BASF Handbook on Basics of Coating Technology (American Coatings Literature)

791 Pages·2007·19.03 MB·English

by  Artur Goldschmidt

Umschlag_BASF Handbuch 2. Auflage.qxd 07.08.2007 10:31 Seite 2
BASF Handbook
Goldschmidt | Streitberger
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Cover picture: BASF Coatings AG
Bibliographische Information Der Deutschen Bibliothek
Die Deutsche Bibliothek verzeichnet diese Publikation
in der Deutschen Nationalbibliographie; detaillierte biblio-
graphische Daten sind im Internet über
http://dnb.ddb.de abrufbar.
© 2007 BASF Coatings AG, Münster/Germany
Vincentz Network, P.O. Box 6247, 30062 Hannover/Germany
All rights reserved. No part of this publication may be stored in a retrieval system
or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the written permission of the publishers.
Please ask for our book catalogue:
Vincentz Network, Plathnerstr 4c, 30175 Hannover, Germany
Tel. [phone], Fax [phone]
[email protected]
www.coatings.de
Layout: Sperling Info Design GmbH, Gehrden/Germany
Printed by Bonifatius GmbH, Paderborn/Germany
ISBN 3-86630-903-1
ISBN 978-3-86630-903-6
2 BASF Handbook on Basics of Coating Technology
Vorspann_e 2 24.08.2007, 15:19 Uhr
Prof. Dr. Artur Goldschmidt/Dr. Hans-Joachim Streitberger
BASF HANDBOOK ON
Basics
of Coating
Technology
2nd revised edition
BASF Handbook on Basics of Coating Technology 3
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Foreword to the second revised edition
Glasurit’s ”Paints and Coatings” manual has been a standard work in the field of coating
materials since it was first published in 1934. Since then a number of editions in Ger-
man were published. The latest edition being first time published also in English in
2003 was well received on a worldwide basis. This second revised and corrected edition
was sponsored by BASF Coatings. Compared to the first edition based on the German
edition of 2002 market data were actualized, some passages revised, more English
references introduced and corrections made.
The manual starts logically with a brief historical summary of painting, its current
economic and technical significance and the social framework underpinning the indus-
try. This is followed by a chapter dealing with product composition, raw materials,
principles of product formulation and the relevant production processes for these prod-
ucts. Descriptions are then given of the properties of the liquid and solid coating mate-
rials for the respective application types, after which a chapter follows that deals with
theoretical aspects of coating compositions. Applications are then explained for the
reader, taking due account of the current significance of the coating processes. In this
chapter the substrate plays a major role because of its impact on the coating process and
outcome. The demands on the environment, health, safety and quality as specified in the
current legislation in Europe and Germany are dealt with in the next chapter. A journey
is then undertaken through the various industrial sectors of the paint and coatings
industry with the aid of a large number of examples and illustrations. This chapter is of
particular interest for newcomers to the industry and practically-minded readers. Stand-
ard tables, general performance indicators, a selection of relevant websites, definitions
of terms and a comprehensive index round off the book.
When reading the manual, please bear in mind that abbreviations are defined the first
time they are used. In addition, you will find a complete list of all abbreviations used in
the book in chap. 9.3. Environmentally compatible coating materials are introduced in
chap. 5.8 referring to more detailed technical information on these materials in the
individual chapters. In any case, the comprehensive index will help you get to the
information you need quickly.
Literature references are cited to enable readers to obtain more in-depth information.
These are assigned to the individual chapters and may therefore be repeated on occa-
sion. Many comments and scenarios are based on experience gained by BASF Coatings
and are therefore not necessarily assigned to specific quotations.
Statutory provisions and mostly DIN EN standards have been followed for the terms
and units used. Readers will therefore find that many expressions traditionally used in
the industry have not been employed. By using standardized expressions, however, we
wish to contribute to a uniform specialist terminology and therefore to the prevention of
ambiguity or misunderstandings. An appendix of acronyms is included for reference.
Manufacturers, users, the academic community, institutes and authorities have varied
expectations for the manual. The publishers have attempted to address a broad range of
BASF Handbook on Basics of Coating Technology 5
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topics, based on the response to the previous edition and on the current technical and
social developments, but have consciously avoided the in-depth treatment of specialist
aspects to prevent the book’s scope from becoming too unwieldy.
