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COATINGS TECHNOLOGY HANDBOOK Third Edition © 2006 by Taylor & Francis Group, LLC A CRC title, part of the Taylor & Francis imprint, a member of the Taylor & Francis Group, the academic division of T&F Informa plc. COATINGS TECHNOLOGY HANDBOOK Third Edition Edited by Arthur A. Tracton Boca Raton London New York Singapore © 2006 by Taylor & Francis Group, LLC Published in 2006 by CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2006 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group No claim to original U.S. Government works Printed in the United States of America on acid-free paper 10987654321 International Standard Book Number-10: 1-57444-649-5 (Hardcover) International Standard Book Number-13: 978-1-57444-649-4 (Hardcover) This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging-in-Publication Data Catalog record is available from the Library of Congress Visit the Taylor & Francis Web site at and the CRC Press Web site at Taylor & Francis Group is the Academic Division of T&F Informa plc. © 2006 by Taylor & Francis Group, LLC For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC) 222 Rosewood Drive, Danvers, MA http://www.taylorandfrancis.com http://www.crcpress.com v Preface to Third Edition The world of coatings is very broad. The application techniques are many, and the uses are numerous. Technical people need to be aware of many things. One study said that a coating chemist must be proficient in 27 different disciplines. This book is directed at supplying a broad cross-index of some of the different aspects to help the technical person. It is not meant to be an in-depth treatise on any subject. It is meant to give insight into the various subjects covered. The chapter authors or the editor may be contacted for more information or direction on the subjects. To aid the person involved in coatings, inks, or adhesives, be they chemists, engineers, technicians, researchers, or manufacturers, chapters are given in the areas of fundamentals and testing, coating and processing, techniques and materials, and surface coatings. Each section contains information to expand the awareness and knowledge of someone practicing in the field. The objective is to help people solve problems and increase their level of technology. With time, technology increases, as shown by the chapter on statistical design of experiments, and the chapter on using equipment to determine ultraviolet (UV) resistance. Newer materials such as fluorocarbon resins, polyurethane thickeners, and high-temperature pigments are included as well as older materials such as alkyds, clays, and driers. To accomplish the presentation of technology, this book has been expanded to 118 chapters by adding new material and updating other material. Hopefully, the reader will expand his or her knowledge and further push the envelope of technology. The editor gratefully acknowledges the many contributions of the chapter authors and the publishers who have made this book possible. Arthur A. Tracton DK4036_C000.fm Page v Friday, July 1, 2005 1:40 PM © 2006 by Taylor & Francis Group, LLC vii Contributors N. J. Abbott Albany International Research Company Dedham, Massachusetts Harold Van Aken GretagMacbeth New Windsor, New York Walter Alina General Magnaplate Corporation Linden, New Jersey Mark J. Anderson Stat-Ease, Inc. Minneapolis, Minnesota Robert D. Athey, Jr. Athey Technologies