COATINGS
TECHNOLOGY
HANDBOOK
Third
Edition
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
Published in 2006 by CRC Press
Taylor & Francis Group
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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
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, MinnesotaRobert D. Athey, Jr.
Athey Technologies El Cerrito, CaliforniaBrian E. Aufderheide
W. H. Brady Company Milwaukee, WisconsinBruce 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, DelawarePeter A. Callais
Pennwalt Corporation Buffalo, New YorkNaomi 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
viii
Marcel Dery
Chemical Fabrics Corporation Merrimack, New Hampshire
Arnold H. Deutchman
BeamAlloy Corporation Dublin, OhioJohn W Du
BYK-Chemie USA Wallingford, ConnecticutRichard 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, SwedenAlbert G. Hoyle
Hoyle Associates Lowell, MassachusettsH. F. Huber
Hüls Troisdorf AG Troisdorf/Marl, GermanyMichael 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
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, MassachusettsDonald M. MacLeod
Industry Tech Oldsmar, FloridaAlgirdas Matukonis
Kaunas Technical University Kaunas, Lithuania
John A. McClenathan
IMD Corporation Birmingham, AlabamaChristopher 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, GermanySamuel 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, Tennesseex
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, TennesseeArthur A. Tracton
ConsultantBridgewater, 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, TennesseePatrick J. Whitcomb
Stat-Ease, Inc. Minneapolis, MinnesotaK. Winkowski
ISP Corporation Piscataway, New JerseyKurt 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
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.
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
xiii 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
xiv
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
xv 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
xvi
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
xvii 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