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Abstract: Autophoretics (A-coat) is a coating process used to adhere a polymer Microscopy: Two forms of microscopy were employed to study the surface of AP coated
protective coating to steel components. Environmentally speaking, A-coat is very clean specimens. First the surface of AP coated specimens were studied under 10x and 100x
compared to alternatives. It does not emit VOCs or contain hazardous chemicals. It magnification to find coating defects, observable corrosion, or coating erosion. After
can also be easily reconditioned and recycled. However, due to consumer demands, this study was complete any defects would be further studied under a Field Emission-
manufacturing companies are now looking beyond their four walls, far up the supply Scanning Electron Microscope (FE-SEM).
chain, to evaluate the total environmental impact of a products materials. Currently Standard Microscopy Results: The standard surface microscopy evaluation detected
A-coat uses a Polyvinylchloride (PVC) coating base, which gives off chlorine gas, during multiple defects in the coating surface (seen below). These defects appeared to be
the materials manufacturing process. Due to this, a West Michigan manufacturing voids in the coating. These void locations were too big to be detected using the BET
company is evaluating conventional autophoretic paint cost and performance against a experiment but too small to be observed by the naked eye. When corroded specimens
greener epoxy based A-coat, as well as a powder paint alternative. This company were examined these void locations were the localized points of failure.
sponsored an in depth laboratory study of A-coat to evaluate the protective qualities
of this material with regard to corrosion, long-term adhesion, and longevity/durability.
The purpose of this study is to ascertain if powder paint or epoxy A-coat would be
equivalent or superior to conventional A-coat while decreasing environmental impact.
Coating Surface
Step 1:
The base substrate is first cleaned in a multi-
step process. Once cleaned the material is
dipped into the emulsion and left to sit.
Base Metal Surface Iron-Oxide Locations
Step 3:
Once the desired thickness is obtained the Tafel Plot
part is removed from the emulsion and cured
in an oven.
Theories: Several theories exist as to why Autophoretic Coat could be failing prematurely
1.Microporosity of the coating
2.The coating is being eroded causing failure to occur
3.Excess acidity, trapped beneath the coating is causing failure
AP & Powder Paint Comparison
Testing Objectives:
To determine if there are microscopic pores or defects in the coating
To measure the corrosion rate of A-coat and powder paint
Use microscopy to study the surface of the coating, before and after corrosion
Conclusions:
Voids in the AP coating are causing the coating to fail sooner than powder coated
Autophoreticly coated material corrodes faster than Powder coated specimens
Surface Porosity: The Bruanuer, Emmet and Teller (BET) gas absorption method was
Micro-pores and micro-defects are not present or too small to cause failure
employed to determine the porosity of AP and powder paint specimens by determining
the amount of gas which the specimens surface absorbs. The gas condenses in the fine
pore structure of the coating creating a layer on the specimens surface. The gas pressure Recommendations: It has been observed that large oil spots on product prior to cleaning
is increased till the surface pores of the specimen are saturated. Comparing the and painting have inhibited the AP process in coating the metal properly, resulting in large
macroscopic surface area to the microscopic area, reveals pore size, pore volume and (visible) voids. The micro-voids are most likely a much smaller form of the same
pore area in a specimen. phenomena. In applications where AP is in consideration, it is recommended that the
Results: This study found that number and size of pores present in both AP and Powder cleaning process (pre-treatment) be further evaluated and improved to prevent micro-oil
Paint coated samples were too small to compromise the coating. spots.