Understanding the Powder Coating Process

Powder coating is a finishing process whereby a free-flowing and dry powder is applied. This type of finishing is different from conventional paint in that a solvent is not required to keep the filler and binder parts as a liquid suspension. The main advantages of this type of finishing are that it is 'green' since there are no VOC (volatile organic compounds) emissions, you get a thicker coat than with a liquid coating, there is no sagging or running and it is possible to recycle the powder coat over-spray. Other advantages are that less hazardous waste are produced; operation costs are lower than with conventional liquid paint and you can achieve many more speciality effects. The first step in applying a powder coat is the production of the powder. You could however, buy powder that is already prepared. The powder production begins with the mixing of polymer granules with a hardener, pigments and other ingredients. This is done in a mixer. This mixture is transferred to an extruder and heated. The mixture is rolled flat before cooling and breaking down into chips. These chips are processed through milling and sieving to produce the powder. The next step is part preparation. This involves the removal of soil, oil, metal oxides, lubrication greases, welding scales and other impurities from the surface to enhance bonding. This can be done by chemical pre-treatment where chromates or phosphates are sprayed on the surface or the item dipped. The process involves de-greasing, de-smutting, etching, rinsing and final phosphating/chromating. Preparation can be through abrasive blasting, sandblasting or shot blasting. This is mostly done in wood, glass and plastic items. Silicon carbide grit blast and cast steel shot or steel grit are the most common mediums. In the electrostatic spray process, electrostatic spray guns are used for the application in a ground/earth part. The powder however, has to be fluidised first so that it can flow smoothly and to separate the grains for improved electrostatic charge. This is achieved through heating. When applied, the powder will melt, it will then flow, gel and cure. The most popular electrostatic coating processes are Electrostatic Fluidised Bed Coating and EMB (Electrostatic Magnetic Brush) coating. The final process in the powder coating process is curing. This involves the exposure of the powder to a high temperature. This is achieved through an infra-red or convection cure oven. Curing is also called cross linking. Source Information: http://www.finishing.com/Library/pennisi/powder.html http://www.metalfinishing.com http://birkenheadpowdercoatings.co.uk/ http://www.gg-powdercoating.com/