AdQual Castech Services

This intensive two day course seeks to provide a clear understanding of all aspects of powder coating technology. The course includes an insight into the formulation and manufacture of coating powders, both thermoplastic and thermosetting. Particular emphasis is given to coating selection (based on the anticipated requirements of the end user), outdoor exposure, corrosion resistance and costs benefits associated with powder coating. Application techniques are discussed in-depth from simple fluidised bed dipping to fully automated electrostatic systems.

Health, safety and environmental isssues are covered for both the manufacturing and application processes.

The course includes a half-day practical session at a nearby powder coating installation, where there will be opportunities to apply coating powders, understand application parameters,and test coatings in production conditions.

Who Should Attend

This course will be particularly useful to those responsible for the introduction and use of coating powders and for those, who on a day-to-day basis, wish to apply them efficiently and effectively.

It is helpful if delegates have some knowledge of surface coatings and the principles associated with their application and use.

Contents of Course

Coating Powders

• History, development, types of coating powder & their basic chemistry
• Typical end-uses/markets for powders

Formulation

• Raw materials, limitations of processing equipment, production techniques often imposed by application & substrate
• Formulation techniques-aiming for robustness, and performance requirements determined by end user expectation
• Thin film powders

Manufacture

• The process & quality control-particle size distribution
• Master batching & processing problems
• Safety, health & environmental issues (SHE)-SPACE
• Future developments in processing

End Use

• Understanding coating selection
• Problems possibly arising from formulation & manufacture
• End-user expectation

The Substrate

• Handling components, jigging & masking
• The pre-treatment of ferrous & non-ferrous metals, wood & MDF, glass plastics
• Simple adhesion theory
• Degreasing
• Mechanical cleaning
• Chemical cleaning & conversion coatings
• Primer coats for improved performance

Application

• History & development of powder coating techniques
• Advantages & disadvantages of powder coating from a coater's perspective
• Choosing an application system: fluidised bed dipping, flock techniques, electrostatic spray & fluidised bed systems

Fluidised Bed Coating

• What is fluidised bed application?
• Pre heating & the relationship of time & temperature
• Manual & automatic application
• Post curing & cooling or quenching

Electrostatic Application

• What is an electrostatic application, charging systems
• Application systems, guns, powder feed, booths, powder recovery & recycling

Practical Industrial Application on the Shop Floor

• Setting up application equipment, transfer efficiency & coating thickness
• Using different powders
• Right first time quality
• Coating rectification
• Good housekeeping & working safely

Curing

• The importance of melt/cure & oven profiling
• Convection ovens
• Radiation ovens, infrared, ultra violet
  

Testing of Powder Coatings

• Colour, gloss, adhesion, melt/cure, hardness & abrasion
• Weathering & corrosion resistance
  

Troubleshooting

• Coating powder defects
• Powder coating defects
• Process problems

Working Safely

• Health, safety & the environment - risk, dust & other hazards
• Legislation
• Standards
  
  

Tutors

Mr Malcolm Griffiths - Consultant Ad-Qual Castech Ltd (Advisory & Training Services for the Finishing Industry).