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2 APRIL 2011
F O C U S O N P O W D E R C O A T I N G S
TECHNICALAssessing film performance ofhybrid powder systems
A further report by ProfessorBarletta and his colleaguesexamines the role of the substratein micro-scale scratching of epoxy-polyester films. Scratch tests havebeen widely used to assess themechanical performance ofpolymeric films applied by differentmethods to a variety of substrates.It has been shown that the scratchresistance of coatings decreasedsignificantly with increasing cross-link density of the coating, and thisis unaffected by film composition orlubrication of the substrate.Although many examinations ofscratch and penetration haveassessed the role of raw materialsand environmental influences, veryfew have paid attention to the roleof the substrate alone or theinterfacial region between thesubstrate itself and the appliedcoatings. This work analyses thedeformation response of epoxy-polyester powder coating filmsdeposited on untreated and micro-corrugated metal substratestogether with substrates pre-coatedwith a layer of release coating,using micro-scale scratch tests.The aim is to clarify the intrinsicrole of the applied film and thesubstrate alone and examine theinfluence of the interfacial adhesionbetween coating and substrate bysystematically altering the scratchtest parameters.
Characterization of the coatingperformance was carried out bymicro-scratch tests, varying theintender type, load and slidingspeed. Hybrid powder coatingswere deposited on smooth andrough 304 steel substrates asreceived, and similar substratespre-coated with an intermediatelayer of silicon-based heat curablerelease coating.
Testing methods are describedfully in this article and thefollowing conclusions are reached:The roughened samples exhibitedbetter adhesion as shown by
better micro-scratch resistance.Film failure in these tests mainlyoccurs by tensile crackingstresses located behind theindenter and the coating. Frictionbetween the scratch tester andthe coatings is governed by thedifference in the substrates theyare applied to; coatings depositedon the silicone are almostdragged by the action of theindenter and the siliconeinterlayer follows the overlyingcoating in its deformation, therebyrelieving the stress imposed bythe tester and limiting thedamage to the powder coating.
Sensitivity of the hybrid coatingto the time of the applied loadingis confirmed, while the penetrationand residual depth of the coatingon the metal substrate is a strictfunction of the scratch speed,whatever the load.
Coatings applied to the softersilicone-based layer are lesssensitive to change in the slidingspeed since the deformation of thesilicone itself relieves the stressfield controlling the deformation ofthe powder coating, and itscapability to recover is a functionof how fast the materials wasdeformed during the test, with thematerials deformed at the highestscratch speed more prone torecover faster than the materialdeformed at lower scratch speeds.
Article entitled “The Role of the Substrate inMicro-scale Scratching of Epoxy-polyesterFilms” by M Barletta and A Gisario, AppliedSurface Science, 15 Feb 2011, 257, (9),4449-4463
INDUSTRYNEWS
PPG begins operation of Tianjinaerospace application supportcentre
PPG has opened its newaerospace application support(ASC) centre at the TianjinAerospace Industrial Park inChina. The Tianjian ASC,together with PPG’s existing
Suzhou site, will help PPG betterserve the needs of the growingChinese aerospace industry. Thesite, which cost a total of $2.1 Min two phases, housesmanufacturing workshops andstorehouses for hazardouschemicals. Following thecompletion of the second phaseof construction, the centre isanticipated to be able to produce200 tons of aerospace coatingsand 100 tons of sealants, and aturnover of 100 aircrafttransparencies per year. The sitewill also provide chemicalsmanagement services and offervalue-added packaging formaterials supplied by clients.
Coatings World, Jan 2011, 16 (1), 10,12(Website: http://www.coatingsworld.com/)
Ferro purchases tile coatingsfacility in Egypt
Ferro Corp has finalized itsacquisition of a newly built ceramiccoatings facility in Fayoum, Egypt,from principals of PharaohsCeramic Group. The new site willpermit Ferro to serve in a morecost-efficient manner the growingmarkets for tile production in Egyptand other Middle East and NorthAfrican counties. Ferro plans toexpand the plant’s capacity byadding new equipment. Followingthe completion of the initialexpansion, Ferro anticipates thesite’s tile frit and glaze outputcapacity to reach 200 M lbs/y.Ferro Tile Coating Systemssupplies decoration materialsapplied in the production ofceramic tiles including frits, glazesand inks.
Coatings World, Jan 2011, 16 (1), 15(Website: http://www.coatingsworld.com/)
Tikkurila to sell its powdercoatings business
Teknos Group Oy will acquire theentire shares held by TikkurilaOyj’s Swedish subsidiaryDickursby Holding AB in Russianindustrial coatings firm TikkurilaPowder Coatings. TikkurilaPowder Coatings’ products are
APRIL 2011 3
F O C U S O N P O W D E R C O A T I N G S
sold and marketed in the Russianmarket under the Ohtek brand.Tikkura decided to sell its industrialpowder coatings operation becauseit is a non-core business. Followingthe sale, Tikkurila will no longer beengaged in powder coatings-relatedbusiness. Tikkurila PowderCoatings, which has around 50workers, will report revenue of €2.3M in 2010.
