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

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.

Knowing Different Types of Powder Coating Guns

Posted on: December 24th, 2016 by byersbushblog

Have you ever seen a powder coating gun?  These types of guns deliver the right intensity to allow the air in the chamber to spray the dry powder.  The powder is charged to ensure that it sticks to the surface to be coated.  Different techniques are often used to produce the electrostatic charge.  Did you know that there are different types of powder coating guns?

Types of Gun

There is no denying that the powder coating gun is one of the most important elements in ensuring that proper powder coating process is accomplished.  The type of gun usually dictates the type of finishing technique applied on a surface.  This means that powder coating guns for thermosetting and thermoplastics are different.

The great news is that all types of powder coating guns never pose risks to the user.  It is also normal for significant amounts of dust to be produced because you have to remember that dry powder is being used.  So what are the types of guns used in powder coating methods today?

  • Craftsman Gun

This type of powder coating gun does not make use of any air compressor.  The craftsman gun is ideal for those who are only starting to do powder coating.  The powder is placed in a small plastic cup, which means frequent refilling.

The grounded object is placed in the cup and loaded onto the gun to start coating.  The powder will be charged by the metal pin at the middle of the gun.  You have to clean the pin regularly because if it becomes coated, it will lessen its efficiency.  The craftsman gun is one of the most affordable in the market.

  • Wagner Sprint X

Many beginners prefer this gun because of the easy availability of replacement parts.  It is fitted with an initiative rotary dial that allows the user to choose among the different setting based on the kind of powder and coat that you want.  The application rate of the Wagner Sprint X is measured at 450 grams per minute and is ideal for beginners in powder coating who are sensitive about the price.

  • Harbor Freight

This is a great gun from a good company.  That is why this type of powder coating gun is an excellent choice for virtually all types of powder coating method.  The company that manufactures this gun sells it in a variety of colors.

  • Gema Optiflex 2

Are you looking for a durable and high performing powder coating gun?  Then this is the right one for you.  A bit pricey because of its power, durability, and warranty, it allows for easy assembly that delivers a smooth spraying action.  With an application rate of 395 grams per unit, it delivers efficient results even if you make multiple coats.  Difficult areas can be coated with ease using its PCC mode and the Faraday cage areas can be covered with efficiency by removing free ions from the charge field.

  • Nordson Encore XT

Light, easy to use and a high quality for a mid-priced powder coating gun.  It comes with 17 customizable settings that you can save for future use.  Skilled powder coaters will find this type of gun of great use because it is highly efficient with Faraday cage issues and covering tight areas.

  • Eastwood Gun

One of the very few guns that has a dual voltage function, it comes with a kit that includes assorted colors, plugs, and tape.  The instruction manual is very useful to correctly operate it.

  • Hotcoat Dual Voltage

Another dual voltage gun that is dependable when doing dual coats.  You can choose from minimum to 25kV voltage settings.  This is useful in covering different types of metal.  The higher the voltage, the more powder sticks to the surface.  Setting it too high though can cause the powder to bounce off.  This type of powder coating gun also has a kit that comes with powders.

So many types of powder coating guns to choose from.  But if you really want to get things right, trust the experience of the experts in powder coating processes.

Contact Byers Bush powder coating today to let the experts handle your coating jobs with high efficiency and high performance, resulting in giving quality metal protection.

History of Corrosion Prevention Coat Called Powder Coating

Posted on: December 22nd, 2016 by byersbushblog

Powder coating is one of the widely used processes in various industries today.  It has provided a more environment friendly solution to creating a beautiful and durable finish in cars, appliances, and buildings among others.  But, do you know how this process found its way into modern usage?  Let’s take a look at the history of powder coating.

Its Beginnings

Would you believe that powder coating first came about during the 1940s?  It was the result of the European finishing and coating industry coming under pressure to deliver a process and dry coating that would be friendlier to the environment.  The coating method used at the time involved flame spraying using flammable gases to generate enough heat that would melt the coating for the material.

Dr. Erwin Gemmer found a way for the bed application to be fluidized, making it possible for use with thermoplastic resins on metal.  This was definitely a more efficient way of coating compared to flame spraying.  Between the periods of 1958 to 1965, almost all powder coating processes made used of fluidized bed.  Majority of the processes were by nature functional resulting in the creation of film that has an acceptable thickness of 6 to 20 mils.

The thick film were usually applied to electrical insulations including abrasion and corrosion resistance methods.  The coating materials were made of CAB, plasticized PVC, nylon 11, polyethylene, chlorinated polyether, polyester, and other materials.

For the next 40 years the powder coating process would experience dramatic improvements in terms of application and efficiency with the introduction of the powder coating oven.  During the 1980s the use of the powder coating oven had almost dominated application processes and led to the innovative advancements in resin and powder coating procedures by yielding decreased waste, better efficiency, and lower operation costs.

