Getting the most

out of
powder coatings

Makers of the largest, most complete line of fluoropolymer coatings in the world
 What is powder coating?
Simply stated, powder coating is the pro-
cess of coating a surface with a powdered
material (as opposed to a liquid).
Powder coating materials are comprised
of polymeric resins (and often additives and
pigments) that have been reduced to small
particles with an average diameter of 25 to 90
microns. The main difference between powder
and conventional liquid coatings is that pow-
der coatings are applied in the form of free-
flowing powders, whereas liquid coatings
require water or an organic solvent to keep
the resin in the form of a suspension.
The great advantage of powder coatings
is that they can be applied with almost zero
environmental problems. The application
processes for powder coatings are essentially
mechanical and thermal — there are no VOC-
bearing effluents or wash-down solutions to
clean up. In addition, the application methods
are relatively inexpensive.
Both thermoplastic and thermosetting
resins are available as powder coatings.
• A thermoplastic powder coating melts
when it is heated for a second (and subse-
quent) time. Examples of thermoplastics in-
clude polyethylene, polypropylene and nylon.
• A thermosetting powder coating does
not melt after curing. Examples include epoxy,
polyester, acrylic and
PPS. When these resins
are cured, a chemical
cross-linking reaction is
triggered, which gives
the coating many of its
desirable properties.
Many powder-coating
materials adhere to
metallic substrates with-
out the use of primers.
But resins such as fluo-
ropolymers require the
use of a separate primer Air enters here
layer to ensure adhesion
under pressure
to the substrate.
The most common resins used in powder
coatings are polyester, polyester-epoxy,
straight epoxy, and acrylics. These materials
have a broad spectrum of uses and are avail-
able from various suppliers. In contrast, Whit-
ford offers a number of specialized powder
coatings with outstanding properties — in-
cluding excellent release and resistance to
high temperatures — for use in particularly
demanding applications.
Since their inception in the 1960s, powder
coatings have gained acceptance on a vast
array of metal parts, both consumer and in-
dustrial. Common applications include auto-
motive components such as body panels and
oil filters, architectural items such as alu-
minum columns and window frames, and ma-
terial handling products such as valves and
pipes in the chemical processing industry.
How to apply them
Powder coatings are normally applied in
one of two ways — either by fluidized bed or
by electrostatic spray.
1. Fluidized bed: Preheated parts are
dipped into a bed of powder that is made
fluid-like by small streams of air arising from
beneath the powder. As the fluidized powder
comes into contact with the heated part, it
melts and fuses to the surface of the part. The
coated parts are placed back in an oven for
the final flow-out of the powder.
Fluidized bed
Air passes through vents, Powder adheres,
“liquifying” powder, fusing to heated part
causing it to rise
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 This technique requires little equipment to run, drip, or sag.
other than the bed, a source of air, and a Overall coating thickness can be built to
means of heating the parts. A variation of this maximum levels allowed by the resin without
technique is to apply a negative electrostatic fear of blistering. In general, powder-coated
charge to the powder which draws the pow- parts are more resistant to cracking, peeling,
der particles to the part via electrostatic at- and marring during handling and normal use.
traction. Thicker coatings also tend to be tougher and
2. Electrostatic spray: An electrostatic more durable and are particularly useful on
charge brings the particles and the part to- corrosion-prone applications where thicker
gether. One benefit is that the parts are coatings provide added protection. They also
coated uniformly — even on the back side of help cover small surface defects such as
the part — because the attraction between sharp edges, dimples, and machining marks.
the powder and the part is uniform, all around As a result, some secondary machining oper-
the part. Then the part is heated so that the ations, such as polishing, grinding, or debur-
powder melts, fusing to the part surface. ring may be eliminated.
2. Advantages in deep-well applications:
This is the application method of choice
Powder coatings can be advantageous when
for coating many parts at once, or when the
applied to parts that have recesses and de-
coating thickness needs to be controlled.
pressions (see page 7). Using the fluidized-
bed method of application,
Electrostatic spray powder coatings can be applied
almost evenly to channels, key-
Spray gun
ways, holes and other recesses.
