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Preface ............................................................... xiii Acknowledgments ............................................... .......... xv I Powder Coating: An Overview ............................................... I Economic Benefits ........................................3 Environmental Benefits .....................................4 Environmental and Safety Regulations ..............................................5 Becoming Informed and Staying that Way (AFP/SME 2000) .............. 0 2 Powder-coating Materials and Their Performance Properties ............................................. 13 Types of Powders .............................................. 13 Conclusion ...........................................................26 3 Calculating Coverage and the Cost of Powder Coatings ....... 29 Cost ...............................................................29 Making Purchase Decisions ...................... .........32 4 Powder Process and Electrostatic Theory ............................. 33 Corona Charging and Tribocharging .............................................. 33 Back lonization, Finish Quality, and Transfer Efficiency ................... 35 Faraday Cage Effect .......................................... ............. 37 Free Ion Collection (IC) Device .............................................. 39 High-voltage Power Generation ..............................................40 Internal and External Charging Guns ..............................................40 5 Powder Curing and Ovens .................................................... 43 Heating Functions ..............................................43 Dry-off Ovens .............................................. 54 Safety ..............................................55 Oven Profiling ..............................................56 6 Pretreatment for Powder Coats ........................................... 59 Soils ......... ..................................................... 60 Pretreatment .............................................63 Phosphate Coatings .............................................71 Rinsing ............................................. 74 7 Pretreatment Washer System Design and Construction ...... 91 Wash Systems ........................................ 91 Deionizer (DI) Designs ..........................................94 Reverse Osmosis (RO) ..........................................96 Pretreatment Stages ..........................................98 Tanks ......................................... 100 Conveyors ........ ............................ ....... 102 Nozzles ....................................................... 103 Three-stage Systems ............................... ........... 104 Five-stage Systems ................................. ......... 107 Determining the Initial Charge .......................................... 109 Base and Acid Definition .......................................... 109 Measuring Washer Zone Time ................... ....................... I I Rinsing ......................................... 113 8 Monitoring and Maintaining Pretreatment Systems ........... 117 Total Dissolved Solids (TDS) and pH ......................................... . 118 Phosphate Coatings ................................ .......... 121 Checking for Quality .............................................. 122 The Value of Titration ............................... ........... 127 Descaling Procedure ............................... ........... 132 Checking for Total Dissolved Solids .......................................... 138 Phosphate Coating Weights on Iron and Steel ................................. 140 9 Avoiding Pretreatment Failure ........................................... 14 1 Operating and Maintenance Manuals .......................................... 142 oders .....***********************............ 149 Spraying r,., ....................................... 149 Particle Distribution ............... ...................................................... 153 Hoses ........................................... . . . . . . ........................... 157 I I Powder Booths .......................... ..................... 159 Design C riteria .................................................................................. 161 Paint Booth Materials ............................ ........ . 175 Fire Protection ........... ........ . . ............. 175 Humidity ....................... ................................................................... 176 Airflow Factors ........................................ 177 Hooks and Racks ...................................... 179 Conveyors ....................................... 182 12 Applications and Operating Conditions ............................... 185 Particle-size Distribution ........................................ 185 Operating Conditions ........................................ 187 Powder Storage ........................................ 190 Masking ........................................ 193 13 Clean, Safe, Quality Operations ........................................ 195 Defining Cleaning Procedures ........................................ 196 Establishing a Controlled Environment ..................................... 199 Compressed Air ............................................................. .... 207 Safety ..... .....................................216 Vacuums ............... ............................ .......... 223 Clean Rooms ........................................ 225 14 Performance Testing ............................................ 227 ASTM Standards ......................................228 Chemical Resistance .................................. 244 15 Troubleshooting ...................................................... .245 Off Color .......................................245 Off Gloss .......................................256 Poor Adhesion to the Substrate .........................................258 Poor Adhesion to the Powder Coating (Recoatability) ...................259 Transfer Efficiency ................................... 259 Fluidization ........................................... 263 Clumping, Blocking, or Sintering ............................... 267 Unacceptable Surface Appearance ...............................269 Protrusions ........................................... 271 Craters, Pinholes, and Fisheyes ...............................273 Coating Choice ... .................... ........... 273 16 Job Descriptions and Policies ............................................... 277 Powder Coating Positions ............................... 277 Company Policy Manual ...............................298 17 Lean ................................................................ 303 Manufacturing Without Waste ............................... 303 Improving Productivity by Eliminating Waste ............................... 307 Lean Rules ...........................................308 Management Responsibility ...............................308 Cycle Time ....... ....... ...... ........ .......312 18 UV Curing Techniques and Processes .................................. 315 UV-lamp System Basics .............................. 316 UV Bulbs ............................................316 UV-lamp Systems Comparisons ...............................317 Conclusion ...........................................320 Appendix A: Powder Coating Test *........................................ 321 Appendix B: Glossary ................................................................. 331 Appendix C: Metric Conversion Tables .................;................... 345 Index .......................................................................................... 349Library of Congress Subject Headings for this publication: Plastic coating, Plastic powders