Emmanouil Spyrou. Powder Coatings Chemistry and Technology. Jörg Sander. ebook. Symposium. Symposium

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1 Emmanouil Spyrou Powder Coatings Chemistry and Technology Jörg Sander Coil Coating 3 Revised Edition rd ebook European Coatings European Coatings European Coatings European Coatings Symposium Symposium Tech Files Tech Files

2 Jörg Sander Coil Coating Jörg Sander: Coil Coating Copyright 2014 by Vincentz Network, Hanover, Germany ISBN:

3 Cover: Salzgitter Stahl, Salzgitter/Germany Bibliographische Information der Deutschen Bibliothek Die Deutsche Bibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliografie; detaillierte bibliografische Daten sind im Internet über abrufbar. Jörg Sander Coil Coating Hanover: Vincentz Network, 2014 European Coatings Tech Files ISBN ISBN Vincentz Network GmbH & Co. KG, Hanover Vincentz Network, Plathnerstr. 4c, Hanover, Germany This work is copyrighted, including the individual contributions and figures. Any usage outside the strict limits of copyright law without the consent of the publisher is prohibited and punishable by law. This especially pertains to reproduction, translation, microfilming and the storage and processing in electronic systems. The information on formulations is based on testing performed to the best of our knowledge. The appearance of commercial names, product designations and trade names in this book should not be taken as an indication that these can be used at will by anybody. They are often registered names which can only be used under certain conditions. Please ask for our book catalogue Vincentz Network, Plathnerstr. 4c, Hanover, Germany T , F books@european-coatings.com, Layout: Danielsen Mediendesign, Hanover, Germany Printed by: Quensen Druck + Verlag GmbH & Co. KG, Hildesheim, Germany ISBN ISBN

4 European Coatings Tech Files Jörg Sander Coil Coating Jörg Sander: Coil Coating Copyright 2014 by Vincentz Network, Hanover, Germany ISBN:

5 European Coatings Tech Files Another interesting book hint... Also as ebook! >> European Coatings Handbook Brock Groteklaes Mischke, 2010, 2nd Edition, 432 pages, hardcover 139,- order-no. 544 ebook: 544_PDF European Coatings Handbook Comprehensive and based on practice sum up the aims of the European Coatings Handbook. The book covers the full spectrum of coatings formulation in a single volume. Topics range from the underlying chemistry to process engineering, from safety to quality control, as well as the regulatory issues involved in the manufacture and application of coatings. The book contains the latest information on all aspects in all parts of coatings composition, application methodology, quality assurance, industrial health, and safety is highly useful. Order at: Vincentz Network P.O. Box Hannover Germany Tel Fax order@vincentz.net

6 Foreword During my entire business career, I have seen many industrial applications of paints and coatings to metal, be it on extruded profiles, bicycle frames, escalator steps, car bodies, wheel rims and automotive trim parts, or beverage cans, to name a few. The most appealing application for me, however, has always been the continuous coating of metal coils. Coil coating provides fascinating ways of producing coated metal goods. Highly sophisticated processes and the proficient and sustainable use of elaborate process chemicals and materials bring about durable, high-quality painted products. These can be processed to create a wide range of articles with an abundance of uses, technical features, shapes, and surface aspects. This present book is based on the manuscript of a tutorial I held during the European Coatings Conference Coil and Can Coating that was organised by Vincentz Network in Berlin in October It is the first comprehensive English-language description of the coil coating technology available to the public in years. To make the book attractive for the insiders of the coil coating community and instructive for newcomers to this exciting technology alike, a good deal of elaboration was needed beyond the conference script. Thus the book embraces both: A synopsis, maybe also a useful look at the bigger picture for those already conversant with the subject, and an in-depth introduction for those who want to familiarise with it. In particular, students of process and equipment engineering, surface science, pretreatment and paint technologies, but also of architecture and metal design shall find detailed, and, I hope, popular descriptions, explanations, and interesting connections demonstrated. I am grateful to many colleagues in the business who helped in discussions and by providing detail information about their specialist subjects. A particular pleasure was meeting Dr. Bernd Meuthen, Past President of the ECCA, long-standing President and Honorary President of the German ECCA Group, and lead author of a German standard publication on the topic, during my very early days in the business. I have been very much indebted to Bernd for sharing his profound knowledge and his enthusiasm for coil coating that I have always admired. The compilation on standards, one of his very particular interests, is based on his earlier work. Sadly, Bernd Meuthen died on October 24, And so I feel it fitting to dedicate this work to his memory. I hope it helps to inspire and enthuse future coil coating chemists and engineers as Bernd was able to do. Velbert, Germany, October 2013 Jörg Sander Jörg Sander: Coil Coating Copyright 2014 by Vincentz Network, Hanover, Germany ISBN:

