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Powder Coating Faq

1. What is powder coating?

Powder is a dry coating. Instead of being dissolved or suspended in a liquid medium, such as solvent or water, powder is applied in a dry granular form. This material is a little finer than ground pepper but coarser than flour, and is applied directly to the surface to be coated. The powder is created by blending the various components (binder, resins, pigments, fillers and additives) and processing them through an extruder into a continuous mass. This homo-genous mass is cooled and broken into small chips, which are then ground into the powder. Each particle contains within it the necessary components for reforming into the finished coating. After the powder is applied to the substrate (Part), typically using an electrostatic spray process, the substrate is place in an oven where it cures, melting the powder into a smooth film on the surface of the substrate.

 

2.Why choose powder coating over paint?

 

* Significantly more durable than conventional wet paints – extremely resistant to chips, abrasion, heat, UV light, fuel and chemicals * Environmentally friendly – no hazardous materials or disposal concerns * Can be less expensive than liquid coatings with superior results possible * Wide selection of OEM and custom colors available including translucent’s and metallic’s * Consistent application – no runs, drips or sags * Extremely quick – part is ready for service in less than an hour after heat cure * Proven award-winning results!

 

3. What Can Be Powder Coated?

All around you, from your car, to your motorcycle, your bike, your workplace, your home and garden there are thousands of items that are powder coated. Once you have opened your eyes to the possibilities, the list is endless!

 

4. Why powder coating?

Powder coating offers the consumer a superior finish while adding many performance properties such as excellent resistance to corrosion, chemicals, heat, impact, abrasion, UV rays and extreme weather conditions. Not only is powder coating exceptionally tough and impact resistant it can easily withstand flexing action.

 

5. Does powder finishes effect the environment?

This one of best reason for using powder over a liquid finish is that it’s environmentally friendly and virtually pollution free. No volatile organic compounds (VOC s) or solvents to evaporate into the atmosphere. And powder is not such a health risk to our employees. Powder is so environmentally friendly that all of the air born powder in the booth goes through the powder booth filter system and is then vented back into the work area. In fact one of the major elements in expanding the market for powder coating has been the implementation over the past 30 years of stringent air pollution controls set by the U.S. environmental protection agency.

 

6. What powder is best against weather?

Polyester powders provide additional protection against outside weathering conditions. Polyester powders do provide additional advantages in protection against ultraviolet and weathering resistance.

 

7. How does powder get applied?

The application process involves applying a charge to the dry powder particles and spraying them onto a grounded substrate (part). The substrate is grounded so the powder will be attracted to it.

 

8. Is powder coating more durable than liquid paint?

The most popular liquid finishes are high solid acrylic urethanes which use solvents and hardeners in the application process. Acrylic urethanes are not as hard or flexible as powder resins. Powders are made from resins that need to be heated in order to flow and cross link to a substrate (part). This makes for a superior adhesion to substrates (part) making powder coating ten times more durable then the most popular liquid finishes. And powder coat colors stay brighter and more vibrant longer then liquid finishes.

 

9. Is this a new process and where is it used?

Powder coating is relatively new; the process has been around for sum years. It has been the number one finish choice of many manufacturers, in a wide range of industries for many years. Powder coating in the United States is just starting to take off, in Europe more then 60% of all finish application is powder coated. In the United States the application of powder finishes is only 20% vs. liquid applications. Powder coating finishes can be found on motorcycles, automobile parts and frames, agricultural equipment, architectural applications, garden equipment, aviation parts and recreation equipment including bicycles, boats, recreational vehicles, ATV’s and golf equipment, and even artist that work in metal are fining out that power coating clears keeps there work in copper brass etc, looking the same is the day there work of art was created. A superior finish combined with durability greatly reduces required maintenance and extends the life of any coated product thus making powder coating the right choice.

 

10. Is powder coating more expensive than liquid finishes?

The powder material is less expensive compared to liquid finishes. Also, less labor is involved in the preparation of a substrate (part), resulting in overall cost.

