Third Edition
COATINGS TECHNOLOGY HANDBOOK
© 2006 by Taylor & Francis Group, LLC
Third Edition
COATINGS TECHNOLOGY HANDBOOK Edited by
Arthur A. Tracton
Boca Raton London New York Singapore
A CRC title, part of the Taylor & Francis imprint, a member of the Taylor & Francis Group, the academic division of T&F Informa plc.
© 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 10 9 8 7 6 5 4 3 2 1 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. 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 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
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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
v © 2006 by Taylor & Francis Group, LLC
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Contributors
N. J. Abbott
Deepak G. Bhat
Peter A. Callais
Albany International Research Company Dedham, Massachusetts
GTE Valenite Corporation Troy, Michigan
Pennwalt Corporation Buffalo, New York
Thomas P. Blomstrom
Naomi Luft Cameron
Harold Van Aken GretagMacbeth New Windsor, New York
Monsanto Chemical Company Springfield, Massachusetts
Walter Alina
Kenneth Bourlier
General Magnaplate Corporation Linden, New Jersey
Union Carbide Corporation Bound Brook, New Jersey
Mark J. Anderson Stat-Ease, Inc. Minneapolis, Minnesota
Robert D. Athey, Jr. Athey Technologies El Cerrito, California
J. David Bower Hoechst Celanese Corporation Somerville, New Jersey
E. I. du Pont de Nemours & Company Wilmington, Delaware
Patrick Brennan Q-Panel Lab Products Cleveland, Ohio
Bruce R. Baxter Specialty Products, Inc. Lakewood, Washington
William F. Beach Bridgeport, New Jersey
Robert W. Carpenter Windsor Plastics, Inc. Evansville, Indiana
Chi-Ming Chan Raychem Corporation Menlo Park, California
Gary W. Cleary Donald L. Brebner
Brian E. Aufderheide W. H. Brady Company Milwaukee, Wisconsin
Datek Information Services Newtonville, Massachusetts
George E. F. Brewer George E. F. Brewer Coating Consultants Birmingham, Michigan
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
Edward A. Bernheim
Lisa A. Burmeister
David R. Day
Exxene Corporation Corpus Christi, Texas
Aqualon Company Wilmington, Delaware
Micromet Instruments, Inc. Cambridge, Massachusetts vii
© 2006 by Taylor & Francis Group, LLC
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Marcel Dery
K. B. Gilleo
Herman Hockmeyer
Chemical Fabrics Corporation Merrimack, New Hampshire
Sheldahl, Inc. Northfield, Minnesota
Hockmeyer Equipment Corporation Elizabeth City, North Carolina
Arnold H. Deutchman
William S. Gilman
BeamAlloy Corporation Dublin, Ohio
Gilman & Associates South Plainfield, New Jersey
John W Du
F. A. Goossens
BYK-Chemie USA Wallingford, Connecticut
Stork Brabant Boxmeer, The Netherlands
Richard P. Eckberg
Joseph Green
General Electric Company Schenectady, New York
FMC Corporation Princeton, New Jersey
Jesse Edenbaum
Douglas Grossman
Consultant Cranston, Rhode Island
Q-Panel Lab Products Cleveland, Ohio
Eric T. Everett
Clive H. Hare
Q-Panel Lab Products Cleveland, Ohio
Coating System Design, Inc. Lakeville, Massachusetts
Carol Fedor
William F. Harrington, Jr.
