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COATINGSTECHNOLOGYHANDBOOK
ThirdEdition
© 2006 by Taylor & Francis Group, LLC
A CRC title, part of the Taylor & Francis imprint, a member of theTaylor & Francis Group, the academic division of T&F Informa plc.
COATINGSTECHNOLOGYHANDBOOK
ThirdEdition
Edited by
Arthur A. Tracton
Boca Raton London New York Singapore
© 2006 by Taylor & Francis Group, LLC
Published in 2006 byCRC PressTaylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300Boca Raton, FL 33487-2742
© 2006 by Taylor & Francis Group, LLCCRC Press is an imprint of Taylor & Francis Group
No claim to original U.S. Government worksPrinted in the United States of America on acid-free paper10 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 withpermission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publishreliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materialsor 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, orother means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any informationstorage or retrieval system, without written permission from the publishers.
01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. Fororganizations 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 foridentification and explanation without intent to infringe.
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and the CRC Press Web site at Taylor & Francis Group is the Academic Division of T&F Informa plc.
© 2006 by Taylor & Francis Group, LLC
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
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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 proficientin 27 different disciplines. This book is directed at supplying a broad cross-index of some of the differentaspects to help the technical person. It is not meant to be an in-depth treatise on any subject. It is meantto give insight into the various subjects covered. The chapter authors or the editor may be contacted formore 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 andprocessing, techniques and materials, and surface coatings. Each section contains information to expandthe awareness and knowledge of someone practicing in the field. The objective is to help people solveproblems and increase their level of technology. With time, technology increases, as shown by the chapteron 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-temperaturepigments 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 addingnew material and updating other material. Hopefully, the reader will expand his or her knowledge andfurther push the envelope of technology.
The editor gratefully acknowledges the many contributions of the chapter authors and the publisherswho have made this book possible.
Arthur A. Tracton
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© 2006 by Taylor & Francis Group, LLC
vii
Contributors
N. J. Abbott
Albany International Research Company
Dedham, Massachusetts
Harold Van Aken
GretagMacbethNew Windsor, New York
Walter Alina
General Magnaplate Corporation
Linden, New Jersey
Mark J. Anderson
Stat-Ease, Inc.Minneapolis, Minnesota
Robert D. Athey, Jr.
Athey TechnologiesEl Cerrito, California
Brian E. Aufderheide
W. H. Brady CompanyMilwaukee, Wisconsin
Bruce R. Baxter
Specialty Products, Inc.Lakewood, Washington
William F. Beach
Bridgeport, New Jersey
Edward A. Bernheim
Exxene CorporationCorpus Christi, Texas
Deepak G. Bhat
GTE Valenite CorporationTroy, Michigan
Thomas P. Blomstrom
Monsanto Chemical CompanySpringfield, Massachusetts
Kenneth Bourlier
Union Carbide CorporationBound Brook, New Jersey
J. David Bower
Hoechst Celanese CorporationSomerville, New Jersey
Donald L. Brebner
E. I. du Pont de Nemours & Company
Wilmington, Delaware
Patrick Brennan
Q-Panel Lab ProductsCleveland, Ohio
George E. F. Brewer
George E. F. Brewer Coating Consultants
Birmingham, Michigan
Lisa A. Burmeister
Aqualon CompanyWilmington, Delaware
Peter A. Callais
Pennwalt CorporationBuffalo, New York
Naomi Luft Cameron
Datek Information ServicesNewtonville, Massachusetts
Robert W. Carpenter
Windsor Plastics, Inc.Evansville, Indiana
Chi-Ming Chan
Raychem CorporationMenlo Park, California
Gary W. Cleary
Cygnus Research CorporationRedwood City, California
Carl A. Dahlquist
3M CompanySt. Paul, Minnesota
B. Davis
ABM Chemicals LimitedStockport, Cheshire, England
Richey M. Davis
Hercules IncorporatedWilmington, Delaware
David R. Day
Micromet Instruments, Inc.Cambridge, Massachusetts
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viii
Marcel Dery
Chemical Fabrics CorporationMerrimack, New Hampshire
Arnold H. Deutchman
BeamAlloy CorporationDublin, Ohio
John W Du
BYK-Chemie USAWallingford, Connecticut
Richard P. Eckberg
General Electric CompanySchenectady, New York
Jesse Edenbaum
ConsultantCranston, Rhode Island
Eric T. Everett
Q-Panel Lab ProductsCleveland, Ohio
Carol Fedor
Q-Panel Lab ProductsCleveland, Ohio
William C. Feist
ConsultantMiddleton, Wisconsin
R. H. Foster
Eval Company of AmericaLisle, Illinois
James D. Gasper
ICI Resins USWilmington, Massachusetts
Sam Gilbert
Sun Chemical CorporationCincinnati, Ohio