 

11. Can Champion Coating do liquid finishes?

Champion Coating can apply liquid finishes. We have trained personal and the equipment and permits required. But recommend powder for is superior protection and durably.

 

12. Does powder coating drip, run or sag?

Because of the way powder is applied to the substrate (part) using electrolysis, the powder goes on uniformly. The powder is then heated in an oven to let the powder flow and crosslink to a hard and long lasting finish. The end product is drip, run and sag free.

 

13. Can you powder coat over existing finish?

No, because one of the steps in powder coating requires the substrate (part) to be cleaned usually by media blasting, this removes all existing finishes.

 

14. Can I powder coat over chrome parts?

Your substrate (part) which has chrome already on it will need to be media blasted to remove the top layer of chrome off. This will leave the copper and nickel coatings on the substrate (part). The coatings that are left on the substrate (part) are ok to be powder coat over, but we will need to pre-bake the part to make sure the coatings are stable. If the pre-bake cycle doesn’t blister the copper and nickel coatings we will then put the powder on.

 

15. Are there any limits in the degree of detail that can be achieved with powder?

Finishes in liquid allows for more flexibility when doing multiple overlays with extreme color contrast, but in most cases we can do pin stripes, fades, and even flames better with powder.

 

16. Can coil springs be powder coated?

Powder coatings are very flexible, and can flex with the metal as the spring, coils and recoils to its stationary position. Also epoxy, acrylic and hybrid powders provide excellent adhesion and hard-ness for improved resistance to chipping, abrasion, corrosion, and chemicals; and it’s flexible enough to be formable without cracking.

 

17. How does the process work?

The process is relatively simple. A finely ground powder is applied to a part using a powder gun that charges the powder being applied so that the powder electrostatically adheres to the grounded part. The part is then placed in the curing oven where the powder melts and cures, becoming cross linked to the part producing a continuous hard coating.

 

18. Does powder coating require any preparation?

One of the keys to a long lasting powder finish is in the preparation of the metal. Champion Coating takes great care in the preparation process. We blast each part down to bare metal to create a surface that will assure in good adhesion and consistent flow of the powder. Each part goes through a series of cycles for washing, chemically treating and rinsing to ensure that the powder will have a good foundation in which to cross link to. This process is to assure that all additives are removed from the surface. We then pre-bake each piece to purge trapped moisture, oils and gasses that cause reactions to the powder finish. This process will insure that the part that gets powder coated will be the most durable finish available today.

 

19. Why monitor the part temperature in the oven?

Different powders have a temperature specification and a length of time needed for the curing process. Champion Coating has the equipment to monitor the part in the oven, to know when the part is up to temperature in which the curing process is to start. If the part is under cured it can be less chip resistant, and if the powder is over cured it may discolor or have an amber cast to it.

 

20. What kind of metal can be coated?

Parts made from aluminum, steel, brass, copper, bronze, magnesium and titanium can be powder coated. Magnesium and Aluminum Castings may experience out-gassing causing bubbles in the finish.

 

21. Can metal parts that are die cast be powder coated?

Die cast metals along with extruded and forged metals can be powder coated. If your cast parts are made from a low density metal, we will need to include some additional steps in the prepping process before we can powder coat your cast part.

 

22. Can parts be coated with clear powder coating?

Powder clear will keep newly polished aluminum rims looking like the day they where polished. Clear powder is also good to protect plumbing and inside, outside lighting fixtures.

 

23. Can powder be applied to ceramic or glass (non-conductive materials)?

Glass can be coated, but it’s on a job by job basis. It takes a certain type of powder and testing the glass to see if it will work. Ceramics and porcelain can also be powder coated.

