The PPA 571 coating protect metal fencing from corrosion for 15 years

Powder Coating Non-Metal Materials

Posted on: February 9th, 2017 by byersbushblog No Comments

Fact: it is utterly challenging to powder coat non-metallic materials.  Why?  Because they lack the necessary electric conductivity that will support the entire electrostatic process that serves as the foundation for powder coating.  So does this mean it is impossible to powder coat non-metal materials?  Is there a workaround that can be easily done?  Let’s take a look.

Powder Coated Materials

There are a number of materials that are preferred for use with the powder coating process.  Obviously, the most commonly preferred is metal because of its high electric conductivity.  However, aside from metal, you may also use wood, composites, glass, plastic, and MDF among others.

With non-metal products, the first thing that you must establish is that the material should be able to withstand high temperatures.  For example, with plastics, most of these will melt once the temperature reaches 400 degrees; it will be simply too hot for it to withstand.  You also need to know how long the material can be subjected to high temperatures.

Powder Coating Non-Metallic Materials

Now, the challenge, how do you powder coat non-metallic items?  This is considering that they are not electrically conductive.  First off, when powder coating metals, electrostatic charge is used to allow the powder to attach to the metal for the duration that the material remains grounded.

For other non-metallic materials like glass, wood, or plastic that lack the electric conductivity, you cannot spray powder.  Why?  Because you will be wasting the powder, because there is no way that it will stick to the material and will just end up on the ground wasted.  What do you do?

One of the best solutions is to pre-heat non-metallic materials before they are subjected to the powder coating process.  Put the object in the oven and heat it up.  Afterwards, remove the object from the oven and apply the powder before the material completely cools down.  Once the powder comes in contact with the pre-heated section of the material, it will melt slightly upon contact allowing it to stick.

After completely coating the material, you can put it back into the over and allow it to cure normally to complete the process.  Some powder coating services have also suggested washing the material with water so that it creates a temporary conductive surface that will allow the powder to stick to allow for the powder coating process to continue.

Other Method

It is necessary to point out some precautions when doing powder coating on pre-heated, non-metallic items.  Some of the things that you must actively watch out for are:

  • Ensuring the powder coat is not too thick;
  • Overlooking the amount of powder used because it immediately melts upon contact; and
  • Making sure that the coat does not run like paint or create craters because this will affect the chip resistance of the finish.

Another avenue to pursue is a method known as hot-flocking, wherein you heat only the part that will be powder coated up to the point where the temperature can cure the powder.  Remove the material from the oven and spray the powder immediately.  The powder melts upon contact and will instantly flow.  Although seemingly simpler, the chances of applying too much coating increases.

Just like in powder coating metallic materials, the ability to coat several types of materials simultaneously is very possible.  This is even if many are not aware that non-metallic materials can be powder coated.  Achieving a beautiful finish similar to metallic objects can be done with a bit of patience.

The great news is that this expands you creative horizon allowing you to apply powder coat on virtually any type of materials (depending on its ability to withstand heat).  You can now execute beautifully crafted designs with ease.

If you need help with your powder coating needs, the 40 years of experience of Byers Bush Powder Coating Inc. will serve you well.  Contact Byers Bush today to get the benefits of high performance powder coating for metal and non metal equipment.

Powder Coating Benefits in Car Restoration

Posted on: February 6th, 2017 by byersbushblog

Have you ever tried to powder coat a car that is being restored?  If you haven’t then you may be missing out on something great.  Aside from giving you plenty of color choices, powder coating also offers numerous textures that can virtually match any type of finish that you want.  Regardless of the era, you can be sure that powder coating will deliver a finish that will match the original.  Let’s take a look at the powder coating benefits in car restoration compared to other processes.

Powder Coating

Let’s tackle powder coating first because you may not believe how magical a solution it is.  Visually, powder coating offers an excellent finish that is so durable that it will protect the metal parts from rust.  Less expense on anti-rust treatment is already a plus for you.

Now, what’s the take cost-wise?  Half a pound of powder normally runs at about $7 and the clear coat is priced the same so the total is $14.  That is the baseline for the materials that you will need.  Let us concentrate on this and assume that the cost of labor is the same for all restoration processes.  Cleaning the parts to bare metal will be part of the media blasting that should be covered by the labor.

