Paint Technology Handbook

by Talbert; Rodger

• ISBN13: 9781574447033
• ISBN10: 1574447033
• Format: Hardcover
• Copyright: 2007-09-27
• Publisher: CRC Press

Summary

Modern paints and coatings offer an astounding variety of formulations that are used to improve the durability, appearance, and lifespan of countless products. From cars to furniture, computers, and mechanical components, paints and coatings play a vital role in nearly every manufactured product available.A Written by an industry insider with more than 30 years of experience, the Paint Technology Handbookprovides a practical and straightforward guide for the design of coatings systems. The author emphasizes the importance of understanding paint materials, manufacturing techniques, testing, application methods, and equipment in order to meet product-specific needs. Encompassing processes and equipment used for manufacturing the paints themselves as well as application systems, this book reviews the essential techniques and equipment for deposition and finishing systems. Following a discussion of color standards, metamerism, and color matching, the book covers analytical methods andinstrumentation to determine, measure, and control paint color. The book presents a complete evaluation of liquid paint application technologies, including spray and electrodeposition techniques. Concluding chapters cover curing, testing methods for finished materials, quality control techniques, and performing cost analyses. Enabling you to develop and fulfill product-specific criteria with realistic, cost-effective solutions, the Paint Technology Handbookprovides a primary, one-stop resource for designing and operating optimal paint and surface finishing systems.

