Rather than allowing the parts to dry between coats, everything is done at once, which saves money and time. The powder is less costly than paint, and it takes up less space when stored. As far as the finish is concerned, powder coating is more durable than most other options.
When it cures, the powder will form chemical bonds in the process and creating a flexible, durable finish. Powder coated parts are highly resistant to corrosion, flaking, and scratching. While mil spec powder coating has a few common finishes and colors, one of the biggest benefits of the method is the potential for customization.
Powder manufacturers will create unique blends to match any color, texture, and finish. There are few competitive options in terms of versatility and range.
The processes release no harmful chemicals into the air, and they produce less waste. However, expert painters know to avoid inhaling the powder and to wear safety gear that minimizes skin contact.
The powder coating application and drying processes create a finish not found in any other paint product. Because the powder melts and reforms as a solid, it creates a smooth surface without drips or runs. Powder coating is easy to maintain; no special solvents or cleaners are required.
In most applications, an occasional wipe with soapy water is enough to keep parts clean and useful for years into the future. The range of suitable materials for the powder coating process is limited to materials that can withstand the temperatures required to melt and cure the powder coating material without melting, deforming, or burning itself. The chosen material also helps determine the coating method employed.
Since metals can be electrically grounded, the coating material is generally applied to metal substrates via the electrostatic spray deposition method, but they can also be applied via the fluidized bed method. On the other hand, since non-metals cannot be sufficiently grounded, they require that the powder coatings be applied through the fluidized bed powder coating method. Powder coatings can be applied in a wide range of colors, finishes, textures, and thicknesses that are not readily achievable through conventional liquid coating methods.
Capable of being manufactured in virtually any color, powder coating materials can be formulated for both protective and decorative applications. The final finish achieved by the powder material ranges from matte to glossy, and clear to glittered or metallic. Various textures are also available for decorative purposes or hiding surface imperfections. The powder coating process allows for a wider range of coating thicknesses. Compared to the liquid coating process, powder coating can more readily produce thicker, even coatings, especially when using the fluidized bed coating method.
Using the ESD method, it is also possible to achieve thin, even coatings; albeit, not as thin as the coatings achieved via the liquid coating process. The powder coating method offers several advantages over conventional liquid coating methods, including increased durability, capabilities for more specialized finishes, less environmental impact, faster turnaround time, and lower material costs. In addition to being available with a wide range of finish options, powder coatings are generally more long-lasting and durable than liquid coatings.
They demonstrate higher resistance to impact, moisture, chemicals, and wear, and offer greater protection from scratches, abrasion, corrosion, fading, and general wear. These characteristics make them well-suited for high use and high traffic applications. Another advantage of the powder coatings is the lack of solvent and carbon dioxide emissions, hazardous waste material that requires disposal, and, generally, surface primer requirements. These exclusions limit the amount of toxic and carcinogenic substances being released into the environment throughout the process and contribute to the recognition of powder coating as a more environmentally-friendly alternative to liquid coatings.
The process can have much lower long-term costs compared to the liquid coating process due to its having a generally quicker turnaround and greater coating material utilization. Since the curing stage of powder coating allows powder coated parts to be assembled, packaged, and shipped immediately after the part is cool, parts spend less time in inventory which enables manufacturers and finishing service providers to have a faster turnaround and less storage space requirements.
The process also allows for overspray material to be collected and recycled instead of wasted, which decreases the amount of waste product requiring disposal, increases the coating material utilization rate, and lowers the cost of materials over time. Although the powder coating process offers several important advantages over liquid coating, there are also limitations to the process.
Limitations of powder coating include a restricted range of suitable substrate materials, difficulty producing even, thin coatings, longer lead times for color changing coatings, longer dry and cure times for large parts, and higher start-up costs. As mentioned previously, substrate materials must be able to withstand the temperature requirements of the curing stage to be suitable for powder coating applications.
Even if a material can withstand the heat, achieving an even coating can still prove to be problematic, especially for thin or multi-color coatings.
Thin coatings are difficult to produce as it is challenging to control the amount of powder material that is applied to the substrate during the application stage while still ensuring an even coating.
Multi-color coatings are difficult to produce quickly because any overspray must be thoroughly gathered and cleaned from the spray area between color changes; otherwise, it may cause cross-contamination in recycled or reused materials. While the powder coating process can have lower costs over time, for specific coating applications, it may be more cost-effective to use liquid coatings.
For example, while powder coated parts typically have faster turnaround, large, thick, or heavy parts tend to require higher temperatures and more extended curing and drying times; not only would these lengthened cure schedules delay the production process, they would also lead to higher energy costs.
For manufacturers and finishing services providers starting up, the initial investment in powder coating equipment also tends to be higher than with liquid coating as the process requires a spray gun, specialized spray booth, and a curing oven. The last two pieces of equipment add substantially to the initial start-up costs and may make powder coating unsuitable for a low budget operation.
The powder coating process can be used in a wide variety of manufacturing applications. The specific production requirements of an application — e. For manufacturers who cannot perform in-house powder coating operations, their prototype, short, and long production run jobs can be handled by a job shop or finishing service provider who offers powder coating services.
Job shops exist in all sizes from one person operations to businesses with hundreds of trained employees and with a wide range of coating capabilities and specialties. For high volume coating applications, finishing service contractors can also prove to be a viable option. These contractors can design and build custom systems for coating specific parts, which ensures that the parts are coated consistently and to the required specifications.
The chemical bonding process strengthens the powder coating because once cured, the bonds solidify. One of the most significant advantages of using powder coatings is that once solidified, more layers can be added id thickness is desired. Thicker coatings mean longevity and increased protection. Powder coatings are suitable for metal because they repel corrosive materials, such as chemicals and water.
This is hands down one of the most durable coatings you could use as a finish for a variety of surfaces, not just metal. The chemical bonds give a superior coating that makes it suitable for both machinery and everyday items. The longevity of the product will highly depend on several factors. These factors include the quality of preparation, type of powder coating used, and the environment in which the product is exposed. Powder coating finishes can last up to 20 years , but due to the consistent use, exposure to UV light, and outdoor environment may break it down faster.
Different coatings also have varying lifespans. For instance, coatings that have fluoropolymers and urethanes can last longer. They are designed to withstand extreme conditions and are better suited for outdoor products. Epoxy coatings, on the other hand, may last very long indoors, but once exposed to the outdoors, they break down a lot faster. Powder coatings have several advantages, which makes them an excellent choice for metal fabrication.
Apart from the legendary durability, here are more strong points that you may want to consider when choosing a finish. Environmentally Friendly : This an eco-friendly option as it is reusable and recyclable.
Thermoplastic coatings especially can be reshaped very easily, unlike thermosets. The powder is also used precisely with minimal wastage, unlike paint, where you experience a lot of oversprays. Powder coating does not release volatile organic compounds that may harm the environment. Cost-Effective: With powder coating finishes, the upfront experience will seem significant, and possibly overwhelming for some. Over time, however, the coat is much lower compared to other different types of finishes.
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