PROTECTIVE

COATINGS FOR
METALS
Presentation by : Ar. Navneet Singh
PROTECTIVE COATINGS
• Protective coatings and films on metals serve as barriers
between the environment and the underlying substance,
preventing the metal from corrosion and abrasion.

• It is essential to use a coating that will corrode before

the underlying metal does, thus keeping the metal as
protected as possible.
 Barrier coatings—interfering with corroding elements and
isolating them from the metal surface
 Galvanizing coatings—which corrode preferentially to the
underlying substance
• To ensure the performance of protective coatings, they must be
assessed for a variety of characteristics, which may vary based
on the coating type. This may include:
 Thickness identification
 Elemental composition determination
 Fracture mechanism determination
 Understanding film chemistry, thickness and hardness
 Chemical compositions/variations correlation

• There are a variety of methods in which metal coatings are

applied. Metal coatings can be sprayed on in either liquid or
powder form. A product can be dipped into a metal coating or
electroplated, as well. There are a variety of factors that
determine which method of application is best for the metal
coating, including:
 Time frame
 Cost
 Level of thickness
 Appearance
 Effectiveness
 ADVANTAGES
• Increased surface thickness
• Aesthetic improvements
• Corrosion resistance
• Increased strength
• Increased adhesion
• Durability
• Improved electrical conductivity
• Chemical resistance
• Enhanced solderability
• Enhanced electrical conductivity
 COMMON PROCESSES
• Anodizing
 Most common with aluminum, this method increases the thickness of aluminum
oxide that occurs when aluminum is exposed to oxygen.
 It makes aluminum (and some other metal surfaces) more resistant to corrosion
and can also provide a more adhesive surface for additional coatings.

• Hot Dipping
 Also known as galvanizing, this process involves dipping steel into hot zinc to form
a coating of zinc oxide layer.
 This layer is resistant to rust, and will not flake off due to a metallurgic bond
between the substrate and the coating.
 If later welded, the steel must be painted with a zinc paint to prevent rusting of the
joints.

• Electroplating
 Involves immersing a metal component into a bath containing a dissolved metal –
typically cadmium, chromium, or nickel – and running an electrical current through
it.
 This coats the item with a thin layer of metallic particles.
 Uniform thickness is difficult to achieve with this method, and parts subject to
abrasion will need to be repeatedly coated.
• Chemical Process
 Sometimes used for paint priming, metal coloring, and corrosion protection.
 Involves creating a thin film of sulfide and oxide on a metal surface though
chemical reaction.

• Porcelain Enamel
 Popular on cast-iron cookware and restroom partitions, as it protects against
both scratches and graffiti.

• Painting
 Most popular of the different types of coatings, paints can be applied via a
handful of popular methods : e-coatings, powder coatings, and liquid coatings.
GALVANIZING
• Galvanizing is a process by which a layer of zinc is
applied to a ferrous metal to prevent corrosion.
• Zinc metal is generally used as a coating for protecting
iron and steel products from corrosion because it has
excellent corrosion resistance.
• The excellent field performance of zinc coatings results
from their ability to form dense, adherent corrosion
product films and a rate of corrosion considerably below
that of ferrous materials, some 10 to 100 times slower,
depending upon the environment.
• While a fresh zinc surface is quite reactive when
exposed to the atmosphere, a thin film of corrosion
products develops rapidly, greatly reducing the rate of
further corrosion (typically takes approximately 6-12
months to fully develop).
GALVANIZING
• In the hot dip galvanizing process, steel is dipped into hot zinc,
which forms a durable and thick layer on its surface to protect
it from corrosion.

• The zinc acts as the sacrificial anode in most applications and

corrodes rather than the underlying metal.

• Hot dip galvanized steel products are recyclable and resistant

to abrasion, impact, temperature, and turbulence.

• Galvanizing forms a metallurgical bond between the zinc and

the underlying steel or iron, creating a barrier that is part of
the metal itself.

• The finish is a dull gray and has a crystalline appearance.

• The galvanized steel can be painted to achieve a specific color.

• When galvanized metal is welded, the weld and exposed steel

must be coated with a special zinc paint to prevent the joint
from rusting since the galvanized coating has been removed.
GALVANIZING
• Hot dip galvanizing provides thick, durable corrosion
protection, and it can be applied rapidly—offsite and
under controlled conditions.