The scope of the book nevertheless meets the objective of publishing a work of refer-
ence that provides satisfactory answers to paint-related issues for both newcomers and
experts.
We wish to express our gratitude to the many employees of BASF Coatings AG who
have contributed valuable suggestions and detailed information. Our special thanks go
still to Klaus-Peter Löbbe and for the second edition to the management team of BASF
Coatings and to Raimar Jahn. We also thank Dr. P. Bachhausen and Dr. W. Kreis for
their assistance as well as the publishers for their patient advices.
Prof. Dr. A. Goldschmidt and Dr. H.-J. Streitberger
Wiedenbrück, July 2007
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8 BASF Handbook on Basics of Coating Technology
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Content
1 Introduction
2 Coating Material
3 Coatings
4 Coating Technology
5 Safety, Environmental Protection and Health
6 Principles of Quality Management
7 Coating Industries
8 Industrial Standards
9 Appendix
10 Index
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10 BASF Handbook on Basics of Coating Technology
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Content
1 Introduction...................................................................................................................... 15
1.1 Definition, Tasks and Economic Importance .................................................................... 15
1.2 Retrospective...................................................................................................................... 21
1.3 Bibliography....................................................................................................................... 25
2 Coating Material .............................................................................................................. 27
2.1 Raw Materials .................................................................................................................... 27
2.1.1 Film Forming Agents......................................................................................................... 30
2.1.1.1 Natural Materials................................................................................................................ 33
2.1.1.2 Synthetic Resins................................................................................................................. 49
2.1.2 Solvents.............................................................................................................................. 125
2.1.2.1 Theory of Solubility........................................................................................................... 127
2.1.2.2 Physical Properties............................................................................................................. 130
2.1.2.3 Chemical and Physiological Properties............................................................................. 133
2.1.2.4 Important Solvents for Coatings........................................................................................ 133
2.1.3 Pigments and Extenders..................................................................................................... 137
2.1.3.1 Physical Principles for Chroma and Hiding Power........................................................... 142
2.1.3.2 The Most Important Pigments for Coating Materials....................................................... 145
2.1.3.3 Extenders............................................................................................................................ 165
2.1.4 Plasticizers and Additives.................................................................................................. 168
2.1.4.1 Plasticizers.......................................................................................................................... 168
2.1.4.2 Additives............................................................................................................................. 172
2.1.5 Summary............................................................................................................................. 192
2.2 From Raw Material to Coating Material........................................................................... 193
2.2.1 General Rules on Drawing up Formulations..................................................................... 194
2.2.1.1 Purpose and Quality........................................................................................................... 194
2.2.1.2 Production Resources, Application Systems and Object to be Painted............................ 194
2.2.1.3 Function in Paint System................................................................................................... 195
2.2.1.4 Cost Effectiveness and Availability................................................................................... 196
2.2.1.5 Occupational Health, Safety and Environmental Protection Regulations........................ 197
2.2.2 Material Flow in a Paint Factory....................................................................................... 197
2.2.3 Theory of Dispersion ......................................................................................................... 200
2.2.3.1 Pigment Specific Properties for Dispersion Processes ..................................................... 200
2.2.3.2 Wetting and Decomposition of Agglomerates................................................................... 203
2.2.3.3 Stabilization of Pigment Dispersions ................................................................................ 208
2.2.3.4 Optimum Mill Base Formulation....................................................................................... 217
2.2.4 Production of Coating Materials........................................................................................ 220
2.2.4.1 Processing Sequences in a Paint Plant............................................................................... 221
2.2.4.2 Agitation and Agitators...................................................................................................... 222
2.2.4.3 Dispersersing and Dispersers............................................................................................. 228
2.2.4.4 Separation Processes in the Manufacture of Paint............................................................ 246
2.2.5 Summary............................................................................................................................. 253
2.3 Characterization of Coating Materials............................................................................... 254
2.3.1 Measurement Accuracy...................................................................................................... 256
2.3.2 Testing Raw Materials and Coating Materials.................................................................. 259
2.3.2.1 Safety and Environment Related Performance Indicators............................................... 259
2.3.2.2 Chemical Characterization................................................................................................. 264
2.3.2.3 Physical Data...................................................................................................................... 274
2.3.3 Pigment Specific Tests....................................................................................................... 300
2.3.3.1 Indicators of the Pigment as a Raw Material .................................................................... 301
2.3.3.2 Tests with the Pigmented Coating Material....................................................................... 311
2.3.4 Processibility of Coating Materials................................................................................... 315
