Architectural Powder Coatings

Transcription

1 Architectural Powder Coatings Mike Withers Axalta Powder Coatings

2 What are Powder Coatings Coating in a fine powder form Electrostatically applied Fused at elevated temperature Virtually no VOCs HAPs Free Reclaimable very efficient No Hazardous Waste May contribute to LEED credits

3 Manufacturing Powder Coatings Sieve possible post blend Package Formulation 2 Pre-mix Grind or Micronize 5 Extrusion 3 4 Brittle or Chip

4 Formulation Finely Divided Particles containing: Organic Polymers Extender Pigments Flow and Leveling Aids Additives

5 Premixing Pre-mixer in operation Dry materials are blended at high speed to create a homogeneous mixture. Materials remain in their original state.

6 Extrusion Pre-Mixed Raw Material Extruder Chilled Rollers Cooling Belt Brittle

7 Grinding 01 Grinding Grinding reduces flake into desired micron size by impact fracturing 02 Sieving Sieving removes large particles for reprocessing or elimination 03 Packaging Packaging in boxes, drums, or bulk

8 Manufacturing Process Powder Coating Manufacturing Process

9 Thermoplastic Powder Coatings Characteristics Thermoplastic powder coatings have been specifically formulated as a tough chip-resistant finish providing excellent corrosion and UV protection. Advantages Excellent corrosion chemical, and impact resistance Uses Interior and exterior Typical Applications Outdoor furniture, Light poles, Sign posts, Railings and stairways, Fencing panels, Bike racks, Cable grids, Battery trays, Perforated steel

10 Polyester Urethane Characteristics Advantages Uses Typical Applications Smooth, thin film capability Excellent mar and chip resistance Wide range of chemical and physical properties Normally have good weatherability Utilize blocked crosslinkers which require minimal temperature to react Excellent resistance to UV Excellent resistance to heat Excellent appearance at thinner films Excellent application characteristics Disadvantages Low cure limitations (needs temps above 360 F) Can show pinholes (outgassing) from e-cap if above 3 mils Lawn furniture, Automotive Wheels and trim Lawnmowers Bicycles Fluorescent Light Fixtures Lawn and Garden Equipment Electrical Enclosures Playground Equipment Range Panels Air Conditioners Automotive Trim Patio Furniture

11 Polyester TGIC Characteristics Advantages: Uses Typical Applications Triglycidylisocyanurate (TGIC) Faster or lower temperature cure Excellent thick film mechanicals Excellent edge coverage Good overbake resistance Good weatherability Excellent resistance to UV & heat Super durable versions Lower cure temp than urethanes Good edge coverage Disadvantages Not as smooth at thin films Potential health & safety issues Fencing Air conditioners Lawn furniture Tool boxes Automotive wheels Transformers HVAC Fencing Lawn furniture Playground equipment Construction equipment

12 HAA Polyester Characteristics Hydroxyalkylamide (HAA), polyester chemistry. Standardized Global Technology No special labeling requirements Can be formulated to Meet AAMA 2603 and 2604 performance Meets requirements of major agricultural and construction OEMs Advantages Improved cure response compared to standard polyesters (lower temp/time) Superior charging properties, coupled with excellent transfer efficiency FDA compliant in selected formulations as per 21 CFR Excellent weathering performance Uses Architectural General Industrial Appliances Lighting and interior fixtures Typical Applications Railings, awnings, storefronts Outdoor furniture HVAC Fencing Light poles, sign post Playground equipment Construction equipment

13 13 Natural Weathering by Chemistry (gloss retention in months) Gloss Loss (%) Months of South Florida Exposure

14 14 Natural Weathering High Performance Powders Gloss Loss (%) Months of Exposure 1 Year AAMA Year AAMA Year AAMA 2605

15 Epoxy Characteristics Advantages: Uses Typical Applications First thermoset powder coating used Electrical Resistance Excellent combination of - Hardness - Corrosion resistance - Chemical resistance - Flexibility Major limitation is poor weatherability Wide range of curing rates and temperatures Good chemical resistance Possible fast cure Very low gloss system possible Excellent functional applications Disadvantages Poor UV resistance Poor overbake Under-the hood automotive part Metal office furniture Shelving Garden tools and steel pipes Primarily used in functional applications Pipe coatings Automotive underbody/ underhood Electrical components Rebar Primer