No other application method re-
sults in coatings as uniform and
blister-free in these areas. This is
because coating thickness de-
Electrostatic pends primarily on the heat in the
charge part, not on electrostatic attrac-
tion or how well volatile carriers
Air/powder input are driven off, as is the case with
Powder surrounds
part, attracted liquid coatings.
Power supply electrostatically
3. Easier to use: Cleanup is
Diagram of typical electrostatic powder application process. greatly simplified with powders.
Cleanup of liquid coatings often
Advantages vs liquid coatings requires stripping agents and solvents that
must be discarded. In contrast, a powder
Powder coatings offer several advantages booth or spray area can be cleaned up by
over liquid coatings in terms of performance, simply vacuuming the powder overspray.
ease and efficiency of use, cost, and environ-
mental concerns. 4. More efficient: If the powder overspray
is not contaminated, it can be collected and
1. Better performance from higher film recycled (liquid coatings cannot), so it is pos-
thickness: Powder coatings provide the same sible to use nearly 100 percent of the coating
level of corrosion, wear protection, and re-
material.
lease as their liquid counterparts — if applied
at the same film thickness. However, in com- 5. Low capital investment: Many of the ad-
parison to liquid coatings, powders make vantages of powder coatings lie in what they
thicker films possible because they tend not enable users to avoid. For instance, powder
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coatings do not require investment in expen-
sive cleanup and effluent monitoring systems.
In addition, far less wastewater is generated,
resulting in fewer problems and expenses as-
sociated with waste disposal.
6. Cost savings in operations: The savings
in energy, labor, rework, material, line efficien-
cy, waste disposal, air processing, and clean-
up can be substantial compared to liquids.
7. More environmentally friendly: Powders
enable the elimination of solvents and haz-
ardous wastes. Unless the coatings are acci-
dentally overheated during the fusing pro-
cess, powder coatings emit zero or near- zero
VOCs during the coating process.
Drawbacks vs liquid coatings
Not all advantages, however, lie on the
side of powder. Liquid coatings are often pre-
ferred because of their ability to form thin films
or to be cured at lower temperatures.
1. Liquids are well suited to thin coatings:
Thinner coatings are advantageous in many
applications, particularly on small mechanical
parts where assembly or operations would be
impeded by a coating that is thicker than
about 38 microns (1.5+ mils).
2. Higher fusing temperatures: Liquid coat-
ings fuse through drying and curing, in which
the volatile carriers are driven off by heat,
leaving only the solids behind. Volatile compo-
nents can be removed over a wide range of
temperatures, from about 65˚-370˚C (150˚-
700°F), in a time/temperature relationship. So
some liquid systems can be processed at low
temperatures and still incorporate high-melt-
ing components into the cured coating.
On the other hand, a powder coating such
as PFA must reach its specific melt tempera-
ture before it can flow and fuse. Yet some fu-
sion temperatures are incompatible with
certain substrate materials. For instance, fus-
ing a die-cast part at 370°C (700°F) is likely to
produce eruptions from subsurface voids.
Also, forged aluminum parts should not be
fused above 205˚C (400°F) because they may
soften. Thus, when selecting a powder coat-
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ing, it is important to ensure that the fusing
temperature of the powder is compatible with
the temperature resistance of the substrate.
When to specify powder
Powder coatings are particularly well
suited to applications where thicker films are
desirable because of their increased durabil-
ity and resistance to corrosion.
1. Thick-films: Powder coatings are ideal
for applications where thick liquid coatings of
similar properties would ordinarily have been
specified, but where VOCs are unacceptable.
Also, powder coatings should be considered
when the necessary buildup of film thickness
with liquids may result in blistering.
2. Corrosion: Powder coatings are applied
to retard or eliminate corrosion in many indus-
trial applications.