 

24. Is there a powder coating that fights germs?

Anti-microbial powder coatings are used to provide supplemental protection against the growth of microorganisms such as bacteria, algae or fungi. These powder coatings possess high temperature stability and excellent color retention. In addition to protecting against microorganisms, anti-microbial powder coatings are durable enough to with stand exterior elements. Anti-microbial powder coatings are NSF and EPA FIFRA approved for drinking water contact and FDA approved for food packaging applications.

 

25. Can powder colors be matched?

Powder colors can be matched. If the color needed is not within the standard colors available by the manufacturer, a sample can be sent to the manufacturer to match. Extra time would be required for this process.

 

26. Are candy powders available?

Candy along with transparent colors are available in powder, there are even fluorescent colors.

 

27. Are there different finishes available?

Powders come in high and low gloss, Metallic, textured, and clear finishes. Powder textures range from smooth to wrinkled and even matte. Rough powder textures are designed to hide imperfections that may be a surface.

 

28. How can I go about choosing a color?

Champion Coating has thousands of color chips to choose from. We will assist you in the selection of the color right for you.

 

29. Does Champion Coating use reclaimed powder?

First we use powders that are 100% virgin. Reclaimed powder could have contaminates in it, and that contamination could create defects within the finished powder.

 

30. What does media blasting do, and how is glass beading different?

Media blasting ‘etches’ the surface of the metal, creating a solid bond for excellent adhesion of the powder during the curing process. Glass bead media uses a round glass media that pocks the surface, leaving a smoother surface rather than an etched surface. Glass bead media is used more for aesthetics rather than functional uses.

 

31. Can dents or imperfection be filled?

Surface restoration is possible on some metal by building up the surface using different types weld or brass as fillers. We can also use special hi temperature fillers to aid in the restoration process.

 

32. What do I need to do to prepare my part for you?

The parts we received in our shop must be totally disassembled and degreased.

 

33. Can polished parts be coated in clear?

Clear powder coat is available in semi gloss and high gloss. Polished parts coated with clear eliminate the need to continently re-polish your parts.

 

34. Will heat damage your substrate (part)?

No, the temperature used to cure the powder is less than 400 degrees. Titanium, steel, aluminum, magnesium are not affected by these temperatures. The temperature would have to be heated above 700 degrees to in order to affect most substrates.

 

35. Can thickness of the powder coat be measured on a substrate (part)?

Champion Coating uses a powder measurement tool for a non-destructive test to assure that the correct amount of powder has been applied prior to the curing process.

 

36. Why is a destructive test used on powder coating?

The destructive test would require a separate test substrate, which would show how the powder adhered to the test substrate but will also damage the test panel. This test is predominately used when coating large quantities of like products as a quality control tool.

 

37. Why is a non-destructive test used on powder coating?

The non-destructive test is used to check the film thickness of the powder without damaging the powder coating on the substrate.

 

38. Can wood be powder coated?

Powder is being applied to medium density fiberboard (MDF) used in furniture, cabinetry, speaker cabinets, etc. with successful results. Wood itself can be powder coated, but the temperature that is required to cure the powder would pull the moisture out of the wood, leaving a grainy finish. Appling powder coating to wood products is not practical or recommended that is time. New powders are under development and in the near future wood and even some plastics will be getting a coat of powder.

 

39. What is the most cost effective way to powder coat?

The most cost effective way is to have a number of pieces done at one time, this will cut down additional setup time and this will save you money.

 

40. What is the approximate turnaround time on jobs?

We complete all jobs in the order they are received. We offer timely service; however, we do not rush a job because we take great pride in providing quality work. We try to keep turnaround time to a maximum of 3 days. We will notify you of any delays.

 

41. If I ship my parts to Champion Coating, how do I package them?

We ask you to ship your parts in a sturdy box and place padding between them so they do not rub together. Please place small parts in a plastic Ziploc bag or plastic bubble wrap. We will package parts carefully and return them to you COD unless we agree on other arrangements.

 

42. What forms of payment do you accept?

We accept checks, Visa and MasterCard.

 

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