2.3.5 Summary............................................................................................................................. 318
2.4 Literature............................................................................................................................ 318
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Content
3 Coatings............................................................................................................................. 323
3.1 From Coating Material to Coating : The Film Formation................................................. 323
3.1.1 Wetting and Flow............................................................................................................... 323
3.1.2 Solidification of the Film................................................................................................... 325
3.1.2.1 Physical Drying.................................................................................................................. 327
3.1.2.2 Chemical Curing................................................................................................................ 331
3.1.2.3 Flows in the Solidifying Film............................................................................................ 332
3.1.3 Film Shrinkage................................................................................................................... 333
3.1.4 Special Features of High Solid Paints and Waterborne Paints.......................................... 334
3.1.5 Monitoring the Film Forming Process with Measuring Instruments................................ 336
3.1.5.1 Flow and Sag...................................................................................................................... 337
3.1.5.2 Film Formation of Air Drying Paints ................................................................................ 338
3.1.5.3 Indirect Methods................................................................................................................ 338
3.1.6 Summary............................................................................................................................. 340
3.2 Properties and Testing the Coatings .................................................................................. 340
3.2.1 Film Thicknesses................................................................................................................ 341
3.2.1.1 Wet Films............................................................................................................................ 342
3.2.1.2 Dry Films............................................................................................................................ 342
3.2.2 Dry Film Density................................................................................................................ 349
3.2.3 Measurement of Voids in Coating Films........................................................................... 350
3.2.4 Visual Properties................................................................................................................ 351
3.2.4.1 Gloss................................................................................................................................... 352
3.2.4.2 Color and Coloristic........................................................................................................... 360
3.2.5 Mechanical Properties........................................................................................................ 372
3.2.5.1 Adhesion............................................................................................................................. 373
3.2.5.2 Elasticity............................................................................................................................. 385
3.2.5.3 Hardness............................................................................................................................. 396
3.2.5.4 Abrasive Resistance and Mar Resistance.......................................................................... 403
3.2.5.5 Other Tests.......................................................................................................................... 405
3.2.6 Summary............................................................................................................................. 406
3.3 Durability of Coatings....................................................................................................... 406
3.3.1 Fundamental Features of Ageing....................................................................................... 406
3.3.2 Ageing Tests....................................................................................................................... 414
3.3.2.1 Test Methods for Surface Durability................................................................................. 415
3.3.2.2 Corrosion Protection Tests................................................................................................. 424
3.3.2.3 Chemical Resistance.......................................................................................................... 431
3.3.3 Summary............................................................................................................................. 433
3.4 Literature............................................................................................................................ 433
4 Coating Technology.......................................................................................................... 437
4.1 Substrate Impact................................................................................................................. 439
4.1.1 Wood and Wood Materials................................................................................................. 440
4.1.1.1 Wood as a Material............................................................................................................. 440
4.1.1.2 Wood as a Workpiece......................................................................................................... 442
4.1.1.3 Pretreatment of Wood......................................................................................................... 444
4.1.1.4 Surface Refinement of Wood Panels................................................................................. 445
4.1.2 Metallic Materials.............................................................................................................. 446
4.1.2.1 Properties of Metals........................................................................................................... 446
4.1.2.2 From the Material to the Workpiece.................................................................................. 451
4.1.2.3 Pretreatments...................................................................................................................... 452
4.1.3 Plastics................................................................................................................................ 464
4.1.3.1 Plastic Types and Properties.............................................................................................. 464
4.1.3.2 Pretreatment........................................................................................................................ 467
4.1.4 Mineral Substrates.............................................................................................................. 470
4.1.4.1 Concrete, Mortar, Plaster................................................................................................... 470
4.1.4.2 Glass................................................................................................................................... 472
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