Coatings World, Jan 2011, 16 (1), 15(Website: http://www.coatingsworld.com/)
DuPont Performance Coatingsopens new coatings technologycentre in USA
DuPont recently inaugurated itsnew Coatings Technology Centre atthe Experimental Station inWilmington, DE, USA. The focus ofthe new R&D unit will be onDuPont Refinish Systems productsthat support the automotivecollision sector and on DuPontIndustrial Coating Solutions, whichsells a variety of liquid and powderindustrial finishes. DuPontPerformance Coatings (DPC) setup the centre, and the R&D projectis part of DPC’s efforts to expandits global coatings business.
Coatings World, Jan 2011, 16 (1), 15-16(Website: http://www.coatingsworld.com/)
Key Finishes LLC celebrates grandopening
Key Finishes LLC has inauguratedits toll bonding facility in Columbus,OH, USA. The 5500 sq ft facilityallows the company to providecomplete service, cradle-to-gravemetallic bonding, filling an openniche in the powder coatingssector. Key Finishes has an initialcapacity to produce roughly 2 Mlbs/y of bonder metallic powdercoatings, with plans for a futureexpansion.
Paint & Coatings Industry (PCI), Jan 2011, 27(1), 18 (Website: http://www.pcimag.com/)
AkzoNobel aims for sales growth inIndia with new coatings plant
With the opening of a newAkzoNobel Industrial Coatings
plant at Bangalore, India, thecompany aims to grow morerapidly over the next 5 years,increasing turnover in India to €1bn. The plant, which willmanufacture steel tape coatingsand coatings for specialist plastics,is located on AkzoNobel’s existingHoskote site where marine paints,yacht lacquers, protective coatings,car repair lacquers, and powdercoatings are produced. It willmanufacture 18 M litres/y withscope for further expansion.AkzoNobel currently has around 6production facilities, 2 researchlaboratories, around 10 salesoffices (representing both coatingsand speciality chemicals), and1500 employees in India.
Het Financieele Dagblad, 7 Feb 2011,(Website: http://www.fd.nl/) (in Dutch)
AkzoNobel expands in Mexico
AkzoNobel is constructing apowder coatings facility atApodaca, Mexico, scheduled forstart-up in 3Q 2011. The plant isaimed at meeting rising demandin Latin America. The firm’sexisting factory in Monterrey isoperating at near full capacity.
Chemical Week, 14 Feb 2011, (Website:http://www.chemweek.com)
AkzoNobel’s paints become moreexpensive
Rising pries for oil and other rawmaterials are creating problemsfor Akzo Nobel. 4Q 2010 profitswere lower than expectedbecause of higher costs. Mid-single digit percentage rises inraw material prices are alsoexpected in 2011. Akzo’s bosshas announced price increasesfor the current quarter in order tostrengthen margins. 4Q EBITDAwas up 3% at €377 M on salesup 17% at €3.6 bn. Akzo islooking for sales growth of 5% in2011 and a rise in EBITDA. Oneanalyst is confident. The outlookis less pessimistic than expected.Elsewhere, Solvay causedsurprise with a jump in profit in4Q 2010. Operating profits fromcontinuing business were up 75%
at €155 M. The company hasalso announced acquisitions.Proceeds from the sale of thedrugs division to AbbottLaboratories for $4.5 bn will beinvested.
Handelsblatt Wirtschafts- und Finanzzeitung,18 Feb 2011, (35), 27 (Website:http://www.handelsblatt.com) (in German)
A Schulman restructures powdercoating activity
Following the acquisition of itscompetitor ICO Polymers, ASchulman is restructuring some ofits activities. It plans to close orsell the plant at Verolanuova, Italy(former ICO) by the start of 2012.Technical powder production willbe moved to Gorla Maggiore. ASchulman will invest in the soleItalian site, expanding capacity forspeciality powder, masterbatchand compounds. The firm is toclose its speciality powderBraeside plant near Melbourne,Australia by the end of Aug 2011.It will retain only one Australianfacility at Brendale near Brisbane.Prior to the acquisition of ICO,Schulman had no Australianproduction sites. It will supplyproducts from plants in Malaysia,Indonesia, China and a new plantbeing built in India. The existingAustralian business made a lossof $1-2 M in the 2Q 2010-2011(period ending Aug 2010). ASchulman is to cut its totalworkforce of over 2900 by 40-60.Restructuring charges will amountto several million dollars.
Chimie Pharma Hebdo, 14 Feb 2011, (539),8 (Website: http://www.industrie.com/chimie)(in French)
Jotun targets powders growth inMiddle East
Jotun’s powder coatings operationis aiming for a 15% growth in2011 in the Gulf CooperationCouncil (GCC) countries ofKuwait, Oman, Qatar, SaudiArabia, UAE and Bahrain. TheNorwegian firm claims it alreadyholds 70% of the powder coatingssector in the GCC region,excluding Saudi Arabia, where it