Q-Panel Lab Products Cleveland, Ohio
William C. Feist Consultant Middleton, Wisconsin
R. H. Foster Eval Company of America Lisle, Illinois
Uniroyal Adhesives and Sealants Company, Inc. Mishawaka, Indiana
J. Rufford Harrison E. I. du Pont de Nemours & Company Wilmington, Delaware
Helen Hatcher
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
ICI Resins US Wilmington, Massachusetts
Johnson Matthey Pigments & Dispersions Kidsgrove, Stoke-on-Trent, Staffs, United Kingdom
Sam Gilbert
Jack Hickey
Ashok Khokhani
Sun Chemical Corporation Cincinnati, Ohio
International Paint Company Union, New Jersey
Engelhard Corporation Iselin, New Jersey
James D. Gasper
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Carol D. Klein
Ronald A. Lombardi
Helmut W. J. Müller
Spectra Colors Corporation Kearny, New Jersey
ICI Resins US Wilmington, Massachusetts
BASF AG Ludwigshafen/Rhein, Germany
Lisa C. Klein
Donald M. MacLeod
Richard Neumann
Industry Tech Oldsmar, Florida
Windmöller & Hölscher Lengerich/Westfalen, Germany
Algirdas Matukonis
Robert E. Norland
Kaunas Technical University Kaunas, Lithuania
Norland Products, Inc. North Brunswick, New Jersey
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
John A. McClenathan
Milton Nowak
IMD Corporation Birmingham, Alabama
Troy Chemical Newark, New Jersey
Christopher W. McGlinchey
Michael O’Mary
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
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
Lohmann GmbH Neuwied, Germany
Detlef van Peij
Samuel P. Morell S. P. Morell and Company Armonk, New York
Solventborne Coatings — Europe Elementis GmbH Cologne, Germany
Harry G. Lippert
Wayne E. Mozer
Kim S. Percell
Extrusion Dies, Inc. Chippewa Falls, Wisconsin
Oxford Analytical, Inc. Andover, Massachusetts
Witco Corporation Memphis, Tennessee
H. Thomas Lindland Flynn Burner Corporation New Rochelle, New York
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Edwin P. Plueddemann
Jaykumar (Jay) J. Shah
Subbu Venkatraman
Dow Corning Corporation Midland, Michigan
Decora Fort Edward, New York
Raychem Corporation Menlo Park, California
Liudas Pranevicius
Douglas N. Smith
Vytautas Magnus University Kaunas, Lithuania
Waterborne Coatings — Global Elementis GmbH Cologne, Germany
Theodore G. Vernardakis BCM Inks USA, Inc. Cincinnati, Ohio
Charles P. Rader Advanced Elastomer Systems, L.P. Akron, Ohio
Steve Stalker
Lawrence R. Waelde
ITW Industrial Finishing Glendale Heights, Illinois
Troy Corporation Florham Park, New Jersey
Valentinas Rajeckas
Henry R. Stoner
Leonard E. Walp
Kaunas Polytechnic University Kaunas, Lithuania
Henry R. Stoner Associates North Plainfield, New Jersey
Witco Corporation Memphis, Tennessee
H. Randhawa
D. Stoye
Patrick J. Whitcomb
Vac-Tec Systems, Inc. Boulder, Colorado
Hüls Troisdorf AG Troisdorf/Marl, Germany
Stat-Ease, Inc. Minneapolis, Minnesota
Richard Rathmell
Larry S. Timm
K. Winkowski
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
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
Milton C. Schmit Plymouth Printing Company, Inc. Cranford, New Jersey
x © 2006 by Taylor & Francis Group, LLC
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 A. Vaˇskelis Lithuanian Academy of Sciences Vilnius, Lithuania
Forschungsinstitut fur Pigmente and Lacke Stuttgart, Germany
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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.
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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
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32 Cathodic Arc Plasma Deposition ...................................................................................32-1 H. Randhawa 33 Industrial Diamond and Diamondlike Films ...............................................................33-1 Arnold H. Deutchman and Robert J. Partyka 34 Tribological Synergistic Coatings...................................................................................34-1 Walter Alina 35 Chemical Vapor Deposition............................................................................................35-1 Deepak G. Bhat 36 Solvent Vapor Emission Control ....................................................................................36-1 Richard Rathmell 37 Surface Treatment of Plastics..........................................................................................37-1 William F. Harrington, Jr. 38 Flame Surface Treatment ................................................................................................38-1 H. Thomas Lindland 39 Plasma Surface Treatment...............................................................................................39-1 Stephen L. Kaplan and Peter W. Rose 40 Surface Pretreatment of Polymer Webs by Fluorine.....................................................40-1 R. Milker and Artur Koch 41 Calendering of Magnetic Media .....................................................................................41-1 John A. McClenathan 42 Embossing ........................................................................................................................42-1 John A. Pasquale III 43 In-Mold Finishing............................................................................................................43-1 Robert W. Carpenter 44 HVLP: The Science of High-Volume, Low-Pressure Finishing ....................................44-1 Steve Stalker 45 A Practical Guide to High-Speed Dispersion ................................................................45-1 Herman Hockmeyer
III
Materials 46 Acrylic Polymers ..............................................................................................................46-1 Ronald A. Lombardi and James D. Gasper 47 Vinyl Ether Polymers.......................................................................................................47-1 Helmut W. J. Müller 48 Poly(Styrene-Butadiene) .................................................................................................48-1 Randall W. Zempel
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49 Liquid Polymers for Coatings.........................................................................................49-1 Robert D. Athey, Jr. 50 Polyesters ..........................................................................................................................50-1 H. F. Huber and D. Stoye 51 Alkyd Resins .....................................................................................................................51-1 Krister Holmberg 52 The Polyurea Revolution: Protective Coatings for the 21st Century ..........................52-1 Bruce R. Baxter 53 Phenolic Resins ................................................................................................................53-1 Kenneth Bourlier 54 Coal Tar and Asphalt Coatings .......................................................................................54-1 Henry R. Stoner 55 Vulcanizate Thermoplastic Elastomers..........................................................................55-1 Charles P. Rader 56 Olefinic Thermoplastic