Applying the powder coat on a clean bare metal, you have to put it in the oven for 20 minutes and allow it to cool down after.  Since we assumed that we would be using clear coat as well, that would be another 22 minutes of baking to completely coat the material.

So, for $14 and 44 minutes of coating, you get a beautiful and durable finish that will stay that way for at least 20 years

2 Parts Automotive Paint

This is an excellent choice if you’re going for an amazing look that is durable.  Rustproofing will also be covered due to the protection from the paint.  Price-wise, it is comparatively more expensive.  A quart or pint of automotive paint will cost you roughly $30.  You will also need to get a harder, which is another $30.

Depending on the type of finish that you want (glossy, semi-glossy, flat) you will need the matching type of clear coat.  Clear coats for automotive paints also require hardeners.  You also would need to spend for the primer.  At this point, the cost of the materials for the restoration is well over $100 for every gloss-level or color you want to use.

Several coats have to be applied and the paint gun requires cleaning in between the coats.  The time you have spent is already far beyond an hour considering that you also need to give the paint time to completely dry up before applying the next coat.

For more than $100 worth of supplies and quite possibly a whole day’s work, powder coating still seems to be the better choice.

Plating

Many of us are familiar with plating using materials like cadmium, zinc, nickel, and chrome among others.  If you choose chrome, you can be sure that it is expensive!  So you go down a bit and make use of chrome plating.

You can do the plating yourself with the use of a plating kit or have a plater do it for you.  Using a plater requires that you fill up a minimum order price.  So if the minimum for example is 100 brackets, it does not matter if you have only 1 or 10 brackets, you still pay the minimum price for 100 brackets.  Get the picture?

Durability-wise you have to be aware that the finish will eventually tarnish or get dull.  This means it will not last at least 20 years.  So powder coating still comes out on top.

Spray Painting

This is perhaps the cheapest and easiest option by far.  Will it look good?  Honestly, it will look cheap (just like the price you paid for it) and durability is questionable.  So if you truly value your car and you are serious in restoring it, you wouldn’t even be thinking about this option.

So when it comes to car restoration, there is no better option and value for your money than powder coating.  And when it comes to powder coating, there is no one else to turn to but Byers Bush Powder Coating Inc.  Contact Byers Bush to restore and protect your car parts to be more durable against rust with powder coating.

Comparing Powder Coating and Paint

Posted on: February 3rd, 2017 by byersbushblog

Two of the most common choices for coatings and restoration are powder coating and paint.  Each has its own benefits and people have their own reasons why they prefer one over the other.  However, is one really better than the other?  You decide after this general comparison.

Overview

The value of coating especially in the medical, construction, automotive, aerospace and electronics industries is priceless.    Aside from improving the overall appearance, coatings help increase the strength and durability of the metals.

The dominant choice before was to use paint as coating, but just a few years ago, powder coating began to rise as the more popular option.  In fact, over 15% of the total industrial finishing market relies on powder coating because it presents improvements over liquid paint coatings in terms of resistance to:

  • Moisture;
  • Chemicals;
  • Impact;
  • Ultraviolet light; and
  • Extreme weather conditions.

Powder Coating Application

Normally there are two ways that powder coating is applied.  The process can either be with thermoplastics or thermoset polymers that are applied as free-flowing dry powder.  What is the difference between the two?

With thermoplastic, the powder melts and flows as heat is applied to the material.  It retains its chemical composition even as the powder cools and solidifies.  On the other hand, thermosetting chemically cross-links with the other reactive components resulting in the changing of the chemical structure of the cured coating.  The thermoset powder coating will also melt as it is exposed to heat.

Unlike thermoplastic, thermosetting remains stable in heat and will not revert to its liquid state when reheated.  Thermoset can also be sprayed on to create thinner films that give off a better appearance compared to thermoplastic coating.

Powder Advantage

Did you know that powder coatings are suitable replacement for paint coatings even on metal household appliances as well as tools, office furniture, and all types of vehicles including its parts?  Is there any difference between the conventional liquid paint and powder coating?  Basically, the main difference lies in the fact that powder coating does not require solvent to hold the binder and filler while in liquid suspension form.

