Paint Technology Handbook

Preface
Author
Chapter1 Part Preparation Processes and Equipment
1.1 Cleaning
1.1.1 TypesofSoil
1.1.1.1 RustInhibitors
1.1.1.2 ShopDirt
1.1.1.3 Carbon
1.1.1.4 Oxidation
1.1.1.5 Wax
1.1.1.6 Soaps
1.1.1.7 Polymers
1.1.1.8 Silicone
1.1.2 Mechanical Cleaning
1.1.2.1 Blasting
1.1.2.2 Blast Media
1.1.2.3 Vibratory Cleaning or Tumbling
1.1.3 Chemical Cleaning
1.1.4 Chemical Cleaning Processes
1.1.4.1 HandWipe
1.1.4.2 Immersion Cleaning
1.1.4.3 Hand-Held Spray Wand
1.1.4.4 Ultrasonic Cleaning
1.1.4.5 Recirculating Spray Washers
1.1.5 Common Industrial Chemical Cleaners
1.1.5.1 Alkaline Cleaning
1.1.5.2 Neutral Cleaners
1.1.5.3 Acid Cleaners
1.1.6 Surfactants
1.1.7 Factors that Affect the Performance of the Cleaner
1.1.7.1 Quality of Water Supply
1.1.7.2 Soils in Solution
1.1.7.3 Time
1.1.7.4 Temperature
1.1.7.5 SprayPressure
1.1.7.6 Concentration

1.1.8 Methods Used to Measure Cleaning Results
1.1.9 Summary
1.2 Conversion Coatings
1.2.1 Iron Phosphate
1.2.2 Coating Weight
1.2.3 Iron Phosphate Controls
1.2.3.1 Temperature
1.2.3.2 Chemical Concentration
1.2.3.3 Acid Consumed
1.2.4 Zinc Phosphate
1.2.5 Activating (Prior to Zinc Phosphate)
1.2.6 Comparison of Iron Phosphate to Zinc Phosphate
1.3 Rinsing
1.3.1 Rinse and Rinse Seal
1.3.2 Reverse Osmosis (RO) or Deionized (DI) WaterRinse
1.4 Typical Spray Washer Systems
1.4.1 Stages of Pretreatment
1.5 Substrates
1.5.1 Metal Substrates
1.5.1.1 Steel
1.5.1.2 Aluminum
1.5.2 Plastic Substrates
1.5.3 Wood Substrates
1.6 Washer Design
1.6.1 Washer Components
1.6.1.1 Solution Tanks
1.6.1.2 Drainage Spaces
1.6.1.3 Tank and Housing Materials
1.6.1.4 Zinc Phosphate Tank
1.6.1.5 Sludge Removal Tank
1.6.1.6 Access Doors, Ladders, and Lighting
1.6.1.7 Pumps
1.6.1.8 Nozzles
1.6.2 Water Conservation
1.7 Washer Maintenance and Control
1.7.1 Mechanical Maintenance
1.7.2 Chemical Maintenance
1.7.2.1 TDS
1.7.2.2 Temperature
1.7.2.3 pH Measurement
1.7.2.4 Washer Control Methods
1.7.2.5 Manual Bath Control
1.7.2.6 Automated Control Techniques
1.7.2.7 Metering Pumps
1.7.2.8 Theory of Automated Control
1.7.2.9 Conductivity Control
1.7.2.10 Contacting Conductivity
1.7.2.11 Non contacting Conductivity
1.7.2.12 Zinc Phosphate Control
1.7.2.13 pH Controllers
1.7.2.14 Interfacing Controllers with a Computer
1.7.2.15 Data Acquisition Tools
1.7.2.16 Computer Control Systems

Chapter 2 Paint Components
2.1 Resin (Binder)
2.1.1 Oils and Oleoresinous Varnishes
2.1.2 Alkyd Resins
2.1.3 Polyester Resins
2.1.4 Acrylic Resins
2.1.5 Amino Resins
2.1.6 Epoxy Resins
2.1.7 Urethane Resins
2.2 Pigments
2.2.1 White Pigments
2.2.1.1 Titanium Dioxide
2.2.1.2 Zinc Oxide
2.2.1.3 Antimony Oxide
2.2.1.4 White Lead
2.2.2 Yellow Pigments
2.2.2.1 Yellow Dyes
2.2.2.2 Benzidine Yellows
2.2.2.3 Lead Chromates
2.2.2.4 Zinc Chromate
2.2.2.5 Yellow Iron Oxides
2.2.2.6 Cadmium Yellow
2.2.3 Green Pigments
2.2.3.1 Phthalo Green
2.2.3.2 Chromium Oxide
2.2.3.3 Lead Chrome Greens
2.2.4 Blue Pigments
2.2.4.1 Phthalocyan in eBlues
2.2.4.2 Prussian Blue
2.2.4.3 Ultramarine Blue
2.2.5 Red Pigments
2.2.5.1 Toluidine Reds
2.2.5.2 Arylamide Reds
2.2.5.3 Red Iron Oxide
2.2.6 Black Pigments
2.2.6.1 Black Iron Oxide
2.2.6.2 Carbon Blacks
2.2.7 Metallic Pigments
2.2.7.1 Aluminum Pigment
2.2.7.2 Mica
2.3 Extenders
2.3.1 Barites
2.3.2 Kaolin Clay
2.3.3 Talc
2.3.4 Calcium Carbonate (Limestone)