• Galvanized steel products last for decades and are

completely recyclable.

• They are durable, corrosion resistant, and protect

against abrasion, corrosive fluids, turbulence, heat, cold,
and impact forces.

• The simplicity of the galvanizing process is a distinct

advantage over other methods of providing corrosion
protection.
GALVANIZING

• During galvanizing, the molten zinc reacts with the iron in the steel to
form a series of zinc/iron alloy layers.

• The photomicrograph of a galvanized steel coating cross-section shows a

typical coating microstructure consisting of three alloy layers and a layer
of pure metallic zinc.

ADVANTAGES
• Lower Initial Cost
• Durability
• Longevity
• Availability
• Sustainability
• Aesthetics
GALVANIZING
• Prior to immersion in the zinc bath, the steel is chemically
cleaned to remove all oils, greases, soil, mill scale, and
oxides.
• Surface preparation is critical as zinc will not react with
unclean steel.
• After surface preparation, the steel is immersed in the
molten (830 F) zinc bath.
• The bath consists of more than 98% pure zinc and the
remaining 2% or less consists of additives most commonly
aluminum, nickel.
• These additives help with zinc fluidity and consumption,
coating appearance, and other efficiencies.
• While in the galvanizing kettle, the molten zinc
metallurgically reacts with the iron in the steel to form the
coating.
GALVANIZING
• Hot-dip galvanized coatings are used on many
materials in construction sectors from electric
utility to artistic sculptures.
• Ranging in size from small parts such as nuts,
bolts and nails to large structural shapes,
galvanizing is integral to infrastructure.
• Most commonly batch hot-dip galvanizing is
used in atmospherically exposed steel; however,
it is also used in fresh and salt water
applications, buried in soil, embedded in
concrete, and much more.
• Size can be a limitation to the application of
hot-dip galvanizing; however, the average
length of zinc baths in is 40 feet and 55-60 foot
kettles are common.
Coating Characteristics
• The batch hot-dip galvanized coating consists of a series of
zinc-iron alloy layers with a surface layer of pure zinc.
• The unique intermetallic layers are tightly bonded (3,600
psi) to and harder than the base steel, offering excellent
abrasion resistance.
• The zinc-iron alloy layers, metallurgically bonded to the
steel, become an integral part of the steel rather than just a
surface coating.
• Another unique characteristic of the batch hot-dip
galvanized coating is its uniform, complete coverage.
• During the diffusion reaction in the kettle, the zinc-iron
alloy layers grow perpendicular to all surfaces.
• Additionally because hot-dip galvanizing is a total
immersion process, all interior surfaces of hollow structures
and difficult to access recess of complex pieces are coated.
• This complete, uniform coverage ensures critical points
where corrosion commonly starts have the same protection
as accessible, flat exterior surfaces.
GALVANIZING- Process
• There are three fundamental steps in the hot-dip
galvanizing process; surface preparation, galvanizing,
and inspection
Surface Preparation
• Pre-treatment is performed to provide a chemically clean surface.

• Mechanical cleaning is conducted to remove any imperfections on the

surface, using a range of options that include sandpaper, steel brushes,
spatulas, rotary brushes etc.

• The steel then goes through a series of three cleaning steps; degreasing,
pickling, and fluxing.

• Chemical cleaning, in the form of degreasing, is implemented to remove

any solid materials that may inhibit adherence to the surface, such as
greases and oils and organic residues.

• The first rinsing ensures that there is no surface contamination during

the pickling process, especially since acid pickling is used to remove any
oxidation, incrustation or scales. Solutions based on hydrochloric and
sulphuric acids are generally used.

• The final surface preparation step, fluxing, will remove any remaining
oxides and coat the steel with a protective layer to prevent any further
oxide formation prior to galvanizing.

• Proper surface preparation is critical, as zinc will not react with unclean
steel.
Galvanizing
• After surface preparation, the steel is
dipped in the molten (830 F) bath of at
least 98% zinc.
• The immersion time determines the
thickness of the zinc layer, which is
generally 1 to 2 min.
• Although the melting point of pure zinc is
419.5°C, the bath is maintained at 440–
470°C due to the operating conditions and
the additions of the other metals (nickel,
aluminium, copper, lead, iron, cadmium
and tin).