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8 Contents 7 Contents 1 Coil coating principle, market and applications Introduction Coil coating process Metalworking with precoated coil Inherent benefits of coil coating Coil coating market in Europe Applications of precoated metal Overview Building applications Transport applications Applications in appliance and general industries Packaging applications European Coil Coating Association, ECCA History of coil coating Corrosion protection Principles of function Corrosion phenomena Strategies for corrosion inhibition Metal oxide formation, passivation and conversion coating Cathodic protection Design of organic coating systems Diffusion barriers Pigments Function of individual coating layers Industrial cleaning Introduction Why cleaning? Contaminations Cleanliness and surface tension Paint adhesion Aqueous cleaning Overview Alkaline cleaners Mechanism of alkaline cleaning, bath age and control Surfactants Cleaning physics Influence factors Rinsing and maintenance Jörg Sander: Coil Coating Copyright 2014 by Vincentz Network, Hanover, Germany ISBN:

9 8 Contents 4 Pretreatment Introduction Substrates Overview: Particular substrates for coil coating Steel Blast furnace process Steel making and refining Galvanised steel Aluminium Bauxite refining and Al electrolysis Properties of aluminium and its alloys Basics of pretreatment technology Pretreatments for coil coating Alkaline passivation Iron phosphating Chromating Yellow chromating (chromium chromating) Green chromating [Ti,Zr]F 6 based processes: Chromium-free pretreatment Basics Chemistry Conversion layer composition Performance Architectural application Synopsis: State-of-the-art coil coating pretreatments Recent pretreatment development Pre-commercial processes Primer-pretreatment Application Immersion and spray processes Alternative application processes Environmental considerations Legislation Environment: Labelling and emissions Waste Treatment Coil coating paints Definition Ingredients: Carrier media Drying and curing mechanisms Physical drying Chemical curing, crosslinking Radiation curing systems Powder paints Binder resins Introduction Polyvinyl chloride, PVC Polyvinylidene difluoride, PVdF Epoxy resins Polyester resins... 76

10 Contents Raw materials for polyester resins Crosslinking of polyesters with melamines Crosslinking of polyesters with polyisocyanates Polyurethanes Acrylic resins Binder resins: Comparison and uses Coil coating paints statistics Roles and classes of pigments Introduction Anticorrosive pigment Overview Active pigments lead and chromate pigments Active pigments phosphate pigments Other active anticorrosive pigments Barrier and sacrificial pigments Colouring and extender pigments Auxiliaries Coil coating line equipment Cleaning and pretreatment installations Cleaning Pretreatment application Advances in plasma technology for cleaning and pretreatment Strip travel and planarity control Coater technology Roll-coaters Roll-coater operation Coater rolls Control of the roll-coating process Auxiliary equipment Other paint application techniques Curing and oven technologies Thermal curing Convection ovens Infrared and near-infrared curing Induction curing Comparison of thermal curing techniques Radiation curing Cooling and exhaust management Examples of modern coil coating installations Performance testing Introduction Coating thickness Adhesion testing Overview Application tests Tests involving deformation Other adhesion tests Laboratory methods

