.2.1 Power-Spray Cleaning
4.2.2 Immersion Cleaning
4.2.3 Electrocleaning
4.2.4 Hand Wiping
4.2.5 Spray-Wand Cleaning
4.2.6 Cleaning Chemistries
4.2.6.1 Alkaline Cleaners
4.2.6.2 Neutral Cleaners
4.2.6.3 Acid Cleaners
4.3 Conversion Coating
4.3.1 Galvanized Steel
4.3.2 Aluminum
4.3.3 Steel
5. Powder Coating Application Methods
5.1 Fluidized Powder-Bed Processes
5.1.1 Construction
5.1.2 Fluidization
5.1.3 Bed Density
5.2 Electrostatic Fluidized-Bed Processes
5.2.1 Application
5.2.2 Powder Characteristics
5.2.3 Equipment Characteristics
5.2.3.1 Safety Considerations
5.2.3.2 Design and Application
5.3 Electrostatic Powder Spraying
5.3.1 Advantages
5.3.2 Equipment
5.3.3 Powder-Feeder Units
5.3.3.1 Powder Delivery Hoses
5.3.3.2 Applicators
5.4 Application Factors
6. Powder-Spray Booths and Recovery Systems
6.1 Spray Booths
6.1.1 Gravity-Assisted Booths with Cyclone Recovery
6.1.2 Quick-Color-Change Booth with Cyclone Recovery
6.1.3 Rigid Booth with Cyclone Recovery
6.2 Other Booth Technologies
6.2.1 Horizontal Coating Booth
6.2.2 Belt Booth
6.2.3 Chain-on-Edge Booth
6.2.4 Collector System
6.2.5 Self-Contained Booth
6.2.6 Side-Draft Spray Booth
6.2.7 Open-Collector-Cartridge Filtration
6.2.8 Reverse-Jet-Cleaning Mechanism
6.2.9 Collector-Inlet Design
6.2.10 Cartridge-Mounting Arrangement
6.3 Color-Change Considerations
7. Powder Coating System Design Considerations
7.1 Location
7.2 Utilities
7.3 Operation
7.3.1 System Cleanliness
7.3.2 System Components
7.3.3 Health Hazards
8. Heating
8.1 Preheating
8.2 Post-Heating
8.3 Process Considerations
8.4 Methods of Heating
8.4.1 Gas or Electric Convection
8.4.2 Infrared Radiation
8.5 Oven-Cavity Atmosphere
8.6 Safety
9. Storage and Handling
9.1 Excessive Heat
9.2 Humidity and Water
9.3 Contamination
9.4 Storage Recommendations
9.5 Safety
10. Touch-up, Recoat, and Stripping
10.1 Touch-up
10.2 Recoat
10.2.1 Coat Entire Part
10.2.2 Rebake
10.3 Stripping
10.3.1 Chemical Strippers
10.3.2 Burn-off Ovens
10.3.3 Shot Blasting
10.3.4 Cryogenic Stripping
10.3.5 Stripping Cured Coatings
10.3.6 Evaluation
11. Quality Control and Troubleshooting
11.1 SPC
11.2 Quality Variations
11.2.1 Troubleshooting
Appendices
Appendix I: The Future of Powder Coating
I.1 Advantages
I.2 Materials
I.3 Applications
Appendix II: Sales Growth and Diversification
II.1 Horizontal Integration
II.2 Vertical Integration
II.2.1 Case Study
Reference
Appendix III: Juggling Customers, Competitors, Compliance, and Change
III.1 Evolution of the Job Shop
III.1.1 Mom-and-Pop and Garage Shops
III.1.2 Small Coaters
III.1.3 Large Coaters
III.1.4 OEM Coaters
III.2 How Most Job Shops Operate
III.2.1 One-Time Jobs
III.2.2 Occasional Jobs
III.2.3 Repeat Jobs
III.2.4 Carrot Jobs
III.3 Competition
III.3.1 Local Jobs
III.3.2 Niche Jobs
III.3.3 Big Opportunities
III.3.4 OEMs
III.3.5 Remaining Competitive
III.4 Surviving in the New Millennium
III.4.1 Customers
III.4.2 Competitors
III.4.3 Compliance
III.4.4 Change
III.5 Summary
Reference
Index
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