This document discusses the process of applying coatings successfully. It outlines the key steps: cleaning and pretreatment to activate the substrate, various coating application methods, drying and curing using techniques like hot air, IR or UV, and finally control and testing of the coated surface. It provides details on techniques like plasma pretreatment, automated vs manual application, advantages of different drying methods, and types of tests for properties like scratch resistance and thickness. The document aims to explain the full coating application flow and important considerations at each step.

1. Roadshow Smart Coating Application Lab
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3. Towards successful coating application
Daan Dewulf
Project Engineer Coatings
Daan.Dewulf@sirris.be
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4. Not very succesful…
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5. Applying coatings succesfully : not as easy as it
sounds…
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 What are the expectations?
 Functionality
 Indoor/outdoor exposure
 …
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 Even more so: limitations?
 Plastic, metal, wood, mineral,…
 Surface/workpiece
 Temperature resistance?
 Applications technology?
 Curing conditions?
 …

6. How to apply coatings - Flowchart
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

7. How to apply coatings - Flowchart
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

8. Cleaning and pretreatment
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Cleaning & pretreatment leads to
activation of the substrate
 Increase wettability
 Increase adhesion
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
No plasma

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Removal of surface
contaminants
 Dust, oils, rust
 Physical/Mechanical
 Sand blasting
 wiping
 Ionized air
 Anti-static
 Chemical
 Degreasing
 Solvent ultra sonic
PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
Cleaning

10. Pretreatment
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
Treatment of surface
 Chemical
 Priming
 Etching
 Physical
 Flame/oxidative gas
 Corona/glow discharge
 Plasma

11. Pretreatment
14/04/2016
Flame treatment
Surface oxidation leads to increase in polarity
Continuous
Simple
Effective
Thermal stress on components
Not really suited for heat sensitive surfaces
Very short-term effect
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

12. Pretreatment
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Corona treatment
AC voltage electrode in stead of a flame
Oxidizes the surface by high energy oxygen ions
Adding and deleting electrons (+,- sites)
Continuous
No thermal stress
Limited reach
Plane surfaces and films (1D-2D)
Short-term effect
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

13. Pretreatment
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Plasma treatment
Like corona, plasma is the electrical
ionization of a gas
Plasma discharge creates a smooth
undifferentiated cloud of ionized gas with
no visible electrical filaments
More effective than corona
Effect can last several weeks
Suitable for difficult to activate
substrates (3D)
smaller area of activation
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

14. Pretreatment @ Smart Coating Lab
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

15. Pretreatment
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

16. How to apply coatings - Flowchart
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

17. Coating application
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
Coating is sprayed (atomized)
(1D-2D-3D)
Coating not sprayed
(1D-2D)
Pneumatic high pressure Brush, roll, wipe
Pneumatic low pressure (HVLP) Dipping
Hydraulic (pressure feed, HVLP) Flowing
Rotation (bel) Bar coating/Meyer bar
Electrostatically assisted Electrodeposition

18. Dipcoating Flow coating Bar coating/
Meyer bar
1D-2D coating application
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

19. Pneumatic low
pressure/HVLP
Hydraulic pressure
feed/HVLP
Manual 1D-2D-3D Application
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

20. Programming knowledge
Higher investment cost
Profound knowledge of
different parameters
Automated 1D-2D-3D application
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
High flexibility
Reliability
Reproducibility
Parameter optimization
Parameters
 Nozzle diameter
 Coating viscosity
 Air pressure
Influences on
 Overspray
 Surface quality
 Coating speed

21. Automated application
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
Programming tool: Simplified Robot Programming
(SRP)

22. How to apply coatings - Flowchart
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

23. Drying and curing/hardening
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 Drying
 Elimination of solvents
 Densification
 Reactions
 Condensation
 Polymerization
 Oxidation/reduction
 Chemical modification
 2K systems
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

24. Drying and curing
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 Thermal curing
 Hot (circulating) air
 IR curing
 Radiation curing
 UV curing
 UV-LED curing
 (Electron beam)
 (Microwave)
 (laser)
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

25. Drying and curing @ Smart Coating Lab
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANINGDrying and curing @ Smart Coating Lab

27. Drying and curing
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IR drying
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

28. Drying and curing
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UV curing
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

29. Drying and curing
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
Hot air IR UV
Thick/pigmented
coatings
++ ++ -
Coating complexity/Cost - - ++
Drying/Curing times -- + ++
Energy consumption/
Ecological footprint
-- + +
Maintenance cost ++ +- +-
Investment cost +- +- -
Throughput - + ++
Hot air IR UV
Heat transfer ++ + /
Installation size ++ - -
Flexible technology ++ - -
Line-of-sight effect/
shadowing
++ - --
Thermal stress -- + ++
Heat sensitive substrates -- + ++
VOC - - ++
Health issues + + --

30. How to apply coatings - Flowchart
14/04/2016© sirris | www.sirris.be | info@sirris.be | 31
PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING

31. Control & testing
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PRETREATMENT APPLICATION
DRYING &
CURING
CONTROL &
TESTING
CLEANING
 Scratch resistance
 Cross-cut
 UV-degradation
 Abrasion resistance
 Thickness ( on metal)
 Gloss
 Contact angle
 Surface topography

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33. +32 472 38 11 60
Daan.dewulf@sirris.be
Daan Dewulf – Project Engineer Smart Coatings
14/04/2016© sirris | www.sirris.be | info@sirris.be |