El Cerrito, California Brian E. Aufderheide W. H. Brady Company Milwaukee, Wisconsin Bruce R. Baxter Specialty Products, Inc. Lakewood, Washington William F. Beach Bridgeport, New Jersey Edward A. Bernheim Exxene Corporation Corpus Christi, Texas Deepak G. Bhat GTE Valenite Corporation Troy, Michigan Thomas P. Blomstrom Monsanto Chemical Company Springfield, Massachusetts Kenneth Bourlier Union Carbide Corporation Bound Brook, New Jersey J. David Bower Hoechst Celanese Corporation Somerville, New Jersey Donald L. Brebner E. I. du Pont de Nemours & Company Wilmington, Delaware Patrick Brennan Q-Panel Lab Products Cleveland, Ohio George E. F. Brewer George E. F. Brewer Coating Consultants Birmingham, Michigan Lisa A. Burmeister Aqualon Company Wilmington, Delaware Peter A. Callais Pennwalt Corporation Buffalo, New York Naomi Luft Cameron Datek Information Services Newtonville, Massachusetts Robert W. Carpenter Windsor Plastics, Inc. Evansville, Indiana Chi-Ming Chan Raychem Corporation Menlo Park, California Gary W. Cleary Cygnus Research Corporation Redwood City, California Carl A. Dahlquist 3M Company St. Paul, Minnesota B. Davis ABM Chemicals Limited Stockport, Cheshire, England Richey M. Davis Hercules Incorporated Wilmington, Delaware David R. Day Micromet Instruments, Inc. Cambridge, Massachusetts DK4036_C000.fm Page vii Friday, July 1, 2005 1:40 PM © 2006 by Taylor & Francis Group, LLC viii Marcel Dery Chemical Fabrics Corporation Merrimack, New Hampshire Arnold H. Deutchman BeamAlloy Corporation Dublin, Ohio John W Du BYK-Chemie USA Wallingford, Connecticut Richard P. Eckberg General Electric Company Schenectady, New York Jesse Edenbaum Consultant Cranston, Rhode Island Eric T. Everett Q-Panel Lab Products Cleveland, Ohio Carol Fedor Q-Panel Lab Products Cleveland, Ohio William C. Feist Consultant Middleton, Wisconsin R. H. Foster Eval Company of America Lisle, Illinois James D. Gasper ICI Resins US Wilmington, Massachusetts Sam Gilbert Sun Chemical Corporation Cincinnati, Ohio K. B. Gilleo Sheldahl, Inc. Northfield, Minnesota William S. Gilman Gilman & Associates South Plainfield, New Jersey F. A. Goossens Stork Brabant Boxmeer, The Netherlands Joseph Green FMC Corporation Princeton, New Jersey Douglas Grossman Q-Panel Lab Products Cleveland, Ohio Clive H. Hare Coating System Design, Inc. Lakeville, Massachusetts William F. Harrington, Jr. Uniroyal Adhesives and Sealants Company, Inc. Mishawaka, Indiana J. Rufford Harrison E. I. du Pont de Nemours & Company Wilmington, Delaware Helen Hatcher Johnson Matthey Pigments & Dispersions Kidsgrove, Stoke-on-Trent, Staffs, United Kingdom Jack Hickey International Paint Company Union, New Jersey Herman Hockmeyer Hockmeyer Equipment Corporation Elizabeth City, North Carolina Krister Holmberg Chalmers University of Technology Göteborg, Sweden Albert G. Hoyle Hoyle Associates Lowell, Massachusetts H. F. Huber Hüls Troisdorf AG Troisdorf/Marl, Germany Michael Iskowitz Kop-Coat Marine Group Rockaway, New Jersey Joseph L. Johnson Aqualon Company Wilmington, Delaware Stephen L. Kaplan Plasma Science, Inc. Belmont, California Douglas S. Kendall National Enforcement Investigations Center U.S. Environmental Protection Agency Denver Federal Center Denver, Colorado Ashok Khokhani Engelhard Corporation Iselin, New Jersey DK4036_C000.fm Page viii Friday, July 1, 2005 1:40 PM © 2006 by Taylor & Francis Group, LLC ix Carol D. Klein Spectra Colors Corporation Kearny, New