Elastomers................................................................................56-1 Jesse Edenbaum 57 Ethylene Vinyl Alcohol Copolymer (EVOH) Resins .....................................................57-1 R. H. Foster 58 Elastomeric Alloy Thermoplastic Elastomers ...............................................................58-1 Charles P. Rader 59 Polyvinyl Chloride and Its Copolymers in Plastisol Coatings ....................................59-1 Jesse Edenbaum 60 Polyvinyl Acetal Resins....................................................................................................60-1 Thomas P. Blomstrom 61 Polyimides ........................................................................................................................61-1 B. H. Lee 62 Parylene Coating..............................................................................................................62-1 William F. Beach 63 Nitrocellulose ...................................................................................................................63-1 Daniel M. Zavisza 64 Soybean, Blood, and Casein Glues .................................................................................64-1 Alan Lambuth 65 Fish Gelatin and Fish Glue..............................................................................................65-1 Robert E. Norland 66 Waxes ................................................................................................................................66-1 J. David Bower 67 Carboxymethylcellulose ..................................................................................................67-1 Richey M. Davis xiv © 2006 by Taylor & Francis Group, LLC
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68 Hydroxyethylcellulose .....................................................................................................68-1 Lisa A. Burmeister 69 Antistatic and Conductive Additives..............................................................................69-1 B. Davis 70 Silane Adhesion Promoters.............................................................................................70-1 Edwin P. Plueddemann 71 Chromium Complexes ....................................................................................................71-1 J. Rufford Harrison 72 Nonmetallic Fatty Chemicals as Internal Mold Release Agents in Polymers .............72-1 Kim S. Percell, Harry H. Tomlinson, and Leonard E. Walp 73 Organic Peroxides............................................................................................................73-1 Peter A. Callais 74 Surfactants for Waterborne Coatings Applications......................................................74-1 Samuel P. Morell 75 Surfactants, Dispersants, and Defoamers for the Coatings, Inks, and Adhesives Industries ........................................................................................................75-1 John W Du 76 Pigment Dispersion .........................................................................................................76-1 Theodore G. Vernardakis 77 Colored Inorganic Pigments...........................................................................................77-1 Peter A. Lewis 78 Organic Pigments ............................................................................................................78-1 Peter A. Lewis 79 Amino Resins ...................................................................................................................79-1 George D. Vaughn 80 Driers ................................................................................................................................80-1 Milton Nowak 81 Biocides for the Coatings Industry ................................................................................81-1 K. Winkowski 82 Clays..................................................................................................................................82-1 Ashok Khokhani 83 Fluorocarbon Resins for Coatings and Inks..................................................................83-1 Kurt A. Wood 84 High Temperature Pigments...........................................................................................84-1 Helen Hatcher 85 Polyurethane Associative Thickeners for Waterborne Coatings .................................85-1 Douglas N. Smith and Detlef van Peij
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IV
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 ................................................................................................92-1 Richard P. Eckberg 93 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..........................................................................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
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104 Decorative Surface Protection Products......................................................................104-1 Jaykumar (Jay) J. Shah 105 Coated Fabrics for Protective Clothing .......................................................................105-1 N. J. Abbott 106 Coated Fabrics for Apparel Use: The Problem of Comfort........................................106-1 N. J. Abbott 107 Architectural Fabrics .....................................................................................................107-1 Marcel Dery 108 Gummed Tape ................................................................................................................108-1 Milton C. Schmit 109 Transdermal Drug Delivery Systems ...........................................................................109-1 Gary W. Cleary 110 Optical Fiber Coatings ..................................................................................................110-1 Kenneth Lawson 111 Exterior Wood Finishes .................................................................................................111-1 William C. Feist 112 Pharmaceutical Tablet Coating.....................................................................................112-1 Joseph L. Johnson 113 Textiles for Coating........................................................................................................113-1 Algirdas Matukonis 114 Nonwovens as Coating and Laminating Substrates....................................................114-1 Albert G. Hoyle 115 General Use of Inks and the Dyes Used to Make Them .............................................115-1 Carol D. Klein 116 Gravure Inks...................................................................................................................116-1 Sam Gilbert 117 Artist’s Paints: Their Composition and History..........................................................117-1 Michael Iskowitz 118 Fade Resistance of Lithographic Inks — A New Path Forward: Real World Exposures in Florida and Arizona Compared to Accelerated Xenon Arc Exposures........................................................................................................................118-1 Eric T. Everett, John Lind, and John Stack
xvii © 2006 by Taylor & Francis Group, LLC
