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Towpreg Manufacturing Techniques
Published in R. Alagirusamy, Flexible Towpregs and Their Thermoplastic Composites, 2022
Vijay Goud, R. Alagirusamy, Apurba Das
Powder coating of fibers is an environmentally friendly process as no solvent is required. The fibers are under less stress during impregnation. High utilization as well as recovery of powder, along with elimination of expensive solvents, is an economic advantage obtained through powder coating. In powder coating, the flow of the resin is along the fiber; thereby, complete wet out can be achieved at lower pressures.
Failure to Consider All Costs of the Operation
Published in Gerald J. Watson, Jesse J. Derouin, Critical Thinking, 2020
Gerald J. Watson, Jesse J. Derouin
While working for a large office furniture company as a manufacturing engineer, one of the many responsibilities I had was to enter the bill of material, routing into the computer system and certifying its accuracy. The frame for a new product was a purchased part that was priced free on board (FOB) vendor, which means that the customer is responsible for paying the incoming freight. The frame was powder coated with aluminum color before shipping and the quality was guaranteed to be 100 percent usable. Powder coating is a method of finishing that is applied as a free-flowing dry powder and then allowed to cure under heat to form a skin, which is a hard finish that is usually more durable than most other type of finishes.
2 Composite Based Anticorrosive Coating
Published in S.K. Dhawan, Hema Bhandari, Gazala Ruhi, Brij Mohan Singh Bisht, Pradeep Sambyal, Corrosion Preventive Materials and Corrosion Testing, 2020
S.K. Dhawan, Hema Bhandari, Gazala Ruhi, Brij Mohan Singh Bisht, Pradeep Sambyal
McAndrew et al. (1998) proposed that the conducting polymer film acts as a barrier coating. Regardless of the barrier properties of conducting polymer films, any barrier coating can only protect the metal if it is firmly intact with the metal substrate. Once the substrate is exposed to the environment, corrosion may take place within the damaged area because the corrosive ions can penetrate into the substrate (Beentjes et al. 2004). The detachment of the coating may be avoided if it shows sufficient adhesion to the substrate. Epoxy-based coatings are well-known and are superior in several respects to conventional paints due to their better scratch hardness and better adhesion on the metal surface. However, epoxy coatings are found to often fail on exposure to corrosive environments for a longer period. In order to improve the efficiency and adhesion property of conducting polymer-based coating on the metal surface, the use of powder coating technique has been performed. The significant benefits of using powder coating technique are to attain durable, environmentally friendly and inexpensive coating that gives excellent finish in a single coat.
Electrostatic powder coating process optimisation by implementing design of experiments
Published in Transactions of the IMF, 2021
In the automotive industry, tractor cab manufacturers are attempting to upgrade their quality for better competition. Corrosion is the common problem of steel constructions. Coating of steel (with polymers containing anti-corrosion pigments enriched with additives) is one of the widely used applications for corrosion protection. Powder coatings are polymer-based resins. They are combined with curatives, pigments, and flow modifiers ground into a dry powder. Then powder coating is applied by spraying onto the pre-cleaned surface (metal or plastic products). To provide the expected durability, ISO 12944-51 classifies corrosivity (atmospheric) from C1 to C5, the C index (1–5) meaning the number of coats.
Managing the powder coat waste stream: an industrial experimentation approach
Published in Production Planning & Control, 2023
The ongoing industrial development has led to massive hazardous and non-hazardous industrial waste. The rise in environmental- and health-related risks associated with industrial wastes and by-products has captured the attention of government agencies and scientific researchers globally (EPA 2022). One of the under-researched industrial waste streams is thermosetting or thermoplastic resin powder waste, generated during powder coating, which is a dry powder-based painting method used for coating metal surfaces of automotive, appliances and other industrial products (EPA 2017; Gianello and Bhattacharya 2020; Krishna and Patowari 2013). A powder coating system is a surface finishing process in which dry and free-flowing powder is added to a surface, melted, and then hardened to make an even coating (Du et al. 2016). Although the powder coating method is accepted as an environment-friendly and cost-effective coating option with no volatile air emissions (unlike liquid coating), it is still prone to wastage. A large volume (ranging from 5 to 15%) of powder gets wasted during coat application (Karaoglan and Ozden 2021). Furthermore, with a rise in the customized coating, which require small production runs of varied powder coat colours, the volume of PCW has amplified significantly. As the global estimates, more than 800,000 tonnes of PCW were dumped at landfill sites worldwide in 2020 (EPA 2022). Owing to its additional disposal cost of incineration to producers, a large portion of landfilled PCW is in form of fine powder (or fines) containing 40–50% plastics. The landfilled fine powder containing microplastics leaks into the soil leading to the contamination of the soil structure and groundwater, thereby adversely impacting the regional ecology (The Lancet Planetary Health 2017). Furthermore, the practice of reuse, recycling and recovery of PCW is limited due to its complex composition and the high pressure on producers to use virgin powder to achieve zero surface defects (Lothongkum et al. 2007).
Enhanced corrosion protection by powder coatings on hot rolled steel (HRS) for high-temperature applications
Published in Transactions of the IMF, 2019
Typically, Hot Rolled Steel (HRS) exhibits properties such as moderate production costs that make it suitable for the manufacture of silencers and mufflers. To protect the steel from deterioration by either corrosion at room temperature or by oxidation at high temperature, protective coatings are often applied,1 especially steel used for silencers and mufflers, which have an operating temperature up to 550oC. Many finishing industries are seeking alternative coatings which have less or no Volatile Organic Compounds (VOC), in particular, due to tightening legislations. In this situation, powder paint is offering many advantages including no VOC, energy savings and the elimination of hazardous waste.2,3 Steel is used for broad purposes in the engineering industry. Steel, as mostly employed in service life, is subject to deterioration either by corrosion at room temperature or by oxidation at high temperature.3 To provide reliability to silencers and mufflers at high operating temperature, a heat resistant coating is required; mainly achieved by applying wet paint. However, concerns over increasingly stringent environmental and health and safety legislation regarding VOC level, require engineering companies to investigate alternative low or no VOC high-temperature coating systems. In this requirement powder coating was selected due to its VOC free content.1,2 Powder coating provides a reliable barrier coating for substrates such as aluminium, steel and alloys. It also provides UV protection, abrasion resistance and corrosion resistance. Most of the powder coatings, which require high-temperature resistance are silicone based. It is known that coatings or paints incorporating silicone resins have high heat resistance.4 The silicone resin skeleton formed of a siloxane bond (–O–Si–O–), can maintain its binder characteristics after heating. Therefore, in this study, polysiloxane based powder coating has been used for high-temperature powder coating applications. A drawback of the powder coating for high-temperature application is coating delamination due to the expansion and retraction effect, known as mismatch thermal coefficient between substrate and coating. In high-temperature applications it is often noted that cracking and flaking of the coating leads coated components to corrode due to loss of corrosion barrier properties.5 Thus, in this study, it was aimed to increase the flexibility of the powder coating which will be used in high-temperature applications of up to 550°C. To increase the flexibility and corrosion protection of the powder coating the composition was comprised of fibres to enhance properties such as increased corrosion resistance, improved adhesion and thermal stability before and after high-temperature treatment.