Jersey Lisa C. Klein Ceramic and Materials Engineering Rutgers — The State University of New Jersey Piscataway, New Jersey Joseph V. Koleske Charleston, West Virginia Alan Lambuth Boise Cascade Boise, Idaho Kenneth Lawson DeSoto, Inc. Des Plaines, Illinois B. H. Lee Ciba-Geigy Corporation Ardsley, New York Peter A. Lewis Sun Chemical Corporation Cincinnati, Ohio Raimond Liepins Los Alamos National Laboratory Los Alamos, New Mexico H. Thomas Lindland Flynn Burner Corporation New Rochelle, New York Harry G. Lippert Extrusion Dies, Inc. Chippewa Falls, Wisconsin Ronald A. Lombardi ICI Resins US Wilmington, Massachusetts Donald M. MacLeod Industry Tech Oldsmar, Florida Algirdas Matukonis Kaunas Technical University Kaunas, Lithuania John A. McClenathan IMD Corporation Birmingham, Alabama Christopher W. McGlinchey The Metropolitan Museum of Art New York, New York Frederic S. McIntyre Acumeter Laboratories, Inc. Marlborough, Massachusetts Timothy B. McSweeney Screen Printing Association International Fairfax, Virginia R. Milker Lohmann GmbH Neuwied, Germany Samuel P. Morell S. P. Morell and Company Armonk, New York Wayne E. Mozer Oxford Analytical, Inc. Andover, Massachusetts Helmut W. J. Müller BASF AG Ludwigshafen/Rhein, Germany Richard Neumann Windmöller & Hölscher Lengerich/Westfalen, Germany Robert E. Norland Norland Products, Inc. North Brunswick, New Jersey Milton Nowak Troy Chemical Newark, New Jersey Michael O’Mary The Armoloy Corporation DeKalb, Illinois Robert J. Partyka BeamAlloy Corporation Dublin, Ohio John A. Pasquale III Liberty Machine Company Paterson, New Jersey Patrick Patton Q-Panel Lab Products Cleveland, Ohio Detlef van Peij Solventborne Coatings — Europe Elementis GmbH Cologne, Germany Kim S. Percell Witco Corporation Memphis, Tennessee DK4036_C000.fm Page ix Friday, July 1, 2005 1:40 PM © 2006 by Taylor & Francis Group, LLC x Edwin P. Plueddemann Dow Corning Corporation Midland, Michigan Liudas Pranevicius Vytautas Magnus University Kaunas, Lithuania Charles P. Rader Advanced Elastomer Systems, L.P. Akron, Ohio Valentinas Rajeckas Kaunas Polytechnic University Kaunas, Lithuania H. Randhawa Vac-Tec Systems, Inc. Boulder, Colorado Richard Rathmell Londonderry, New Hampshire Donald A. Reinke Oliver Products Company (Retired) Grand Rapids, Michigan Peter W. Rose Plasma Science, Inc. Belmont, California D. Satas Satas & Associates Warwick, Rhode Island Milton C. Schmit Plymouth Printing Company, Inc. Cranford, New Jersey Jaykumar (Jay) J. Shah Decora Fort Edward, New York Douglas N. Smith Waterborne Coatings — Global Elementis GmbH Cologne, Germany Steve Stalker ITW Industrial Finishing Glendale Heights, Illinois Henry R. Stoner Henry R. Stoner Associates North Plainfield, New Jersey D. Stoye Hüls Troisdorf AG Troisdorf/Marl, Germany Larry S. Timm Findley Adhesives, Inc. Wauwatosa, Wisconsin Harry H. Tomlinson Witco Corporation Memphis, Tennessee Arthur A. Tracton Consultant Bridgewater, New Jersey George D. Vaughn Surface Specialties Melamines Springfield, Massachusetts A. Vaˇskelis Lithuanian Academy of Sciences Vilnius, Lithuania Subbu Venkatraman Raychem Corporation Menlo Park, California Theodore G. Vernardakis BCM Inks USA, Inc. Cincinnati, Ohio Lawrence R. Waelde Troy Corporation Florham Park, New Jersey Leonard E. Walp Witco Corporation Memphis, Tennessee Patrick J. Whitcomb Stat-Ease, Inc. Minneapolis, Minnesota K. Winkowski ISP Corporation Piscataway, New Jersey Kurt