2.4 Solvents
2.4.1 HydrocarbonSolvents
2.4.1.1 Toluene
2.4.1.2 MineralSpirits
2.4.1.3 Xylene
2.4.2 Oxygenated Solvents
2.4.2.1 Buty lAlcohol
2.4.2.2 Ethyl Alcohol
2.4.2.3 Ethylene Glycol  Mono ethyl Ether
2.4.2.4 Acetone
2.4.2.5 Methyl Ethyl Ketone (MEK)
2.4.2.6 MethylI sobutyl Ketone
2.4.2.7 Butyl Acetate
2.4.2.8 Ethyl Acetate

2.5 Additives
2.6 Summary

Chapter 3 Liquid Organic Coatings
3.1 Coatings Selection
3.1.1 Appearance
3.1.2 Performance
3.1.3 Other Factors
3.2 Paint Classifications
3.2.1 Paints Classifed by Task
3.2.1.1 Primers
3.2.1.2 Sealers and Surfacers
3.2.1.3 Topcoat
3.2.2 Paints Classifed by Physical Type
3.2.2.1 Water borne Coatings
3.2.2.2 High-Solids Coatings
3.3 Film Formation
3.3.1 Application
3.3.2 Fixation
3.3.2.1 The Evaporation Factor
3.3.2.2 Rheology
3.3.2.3 Flocculation and Settling
3.3.2.4 Kick-Out
3.3.3 Cure
3.3.3.1 Air Dry
3.3.3.2 Catalyzed Materials
3.3.3.3 Baking Enamels
3.3.4 Dry Film Properties
3.3.4.1 Gloss
3.3.4.2 Hiding Power (Opacity)
3.3.4.3 Color
3.3.4.4 Strength,Hardness,and Brittleness
3.3.4.5 Depth of Color (Metal-FlakePaints)
3.3.5 How Paint Wears Out

Chapter 4 Paint Manufacturing Process
4.1 Equipment Used for Pigment Paste Manufacturing
4.1.1 High-Speed Mixers (HSD,HLM)
4.1.2 Vertical or Horizontal Continuous Mill
4.1.3 Sand Mill
4.1.4 Roll Mill
4.1.5 Ball Mill

Chapter 5 Color Matching and Color Control
5.1 Color Variables
5.2 Metamerism
5.3 Color Measurement Equipment
5.3.1 Color Difference Equations
5.3.2 Tristimulus Filter Colorimeters
5.3.3 Spectrocolorimeters
5.3.4 Computerized Color Matching
5.4 Color Glossary
5.5 Color Standards and Metamerism

Chapter 6 Liquid Paint Application Systems
6.1 Part Preparation
6.1.1 Smoothing
6.2 Spray Application of Paint
6.2.1 Methods of Atomization
6.2.2 Manual Spray Guns
6.2.3 Automatic Spray Equipment
6.2.4 Spray Systems
6.2.4.1 Suction or Siphon Systems
6.2.4.2 PressureFeedSystems
6.2.4.3 Circulating Systems
6.2.4.4 Plural Component Mixing Equipment
6.2.4.5 Air Nozzles
6.2.4.6 Fluid Nozzles
6.2.4.7 Proper Fluid Pressure
6.3 Airless Spray Guns
6.3.1 Fluid Needles and Tips for Airless Systems
6.4 Air-Assisted Airless Spray Guns
6.5 High-Volume Low-Pressure (HVLP)
6.6 Electrostatic Application
6.6.1 Manual Electrostatic Spray Equipment
6.6.2 Coating Formulation for Electrostatic Application
6.6.3 Advantages
6.6.4 Disadvantages
6.6.5 Automatic Spray Equipment
6.6.5.1 Automatic Air-Spray Guns
6.6.5.2 Rotary Atomizers
6.6.5.3 Automatic Spray Supporting Equipment
6.6.5.4 Gun Movers
6.6.5.5 Robotic Painting
6.6.5.6 Summary
6.7 Alternative Application Methods
6.7.1 Dip Coating
6.7.1.1 Advantages of Dip Coating
6.7.1.2 Limitations of Dip Coating
6.7.2 Flow Coating
6.7.2.1 Advantages of Flow Coating
6.7.2.2 Limitations of Flow Coating
6.7.3 Roller Coating
6.7.3.1 Advantages of Roller Coating
6.7.3.2 Disadvantages of Roller Coating
6.7.4 Curtain Coating