With powder coating, electrostatic spray deposition (ESD) is normally used together with curing by heat.  This presents several advantages compared to conventional liquid paint coating, like:

  • Unlike paint coating, powder has little to no volatile organic compound (VOC) emission;
  • Powder coat finish is more durable compared to conventional paint;
  • Thicker coatings can be achieved with powder coating and does not have running or sagging problems;
  • 100% powder coat usage is possible because overspray can be recycled;
  • Finished surface appearance is more uniform with powder coat; and
  • Specialty effects can be done easier with powder coat compared to liquid paint or other coating process for that matter.

Manufacturing

The particle sizes for powder coating range from 30 to 50μm with glass transition temperature of 200 degrees.  This means that the manufactured particle sizes of powder coating can deliver more efficient coating results.

Depending on the particular application that you choose, the film buildup can be more than 50μm if you want to have a smoother coat.  Some manufacturers prefer to have a slight orange peel effect because it helps to hide some defects on the metal material that may have been caused during the manufacturing process.

As for the surface texture, differences may happen due to the difference in curing kinetics or the visco-elastic properties, which will result in creaking noises as the coated surfaces begin to experience some strain.  The solid and fluid characteristics of powder coatings must be determined prior, during, and after the material has been subjected to curing.  This helps to understand how different formulations can work to achieve a specific result from the process including the needed application for the finished coat.

To get the most benefits from powder coating, you need a provider that has extensive experience in the industry like Byers Bush Powder Coating. Contact us to know the benefits of powder coating in protecting your important equipment against rust than paint does.

Understanding How Powder Coating Works

Posted on: December 28th, 2016 by byersbushblog

You can find powder coating almost anywhere today.  It is used mostly as finishing for various types of metals and some forms of plastics.  One of its most potent selling points is its durability.  It is known to considerably resist corrosion and can be deceptively effective in protecting metal railings, fences, and others.  Let’s try and look at the scientific process involved on how powder coating works.

Understanding Powder Coating

Basically, when we talk about powder coating, we are referring to a type of dry finishing process.  This process is so popular that it is used in more than 15% of the entire industrial finishing market.  Its continued popularity is attributed to the fact that it can be used on a wide range of products.

Powder coating was initially introduced about 40 years ago in North America.  The process can be categorized either as thermoplastic or thermoset coating.  With thermoplastic, the powder will not undergo any changes as it goes through the baking stage.  In thermoset, the powder will react to the heat during baking allowing it to bond with other chemical elements resulting in a polymerized finish that is considerably tough.

Because of its toughness and beautiful finish, you can see powder coating being used as decorative and protective finishing.  There are also numerous colors of powder to choose from making it easy to match any color scheme.

How it Works

Polymer resin systems are combined with pigments, flow modifiers, leveling agents, curatives, and other additives.  During the powder coating process, these elements are melted, mixed, cooled, and grounded into uniform powder-like substance.

The material is then subjected to electrostatic spray deposition (ESD), a process that will allow the powder to coat and bind to metal.  This is normally done with the use of a spray gun that will make the electrostatic charged powder particles to stick to the grounded metal portion.

After the parts are fully treated with powder coating, it will then go through a curing process.  The heat from the oven makes the coating chemically react and produce long molecular chains with high cross-link density.  The produced molecular chains will remain resistant to breakdown.  This is the most common method of powder coating being used.  Even non-metallic substrates can be treated with powder coating so you can use it on medium density fiberboard (MDF) and plastics.

There are instances where powder coating will be used during fluidized bed application.  The preheated parts are initially dipped in hopper of fluidizing powder.  This melts that coating, which then flows from the part.  It is essentially to post cure based on the temperature and mass of the part as well as the type of powder being used.

Overall, powder coating process is seen as environment-friendly, cost effective, easy to do, and extremely durable.

Market Demand

Obviously, there is a great demand for powder coating for it to last more than 40 years.  The growth can be attributed to the variety of outdoor materials that need to be powder coated.  The process of powder coating has been extremely useful in protecting materials like snow blowers, frills, lawn mowers, and wheelbarrows among others.  Powder coating makes it possible for these types of materials to combat harsh climates.