A. Wood Arkema, Inc. King of Prussia, Pennsylvania Daniel M. Zavisza Hercules Incorporated Wilmington, Delaware Randall W. Zempel Dow Chemical Company Midland, Michigan Ulrich Zorll Forschungsinstitut fur Pigmente and Lacke Stuttgart, Germany DK4036_C000.fm Page x Friday, July 1, 2005 1:40 PM © 2006 by Taylor & Francis Group, LLC xi Contents I Fundamentals and Testing 1 Rheology and Surface Chemistry 1-1 K. B. Gilleo 2 Coating Rheology 2-1 Chi-Ming Chan and Subbu Venkatraman 3 Leveling 3-1 D. Satas* 4 Structure–Property Relationships in Polymers 4-1 Subbu Venkatraman 5 The Theory of Adhesion 5-1 Carl A. Dahlquist 6 Adhesion Testing 6-1 Ulrich Zorll 7 Coating Calculations 7-1 Arthur A. Tracton 8 Infrared Spectroscopy of Coatings 8-1 Douglas S. Kendall 9 Thermal Analysis for Coatings Characterizations 9-1 William S. Gilman 10 Color Measurement for the Coatings Industry 10-1 Harold Van Aken 11 The Use of X-ray Fluorescence for Coat Weight Determinations 11-1 Wayne E. Mozer 12 Sunlight, Ultraviolet, and Accelerated Weathering 12-1 Patrick Brennan and Carol Fedor 13 Cure Monitoring: Microdielectric Techniques 13-1 David R. Day 14 Test Panels 14-1 Douglas Grossman and Patrick Patton *Deceased. DK4036_bookTOC.fm Page xi Friday, July 1, 2005 1:40 PM © 2006 by Taylor & Francis Group, LLC xii 15 Design of Experiments for Coatings 15-1 Mark J. Anderson and Patrick J. Whitcomb 16 Top 10 Reasons Not to Base Service Life Predictions upon Accelerated Lab Light Stability Tests 16-1 Eric T. Everett 17 Under What Regulation? 17-1 Arthur A. Tracton II Coating and Processing Techniques 18 Wire-Wound Rod Coating 18-1 Donald M. MacLeod 19 Slot Die Coating for Low Viscosity Fluids 19-1 Harry G. Lippert 20 Extrusion Coating with Acid Copolymers and Lonomers 20-1 Donald L. Brebner 21 Porous Roll Coater 21-1 Frederic S. McIntyre 22 Rotary Screen Coating 22-1 F. A. Goossens 23 Screen Printing 23-1 Timothy B. McSweeney 24 Flexography 24-1 Richard Neumann 25 Ink-Jet Printing 25-1 Naomi Luft Cameron 26 Electrodeposition of Polymers 26-1 George E. F. Brewer 27 Electroless Plating 27-1 A. Vakelis 28 The Electrolizing Thin, Dense, Chromium Process 28-1 Michael O’Mary 29 The Armoloy Chromium Process 29-1 Michael O’Mary 30 Sputtered Thin Film Coatings 30-1 Brian E. Aufderheide 31 Vapor Deposition Coating Technologies 31-1 Lindas Pranevicius DK4036_bookTOC.fm Page xii Friday, July 1, 2005 1:40 PM © 2006 by Taylor & Francis Group, LLC [...]... Surface Coatings 86 Flexographic Inks 86-1 Sam Gilbert 87 Multicolor Coatings .87-1 Robert D Athey, Jr 88 Paintings Conservation Varnish 88-1 Christopher W McGlinchey 89 Thermoset Powder Coatings 89-1 Lawrence R Waelde 90 Peelable Medical Coatings 90-1 Donald A Reinke 91 Conductive Coatings .91-1 Raimond Liepins 92 Silicone Release Coatings. .. Silicone Hard Coatings 93-1 Edward A Bernheim 94 Pressure-Sensitive Adhesives and Adhesive Products 94-1 D Satas* 95 Self-Seal Adhesives 95-1 Larry S Timm 96 Solgel Coatings .96-1 Lisa C Klein 97 Radiation-Cured Coatings 97-1 Joseph V Koleske 98 Nonwoven Fabric Binders .98-1 Albert G Hoyle 99 Fire-Retardant/Fire-Resistive Coatings ... .98-1 Albert G Hoyle 99 Fire-Retardant/Fire-Resistive Coatings 99-1 Joseph Green 100 Leather Coatings 100-1 Valentinas Rajeckas 101 Metal Coatings .101-1 Robert D Athey, Jr 102 Corrosion and Its Control by Coatings .102-1 Clive H Hare 103 Marine Coatings Industry 103-1 Jack Hickey xvi © 2006 by Taylor & Francis Group, LLC