• The steel is lowered into the kettle at an angle that allows air to escape from tubular
shapes or other pockets, and the zinc to flow into, over, and through the entire piece.
• While immersed in the kettle, the iron in the steel metallurgically reacts with the
zinc to form a series of zinc-iron intermetallic layers and an outer layer of pure zinc.
Inspection
• The final step is an inspection of the coating.
• A very accurate determination of the quality of the coating can be achieved by a
visual inspection, as zinc does not react with unclean steel, which would leave an
uncoated area on the part.
• Additionally, a magnetic thickness gauge can be used to verify the coating thickness
complies with specification requirements.
 Duplex Systems
• The combination of hot-dip galvanized steel
and paint or powder coating provide a
combined effect.
• The paint/powder extends the life of the
coating by providing an additional barrier
coating to the zinc layers, while the galvanized
steel prolongs the life of the paint coating by
preventing underfilm corrosion and peeling.
• The service life of a duplex system is 1.5 to 2.3
times the sum of the individual systems.
• For example, if the life of the galvanized
coating in a particular environment is 70
years, and the expected life of the paint is 10
years, the expected life of the duplex system
would be at least 120 years (1.5 x (70+10)).
Electroplating
• Electroplating can be defined as the deposit of a very thin layer of metal onto a base
metal in order to enhance or change its appearance.

• Unlike painting, where the new deposit is sprayed on, the chrome (and associated
materials) are applied through the use of an electrical current, hence the term
‘electroplating.’

• Plating bath is used throughout the chroming process.

• The baths are filled with a liquid that contains the desired metal dissolved within it —
which could be silver, gold, nickel or another metal.

• The plating–bath solution serves as a conductive medium, utilizing a low DC voltage.

• The metal item that is to be plated is submerged in the plating bath, and a low-voltage
DC current is applied to the bath.

• The electrolytic process then causes the dissolved metal ions to attach to the surface of
the metal to be plated.

• The thickness of the electroplated layer is determined by the time the item spends in the
plating bath while the current is being applied, and the amount of current used.

• Sometimes the shape and contour of the item can affect the thickness of the plated layer.

• Metal objects with sharp corners and edges will tend to have thicker plating on the
outside corners and thinner plating in the recessed areas. This is due to the corners
being more exposed, therefore attracting more particles.
 Chrome Plating
• Chrome is a metal and one of the naturally occurring
chemical elements, otherwise known as Chromium.

• Chrome in its solid form is not practical but the properties

it contains are valuable when layered on other metals such
as aluminum, stainless steel, brass, copper or plastic.

• Chrome is often confused with other chemicals that give a

shiny finish, like polished aluminium and electro polished
stainless steel.

• Chrome plating is brighter, bluer and more mirror-like that

creates an accurate reflection compared to other finishes.

• Chrome plating is used to provide increased corrosion

resistance, surface hardness, to ease the maintenance
process of the metal or for purely decorative purposes.
 Chrome Plating – Basic
process
• Chrome plating is the practice of electroplating a thin layer of chrome onto a metal object.

• Firstly, the quality of the base material is assessed as well as the desired result of the finish.

• Then the base materials are stripped to reveal the bare metal and all dirt, oil, paint, rust and old
plating is removed.

• After that the bare metal is polished using sanding belts and abrasive wheels to remove any
pitting, scratches and impurities for a smooth finish.

• Subsequently the surgical cleaning process is applied using soap, acid and water solutions which
is essential before plating as any foreign matter can cause the plating to reject.

• Then the object is placed into the chrome plating vat, where it warms to solution temperature and
the electroplating process takes place.

• Chrome plating uses an electrolytic process that applies chromium plating to a metal component
in an electrolytic bath at a rate of about 25 to 30 microns per hour. The substrate first gets
cleaned thoroughly and, if necessary, treated with chemicals to improve the adhesion of the
plating.

• The component then goes into a chrome plating vat, where an electric current deposits chromium
onto the substrate.

• The length of time it is placed in the solution corresponds to the desired thickness of plating.