Table of Contents

Preface	p. xiii
Author	p. xv
Part Preparation Processes and Equipment	p. 1
Cleaning	p. 2
Types of Soil	p. 2
Rust Inhibitors	p. 3
Shop Dirt	p. 3
Carbon	p. 3
Oxidation	p. 3
Wax	p. 4
Soaps	p. 4
Polymers	p. 4
Silicone	p. 4
Mechanical Cleaning	p. 5
Blasting	p. 5
Blast Media	p. 7
Vibratory Cleaning or Tumbling	p. 9
Chemical Cleaning	p. 9
Chemical Cleaning Processes	p. 9
Hand Wipe	p. 9
Immersion Cleaning	p. 10
Hand-Held Spray Wand	p. 10
Ultrasonic Cleaning	p. 11
Recirculating Spray Washers	p. 11
Common Industrial Chemical Cleaners	p. 13
Alkaline Cleaning	p. 13
Neutral Cleaners	p. 16
Acid Cleaners	p. 16
Surfactants	p. 17
Factors that Affect the Performance of the Cleaner	p. 19
Quality of Water Supply	p. 19
Soils in Solution	p. 20
Time	p. 20
Temperature	p. 20
Spray Pressure	p. 20
Concentration	p. 21
Methods Used to Measure Cleaning Results	p. 21
Summary	p. 22
Conversion Coatings	p. 22
Iron Phosphate	p. 23
Coating Weight	p. 24
Iron Phosphate Controls	p. 24
Temperature	p. 25
Chemical Concentration	p. 25
Acid Consumed	p. 25
Zinc Phosphate	p. 25
Activating (Prior to Zinc Phosphate)	p. 26
Comparison of Iron Phosphate to Zinc Phosphate	p. 27
Rinsing	p. 28
Rinse and Rinse Seal	p. 29
Reverse Osmosis (RO) or Deionized (DI) Water Rinse	p. 30
Typical Spray Washer Systems	p. 32
Stages of Pretreatment	p. 32
Substrates	p. 34
Metal Substrates	p. 34
Steel	p. 35
Aluminum	p. 38
Plastic Substrates	p. 38
Wood Substrates	p. 39
Washer Design	p. 39
Washer Components	p. 40
Solution Tanks	p. 40
Drainage Spaces	p. 40
Tank and Housing Materials	p. 41
Zinc Phosphate Tank	p. 42
Sludge Removal Tank	p. 42
Access Doors, Ladders, and Lighting	p. 42
Pumps	p. 43
Nozzles	p. 43
Water Conservation	p. 44
Washer Maintenance and Control	p. 45
Mechanical Maintenance	p. 45
Chemical Maintenance	p. 47
TDS	p. 48
Temperature	p. 48
pH Measurement	p. 48
Washer Control Methods	p. 50
Manual Bath Control	p. 50
Automated Control Techniques	p. 50
Metering Pumps	p. 50
Theory of Automated Control	p. 51
Conductivity Control	p. 51
Contacting Conductivity	p. 51
Noncontacting Conductivity	p. 52
Zinc Phosphate Control	p. 52
pH Controllers	p. 53
Interfacing Controllers with a Computer	p. 53
Data Acquisition Tools	p. 53
Computer Control Systems	p. 53
Paint Components	p. 55
Resin (Binder)	p. 55
Oils and Oleoresinous Varnishes	p. 55
Alkyd Resins	p. 56
Polyester Resins	p. 57
Acrylic Resins	p. 57
Amino Resins	p. 59
Epoxy Resins	p. 59
Urethane Resins	p. 60
Pigments	p. 61
White Pigments	p. 61
Titanium Dioxide	p. 61
Zinc Oxide	p. 62
Antimony Oxide	p. 62
White Lead	p. 62
Yellow Pigments	p. 62
Yellow Dyes	p. 62
Benzidine Yellows	p. 62
Lead Chromates	p. 62
Zinc Chromate	p. 63
Yellow Iron Oxides	p. 63
Cadmium Yellow	p. 63
Green Pigments	p. 63
Phthalo Green	p. 63
Chromium Oxide	p. 64
Lead Chrome Greens	p. 64
Blue Pigments	p. 64
Phthalocyanine Blues	p. 64
Prussian Blue	p. 64
Ultramarine Blue	p. 64
Red Pigments	p. 65
Toluidine Reds	p. 65
Arylamide Reds	p. 65
Red Iron Oxide	p. 65
Black Pigments	p. 65
Black Iron Oxide	p. 65
Carbon Blacks	p. 66
Metallic Pigments	p. 66
Aluminum Pigment	p. 66
Mica	p. 66
Extenders	p. 66
Barites	p. 67
Kaolin Clay	p. 67
Talc	p. 67
Calcium Carbonate (Limestone)	p. 67
Solvents	p. 68
Hydrocarbon Solvents	p. 71
Toluene	p. 71
Mineral Spirits	p. 72
Xylene	p. 72
Oxygenated Solvents	p. 72
Butyl Alcohol	p. 72
Ethyl Alcohol	p. 72
Ethylene Glycol Monoethyl Ether	p. 72
Acetone	p. 72
Methyl Ethyl Ketone (MEK)	p. 73
Methyl Isobutyl Ketone	p. 73
Butyl Acetate	p. 73
Ethyl Acetate	p. 73
Additives	p. 73
Summary	p. 73
Liquid Organic Coatings	p. 75
Coatings Selection	p. 75
Appearance	p. 75
Performance	p. 75
Other Factors	p. 75
Paint Classifications	p. 76
Paints Classified by Task	p. 76
Primers	p. 76
Sealers and Surfacers	p. 76
Topcoat	p. 77
Paints Classified by Physical Type	p. 78
Waterborne Coatings	p. 78
High-Solids Coatings	p. 80
Film Formation	p. 82
Application	p. 83
Fixation	p. 83
The Evaporation Factor	p. 84
Rheology	p. 84
Flocculation and Settling	p. 85
Kick-Out	p. 85
Cure	p. 85
Air Dry	p. 85
Catalyzed Materials	p. 86
Baking Enamels	p. 86
Dry Film Properties	p. 87
Gloss	p. 87
Hiding Power (Opacity)	p. 87
Color	p. 88
Strength, Hardness, and Brittleness	p. 88
Depth of Color (Metal-Flake Paints)	p. 89
How Paint Wears Out	p. 89
Paint Manufacturing Process	p. 91
Equipment Used for Pigment Paste Manufacturing	p. 91
High-Speed Mixers (HSD, HLM)	p. 91
Vertical or Horizontal Continuous Mill	p. 92
Sand Mill	p. 92