Corrosion is an electrochemical process
with three components: a cathode, an anode,
and an electrolyte, and there are many cir-
cumstances in which all are present. Common
examples include metal parts used in or near
sea water or acid solutions; parts made from
dissimilar metals that are joined together; and
vibrating parts that are tightly pressed to-
gether. Specific examples include compo-
nents of CPI systems such as valves, pipes,
hangers, unions, joints, filters, and housings
for motors and pumps.
The key to protecting these parts is total
encapsulation of the surface, which can be
ensured by applying the coating in multiple
layers, if possible. The reason is that, in any
single coating layer, small voids or pin holes
can serve as an electrolytic path for corro-
sives. Multiple coating layers can eliminate
essentially all of these voids by overlapping
them (see diagram next page).
3. Durability: This is a common require-
ment in applications where frequent contact is
made with the coated surface. For example,
the surfaces of equipment used for materials-
handling, packaging, sealing, molds, under-
body parts of vehicles, stone crushing,
pulpwood, grain processing, and building ma-

Two coats to avoid corrosion
Topcoat/
Second coat Prime/
First coat
Pin holes
Substrate
Overlapping layers of the topcoat fill in and cover
any minute pin holes in the prime coat.
terials can often be eroded by the materials
that are being processed. Given enough time, sation for, temperature imbalances.
these surfaces can be completely destroyed
by the materials passing over them. Thick
films of certain powder coatings can slow
down this process. Although a powder coat-
ing may not stop the erosion entirely, it is likely can be cured in the range of 160°-210°C
to prolong the life of parts that are used in
these environments.
4. Release: Liquid coatings are often pre-
ferred for release applications, although fluo-
roplastic powder coatings are frequently used
when extra durability is required. For example,
powder coatings are specified on a number of
paper-handling and mold surfaces where
long-lasting release is critical to the process.
Other examples include slides and chutes for
printing equipment and wear surfaces of xero-
graphic equipment.
A word on fusing
Powder coatings are fused by heating the
coated parts in an oven. In some cases, the
parts are heated prior to powder application.
• Preheating parts: Preheating of parts,
often called “hot flocking” is, of course, nec-
essary when coating via the (non-electrosta-
tic) fluidized-bed method. However, it can also
be quite useful in the electrostatic process.
For example, in cases where unusually high
builds of powder are required, the parts can
be preheated to the fusion temperature of the
powder. This will cause the powder to fuse on
the part as soon as it is applied, enabling a
thicker-than-normal coating to be attained.
• Oven profiling: Every oven has a unique
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heating “profile”. If an oven is set at a tem-
perature of 205°C (400°F), the real oven
temperature may be 215°C (420°F) in the
upper-left corner and 185°C (365°F) in the
lower-right corner, which can damage the
quality of finished coatings if the profile is
not known. For instance, parts in one sec-
tion of the oven might be withdrawn before
fusing is complete or, conversely, could be-
come overheated and burned or blistered.
Therefore, prior to long production runs, a
thermal profile of the oven should be obtained
in order to enable adjustment of, or compen-
• Processing temperatures: The process-
ing (curing or fusing) temperature in the oven
depends on the resin used. Many polymers
(320°-410°F); however, certain high-perfor-
mance resins such as fluoropolymers require
processing temperatures in the range of 300°-
400°C (600-750°F). How this heat is applied to
the part depends on the size of the part, its
composition and shape, as well as the num-
ber of units to be coated. Large, thick items,
such as castings, tend to be fused in convec-
tion ovens where heat is supplied remotely,
via gas or electric heaters. Small parts, such
as stampings and small wrought parts tend to
be cured by banks of IR heaters.
Choosing the process
The choice of how to powder-coat a part
depends on (1) the mass and size of the part,
(2) its thermal conductivity, (3) its shape, and
(4) the number to be coated.
1. Mass and size: For a powder coating to
fuse on the surface, the part must be heated
to the melt (fusion) temperature of the polymer
and remain there for as long as is required for
the powder to melt and flow. This is a time/
temperature relationship (see next page). The
larger and thicker the part, the longer it takes
to reach the fusion temperature of the coating.
Extreme examples: a cast valve body and a
stamped shell of an automotive oil filter.