• Lastly, the parts are cleaned and polished again and inspected for quality and finish.
Applications
Chrome plating is typically applied to everyday household
items and automotive parts including:
• Door knobs, handles and letterboxes
• Shower fittings, bathroom taps and toilet flush, chains,
towel rings and roll holders.
• Interior and exterior lighting
• Interior and exterior car parts
• Motorcycle parts
• Moulds and press tools
• Valves and pumps
• In summary, chrome plating is essential for objects that
need to resist rusting, scratches and other imperfections.
Types of chrome plating
• HARD CHROME PLATING : With hard chrome plating, a thick
deposit of chromium metal is plated onto steel components to
improve surface hardness and wear resistance. Hard chrome
plating is often used on tools and dies where increasing tool life
through improved wear resistance is important.
• DECORATIVE CHROME PLATING a thin layer of chromium is
applied as a decorative topcoat to stainless steel and nickel-plated
components. In this plating application, the thin chromium layer
protects the nickel from oxidation and tarnish while providing the
bright bluish tint as bright decorative chrome.
DECORATIVE (BRIGHT) CHROME PLATING PROCESS
• Decorative chrome plating is the process of depositing a thin
layer of chromium over nickel-plated components as a decorative
(bright) finish. The nickel surface keeps its intended finish longer,
increases its wear ability, provides another layer of protection and a
simpler cleaning process.
• Decorative chrome electroplating is sometimes referred to as nickel-
chrome plating, as it always involves electroplating nickel on the
object before plating chrome.
• Chrome electroplating is an exceptionally thin layer (sometimes 50
millionth of an inch) applied over the nickel.
Common Applications of Hard Chrome
Plating

High Wear, Low Friction, and Improved Corrosion

Resistance
• Hard chrome plating thickness varies between 10 and 500
micrometers
• A hard chrome coating extends the lifespan of machine
components and reduces maintenance downtime and expenses.
• Hard chrome plating can also be useful in repairing damaged,
worn or mis-machined parts.
• A component that is too small or has become worn down can
benefit from applying a thick coating of hard chrome plating to
return it to the correct dimensions.
• Stripping the damaged plating through a chemical process and
applying new hard chrome plating can repair a damaged part.
Applications
• Hydraulic cylinders
• Piston rings
• Rotors and shafts for pumps
• Molds, dies and other forms
• Rollers and bearings
• Valves and gates
• Compressors
• Mechanical and automotive parts
• Agriculture equipment
• Mining equipment
• Paper and timber equipment
• Textile and printing components
• Food and beverage equipment
• Materials:

Most materials can be Hard Chrome plated, including:

• Steel

• Stainless Steel

• Cast Iron

• Copper

• Brass

• Bronze Alloys

• Nickel Alloys
 Decorative Chrome Plating
• Decorative chrome plating is primarily an aesthetic feature, though it also protects
against corrosion and wear.

• However, because decorative chrome is so thin — ranging from about five to eight
micrometers when applied over nickel plating — it does not offer as much durability
as hard chrome plating.

• Has more limited applications than hard chrome plating,

• Provide a thin protective coating when applied to automobile parts, tools and
utensils

• Protects against rust and wear when products get exposed to wet or corrosive
conditions

• Provides a smooth and shiny appearance that is easy to clean

Common Applications
 Car parts
 Tools
 Kitchen utensils
 Musical instrument hardware
 Knobs
 Hardware
 Bathroom accessories
 Tiles
Decorative Chrome Plating
• It requires nickel plating (up to two layers) prior to the
application of the chromium plating.
• While it’s called “chromium plating”, the underlying
layer of nickel is what provides this coating with
practically all of its trademark reflectivity, smoothness,
and much of its corrosion resistance.
• Nickel adheres extremely well to copper, so it’s not
uncommon to have copper and nickel plating before the
final layer of chromium is added.
Advantages
 Improved appearance
 Corrosion resistance
 Easy cleaning
 Some wear resistance ( as compared to base metal)
DIFFERENT CHROME PLATING FINISHES
ANODIZING
• Anodizing is an electrolytic process which provides a
metal with a protective and decorative surface,
enhancing its visual appeal and working qualities.

• The metals that can undergo this treatment range over

different properties, including metals such as
aluminum, alloys, titanium and zinc.

• The process involves the manipulation of oxide layers on

the metals to produce thicker and durable films which
increases the metal’s resistance against wear and
corrosion, providing the metal with a surface that is
more receptive to paint, adhesives and dyes.