K. B. Gilleo
Sheldahl, Inc.Northfield, Minnesota
William S. Gilman
Gilman & AssociatesSouth Plainfield, New Jersey
F. A. Goossens
Stork BrabantBoxmeer, The Netherlands
Joseph Green
FMC CorporationPrinceton, New Jersey
Douglas Grossman
Q-Panel Lab ProductsCleveland, 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 CompanyUnion, New Jersey
Herman Hockmeyer
Hockmeyer Equipment Corporation
Elizabeth City, North Carolina
Krister Holmberg
Chalmers University of Technology
Göteborg, Sweden
Albert G. Hoyle
Hoyle AssociatesLowell, Massachusetts
H. F. Huber
Hüls Troisdorf AGTroisdorf/Marl, Germany
Michael Iskowitz
Kop-Coat Marine GroupRockaway, New Jersey
Joseph L. Johnson
Aqualon CompanyWilmington, Delaware
Stephen L. Kaplan
Plasma Science, Inc.Belmont, California
Douglas S. Kendall
National Enforcement Investigations Center
U.S. Environmental Protection Agency
Denver Federal CenterDenver, Colorado
Ashok Khokhani
Engelhard CorporationIselin, New Jersey
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ix
Carol D. Klein
Spectra Colors CorporationKearny, 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 CascadeBoise, Idaho
Kenneth Lawson
DeSoto, Inc.Des Plaines, Illinois
B. H. Lee
Ciba-Geigy CorporationArdsley, New York
Peter A. Lewis
Sun Chemical CorporationCincinnati, Ohio
Raimond Liepins
Los Alamos National Laboratory Los Alamos, New Mexico
H. Thomas Lindland
Flynn Burner CorporationNew Rochelle, New York
Harry G. Lippert
Extrusion Dies, Inc.Chippewa Falls, Wisconsin
Ronald A. Lombardi
ICI Resins USWilmington, Massachusetts
Donald M. MacLeod
Industry TechOldsmar, Florida
Algirdas Matukonis
Kaunas Technical UniversityKaunas, Lithuania
John A. McClenathan
IMD CorporationBirmingham, Alabama
Christopher 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 GmbHNeuwied, Germany
Samuel P. Morell
S. P. Morell and CompanyArmonk, New York
Wayne E. Mozer
Oxford Analytical, Inc.Andover, Massachusetts
Helmut W. J. Müller
BASF AGLudwigshafen/Rhein, Germany
Richard Neumann
Windmöller & HölscherLengerich/Westfalen, Germany
Robert E. Norland
Norland Products, Inc.North Brunswick, New Jersey
Milton Nowak
Troy ChemicalNewark, New Jersey
Michael O’Mary
The Armoloy CorporationDeKalb, Illinois
Robert J. Partyka
BeamAlloy CorporationDublin, Ohio
John A. Pasquale III
Liberty Machine CompanyPaterson, New Jersey
Patrick Patton
Q-Panel Lab ProductsCleveland, Ohio
Detlef van Peij
Solventborne Coatings — Europe
Elementis GmbHCologne, Germany
Kim S. Percell
Witco CorporationMemphis, Tennessee
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x
Edwin P. Plueddemann
Dow Corning CorporationMidland, Michigan
Liudas Pranevicius
Vytautas Magnus UniversityKaunas, Lithuania
Charles P. Rader
Advanced Elastomer Systems, L.P.
Akron, Ohio
Valentinas Rajeckas
Kaunas Polytechnic UniversityKaunas, 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 & AssociatesWarwick, Rhode Island
Milton C. Schmit
Plymouth Printing Company, Inc.
Cranford, New Jersey
Jaykumar (Jay) J. Shah
DecoraFort Edward, New York
Douglas N. Smith
Waterborne Coatings — GlobalElementis GmbHCologne, Germany
Steve Stalker
ITW Industrial FinishingGlendale Heights, Illinois
Henry R. Stoner
Henry R. Stoner AssociatesNorth Plainfield, New Jersey
D. Stoye
Hüls Troisdorf AGTroisdorf/Marl, Germany
Larry S. Timm
Findley Adhesives, Inc.Wauwatosa, Wisconsin
Harry H. Tomlinson
Witco CorporationMemphis, Tennessee
Arthur A. TractonConsultantBridgewater, New Jersey
George D. VaughnSurface Specialties MelaminesSpringfield, Massachusetts
A. VaskelisLithuanian Academy of SciencesVilnius, Lithuania
Subbu VenkatramanRaychem CorporationMenlo Park, California
Theodore G. Vernardakis
BCM Inks USA, Inc.Cincinnati, Ohio
Lawrence R. WaeldeTroy CorporationFlorham Park, New Jersey
Leonard E. WalpWitco CorporationMemphis, Tennessee
Patrick J. WhitcombStat-Ease, Inc.Minneapolis, Minnesota
K. Winkowski ISP Corporation Piscataway, New Jersey
Kurt A. WoodArkema, Inc.King of Prussia, Pennsylvania
Daniel M. ZaviszaHercules IncorporatedWilmington, Delaware
Randall W. ZempelDow Chemical CompanyMidland, Michigan
Ulrich ZorllForschungsinstitut fur Pigmente
and LackeStuttgart, Germany
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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.
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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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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
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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
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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
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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 WorldExposures in Florida and Arizona Compared to Accelerated Xenon ArcExposures........................................................................................................................118-1
Eric T. Everett, John Lind, and John Stack
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