11 10 Contents Atomic force microscopy Dynamic mechanical analysis Corrosion testing Outdoor exposure tests Accelerated corrosion tests Overview Salt spray test Constant climate humidity Condensation Water soak and boiling tests Filiform corrosion Cyclic humidity Prohesion VDA test UV test and weathering Electrochemical testing General remarks Electrochemical potential Standard potential Corrosion potential/current monitoring Electrochemical impedance spectroscopy Electrochemical techniques with high spatial resolution Scanning vibrating electrode Height-regulated scanning Kelvin probe Research topics Introduction Recycling and renewable materials Functional coatings Nanotechnology Academic and institutional research lines Can coating Introduction: Precoated metal for packaging Substrates and market Pretreatment and base coating Can coatings Coil and sheet lines Specified tests Standardisation Introduction Creation of standards by CEN CEN Standardisation procedure Proposal stage Working stage Enquiry stage Approval stage

12 Contents Implementation stage ECISS, ISO and ASTM General standards and regulations Relevant standardisation bodies Coil coated metal: Terminology and definitions Coil coated metal: Product standards Substrate and test standards Overview Coil coated aluminium Coil coated steel General provisions Cold rolled steel substrates Metallic-coated steel substrates (except packaging sheet) Further cold rolled and metallic coated steel substrates packaging sheet Hot rolled steel substrates Electrical steel Stainless steels Coil treatment lines: Standards and regulations Test methods Overview EN standardisation body in charge EN testing standards Test methods: Further standards Terms and words of art for coatings, coating materials and plastics, and country codes: Standards Building components: Standards on products and test methods CEN bodies in charge Building components standards Special test standards and features for fire protection Quality management and environmental management systems: Standards Selected European organisations Author Index

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14 Introduction 13 1 Coil coating principle, market and applications 1.1 Introduction Coil coating makes use of a simple, but effective principle, i.e. to clean, pretreat and coat flat coils or sheets of steel or aluminium in a continuous operation, before other stages of industrial manufacture [1 4]. The slogan for this concept is: Finish first fabricate later! A conventional process sequence in coil coating consists of: Cleaning Conversion treatment (including optional post-rinse) Drying Primer coating Top coating Foil lamination (optional) An overview of a large coil coating line is depicted in Figure 1.1. Figure 1.1: Schematic of a steel coil coating line Source: Voestalpine Jörg Sander: Coil Coating Copyright 2014 by Vincentz Network, Hanover, Germany ISBN:

15 14 Coil coating principle, market and applications The official definition of the coil coating process is codified in the European Standard EN : It states that coil coating is a method in which an organic coating material is applied on rolled metal strip in a continuous process. This process includes cleaning if necessary and chemical pre-treatment of the metal surface and either one side or two side, single or multiple application of (liquid) paints or coating powders which are subsequently cured or laminated with plastic films. 1.2 Coil coating process Metal coils are fed into a coil coating line from an entry station, where the coils are reeled off an uncoiler (Figure 1.2), and the beginning of one coil fixed to the end of the preceding coil by welding or stitching. The uncoiler station is usually duplicated, or equipped with twin reels, in order to allow for faster coil changes. The metal strip then enters the active section of the line through a loop accumulator. The large accumulator shown in Figure 1.3a has been emptied during the change of a coil, while feeding the strip length that was stored in it to the continuously running process. It waits to be filled up again to be ready for the next coil change. Figure 1.2: Coil reel Figure 1.3: a) Entry accumulator; b) Loop pit Source: ThyssenKrupp Steel Europe Source: a) ThyssenKrupp Steel Europe; b) Alcoa Inc. The active section comprises a degreasing stage, with a brushing section and rinses; one or more pretreatment stages in either immersion or spray technique, followed by another rinse cascade, and a water dryer. In case of so-called no-rinse pretreatment processes, the strip needs to be dried beforehand, and the treatment solution is applied by a roll-coater (chem-coater), before reacting off and evaporating the water in the dryer. The pretreated strip then enters the primer stage with its roll-coater unit and curing oven, followed by a water quench cooler. Afterwards, the finish coater section is passed which again comprises the rollcoater units and curing oven with subsequent cooling. The finish (topcoat) section often has two coater installations that allow

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