• Anodizing also gives the surface a more appealing look

with multicolor effects, along with providing a surface
that is smooth and less prone to friction.
ANODIZING
• While anodizing is most common with aluminum, it can
also be used on other metals such as titanium and zinc.
• However, ferrous metals cannot be anodized because the
iron oxide, or rust, flakes off, which causes the anodized
layer to also flake off.
• When aluminum is exposed to oxygen, a layer of aluminum
oxide is formed on the surface of the metal.
• Anodizing effectively increases the thickness of this
aluminum oxide layer, which makes it more resistant to
corrosion.
• To further increase the durability and corrosion resistance,
a clear sealant can be used.
• The anodizing process also provides better adhesion for
paints and other finishes.
Process
• Metals can be anodized by having an electric current passed through and
electrolyte solution between them (positively charged anode) and a negatively
charged cathode.

• This reaction causes the crystal structure on the anode’s surface to change
and a layer of oxide is deposited on the surface of the metal, or in other words
anode.

• This entire process is known as electrolytic passivation.

• The process also allows a user to have control over it, allowing for
manipulation of the thickness of the film formed and other features of the end
result anodized metal.

• As the metal plays the role of an anode in the process, the entire process is
therefore known as anodizing.

• Anodized metals tend to be porous due to their thick coatings, and therefore
require a sealing process to ensure that they are corrosion resistant.

• Anodic films are used to make anodized finishes more durable, which allows
the metals to be post treated with paints and dyes.
 POWDER COATING
• Preparation

• The process for preparing each part will depend on the base material,
metals, and other materials like fiberglass.

• In general, the part will be thoroughly cleaned to remove any oil or grease
on the surface, and then rinsed.

• Next, the part is etched. This helps remove any surface oxides and
provides more surface area for the powder coating to stick to.

• After etching, the part is rinsed once more.

• The part is dipped in a chemical solution to neutralize the surface.

• Things will vary as each chemical solution is formulated to work with a

specific base material.

• On aluminum, it is either a chromate or phosphate solution. Other options

include zinc and iron phosphates. These chemicals adhere to the surface of
the part and provide the film needed for the powder to stick.

• Last, the part is demineralized to remove any chemical salts on the

surface and prevent any corrosion from happening beneath the powder
coating.
POWDER COATING
• Powder Coating Ingredients
• Once the part is properly prepared to receive coating, it is
time to prepare for the coat application.
• Manufacturers of powder coating systems use a special
blend of polymer resin. They also use necessary curatives
and pigments and additives to create each individual color
and finish according to need.
• All of the ingredients are melted together and blended to
form a uniform mixture which are cooled into bricks.
• Once the bricks are completely cooled and dried, they are
ground down to create the fine powder.
• It is important to note that the color and finish of the
powder is determined at the manufacturing facility based
on the order.
POWDER COATING
Powder Coating Application
• The process used to apply the powder is different from other
coating systems, thanks to its use of electromagnetic
properties.
• This requires some specialized tools, and the powder is
placed inside of a paint gun that charges the particles using
either friction or an electrical source.
• Next, the part that is being coated is grounded to provide
an opposite charge that will attract the particles as they are
sprayed.
• The thickness of the application will vary depending on
whether the coating is external or internal, or the type of
environment that the part will be used in.
• The powder will continue to stick to the surface of the part
as long as it is grounded, which allows for multiple passes
to cover the part.
POWDER COATING
Curing
• Once the part is completely coated it is placed in an oven which
heats the coating to a minimum of 160 degrees Celsius.
• Once the powder reaches this temperature it melts and flows
together, forming long chemical chains which give the coating its
rigidity and durability.
• As it cools, the surface of the finish takes on a gel-like consistency
until it reaches room temperature and is completely cured.
• Most powder coating finishes will not melt again once they have
cured, meaning that they can be used in a wide range of
applications and environments without cause for concern.
Powder coating is a fairly new finishing process, and it requires
specialized tools to achieve the electromagnetic charge.
However, it does offer a wide range of color and finish options
ranging from glossy to matte. It also provides a more durable finish
that is both corrosion and scratch resistant so your coating will last
for years to come. It can be easily cleaned with warm soapy water
and restored to its original shine within minutes.
 POWDER COATING-
Advantages
• Economics – The average transfer efficiency of powder coating is 60-70% and any over spray is a
solid and can be reclaimed and re-used netting virtually no wasted product. The liquid paint
has a transfer efficiency of 30-35%, roughly 50% of the product is evaporated and there is no
possibility of reclaiming over spray. The base product for powder coating is also substantially
cheaper than wet paint.

