Coil Coating

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  • Mar rate – Kynar is more flexible and softer Polyester – SMP Harder resin
  • Coil Coating

    1. 1. “ Coil Coating”
    2. 2. Schematic: Typical Coil Coating Line General Overview (Not to Scale) Dual Uncoilers Joiner Entry Accumulator Exit Accumulator Finish Oven Prime Oven Cleaning Section Pretreat Section Inspection & Physical Test Area Water Quench Recoiler Shear Prime & Quick Change Coaters Water Quench Finish Coater Overall line length - Approximately 700 feet Strip to thread the line - Approximately 2800 feet
    3. 3. Coil Coating: The Process General Overview <ul><li>Receiving </li></ul><ul><li>Entry Section </li></ul><ul><li>Cleaning & Pretreatment </li></ul><ul><li>Coating & Curing </li></ul><ul><li>Exit End </li></ul><ul><li>Physical Testing </li></ul>
    4. 4. Coil Coating: The Process Receiving <ul><li>Record Identity </li></ul><ul><li>Visual Inspection </li></ul><ul><li>Obvious Damage </li></ul><ul><ul><li>Dents, Torn Paper, etc. </li></ul></ul><ul><ul><li>Wet? </li></ul></ul><ul><li>Material Handling Crane or Forklift </li></ul><ul><li>Store for Future Use Capacity: 3 Mos. </li></ul>
    5. 5. Coil Coating: The Process General Overview <ul><li>Receiving </li></ul><ul><li>Entry Section </li></ul><ul><li>Cleaning & Pretreatment </li></ul><ul><li>Coating & Curing </li></ul><ul><li>Exit End </li></ul><ul><li>Physical Testing </li></ul>
    6. 6. Coil Coating: The Process Entry Section <ul><li>Get Steel l- FIFO & ID </li></ul><ul><li>Check Metal Specifications </li></ul><ul><ul><li>Grade/Gauge/Width/Etc. </li></ul></ul><ul><ul><li>Quantity/Coil Size </li></ul></ul><ul><li>Check Condition </li></ul><ul><ul><li>Edges </li></ul></ul><ul><ul><li>Shape </li></ul></ul><ul><ul><li>Zinc Surface </li></ul></ul>
    7. 7. Coil Coating: The Process Entry Section I <ul><li>Coil Cars Floor or Pit </li></ul><ul><li>Pay Off Arbors </li></ul><ul><li>Coil Size </li></ul><ul><ul><li>Width </li></ul></ul><ul><ul><li>ID or OD & Weight </li></ul></ul><ul><li>Joiner/Welder </li></ul>
    8. 8. Coil Coating: The Process Entry Section II <ul><li>De-burring Rolls </li></ul><ul><li>Pre-cleaner </li></ul><ul><li>Entry Bridle </li></ul><ul><li>Entry Tower Hydraulic/Electric </li></ul>
    9. 9. Coil Coating: The Process General Overview <ul><li>Receiving </li></ul><ul><li>Entry Section </li></ul><ul><li>Cleaning & Pretreatment </li></ul><ul><li>Coating & Curing </li></ul><ul><li>Physical Testing </li></ul><ul><li>Exit End </li></ul>
    10. 10. Coil Coating: The Process Cleaning & Pretreatment I <ul><li>Rinse </li></ul><ul><li>Clean & Brush </li></ul><ul><li>Clean & Rinse </li></ul><ul><li>Chemical Treatment </li></ul><ul><ul><li>Single or Multi-Stage </li></ul></ul><ul><li>Final Rinse </li></ul><ul><li>Waste Treatment; Chrome </li></ul>
    11. 11. Coil Coating: The Process Cleaning & Pretreatment II The key to quality is preparing the metal to accept the paint. Pretreatments enhance the corrosion resistance of the system. The type of pretreatments used depends on the base metal. <ul><li>Galvanized - Zinc Phosphate 37S </li></ul><ul><li>Galvalume - Chromate Oxide 1310 </li></ul><ul><li>Final Rinse - Parcolene 62 Chromic Acid </li></ul><ul><li>Dried-in-Place Coatings: 1402W (some Cr. free) </li></ul><ul><li>Duplex Complex Oxide or Zinc Phos. & 1402W </li></ul>
    12. 12. Coil Coating: The Process Cleaning & Pretreatment III <ul><li>A liquid used to produce a corrosion-resistant, organically bonded coating on Aluminum, Galvalume and Galvanized. </li></ul><ul><li>Incorporating a chromate rinse which is the major agent that allows the primer to bond to the substrate and helps prevent corrosion. </li></ul><ul><li>Benefits of Pretreatments: </li></ul><ul><ul><li>Provides superior long term corrosion. </li></ul></ul><ul><ul><li>Effective on Aluminum, Galvalume and Galvanized. </li></ul></ul><ul><ul><li>Coating quality is consistent. </li></ul></ul>