Roll Mill	p. 93
Ball Mill	p. 93
Color Matching and Color Control	p. 95
Color Variables	p. 96
Metamerism	p. 96
Color Measurement Equipment	p. 98
Color Difference Equations	p. 99
Tristimulus Filter Colorimeters	p. 100
Spectrocolorimeters	p. 100
Computerized Color Matching	p. 101
Color Glossary	p. 102
Color Standards and Metamerism	p. 103
Liquid Paint Application Systems	p. 105
Part Preparation	p. 106
Smoothing	p. 107
Spray Application of Paint	p. 107
Methods of Atomization	p. 107
Manual Spray Guns	p. 107
Automatic Spray Equipment	p. 108
Spray Systems	p. 108
Suction or Siphon Systems	p. 109
Pressure Feed Systems	p. 109
Circulating Systems	p. 110
Plural Component Mixing Equipment	p. 113
Air Nozzles	p. 115
Fluid Nozzles	p. 116
Proper Fluid Pressure	p. 117
Airless Spray Guns	p. 118
Fluid Needles and Tips for Airless Systems	p. 118
Air-Assisted Airless Spray Guns	p. 120
High-Volume Low-Pressure (HVLP)	p. 122
Electrostatic Application	p. 125
Manual Electrostatic Spray Equipment	p. 127
Coating Formulation for Electrostatic Application	p. 130
Advantages	p. 130
Disadvantages	p. 130
Automatic Spray Equipment	p. 131
Automatic Air-Spray Guns	p. 132
Rotary Atomizers	p. 133
Automatic Spray Supporting Equipment	p. 135
Gun Movers	p. 135
Robotic Painting	p. 137
Summary	p. 137
Alternative Application Methods	p. 138
Dip Coating	p. 138
Advantages of Dip Coating	p. 138
Limitations of Dip Coating	p. 138
Flow Coating	p. 139
Advantages of Flow Coating	p. 139
Limitations of Flow Coating	p. 139
Roller Coating	p. 140
Advantages of Roller Coating	p. 141
Disadvantages of Roller Coating	p. 141
Curtain Coating	p. 141
Transfer Efficiency and Spray Technique	p. 143
Spray Gun Controls	p. 143
Application Technique	p. 144
Atomization	p. 145
Gun Position	p. 145
Gun Distance	p. 146
Gun Speed	p. 147
Lapping	p. 148
Heated Spray	p. 150
Spray Booths	p. 153
NFPA Requirements	p. 153
Air Make-Up	p. 155
Booth Exhaust Stacks	p. 155
Spray Booth Sizing	p. 155
Spray Booth Height	p. 156
Spray Booth Width	p. 156
Spray Booth Depth	p. 156
Interior Working Dimensions	p. 156
Spray Booth Exhaust Sizing	p. 157
Filtration	p. 157
Curing	p. 161
Convection Curing	p. 161
Duct Design	p. 161
Oven Fuels	p. 162
Materials of Construction	p. 163
Infra Red Curing	p. 163
Oven Maintenance and Cleaning	p. 165
Oven Exhaust	p. 165
Oven Filtration	p. 165
Oven Location	p. 166
The Impact of Catalysts on Curing	p. 166
Heat Recovery	p. 166
Summary	p. 167
Testing Paint Materials	p. 169
Introduction	p. 169
Paint Viscosity	p. 169
Finished Film Testing	p. 169
Paint Test Standards	p. 170
Types of Tests	p. 170
Film Thickness	p. 171
Film Hardness	p. 172
Impact Resistance	p. 172
Tape Adhesion	p. 172
Humidity Testing	p. 173
Salt Spray Testing	p. 173
QUV Testing	p. 174
Outdoor Exposure	p. 174
Temperature-Humidity Testing	p. 174
Rinse Blistering	p. 175
Corrosion Cycling	p. 175
Color Matching	p. 175
Gloss	p. 176
Quality Control	p. 177
Introduction	p. 177
Process Control	p. 177
Scheduling	p. 177
Racking	p. 178
Pretreatment	p. 178
Dry-Off Ovens	p. 179
Cool Down	p. 180
Paint Application	p. 180
Spray Gun Adjustment	p. 180
Paint Material	p. 182
Flash-Off	p. 183
Curing	p. 183
Record Keeping	p. 184
Paint Film Defects	p. 184
Production Defects	p. 184
Orange Peel	p. 185
Sagging	p. 185
Flooding, Floating, and Mottle	p. 185
Silking	p. 186
Solvent Pop, Bubbles, Pinholes, and Craters	p. 186
Fisheyes and Silicone Craters	p. 187
Overspray and Dry Spray	p. 188
Blushing	p. 188
Dirt and Contamination	p. 188
Cost Analysis for Finishing Systems	p. 191
Factors that Affect Cost	p. 191
System Design	p. 191
Quality	p. 191
Substrate Condition	p. 192
Racking	p. 192
Line Data	p. 192
Rework	p. 194
Color Change	p. 194
Applied Cost of Paint	p. 194
Cost per Square Foot of Liquid Spray Coating	p. 194
Example of Cost Calculation	p. 195
Cost of Spray Booth Exhaust	p. 196
Example	p. 197
Solvent-Based Liquid Coating Oven Exhaust Requirements	p. 198
Example	p. 199
Heat Loss from Loading	p. 199
Example	p. 199
Radiant Losses	p. 200
Example	p. 200
Labor and Maintenance Costs	p. 201
Application Labor for Liquid Spray Coating	p. 201
System Support Labor	p. 202
Example	p. 202
Electrical Consumption	p. 202
Example	p. 203
Compressed Air	p. 203
Total Cost of Paint Application	p. 205
Quoting a Part	p. 205
Material Cost	p. 206
Labor	p. 206
Burden	p. 206
Fixed Cost	p. 207
Scrap Cost	p. 207
Add Cost	p. 207
Appendix A	p. 208
Appendix B	p. 209
Index	p. 217
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