Frequently Asked Questions
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Powder coating is a dry finishing process that has become extremely popular since its introduction in North America over in the 1960s. Representing over 15% of the total industrial finishing market, the powder is used on a wide array of products. More and more companies specify powder coatings for a high-quality, durable finish, allowing for maximized production, improved efficiencies, and simplified environmental compliance. Used as functional (protective) and decorative finishes, powder coatings are available in an almost limitless range of colors and textures, and technological advancements have resulted in excellent performance properties.
Powder coatings are based on polymer resin systems, combined with curatives, pigments, leveling agents, flow modifiers, and other additives. These ingredients are melt mixed, cooled, and ground into a uniform powder similar to baking flour. A process called electrostatic spray deposition (ESD) is typically used to achieve the application of the powder coating to a metal substrate. This application method uses a spray gun, which applies an electrostatic charge to the powder particles, which are then attracted to the grounded part. After application of the powder coating, the parts enter a curing oven where, with the addition of heat, the coating chemically reacts to produce long molecular chains, resulting in high cross-link density. These molecular chains are very resistant to breakdown. This type of application is the most common method of applying powders. Powder coatings can also be applied to non-metallic substrates such as plastics and medium density fiberboard (MDF).
The process is an innovative way of applying paint/colors to a certain material that reduces the time needed to completely dry out a paint in order to finely produce a hard finish of a certain product from the colouring/coating process.
Powder coating works by simply applying dry color to a material and baking or cooking the colors unto the surface using heat until it becomes hard finished or to be considered completely attached to the metal.
Powder coating is a high-quality finish found on thousands of products you come in contact with each day. Powder coating protects the roughest, toughest machinery as well as the household items you depend on daily. It provides a more durable finish than liquid paints can offer, while still providing an attractive finish. Powder coated products are more resistant to diminished coating quality as a result of an impact, moisture, chemicals, ultraviolet light, and other extreme weather conditions. In turn, this reduces the risk of scratches, chipping, abrasions, corrosion, fading, and other wear issues.
It’s tough. It looks great. And it lasts a long, long time. In addition to being durable, powder coating is an attractive choice due to environmental advantages.
There is no magic formula for quoting or estimating powder coating cost. That being said there are some general factors that contribute to powder coating cost. In the link below you can see what all goes into quoting your parts.
Practically all powder coatings are not hazardous waste by definition of the Resources Conservation and Recovery Act regulations (RCRA). Disposal methods for waste powder are the same as for non-hazardous wastes, in most states. However, there may be some exceptions and your powder supplier should be contacted regarding proper disposal. Always renew disposal needs with the local authority having jurisdiction over your facility location.
Powder coatings can provide improved performance over liquids when applied to a properly pretreated part. Solvent-borne paints are usually more forgiving of organic soils left on the work piece by sub-par cleaning. Because powder does not have solvents, you need to make sure the washer does a good cleaning job. This is just good operational practice and is not an unusual requirement. Iron phosphate is the most frequently encountered pretreatment used with powder coatings. However, if the highest level of performance is required, zinc phosphate will work admirably with powder as well.
Usually any metal objects are an ideal material for powder coating as long as the metal has the ability to hold a high temperature that will affix the coating. Popular metals for powder coating are normally Mild steel, galvanized or electro-magnetic steel, aluminum, stainless steel and steel alloys.
There are available types of powder for the process such as epoxies which is very durable and has resistance from chemical and corrosive substances while the type of powder has low resistance from high temperature which will not hold well from sunlight causing it to fade. Epoxies is an ideal type of powder that should be used for interior application
Polyesters are the usual choice for exterior application since it offer a flexible amount of characteristic in becoming impact resistance, chemical resistance and also provides a good year of ultraviolet resistance as well while it also comes in many colors and level of glossiness.
Powder coating is more economical than any painting/coloring process of materials, equipment and products. The process is more determine to give consumers, businesses and industries with a long lasting and most durable colour application that does not affect quality on finished surfaces. Powder coated surfaces are more resistant to fading, chipping and stripping that reduces cost for reworking and repainting.
It is a rare case for powder coating to drip, run or sag since the way of applying powder coating involves using electrostatic charge which makes the powder uniformly coats all the surface and at the same time the powder is heated in an oven to let the entire material flow to every surface and be cured to a hard finish that last long without a drip, run and sag.
There are a lot of available types for powder coatings with great benefits and use for certain scenarios and application.
Listed below are some of the types of finishes for powder coating:
Non-aluminum-specific powder coating
Zinc-based powder finishes
Heat Resistant conditions