16 Epoxy/Polyester Hybrid Characteristics Advantages Uses Typical Applications Share many performance characteristics of an epoxy and many application characteristics of the polyester Low cure formulations available Improved resistance to over-bake yellowing Excellent application characteristics (TE) Tough, flexible, used in many of the same applications as epoxies Improved Faraday penetration Good Overbake resistance Automotive parts Office furniture Shelving Garden tools and steel pipes1 Shelving Office Furniture Tools Fire Extinguishers Water Heaters

17 Architectural Coatings Combines aesthetically pleasing colors and finish with long-term exterior durability to protect architectural assets. Ideal applications: Aluminum windows, aluminum entryway doors, hand railings, fences and steel. Features: Highly durable and weatherable, excellent gloss and color retention Technology: Polyester TGIC Standard Durable & Super Durable, TGIC free polyester Standard Durable & Super Durable, Fluoropolymer Gloss: Low to high Uses: Interior and exterior Specification: AAMA 2603, 2604, 2605

18 Architectural Coatings - Fluoropolymer FEVE and PVDF resins. Contains super weathering pigments One coat system Excellent durability on exterior architectural building components Good hardness and flexibility Designed to Meet AAMA 2605 specifications

19 Low Energy Coatings Delivers 25% energy reduction through lower bake temperatures and shorter cure times. Primary segments: General industrial Technology: Epoxy acrylic polyester Features: Lower bake temperature, increased line speed and lower part temperatures, good performance Technology: TGIC polyester, premium weathering TGIC polyester Gloss: Medium to high Uses: Interior and exterior

20 Metallic Effect Multiple ways to create a metallic appearance. Bonded: adhesion or secured joint of coating to metal flake. Dry Blend: A process where material is blended without melting. Extruded: A process utilizing heat and mechanical kneading to achieve a homogenous mixture

21 Textures There are multiple textured looks and various ways to achieve a textured look in powder coatings Primary segments: General industrial Wrinkle Mini-Texture Rolling Texture Tight Ridge Texture

22 Specifications & Testing Purpose Performance based Designed for Windows, Store Fronts and Curtain Walls Aluminum Extrusions GSB & Qualicoat mainly Europe AAMA used for all architectural metals USA Series of Standards ASTM & ISO No comprehensive Specifications for Steel ASTM methods in combination with UV requirements of AAMA

23 ISO & Custom Specs Purpose ISO Environments for Steel substrates ISO short, medium, long Custom specifications using ASTM and ISO standards UV resistance per AAMA for Steel substrates Coating Manufacturer to assist writing your specifications

24 Standard Test Methods

25 What are QUALICOAT & GSB? QUALICOAT & GSB are both a quality label organization committed to maintaining and promoting the quality of coating on aluminum and its alloys for architectural applications. This gives purchasers of coated aluminum the assurance that they will receive a premium-grade product delivering long-term value and consistent quality.

26 Mission and Goals of Qualicoat and GSB To provide best practice rules to obtain a good quality coating on aluminum. To achieve this goal, they are committed to: establishing specifications for processes, products & tests to be used by the coating plants developing and improving these specifications granting licenses to coating plants that apply for the quality label testing and approving chemicals and coating products to be used monitoring the correct application of the specifications in licensed plants.

27 Benefits of QUALICOAT & GSB licensed plants have a distinct competitive edge over their rivals customers and specifiers receive coated products that meet clearly defined quality and performance criteria.

