Electrostatic Powder Coating :
Powder Coating is a manufacturing process called Electrostatic Spray Deposition (ESD) that employs charged particles to a workpiece, by electrostatic power and then attracted to the part which creates a thin and sticky layer on the surface. Powder coatings are compatible with the environment because they don’t require solvent and are economical to be used, which can be recycled and reused many times. Powder coating provides superior edge coverage and powder coated parts virtually have no drips, runs, or sags so your part will have a high quality and durable finish.
This is typically used to achieve the application of the completely dry powder directly to a metal substrate. The workpiece generally travels down a conveyor belt to the spray booth with the application method used by a spray gun. After which, the coated parts enter into an oven baking at 400 degrees Fahrenheit with cure time of 10-30 minutes. During the baking period, the powders melt from the heat and the coating chemically reacts to make long molecular chains, resulting in high cross-link density which creates a tough and indissoluble coating.
The powder coating process was first developed in the 1940s and early 1950s. Initially, organic polymers (or macromolecules) were “flame-sprayed” in a powder form onto metallic bases. Then in the early 1950s, a German scientist developed (and then patented) a fluidized-bed process for Thermosetting Powder Coatings. However, in the 1960s and early 1970s, two developments combined to build new interest in the powder coating process. (1) The growing ecology movement and (2) New application techniques. It was really a combination of these two things that led to the method’s growth and success. In the 1960s, application by electrostatic spray, where powder particles are charged and then sprayed onto a grounded material was then developed.
Powder coatings advantages
1 - Non-toxic and lack of heavy metal such as lead and cadmium
2 - Very efficient as there is little waste created in the process
3 - Free of solvents and harmful vapors resulting in decreasing respiratory diseases and pulmonary infections
4 - Much more durable than paint options as the chemical chains and gels together during curing
5 - High safely comparing with liquid paints regarding fire danger
6 - Easy control and usage and ready to be used without professional instruction to the painting personnel
7 - Saving time and increasing production speed resulting in decreasing energy consumption
8 - Because of the recycling capabilities, it is possible 95% of powder coatings to be used
9 - The high chemical and physical resistance comparing with liquid paints causes to increase coated component’s life
10 - This is the best method to completely customize color and finish
11 - Easy to maintain, no special solvents or cleaners are required, just soapy water
12 - Does not cause damage to surfaces, rust or corrosion
13 - The product has a long shelf life and can be used for many years after which it has been manufactured
14 - The overall quality is unlike any other paint on the market, since the powder melts and flows together