• Safety – Safely applying powder coating requires precautionary measures to avoid breathing in the
powder and getting it on one’s skin. This is an easier task to manage since the product is a solid and
inert (it doesn’t pose a health risk when not being sprayed). The product does not contain harmful
chemicals such as solvents or volatile organic compounds (VOC) that are often found in wet paint.

• Environmental – Since there are no solvents or VOCs, there is no damage to the environment
during application. The waste is also not hazardous and can be disposed in the landfill. Wet paint
contains harmful chemicals that have been proven to deplete the ozone and produces hazardous
waste that needs to be disposed of in an appropriate manner.

• Mechanical – Powder coating generally produces a coating twice as thick as standard paint. The
real advantage is its flexibility and ability to bend and yield with the material it is applied to.

• Production Advantages – The main advantage from a production point of view is that when the
powder coated product comes out of the oven it is completely cured within 20min and ready to be
put to work. Standard liquid paints can take days to completely cure and depend on the
atmospheric conditions.

• Aesthetics: Powder coating allows for much thicker coatings than liquid paint, without running or
sagging. With liquid paint, horizontal and vertical painted surfaces often have differences in
appearances, but powder coating typically provides a uniform visual appearance regardless of
orientation.
POWDER COATING-
Disadvantages
The main concerns with powder coating are:

• It can be difficult to match metallic paint colors

• The start-up cost and cost of keeping an oven running

are high

• It cannot be touched up the same way as with wet paint

POWDER COATING
Epoxies
• Epoxies were the first widely used powders.
• They are very durable, offer excellent hardness and have
arguably the best chemical and corrosion resistance of all
available powders.
• Another plus of this type of powder is its ease of use and a wide
range of cure schedules.
• Epoxies adhere to metals extremely well, with various
pretreatments of the metal providing excellent adhesion,
including phosphate coating and sandblasting.
• The drawback of epoxy powders is that they do not weather well.
• Exterior exposure can cause them to fade and chalk in the sun.
They weather poorly and will often start to degrade on the
surface after a few months. This makes epoxies better suited to
indoor applications.
POWDER COATING
Polyesters
• Polyesters are the most commonly used powders and offer great value for
money.
• The two most widely used types of polyester powder: TGIC (tri glycidyl
isocyanurate) and non-TGIC, which is also known as TGIC-free or
sometimes a ‘Primid’.
• Both TGIC and TGIC-free polyesters offer good mechanical resistance,
including great flexibility and impact resistance, and good chemical
resistance.
• One advantage of this powder is its low cure temperature. This low-
temperature requirement makes it better for sensitive items.
• Polyesters will also provide good overbake resistance to yellowing, which
makes them really easy to use and Standard Polyesters will offer 1-3
years of good UV resistance, so they work well for all interior and some
exterior applications.
• A huge advantage of standard polyesters is the enormous choice of colors,
gloss levels and special effects they’re available in.
• Limited exterior durability is a standard polyester’s main disadvantage.
POWDER COATING
Super Durable Polyesters
• As the name suggests these excellent value powders offer
superior durability when compared with a standard
polyester.
• They are designed to hold their color and gloss to within set
limits for 5 to 10 years more when compared to a standard
polyester.
• Not only is their color and gloss protection better, but they
also provide better humidity and corrosion resistance.
• These Super Durables have become hugely popular over the
last few years as their increased capabilities and great
value for the money have made them popular for interior
applications where improved fade resistance is required
and all manner of outdoor applications.
POWDER COATING
Epoxy-Polyester Hybrids

• Epoxies and polyesters are often mixed together to form hybrids.

• These hybrids remain closely related to pure epoxies but offer superior
weather degradation properties.

• These hybrids can be mixed in various ratios to emphasize the

characteristics of either the epoxy or polyester.

• The polyester will enhance the overbake resistance when compared with a
straight epoxy and they also create ultra-smooth, thin films.

• The combination of the resins can also make them more economical than a
pure epoxy.

• The polyester does reduce the corrosion and chemical resistance of the
epoxies and doesn’t really add any outdoor weatherability to the product.

