Powder Coatings:

History, Types, and Applications

James Baker
 Outline
 Conventional Coatings
 Powder Coating History
 Types of Powder Coatings
 Advantages/ Disadvantages
 Applications
 Lacquers

-Lack of durability
+ Fast Drying
-High maintenance
+Deep shine
-High VOC content
 Enamels

+ Good flexibility and

- Long drying times
durability
- Oxidation
+ Cross-linking
 Urethanes

+ Dry fast - Isocyanate

+ Very durable and component is highly
flexible toxic
 History
 Late 1940’s- Flame spraying of thermoplastic powder developed
 1955- Dr. Erwin Gemmer patents fluidized bed application
 1962- Electrostatic spray method introduced
 Late 1970’s- rapid growth in powder use in Europe
 Early 1980’s- rapid growth in North America and Japan
 Today-
• Fastest growing finishing technology in North America
• Powder coatings account for >10% of all industrial finishing
applications
• Powder coating engine blocks for automobiles is the largest volume job
in the history of the powder industry
 Application Methods
 Electrostatic spray-
 Most common method
 High voltage, low amperage field generated by spray
gun imparts electrostatic charge on powder
 Charged powder sticks to grounded substrate
 Object is heated in oven to cure, powder flows to form
a continuous film
 Application Methods (cont)
 Fluidized Bed
 Heated object is dipped into an air fluidized bed of powder
 Electrostatic Fluidized Bed
 Similar to above, but powder particles are charged
 Flame Spray
 Powder is air fed through a propane flame
 Molten polymer is deposited on substrate
 Suitable for non-conductive substrates or very large objects
 Tribocharge
 Similar to electrostatic spray, but no high-voltage system
 Friction between powder and barrel induces weak static charge
 Powder Coating Types
 In general powder coatings offer excellent:
• Hardness
• Corrosion protection
• Chemical resistance
 Epoxy
H2 H2 OH H2 H2
C O O C C C O O C
H
O O

+ Excellent flexibility
- Fair resistance to over-
baking
- Poor exterior durability
(low UV resistance)
 Epoxy-urethane hybrids
• Similar to epoxy
+ Improved flow
properties
- Lower hardness
 Urethane Polyesters
+ Very good flexibility N N O
* C R C R' O
and weatherability O O
n
+ outstanding thin film
Polyurethane
appearance

N N O O
O N O R O C R' C O
n
N N
C C
O O Polyester

N
C
O
tris(6-isocyanatohexyl) isocyanurate
 Acrylics
+ Excellent color, gloss, CH3
H
weatherability * C C
n
*
H
+ Excellent thin film C O
O
appearance CH3

- Fair flexibility and Poly(methyl methacrylate)

corrosion resistance
 TGIC Polyesters
+ Excellent exterior
O
O
N

durability O N

- Exposure limits when N

O
O

spraying due to TGIC O

TGIC

O O
R O C R' C O
n
Polyester
 Advantages of Powder Coating
 No VOC emissions
 Improved durability
 Over-spray may be reused
 Lower operating and maintenance costs for
finishing lines
 Disadvantages
 Material must be able to withstand curing
temperatures, >260º F (~125ºC)
 Forming films thinner than 1.5mil is difficult
 Electrostatic spraying may only be used for
electrically conductive materials
 Powder is highly flammable
 Conversion from conventional to powder coating
line requires large capital investment
 Automotive Applications

 Engine Blocks
 Frames
 Suspension and Wheels
 Trim and Moldings

BMW and Volvo have developed powder clearcoats

Chrysler, Ford, and GM have powder clearcoats in development
 Other Common Applications
Metal Objects Non-metal Objects
 Appliances  Home-office furniture
 Highway signs  Kitchen cabinets
 Tools  Sinks/shower stalls
 Lawn and garden
equipment  Ceramics
 Office furniture
 A/V furniture and
equipment
 Sports equipment
 References
• Industrial Paint and Powder Magazine
http://www.ippmagazine.com/CDA/ArticleInformation/features/BNP__Features__Item/
0,6897,119461,00.html
• North Carolina DENR Division of Pollution Prevention and Environmental Assistance
http://www.p2pays.org/ref/01/00777/alternat.htm#General%20Description%203
• The powder coating institute- http://www.powdercoating.org/media/pressreleases/