Chapter 7  Transfer Effciency and Spray Technique
7.1 Spray Gun Controls
7.2 Application Technique
7.2.1 Atomization
7.2.2 Gun Position
7.2.3 Gun Distance
7.2.4 Gun Speed
7.2.5 Lapping
7.2.6 Heated Spray

Chapter 8 Spray Booths
8.1 NFPA Requirements
8.2 Air Make-Up
8.3 Booth Exhaust Stacks
8.4 Spray Booth Sizing
8.4.1 Spray Booth Height
8.4.2 Spray Booth Width
8.4.3 Spray Booth Depth
8.4.4 Interior Working Dimensions
8.5 Spray Booth Exhaust Sizing
8.6 Filtration
Chapter 9  Curing
9.1 Convection Curing
9.1.1 Duct Design
9.1.2 Oven Fuels
9.1.3 Materials of Construction
9.2 Infra Red Curing
9.3 Oven Maintenance and Cleaning
9.4 Oven Exhaust
9.5 Oven Filtration
9.6 Oven Location
9.7 The Impac to Catalystson Curing
9.8 Heat Recovery
9.9 Summary
Chapter 10 Testing Paint Materials
10.1 Introduction
10.2 Paint Viscosity
10.3 Finished Film Testing
10.3.1 Paint Test Standards
10.3.2 Types of Tests
10.3.2.1 Film Thickness
10.3.2.2 Film Hardness
10.3.2.3 Impact Resistance
10.3.2.4 Tape Adhesion
10.3.2.5 Humidity Testing
10.3.2.6 Salt Spray Testing
10.3.2.7 QUV Testing
10.3.2.8 Outdoor Exposure
10.3.2.9 Temperature Humidity Testing
10.3.2.10 Rinse Blistering
10.3.2.11 Corrosion Cycling
10.3.2.12 Color Matching
10.3.2.13 Gloss
Chapter 11 Quality Control
11.1 Introduction
11.2 Process Control
11.2.1 Scheduling
11.2.2 Racking
11.2.3 Pretreatment
11.2.4 Dry Off Ovens
11.2.5 Cool Down
11.2.6 Paint Application
11.2.6.1 Spray Gun Adjustment
11.2.7 Paint Material
11.2.8 Flash-Off
11.2.9 Curing
11.2.10 Record Keeping
11.3 Paint Film Defects
11.3.1 Production Defects
11.3.1.1 Orange Peel
11.3.1.2 Sagging
11.3.1.3 Flooding,Floating,and Mottle
11.3.1.4 Silking
11.3.1.5 Solvent Pop, Bubbles, Pinholes, and Craters
11.3.1.6 Fisheyes and Silicone Craters
11.3.1.7 Over spray and Dry Spray
11.3.1.8 Blushing
11.3.1.9 Dirt and Contamination
Chapter 12 Cost Analysis for Finishing Systems
12.1 Factors that Affect Cost
12.1.1 System Design
12.1.2 Quality
12.1.3 Substrate Condition
12.1.4 Racking
12.1.4.1 Line Data
12.1.5 Rework
12.1.6 Color Change
12.2 Applied Cos to Paint
12.2.1 Cost per Square Foot of Liquid Spray Coating
12.2.2 Example of Cost Calculation
12.2.3 Cos to Spray Booth Exhaust
12.2.3.1 Example
12.2.4 Solvent-Based Liquid Coating Oven Exhaust
Requirements
12.2.4.1 Example
12.2.5 Heat Loss from Loading
12.2.5.1 Example
12.2.6 Radiant Losses
12.2.6.1 Example
12.2.7 Labor and Maintenance Costs
12.2.7.1 Application Labor for Liquid Spray Coating
12.2.7.2 System Support Labor
12.2.7.3 Example
12.2.8 Electrical Consumption
12.2.8.1 Example
12.2.9 Compressed Air
12.2.10 Total Cost of Paint Application
12.2.11 Quoting a Part
12.2.11.1 Material Cost
12.2.11.2 Labor
12.2.11.3 Burden
12.2.11.4 Fixed Cost
12.2.11.5 Scrap Cost
12.2.11.6 Add Cost
AppendixA 
AppendixB
Index


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