28 Current situation (2016) Qualicoat (Switzerland) Members (coaters) (2007) Countries (2007) Founded 1986 GSB (Germany) Members 115 (coaters) Countries 21 Founded 1977

29 Current Qualicoat Approvals Class 1 Class 2 Country Cat GU Cat GU Cat GU Textured Cat GU Cat GU Cat GU Textured Others Colombia P-0697 P-0696 P-0489 France P-0720 P-0817 P-0634 P-0752 P-0145 P-1209 P-1254 P-0819 P-0818 P-1083 Germany P-0713 P-0615 P-0673 P-1305 P-1304 P-1240 (AG) Sweden P-0862 P-0767 P-0801 P-0800 P-1141 P-1157 P-1158 P-1089 P-1266 U.K. P-0397 P-0398 P-0399 P-0846 Mexico P-1006 P-1352

30 Current GSB Approvals Class 1 Class 2 Country Cat GU Cat GU Cat GU Textured Cat GU Cat GU Cat GU Textured Others France 171f,l,o 171j,q 171m,n 171p 171h 171i 163e 171e 171g,r 102o Germany 171f,l,o 171j,q 102o 171p 171h 171i 163e 171e 171g,r 161d Sweden 171f,l,o 171j,q 102o 171p 171h 171i 163e 171e 171g,r U.K. 171f,l,o 171j,q 102o 171p 171h 171i 163e 171e 171g,r

31 Approval: Documents

32 Film Thickness Purpose Ferrous and non-ferrous measurements Powder formulated to min 2 mil Ensures flexibility as designed Ensures surface visual characteristics Ensures corrosion protection via level of permeability

33 Gloss Level Purpose Ensure visual appearance as designed +/-5 i.e. Gloss specified is 35, in spec 30-40

34 Outdoor weathering Purpose Ensure gloss and color retention Florida because of UV exposure and night time wetting 90º facing south 1 Year visual slight color deviation, no gloss spec 5 Year delta E 5.0, 30% gloss retention 10 Year delta E 5.0, 50% gloss retention

35 Color Measurement Purpose Determine color deviation CIE-LAB Hunter-LAB

36 Laboratory weathering Purpose QUV-a good for pigment eval QUV-b good for gloss retention eval Xenon arc reasonable overall eval Fresnel (light concentrator) good overall eval No laboratory test method is perfect European standards allow for preliminary approvals after Xenon arc testing

37 Film Erosion Resistance Purpose Less then 10% film loss after weathering

38 Impact Resistance Purpose Check film flexibility Direct Indirect

39 Humidity Resistance Purpose Field of coating performance 100% Humidity 1500hrs, 3000hrs, 4000hrs No blisters greater then few

40 Pretreatment Purpose Non-Chrome according to supplier specs Chromium Chromate or Chromium Phosphate weight tested using x-ray fluorescence Both technologies can achieve AAMA years south Florida Well maintained non-chrome systems meet and exceed the standards

41 Abrasion Resistance Purpose Difficult to reproduce Calculate removal of coating Coefficient of Abrasion

42 Salt Spray Corrosion Resistance Purpose Determine corrosion resistance Neutral salt spray B-117 Acidic salt spray G-85 Annex A5 G-85 is best on Aluminum B-117 for Steel Linear Scribe Panel Testing mainly pretreatment performance Also verifies adhesion properties of coating system Filiform corrosion (crawling under) Special attention to Galvanic Corrosion

43 Chemical Resistance Purpose Determine resistance to specific chemicals Mortar Nitric Acid Detergent Window Cleaner

44 Approved Applicators Purpose Ensure consistent quality to meet performance standards Coating Manufacturer Audit Testing - Approval AAMA no third party approvals Voluntary Qualicoat/GSB approvals

45 Custom Coater Why coat architectural? Pretreatment is critical Qualicoat provides an auditing process and license of aluminum finishes that ensures the process is documented and traceable for future issues. This is basically an insurance policy on the process and future warranty claims. Qualicoat specifications include all products used in the process and those products must be approved by Qualicoat. This ensures the products we are using meet the standards of Qualicoat. There are specific tests that have to be performed each day, week and or month to comply with the License. Twice a year, Qualicoat comes into our facilities and audits our process, records and does independent testing to ensure Trojan meets their standards in the license agreement Overall, for Trojan, the Qualicoat process is similar to ISO and reassures all our customers that we are providing the best quality