If a large, thick steel casting is to be

Time/temperature relationship
Thin
stamped Thicker sheet- Fusion
part metal part temperature
Temperature
Large casting
Time
As the graph demonstrates, the thicker the part,
the more time required to achieve full cure.
coated, it will require hours of “heat soak”
(oven dwell) in order to reach the fusion tem-
perature. Such a part can be coated in a flu-
idized bed or sprayed electrostatically,
depending on its complexity and whether mul-
tiple coats are required.
If the shape is complex (e.g., including
fins, bosses, or holes), then the fluidized-bed
method may be the better way to coat the part
completely. However, if a complex part re-
quires multiple coats for added protection, the
coating must be applied by electrostatic
spray because the conventional (non-electro-
static) fluidized-bed process is a one-step
system (only one coat can be applied).
2. Thermal conductivity: Parts with rela-
tively low thermal conductivity (such as cast
ferrous metals) are often heated for long peri-
ods in a convection oven because they re-
quire a long time to reach the powder’s fusing
temperature. For example, large tanks or com-
pressor bodies often soak overnight in a con-
vection oven to affect a cure on the coating.
On the other hand, highly conductive parts
(such as aluminum and brass) may be cured
rapidly via IR heaters because the parts reach
fusion temperature quickly.
3. Shape of the part: Shape can influence
the choice of application method. For exam-
ple, round, cylindrical, and cubic-shaped
items are usually coated more efficiently using
electrostatic spray. Because the electrostatic
charge enables the powder to wrap around all
sides of the part, the coating is uniform. But:
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irregularly shaped parts — including those
with bosses, indents, keyways, slots and
holes — are often best coated using a flui-
dized bed because this may be the only way
to achieve uniform application of the powder
(see illustration below).
4. Number of parts to be coated: Fluidized
beds lend themselves to batch-coating
processes in which one or more parts are
dipped at one time. In this case, production
rates are typically measured in multiples of 10
parts per hour. On the other hand, electro-
static spraying lends itself to automated appli-
cation, and application rates may reach
hundreds or even thousands of parts per hour.
Difficult applications
Parts comprised of components with dif-
ferent thicknesses, deep recesses, or subject
to high loads can be problematic for powder
coating.
• Thickness ratio: A rule of thumb is to
avoid powder coatings on parts where wall
thickness varies by a ratio of more than four to
one. Example: a part with a thick, solid base
and an array of thin fins or other projections. If
such a part remains in an oven long enough
to fuse the powder on the base, the powder
on the fins could over-bake and degrade. The
tendency for powder coatings to degrade with
exposure to heat is resin specific, and the ef-
fects vary from one type of coating to another.
• Recesses: Another problem when using
electrostatic systems is a deep recess. In
Simple shapes Complex shape
Simple shapes are easy to coat with fluidized-bed
or electrostatic spray systems. Complex shapes
are usually easiest to coat with a fluidized bed.
cases where the width-to-depth ratio is small,
the coating may not be uniform. This problem
is caused by uneven application of powder
due to the “Faraday effect.” Because electro-
static attraction is inverse to distance (like
gravity), charged particles are attracted to the
substrate as they approach the opening of the
recess, leading to a buildup of powder at the
opening and less powder inside the recess.
The Faraday effect
Conventional Electrostatic Fluidized bed
Powder coating
A representation of how the results of the Faraday ef-
fect depend upon the application method. In this
case, the fluidized bed results in the most uniform
application of the powder.
• High loads: When wear resistance is re-
quired, the “PV limit” expresses the maximum
PV (pressure times sliding velocity) value — or
limit of sliding severity — that a composition
can tolerate without catastrophic failure. The
physics of coatings is such that the thicker
they are, the more they act like plastics. Con-
versely, the thinner the coating, the more it
acts like the substrate on which it is applied,
usually a metal. For example, a thin, 12-mi-
cron (0.5 mil) coating may have a PV limit of
150,000; yet the same coating material may
have a PV limit of only 50,000 when applied at
25 microns (1 mil). Because powder coatings
are usually applied at thicknesses of at least
37 microns (1.5 mils), their use in high-load
applications is not usually recommended.