• Hybrids are widely used on items that require good cosmetic appeal along
with good functional properties. Hybrids can be used in some of the same
areas that epoxies are used, but are typically found on indoor appliances
and other household items like furniture, shelving, interior lighting, and
power tools.
POWDER COATING
Fluoropolymers
• Fluoropolymers are typically used in architectural markets due to
their phenomenal weathering properties and color and gloss
retention.
• Their corrosion resistance and excellent weatherability make them
extremely popular for exterior architectural applications like
curtain wall, windows, doors and more.
• The two most common types of Fluoropolymers found in powder
coatings are FEVE and PVDF.
• PVDF Fluoropolymers always need a primer beneath them –
whether liquid or powder and are much more difficult to bond
when creating metallic powders.
• FEVE resins are the most popular within the powder community
for their superior one coat capability and incredible exterior
performance.
• FEVE based Fluoropolymer metallics can also be bonded so
that when applied, the metallic flake is more evenly distributed
throughout the powder for a more consistent appearance.
POWDER COATING
Urethanes

• Urethanes are chemically similar to polyesters, with a

difference in curing agents.

• Urethanes offer a very smooth finish and very good exterior

durability as well as excellent chemical and corrosion resistance
which makes them ideal for things like fuel tanks.

• Other common applications include agricultural equipment, air

conditioners, car rims and doorknobs.

• They are used on door knobs, oven knobs and other such
applications because fingerprints are not as visible.

• One drawback of urethane paint is that at higher mil

thicknesses it can begin to outgas and become brittle.

• Urethanes are also usually more expensive than other types of

powders due to the resin cost.
3. Powder Coating

• This protective finish involves the application of

powdered paint made of specialized resins, filers, and
pigments. The dry powder particles are charged
electrostatically to attract paint particles onto the
surface of the steel where the charge also holds them in
place during curing under high temperatures. Powder
coating is inexpensive and offers an impact-resistant
surface. Moreover, it exists in different colors and is
used for applications in which aesthetics is valued.
Powder Coatings

• A dry powder is electrostatically applied to a metal

part. The part is then cured under heat of about 200
degrees Fahrenheit, which produces a very consistent
and pleasing appearance. Powder coatings are generally
more environmentally friendly than paints since
solvents are not require. Powder coatings come in an
unlimited range of colors.
• PROTECTIVE COATINGS AND PAINT FINISHES: WHAT DOES YOUR APPLICATION
REQUIRE?

• Steel is one of the most commonly used metals in overhead cranes and material handling systems.
That’s because metals like steel are strong, cost effective, and easy to manipulate. However, steel is
also prone to rust in almost any environment, especially when used for caustic applications or if
exposed to harsh conditions.

• To protect your crane system from rust and corrosion, most manufacturers provide options for
protective coatings and paint finishes. Knowing which protective coating will best suit your operation
is important to extend the lifetime of your new system. Here, we will explore several protective
coating and paint finish options for overhead crane systems, and outline the advantages and
recommended applications for each.

• To begin, it can be helpful to know that there are three main paint classifications, which we will
reference in this post: primers, intermediates, and finish coats. Primers are used to wet and adhere
to the substrate (the steel surface or underlying metal) and act as an inhibitor to hinder corrosion.
Intermediates are used to build film thickness. And, the finish coat offers aesthetic value, but it also
provides surface resistance. Depending on the conditions of exposure, it must act as the first line of
defense against weather and sunlight, open exposure and condensation.

• In addition, there are also four types of protective coatings for metal: barrier, inhibitive, sacrificial,
and combination.

• Barrier coatings protect metal by preventing water, oxygen, and electrolyte from coming in contact
with the underlying metal. Inhibitive coatings contain chemicals that hinder corrosion. They react
with the cathode, anode, or other components (oxygen, electrolyte, acid). Sacrificial coatings provide
galvanic protection. In other words, they corrode (sacrifice) instead of the underlying metal,
providing electrons, which reverses the corrosion cell and transforms anodes to cathodes.
• POWDER COATING

• Powder coating involves the application of a dry powdered paint compound made of pigments,
specialized resins, and fillers that melt and fuse together during the curing process to form a painted
finish. The solid powder particles are electrostatically charged using a low-velocity air powered spray
gun. This electrostatic charge attracts paint particles to the substrate surface and holds them in
place during the high temperature curing process. Conventional liquid paint requires a solvent to
keep the binder and filler parts in a liquid suspension form. But, dry powder is applied
electrostatically and cured under heat to allow it to form a protective barrier around the metal
substrate. The powder is usually used to create a hard finish that is tougher than conventional paint.

