Thermoplastics and Thermosets
All forms of powder coating powders fall under two major categories: thermoplastic and thermoset. Thermoplastics are commonly used for their chemical resistance and general durability and are typically applied by fluidized beds. Thermoplastic powder coatings will melt when exposed to high temperatures. This prevents any chemical bonds from forming and allows for the powder coating to be reused.
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When applying a thermoplastic powder coating, the surface that is about to receive the coating will be heated to a temperature that is much higher than the powder&#;s melting point. This is part of what makes them extremely adhesive to metal. When a thermoplastic powder hits a heated surface, it fusion bonds to the surface and then creates a film covering the substrate. They are also known to for their thickness and tend to be more durable than most thermoset powder coatings.
Thermosets are different in that they form chemical bonds during the curing process. These powder coats have resins that hold a lower molecular weight than thermoplastics. This means that during the curing process, when the coating is exposed to high temperatures it will melt into a thin, uniform film and begin to cross with each other or with other reactive components within the powder coating. As a result of this cross-link they form a product that holds a much higher molecular weight and become far less sensitive to heat.
Thermoset coats will offer better protection and long term performance when dealing with metal equipment like electronics or general home applications because they are built to withstand higher temperatures and more direct heat than thermoplastics. Thermoplastic powder coatings and their added flexibility are better suited for surfaces that may be subject to frequent contact such as railings, fences, or playground equipment.
Any materials coated using powder coating will be more resistant to any and all forms of contact when compared to traditional coating methods.
Thermoplastic Resins
Within these two major types of powder coating lie more specific forms of powder coatings based on the resin that is used. Each the resins have different properties that make the powders they are mixed with more suitable for specific applications and environments. If you need a flexible powder coating that provides added resistance to corrosion, then it would be better to select an epoxy based powder coating over a polyester based powder coating.
Nylon
Nylon is one of the most common bases used in thermoplastic powder. More commonly referred to as polyamides, these nylon-based thermoplastics are incredibly durable and provide additional chemical and solvent protection. Polyamide coatings are seen frequently on dishwasher baskets, pipes, valves, and outdoor applications because of its added strength and clean appearance.
Polyester
Thermoplastic polyester powders will not typically require a primer to aid in the adhesion process. Polyester powder coatings can lack some of the impact resistance that other powder coatings may offer, but is still more resistant than traditional liquid paints and coatings. One of polyester powders best properties is its strong resistance to UV. This prevents the powder coating from yellowing or chalking over time.
Polyester powders that are mixed with TGIC (triglycidyl isocyanurate) in the curing process gain additional impact and weather resistance. TGIC polyester makes a great choice for any outdoor items that would need added protection from light, such as patio furniture or panels on large industrial buildings. Polyesters are a versatile form of resin and will commonly be found mixed with others to create a hybrid powder coat.
Epoxy-Polyester Hybrid
Epoxy polyester is a hybrid between two of the most popular powder coating hybrids available. It is more resistant to chalking and over-baking than pure epoxies and coat surfaces to a greater degree. This makes the hybrid a good choice for decorative applications. This powder coating is slightly less resistant to chemicals and solvents and displays a lower surface hardness. This hybrid is usually used for residential applications such as shelving and office furniture.
Thermoset resins
Polyurethane
Not many resins are as versatile as polyester. Polyester can be applied as a thermoplastic or as a thermoset. Polyurethane is a hybrid powder coating of polyester and urethane coatings. Polyurethane has a thin film appearance that is durable and offers strong mechanical and chemical resistance. Polyurethane powder must be applied at a higher heat in the curing process which means parts that contain lead, cast, and sometimes aluminum are unable to be coated.
Epoxy
Thermosets that contain epoxy offer some of the best corrosion and impact resistance of any powder coating finish. You will see epoxy finishes commonly used in the automotive industry and when covering electrical components. Epoxy has an electrical insulation property and can be used as an adhesive, sealant, coating or more with electrical applications. Epoxy coatings are sensitive to light and high heat areas so they should not be used for outdoor applications. This is why you will commonly see epoxy coatings underneath the hoods of cars and in other areas of the vehicle that require a tough and resistant coating without risking exposure or contact with light.