Preparation of substrates
The guidelines regarding surface prepara-
tion of parts prior to coating with powders are
similar to those with liquids. Application of
coatings over dirty, oily parts will result in poor
adhesion and/or reduced performance. Ob-
serving the following guidelines will improve
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coating performance on specific materials.
• Cast aluminum: Both die-cast and sand-
cast aluminum parts can be porous. Prior to
coating, it may be necessary to heat the part
to a temperature above the fusing tempera-
ture of the powder in order to allow any near-
surface cavities to erupt. If these cavities
erupt after the item is coated, the eruptions
will spoil the finished coating.
• Wrought aluminum: Most parts are
chromate conversion-coated prior to pow-
der coating, which improves the corrosion
resistance. On a forged aluminum part, if
the oven processing temperature exceeds
the substrate’s annealing temperature of
218°C (425°F), metallurgical damage can
occur. Some parts that have been substan-
tially work-hardened by forging may be
stress-relieved to the point that they warp
and become misshapen.
• Cold-rolled steel: This material pro-
vides a good surface for coating. It should
be cleaned and phosphated prior to the appli-
cation of powder.
• Hot-rolled steel: This is usually covered
with mill scale that must be removed prior to
coating. Remove the scale by mechanical
means (blasting or tumbling) and then treat
the metal as you would cold-rolled steel.
• Cast iron and steel: Treat these as you
would hot-rolled steel.
Want more information?
Whitford was founded in 1969 to develop
and market high-performance fluoropolymer
and powder coatings. Today, Whitford makes
the largest, most complete line of fluoropoly-
mer coatings in the world.
This brief booklet provides an overview of
ways to take full advantage of the benefits of
powder coatings. Additional information is
available in various publications and may be
obtained by contacting your Whitford repre-
sentative or by going to our website: whit-
fordww.com. You can also email us at
sales@whitfordww.com.
 Whitford Tests for Coating Quality
Impact Test (ASTM D-2794)
Coating on a 0.036 in. thick phosphated steel panel must withstand the impact of a 1/2” Gard-
ner impact tester ball at 26 in.-lb., and reverser. No grazing or loss of adhesion is acceptable.
The coating shall not be able to be removed at the impact area with 3M Y-939 tape.
Adhesion Test (ASTM D-3359)
Scribe parallel lines through the coating to the substrate, spacing the scribe marks 1/4” apart,
over a distance of 1”. Scribe a second set of parallel lines 1/4” apart, perpendicular to the first
set. Apply 3M Y-9239 tape, then remove slowly. There should be no lifting of film between
scribe lines.
Chemical Resistance Test (ASTM D-1308)
Place approximately 10 drops of test solvent (95% by weight of toluene and 5% by weight of
MEK) on the surface of the coating. Allow to stand for 30 seconds. Wipe off with a soft, dry
cloth. The coating shall show no more than a slight circular mark.
Salt-Spray Corrosion Test (ASTM D-117)
Use a 5% salt solution at 33˚-36˚C (92-97°F) in a sealed weather cabinet. Scribe an “X” mark
to bare metal in the coated steel test panel, pretreated with zinc phosphate. Inspect every 24
hours. End test and total hours after 1/4” creepage from scribed area. Creepage shall not ex-
ceed 1/4” in either direction from scribe line after 500 hours of exposure.
Bend Test (ASTM D-522)
Coating on a 0.036” thick phosphated steel panel shall withstand 180° bend over 1/4” man-
drel. There shall be no crazing or loss of adhesion and finish at the bend, and no lifting when
using 3M Y-9239 tape.

How to contact Whitford

Whitford manufactures and maintains sales offices
in many countries. For more information, please
contact your Whitford representative or the nearest Whitford office
(see our website: whitfordww.com) or sales@whitfordww.com.

Makers of the largest, most complete line of fluoropolymer coatings in the world

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