• Powder coating can be relatively expensive, but it is high impact resistant, which means that it
eliminates chipping and scratching. It is most commonly used for applications that involve impact
and particle abrasion, and it extends the life of your crane in caustic environments.

• Powder coating does offer the added benefit of decorative variety because it comes in standard or
custom colors. It also comes in various textures including smooth, wrinkled, matte, and rough.
Powder coating systems are resistant to heat, corrosion, impact, abrasion, most chemicals, and
solvents. They are also resistant to fading from sunlight and UV exposure.

• Powder coating is environmentally friendly because it doesn’t contain volatile organic compounds
(VOC’s), which are pollutants found in the solvents used in liquid paint finishes. They eliminate the
need for users to buy and maintain costly pollution control equipment, which saves money in the long
run.

• Key Industrial Applications: automotive applications, construction, architectural applications,

electrical applications, farm applications, everyday household applications, manufacturing, and
machinery.

•
•
Liquid paints
When it comes to paints, liquid is still beneficial in many cases. In spite
of advances in coatings technology, liquid paint remains the optimal
choice for several situations, such as when:
• The project requires lower cure temperatures
• A process requires faster color changes
• A project requires more color variation
• Products require special masking
• Smoother coats are desired
• The most obvious benefit for wet coatings is probably the fact that this
method affords so much color variety. Especially useful in specialty
markets, the many shades and specialty coatings create far more
choices. Indeed, using liquid paint means you have the option for Teflon
and even glow-in-the-dark coatings
 Powder Coating
• Some situations require the advantages of powder coatings, a
technique which involves electrostatically charging the paint
pigment powder to cause adhesion to the substrate.

• In addition to producing a more durable coating more efficiently

than liquid, powder coating is generally seen as a more
environmentally safe option.

• The powder coating process allows for little-to-no waste. Any powder
not adhered to the target surface is collected and re-used. Because
the paint contains no solvents, virtually no Volatile Organic
Compounds (VOCs) are released into the atmosphere as the paint
ages.

• The technology requires less training than other methods, but the
associated operation and energy costs are higher. However, this
method allows more control over the film thickness. Additionally,
this application is an excellent choice where durability and scratch
resistance is important.
NON-METALLIC COATINGS
• These are available in a wide variety of colours and include:
 Paints
 Baked Epoxy Finishes
 Vinyl Coatings
 Bituminous Coatings
 Vitreous Enamel Coatings
• Baked epoxy finishes are applied to zinc-aluminium coated steel
which is chemically treated to assist bonding. An epoxy primer and
then the final colour coat are baked on separately. This type of
finish is popular for domestic and commercial roofing and wall
cladding for normal conditions.
• In marine and polluted industrial conditions steel can be coated
with a tough vinyl which is laminated to the steel substrate. The
vinyl coating locks out moisture, making an extremely corrosion-
resistant finish.
• Vitreous enamel coatings comprise a layer of glass fused to a
properly prepared steel base.
• Painting should be considered as a complete system that includes
surface preparation, pre-treatment to facilitate adhesion, primer,
intermediate coat or coats and finish coat. Different types of steel
require different pre-treatments and coatings.
• Bituminous coatings are based on bituminous resins such as coal
tar or asphalt. The bituminous resins perform well underground
and in contact with water but do not have good weather durability
when exposed to sunlight.
• Surface working

• Surface-working processes involve the application of certain operations to the

surface of metals to alter their appearance and include:

• blasting Obtaining a mottled or pebbled surface by means of

• cleaning blasting the surface with sand, grit, or steel shot through a nozzle by
air pressure.

• brushing Producing smooth, satin, bright, or buffed

• buffing finishes by means of wheels on high-speed lathes, by

• polishing belts on sanding wheels, or by disks and wheels on hand buffers

and grinders.

• etching A process of chemical etching the surface by means of acid or alkali

solutions to obtain architectural effects.

• grinding A surface texture obtained by the use of grit in a grinding wheel or

disk.

• hammering Metal surfaces can be altered by hammering to obtain the desired

degree of surface alteration.