DK4036_bookTOC.fm... interaction, in which the coating process alters viscosity and rheology affects the process, will be a key concept in our discussions of coating technology 1-1 © 2006 by Taylor & Francis Group, LLC DK4036_book.fm Page 2 Monday, April 25, 2005 12:18 PM 1-2 Coatings Technology Handbook, Third Edition The second factor is time dependency Some inks change viscosity over time even though a constant shear rate is... References .2-13 2.1 Introduction Depending on the nature of the starting material, coatings can be broadly classified into solvent-borne and powder coatings The solvent-borne coatings include both solutions (high and low solid contents) and suspensions or dispersions Methods of application and the markets for these coatings are listed in Table 2.1 2.2 Definitions and Measurement Techniques 2.2.1 Surface... the contact angle, and r is the radius of the 2-1 © 2006 by Taylor & Francis Group, LLC DK4036_book.fm Page 2 Monday, April 25, 2005 12:18 PM 2-2 Coatings Technology Handbook, Third Edition TABLE 2.1 Application Methods and Markets for SolventBorne and Powder Coatings Coating Type Method of Application Solvent-borne Brushing, rolling Spraying Spin-coating Electrodeposition Electrostatic Powder A Market... liquids and therefore of coatings and inks Even more significant is the way in which viscosity changes during coating and printing Newtonian fluids, like solvents, have an absolute viscosity that is unaltered by the application of mechanical shear However, virtually all coatings show a significant change in viscosity as different forces are applied We will look at the apparent viscosity of coatings and inks... the liquid begins to approach Newtonian behavior as shear rate is increased Figure © 2006 by Taylor & Francis Group, LLC DK4036_book.fm Page 4 Monday, April 25, 2005 12:18 PM 1-4 Shear Stress Coatings Technology Handbook, Third Edition Yield Point Plastic Newtonian Pseudoplastic Dilatant Rate (sec.−1) FIGURE 1.1 Shear stress–shear rate curves 1.1 shows the shear stress–shear rate curve and the yield... Rheoplexy is fortunately rare, because it is totally useless as a characteristic for screen print inks © 2006 by Taylor & Francis Group, LLC DK4036_book.fm Page 6 Monday, April 25, 2005 12:18 PM 1-6 Coatings Technology Handbook, Third Edition Viscosity (poise) Rheopectic Thixotropic Rate (sec −1) FIGURE 1.3 Shear stress–shear rate curves: hysteresis loop 1.2.2 Temperature Effects Viscosity is strongly affected... to flow out, producing poor, irregular edge definition An ink with too high a value may flow out © 2006 by Taylor & Francis Group, LLC DK4036_book.fm Page 8 Monday, April 25, 2005 12:18 PM 1-8 Coatings Technology Handbook, Third Edition poorly As pigments tend to increase yield value, color inks are not a problem Clear protective inks can be a problem, especially when a thick film is deposited, as in screen . 100 Leather Coatings 100-1 Valentinas Rajeckas 101 Metal Coatings 101-1 Robert D. Athey, Jr. 102 Corrosion and Its Control by Coatings 102-1 Clive H. Hare 103 Marine Coatings Industry. member of the Taylor & Francis Group, the academic division of T&F Informa plc. COATINGS TECHNOLOGY HANDBOOK Third Edition Edited by Arthur A. Tracton Boca Raton London New York Singapore ©. Infrared Spectroscopy of Coatings 8-1 Douglas S. Kendall 9 Thermal Analysis for Coatings Characterizations 9-1 William S. Gilman 10 Color Measurement for the Coatings Industry 10-1