The use of the right powder recovery technology can increase powder utilization. The decision of whether or not to reclaim powder for reuse depends on the value of the powder that has been oversprayed when compared to the time and cost associated with the recovery process. In the case of a long run of expensive powder, it can be very economical to conduct a 15 minute or longer color change, but in the case of a short run or low-value powder, the time may not be justified.
Thermoset powder materials require a certain amount of thermal energy applied for a certain time to produce the chemical reaction needed to cross-link the power into a film. The powder material will melt when exposed to heat, flow into a level film and then begin to chemically cross-link before ultimately reaching full cure. Various methods can be used to supply the energy needed for cure. Convection ovens use a heat source usually natural gas and fan to distribute and circulate air through a duct inside the oven.
The heated air will in turn heat the part and then the coating. Convection ovens are the most common type of cure oven used for powder. As the part reaches peak temperature it will conduct heat into the coating and cause the powder to cure. Infrared IR ovens, using either gas or electricity as their energy source, emit radiation in the IR wavelength band.
This radiated energy is absorbed by the powder and substrate immediately below the powder without heating the entire part to cure temperature. This allows a relatively rapid heat rise, causing the powder to flow and cure when exposed for a sufficient time.
Parts can be cured in less time in an IR oven, but the shape and density of the part can affect curing uniformity. Combination ovens generally use IR in the first zone to melt the powder quickly. The following convection zone can then use relatively higher airflows without disturbing the powder. These higher flows permit faster heat transfer and a shorter cure time. A variety of radiation curing technologies are available, including near-infrared, ultraviolet UV and electron beam EB.
These processes have the potential to open up new applications for powder coating of heat-sensitive substrates such as wood, plastic parts and assembled components with heat-sensitive details. UV curing requires specially formulated powders that can be cured by exposure to ultraviolet light. The powder first needs to be exposed to enough heat so it is molten when exposed to UV energy; the initial heat source is typically infrared, but convection heating can also be used.
The coating is then exposed to a UV lamp. A photo initiator in the coating material absorbs the UV energy and converts the molten film to a solid cured finish in a matter of seconds. Near-infrared curing also uses specially formulated powders coupled with high-energy light sources and high-focusing reflector systems to complete the powder coating and curing process within several seconds.
Heat-sensitive assembled parts such as internal gaskets, hydraulic cylinders and air bag canisters can benefit from this technology.
Induction ovens are normally used to pre-heat parts before powder coating to help accelerate film build. They are often used in fusion-bonded epoxy coating applications such as concrete rebar and coating of pipe used for gas transmission.
Such systems operate at high line speeds, and film builds of greater than 10 mils are common. Recent developments in several areas of powder application equipment and processing have significantly increased productivity and quality throughout the process, and expanded applications for powder coated parts. These include application on medium-density fiberboard MDF , pultrusions, glass and other unique substrates.
Lower-temperature cure products have been developed to accommodate heat-sensitive substrates. An in-mold powder coating process for plastic parts has been developed in which powder coating material is sprayed onto a heated mold cavity before the molding cycle begins.
During the molding operation, the powder coating chemically bonds to the molding compound, resulting in a product with a coating that is chip and impact resistant. Multi-layer processes have been developed to provide exceptional performance combined with a very high-quality appearance. Primers, basecoats and color coats are being combined with clearcoats on automotive products, boats and other products that demand exceptional quality.
Advances in microprocessors and robotics are also facilitating increased production in powder coating facilities. Robots are typically used where repeatability and high production of a limited variety of components are factors. When combined with analog powder output and voltage controls, robots can adjust powder-delivery settings during coating, maneuvers too difficult to be accomplished manually. Today, powder coating materials are available in virtually every color and a variety of textures and glosses.
Powder coatings are used on hundreds of types of parts and products, including almost all metal patio furniture and the majority of metal display racks, store shelving and shop fixtures.
Wire-formed products such as springs and storage baskets for the home and office are often powder coated. For thermosetting powders, the appliance industry is the largest single market sector. Thermosetting powder materials provide even, thin films with high levels of resistance to chips, impact, detergents and chemicals, which are critical to the appliance industry.
Applications include refrigerators, washer tops and lids, dryer drums, range housings, dishwashers, microwave oven cavities, freezer cabinets, and external air conditioning units.
Automotive applications for powder coated parts include wheels, grills, bumpers, hubcaps, door handles, decorative trim, radiators, air bag components, engine blocks and numerous under-hood components, along with trailers and trailer hitches. Several automakers are now applying powder clearcoats over liquid exterior basecoats, and there are some automobiles that are powder color-coated.
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Have a Question? Curing results in the formation of a protective skin and promotes coating adhesion. In general, curing is performed at F for approximately minutes, although these parameters can vary based on the type of powder coating. This normally entails the removal of grease, oil, dirt and other materials via chemical, physical or mechanical methods to clean the surface and promote coating adhesion.
The powder-coating process is extremely efficient — most jobs require only one coat, which helps to minimize project costs. Powder coating is cheaper than wet paint and results in lower energy and disposal costs. It is also easy to adapt the coating thickness to meet the protective requirements of the project. Powder coating is an excellent choice for applications where aesthetic appeal is important. Thane, Maharashtra.
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