Acrylic
Acrylic powder coating is popular in the automotive industry as well. Commonly used for clear coatings, acrylic powder will cure into a smooth surface that exhibits great impact resistance. When you mix acrylic with a resin such as urethane it can become quite versatile. Acrylic urethane finishes have a great appearance with brilliant color and gloss. The finish has great durability and resistance to chemicals and weathering. This powder coating hybrid has some limiting properties however, notably that it must be rather thin as it can begin to pull back on itself as the thickness increases.
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Powder coating is a dry painting method used in a wide variety of industries. Creating a tough and durable finish, available in a wide range of colours, it always follows the same process.
In its most simple form, powder coating powder is sprayed onto the parts through a handheld gun or range of nozzles in a larger manufacturing process and then cured in an oven. During this heating process, the powder melts, essentially spreading across the entire surface before drying.
Within powder coating, though, there are endless different opportunities to create unique colours and finishes.
All require different powder and different heating, but all provide the same results.
Let&#;s explore the possibilities below.
Different Types of Powder Coating
Specially formulated powder coating finishes have become increasingly durable over recent years as a result of technological advances. So, if you want a standard matte finish or powder coating in a rainbow of pearlescence and sheen, it&#;ll always be a flawless finish that protects the end product. And while costs for powder coating vary, let&#;s explore what the finishing options are.
1: Matte Finish Powder Coating
Simple and effective. The powder coating stalwart is available in any colour from the RAL chart, matte finish powder coating, also known as flat has a gloss level of around 30. While it does reflect some light, it&#;s not as clear-cut as other finishes and provides a perfect complement to any product.
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2: Gloss Powder Coating
Starting at a gloss level of around 70, gloss is a very common powder coating finish, leaving a reflection, but one that isn&#;t highly refined.
Compare that to something like a medium gloss with a gloss level of 75, and a high gloss with a level of 80 and you start getting an almost water-like finish to your powder coating, providing greater definition to all corners and edges.
3: Sparkle Powder Coating
Using flecks of aluminium and mica in the powder, sparkle coating helps provide powder coating finishes from pearlescence through to deep earth metallics.
As the light catches the metallic flecks within the powder coat, you&#;ll be hit with a range of diamond-like light reflected rainbows.
4: Sand Texture Powder Coating
With material added into the coating process, its name is taken from the sandpaper-like texture it creates. Sand texture powder coating creates higher levels of friction, which is required for certain applications.
5:&#;&#;Hammer Powder Coating
The hammer effect can be compared to a sand texture.&#; Its distressed look provides the powder coated product with an antique aesthetic.&#; Metallic pigments of gold or silver weave through a dark undercoating, providing an aged texture which is becoming common in domestic projects.
6: Clear Powder Coating
Common when you are looking at changing the gloss levels on a finish or adding contrast and shine, clear coat powder coating can be added to any colour. The benefit is purely aesthetic as higher gloss levels are often required, although it&#;s common to add a clear coat to metallic powder coating as it protects the finish from oxidizing over time.
&#;7: Chrome & Metallic Powder Coating
Using powder version of metallic materials, chrome and metallic powder coating give you the opportunity to replicate any automotive finishes on your parts. It&#;s recommended that metallic powder coating is coated in a clear layer to slow down any oxidization.
Other Common Powder Coating Finishes
There are a variety of other powder coating finishes that are available and need to be mentioned too, these include.
- Spatter Powder Coating
- Wet & Dry Powder Coating Variations
- Marble Powder Coating
- Wrinkle Powder Coating
The Right Powder Coating Finish
Finding the correct powder coating finish can be overwhelming, but powder coating experts are here to guide your decision.
What industry are you powder coating your parts for? Are there certain requirements you need to meet? Is it a domestic or industrial project? Answering these will help tailor the right powder coating finish for you.
Need a hand? Then fill in the form below and our experts can help you. Based in Wolverhampton, West Midlands, Ercon can provide a powder coating finish wherever in the UK your business is based.
Contact us to discuss your requirements of roll-to-roll coating systems. Our experienced sales team can help you identify the options that best suit your needs.