Responding to the Market

With the continuous innovation experienced by the powder coating method and the emergence of the powder coating oven, the industry became more than equipped to deal with the various issues covering liquid finishing and respond to the market needs.

One of the main issues that was eventually resolved was the problem of finishes not lasting as long as desired to protect the materials.  The high costs, safety concerns, and pollution issues associated with traditional liquid finishing methods were no longer hounding the market.

 

With the use of various technologies and methods of applications that eventually became refined through the years of powder coating experience, even industry pioneers found a way to develop their own environmental friendly processes based on the technology.

 

During the latter part of the 1970s another unique application technique surfaced, but for some reason was never fully appreciated by the market.  This technique relied used epoxy-based slurry that would be sprayed on materials conventionally and baked.  The resulting coated film performed and looks much like those of the other powder coating methods.  However, the common complaint from the market was that the application of the powder slurry frequently clotted as it was being sprayed.  Even if proper adjustment and handling could easily overcome this process, it never became a market standard.

 

In the United States and Europe, fluidized beds were getting huge acceptance even as other application methods were making its way into the market.  Most of these new systems were intended for commercial usage.  The newer methods of powder coating allows for the treatment of new and used parts once they have been chemically cleaned and degreased.

 

So what was once put forth as a European solution to environmental pressures from major markets is now widely used and accepted as a suitable replacement for liquid finishing and has proven to advance the technology even further.

 

Contact Byers Bush now to learn on how proper powder coating can benefit you and get quality metal corrosion prevention coating to protect your valuable tools against rust attack.

Efficiently Disposing Powder Coating Waste

Posted on: December 20th, 2016 by byersbushblog

Did you know that for the longest time powder coating has delivered the environment-friendly solution for finishing metals, ceramics, and other heat-resistant materials?  This substitute to the traditional liquid finishing processes is highly regarded as non-toxic and uses non-volatile organic compounds.  This does not mean though that it does not produce any waste.  How do you dispose powder coating waste?

Types of Waste

In every powder coating process, two types of wastes will be produced.  This happens during the manufacturing of the powder resulting in wasted grains and at the instance of over spraying particles that fail to stick to the material.  Because the residue powder is not toxic, you simply have to collect it properly to ensure proper disposal.

According to some researches, the average powder coating process has an efficiency of 63%.  This means that about 37% is either unused or wasted.  Around 40% of the wasted powder usually ends up in landfills.  Obviously, this considerably high percentage must be reduced to minimize waste through innovative recycling techniques.

Minimizing Waste

Just like in any other waste reduction technique, the principles of Reduce, Reuse, and Recycle come into play.  But how do you apply these to powder coating methods?

 

  • Reduce

Reduction of wasted powder can be done by ensuring good transfer efficiency at first pass.  How do you do this?  Normally, controlling the application methods used will help achieve this like:

  • Powder velocity;
  • Gun positioning;
  • Temperature and humidity control; and
  • Correct powder output.

 

When you keep all of these in the proper range, you reach maximum efficiency, allowing the powder to stick better to the treated surface.  Proper and frequent cleaning is also necessary to reduce wasted powder.  In gathering over-scattered powder, booth recovery systems can help in reusing the powder.

 

  • Reuse

The key in reusing powder is the right equipment combined with good scheduling.  Reclaiming waste can be done by ensuring that over spraying is avoided.  Did you know that scrap powder can be used for other purposes?  For example, you can protect inner parts against rust or be used during testing.  You can do trial runs using wasted powder or mix it with black to be applied for non-cosmetic materials like steel grating.  You need to maintain a large distance between streams when reusing powder and separate the coating materials using discrete recovery systems.

 

  • Recycle

How do you recycle the wasted powder?  One technique is to bake it into a block and dispose of it in non-flammable containers.  The blocks can be easily disposed or reused as counterweights.  You can even mix it with cement to produce solid dry molding blocks or use as padding for soundproofing.

 

Other Disposal Methods

There are also other alternatives on how to dispose powder coating waste.  These can include:

  • Multi-colored products – powder coating can be used in multi-colored products like those found in the commercial office industry. The multi-color is normally produced during the cleaning of the spray guns when color change is needed.  The gathered waste can be sold to this industry.
  • Direct to garbage – generally the powders are non-toxic and pose no threats. To be on the safe side, inspect the powder before throwing it into the garbage.
  • Enlarge the particles – there are three processes to increase the size of the accumulated powder:
    • Pressure compaction – this process can enlarge the otherwise miniscule size of the powder particles. As the size of the powder gets bigger, the easier it is to dispose of.
    • Agglomeration by tumbling – with the help of a liquid binder, mixing, and vibrating, bigger sized particles are produced. This process however can negatively impact the film properties.
    • Agglomeration by heating – this relies on heat to produce a gluey powder surface. Overheating the waste though can cause a different set of problems.

 

Contact Byers Bush Powder Coating, an expert in the field of powder coating with over 40 years of experience, to help you with your coating project and enjoy the powder coating benefits for your investment efficiently.