 

This is why it is not surprising that high market demand for powder coating services can be observed in industries like automotive, furniture making, consumer goods production, and architecture.  In the automotive industry alone, countries like Germany, Brazil, Malaysia, and China make extensive use of powder coating for protecting and finishing car parts.

 

Add to this the production of motorcycles, which has found immense benefits in powder coating.  With motorcycle parts almost completely exposed to the elements, durable and beautiful finish provided by powder coating helps motorcycles to continue functioning for a long time.

 

Now that you know how powder coating works, you need to know as well that not all service providers deliver the same high quality results.

 

Contact Byers Bush Powder Coating to get the best and highest quality powder coating work for your metal tools and enjoy the powder coating benefits in maximizing your business investment.

 

Restoring Faded Powder Coating on Your Tools

Posted on: December 26th, 2016 by byersbushblog

No matter how good the powder coating done to your window frames, extrusions, and furniture, time will come when it becomes faded.  This presents an unsightly presence that can lower the value of your property.  Despite the best of care and maintenance, you simply cannot prevent the inevitable.  So how can you restore faded powder coating and bring back its old glamor?

Reasons for Fading

With all the advances in technology, why does powder coating still fade?  Basically, the deterioration of powder coating can happen in varying speeds depending on the prevailing conditions.  If left untreated or unattended immediately, you can be sure that things can get worse fast.

Before knowing how to restore faded powder coating, it is equally important to understand what contributes to its deterioration.  That way, you know what your options are and how to exercise better care.

For aluminum window frames and extrusions, the most common reason for fading is the exposure to the sun that results in oxidation.  You can see some ugly pit formations that can be attributed to salt corrosion if your property is near the ocean.   Despite the protective finish of aluminum, pitting can still ruin it or can be stained by mortar or stucco.

So, exactly, why does powder coating fade?  Here are some possible reasons why:

  • Just like many manufacturing solutions, powder coating comes with a projected life expectancy. You can extend this with proper care and maintenance, but, the time will come when you have to redo things over.
  • Environmental factors can be one of the most common reasons, not only if you live near the ocean, but also in city centers where there is a high pollution index.
  • If the climate in your area is similar to the UK, then weathering can happen.
  • Improper cleaning methods that harms the powder coating rather than maintain it.
  • The longer it is exposed to the sun, the faster the powder coating will fade.
  • Some powder coating colors will fade faster compared to others.
  • Bird droppings can also negatively impact the coating.
  • Chalking, which results from UV light exposure will affect the binder and ruin the coat.

Prevention Methods

For powder coating, prevention methods are not really intended to prevent fading, but more so to extend the life of the coat so that you do not have to shoulder unnecessary expenses.  The great thing about this is that the prevention methods are quite easy to follow.

Let’s take a look how we can prevent powder coating from fading.

  • Regular cleaning, caring, and maintaining. This should be done more frequently if you are in a high build area, in a city center, or near the coastline.
  • Rely on proper cleaning methods and avoid using high pressure washers or harsh solvents.
  • Keep a record of cleaning and maintenance work to easily identify where the fading began.

Restoration of Faded Aluminum

Let’s face it, faded powder coating on aluminum does not look very good.  In fact, you may even think of throwing it away if it is a piece of furniture.  But you do not have to put up with that ugly look.  Here are some suggested steps on how to restore faded powder coating.

  1. Survey the area to compare the varying elevations and get an idea of the extent of the coating failure.
  2. Clean the area with the right cleaner and degreaser to remove any contaminants.
  3. Place protective masking on the unaffected areas.
  4. Lightly scrape the area and clean again to remove remaining dust and debris.
  5. Apply two-part acrylic powder coat and follow it up with multiple coats if necessary.
  6. Finish by carefully removing the protective masking and cleaning down the entire surface.

To make sure that you do not have to worry about powder coating fading too soon, entrust the work to experienced experts.

Contact Byers Bush, a professional powder coating company in Mississauga in giving quality protection to your valuable equipments.