Satas D., Tracton A.A. (ed.). Coatings Technology Handbook
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Coatings
Technology
Handbook
This Page Intentionally Left Blank
Coatings
Technology
Handbook
Second Edition
Revised and Expanded
edited
by
D.
Satas
Satas
&
Associates
Warwick, Rhode Island
Arthur
A.
Tracton
Consultant
Bridgewater, New Jersey
m
MARCEL
MARCEL DEKKER,
INC.
DEKKER
NEW
YORK
BASEL
ISBN:
0-8247-0439-8
This book is printed on acid-free paper.
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Marcel Dekker, Inc.
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Copyright
0
2001
by Marcel Dekker, Inc. All Rights Reserved.
Neither this book nor any part may
be
reproduced or transmitted in any form or
by
any means,
electronic or mechanical, including photocopying, microfilming, and recording, or by any informa-
tion storage and retrieval system, without permission in writing from the publisher.
Current printing (last digit):
IO987654321
PRINTED
IN
THE UNITED STATES
OF
AMERICA
Preface
Coatings are widely used for many purposes. It is difficult to think
of
an item that does
not have
a
coating of one type or another. Coatings are applied to protect materials from
corrosion and other detrimental effects of the ambient atmosphere. They are used to beau-
tify by changing surface properties such
as
gloss, color, slipperiness, and general appear-
ance. Adhesive coatings are used in laminating and preparing composites. Other coatings
serve as barriers for gases and liquids. Coatings. inks, and adhesives use many of the same
raw materials, making then1 more similar than different. The wide range of application
techniques, coating types, and purposes makes coating technology an extremely diverse
field.
As
general technology pushes the envelope, new coatings and applications are
needed.
Coating technology is transferable from one application to another. It
also
draws
from other technologies. This comprehensive handbook will be of interest and value to
both those already involved
in
coatings and those who plan to work with coatings. A
person practicing one aspect may not be familiar with techniques or materials used for
other applications. Awareness and understanding of these techniques and materials will
help solve problems and improve levels of technology.
This handbook has been expanded by adding new chapters that include discussions
of
more diverse techniques, processes, and materials used for coatings, increasing the
realm of knowledge.
We gratefully acknowledge the many contributors and the staff
of
Marcel Dekker,
Inc., without whose work this book would not have been possible.
D.
Sotus
Arthw
A.
Tracton
iii
This Page Intentionally Left Blank
Contents
Preface
iii
Contributors xiii
PART
1.
FUNDAMENTALS AND TESTING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11
Rheology and Surface Chemistry
3
K. B.
Gilleo
Coating Rheology 19
Chi-Ming Chan and Subbu Venkatraman
Leveling 35
D. Satas
Structure-Property Relationships in Polymers
41
Subbu Venkatraman
The Theory of Adhesion 47
Carl A. Dahlquist
Adhesion Testing 57
Ulrich Zorll
Coating Calculations 73
Arthur A. Tracton
Infrared Spectroscopy of Coatings 79
Douglas
S.
Kendall
Thermal Analysis for Coatings Characterizations 87
Williatn
S.
Gilman
Color Measurement for the Coatings Industry 93
Harold Van Aken
The Use of X-ray Fluorescence for Coat Weight Determinations 97
Wayne
E.
Mozer
V
vi
CONTENTS
12. Sunlight, Ultraviolet, and Accelerated Weathering 103
Patrick Brennan
and
Curol Fedor
13. Cure Monitoring: Microdielectric Techniques
I1
3
Dmid
R.
Day
14. Test Panels
119
Douglas Grossrnan and Patrick Putton
PART
2.
COATING AND PROCESSING TECHNIQUES
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Wire-Wound Rod Coating 129
Donuld M. MacLeod
Slot Die Coating for Low Viscosity Fluids 139
Harry
G.
Lippert
Extrusion Coating with Acid Copolymers and Ionomers 157
Donald
L. Brebner
Porous
Roll
Coater 165
Frecleric
S.
Mclntyre
Rotary Screen Coating 179
F. A. Goossens
Screen Printing 185
Timothy
B.
McSweeney
Flexography
19
1
Richard
Neumann
Ink Jet Printing 203
Naotni
Luft Cameron
Electrodeposition of Polymers 207
George
E.
F. Brewer
Electroless Plating 2 13
A. Vaikelis
The Electrolizing Thin. Dense, Chromium Process 227
Michael O’Mary
The Armoloy Chromium Process 237
Michael 0’Mat-y
Sputtered Thin Film Coatings 243
Brian
E.
Aufierheiie
Reactive Plasma: Deposition and Etching 255
Liudvikas Pranevic‘ius
Cathodic Arc Plasma Deposition 283
H.
Randhawa
CONTENTS
vii
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Industrial Diamond and Diamondlike Films
291
Artrole1
H. Deutchrnan
and
Robert
J.
Partyka
Tribological Synergistic Coatings 299
Walter Alirm
Chemical Vapor Deposition 3 13
Deepak G. Bhat
Solvent Vapor Emission Control 327
Richcrrcl Ratlmell
Surface Treatment of Plastics 335
Willirrru
F.
Harrington,
Jr.
Flame Surface Treatment 343
H.
Thoinas
Lindlarld
Plasma Surface Treatment 35
I
Stephen
L.
Kaplern urd Peter W. Rose
Surface Pretreatment of Polymer Webs by Fluorine 359
R. Milker
urd
Artw
Koch
Calendering of Magnetic Media 367
John
A.
McClenatlm
Embossing 37
I
John
A.
Pasquale
Ill
In-Mold Finishing 377
Robert W. Carpenter
HVLP: The Science
of
High-Volume Low-Pressure Finishing 381
Ste\ve
Stalker
PART
3.
MATERIALS
42. Acrylic Polymers 391
Ronald
A.
Lornbardi
and
James D. Gasper
43. Vinyl Ether Polymers 403
Helmut W.
J.
Miiller
44. Poly(Styrene-Butadiene) 407
Randall W.
Zernpel
45. Liquid Polymers for Coatings 41
1
Robert D.
Athey,
Jr.
46. Polyesters 419
H.
F.
Huber
atd
D.
Stoy
47. Alkyd Resins 435
Krister
Holrnberg