    13. 13. Coil Coating: The Process General Overview <ul><li>Receiving </li></ul><ul><li>Entry Section </li></ul><ul><li>Cleaning & Pretreatment </li></ul><ul><li>Coating & Curing </li></ul><ul><li>Physical Testing </li></ul><ul><li>Exit End </li></ul>
    14. 14. Coil Coating: The Process Coating & Curing I <ul><li>Specification </li></ul><ul><ul><li>Primers, Backer, Topcoat </li></ul></ul><ul><ul><li>Cure time & Line Speed </li></ul></ul><ul><li>Coater Paints Topcoat & Backer at the Same Time </li></ul><ul><li>Usually Two Complete Sets </li></ul><ul><ul><li>Coater, Oven and Quench for Primers and finish Coats </li></ul></ul>Line Direction
    15. 15. Coil Coating: The Process Coating & Curing II <ul><li>Coating Speeds up to 650 fpm </li></ul><ul><ul><li>Speed dependent on cure requirements, gauge and solvent loads </li></ul></ul><ul><li>Ovens mostly Cantenary Type - 130 to 160 ft. long </li></ul><ul><li>Cure is Determined by Peak Metal Temperature </li></ul><ul><li>Cure Occurs in 14 - 22 Seconds </li></ul>
    16. 16. Coil Coating: The Process Coating & Curing III - PRIMER <ul><li>The base layer of the paint applied by the coater to the pretreated substrate. </li></ul><ul><li>It is formulated to provide corrosion protection to the base metal and to enhance adhesion between the top coat (paint) and the base metal. </li></ul><ul><li>Standard Primers: </li></ul><ul><ul><li>Water Based </li></ul></ul><ul><ul><li>Urethane Based </li></ul></ul>
    17. 17. Coil Coating: The Process General Overview <ul><li>Receiving </li></ul><ul><li>Entry Section </li></ul><ul><li>Cleaning & Pretreatment </li></ul><ul><li>Coating & Curing </li></ul><ul><li>Physical Testing </li></ul><ul><li>Exit End </li></ul>
    18. 18. Coil Coating: The Process Physical Testing – Hunter L.A.B. <ul><li>Utilize a Color Difference Meter </li></ul><ul><li>Assigns value corresponding to the amount of light at each wavelength </li></ul><ul><li>Value is compared to and held in tolerance of Color Standard </li></ul>L = +0.2 a = -0.4 b = -0.3 Specimen Light Source Diffraction Grating Diode Array Data Processor Data Display
    19. 19. <ul><li>5/8” diameter steel ball is dropped from a prescribed height onto the panel. </li></ul><ul><li>Effect leaves a deformation that is subject to cross hatch and tape test. </li></ul><ul><li>Tape (Scotch #610) is aggressively adhered and pulled (not peeled) away from the sample. </li></ul>Coil Coating: The Process Physical Testing – Reverse Impact Adhesion
    20. 20. Coil Coating: The Process Physical Testing – Flexibility <ul><li>Brake press forming of metal sample </li></ul><ul><li>Tape (Scotch #610) aggressively applied and pulled away </li></ul>
    21. 21. Coil Coating: The Process Physical Testing – Film Thickness <ul><li>Scribe cut with calibrated blade </li></ul><ul><li>Visual inspection with reticle enable microscope </li></ul><ul><li>Measures Primer DFT </li></ul><ul><li>Measures Topcoat DFT </li></ul>Tooke Gauge
    22. 22. Coil Coating: The Process Physical Testing – Solvent Resistance <ul><li>MEK = Methyl Ethyl Keytone </li></ul><ul><li>Indicates Proper Cure </li></ul><ul><li>Solvent is liberally applied and cheesecloth is stroked back and forth across panel face for prescribed # of strokes </li></ul>
    23. 23. Coil Coating: The Process Physical Testing – Gloss Meter <ul><li>Instrument measures reflected gloss </li></ul><ul><li>Typically measured at 60 ° </li></ul><ul><li>Ultra low gloss measured at 85° </li></ul>
    24. 24. Coil Coating: The Process General Overview <ul><li>Receiving </li></ul><ul><li>Entry Section </li></ul><ul><li>Cleaning & Pretreatment </li></ul><ul><li>Coating & Curing </li></ul><ul><li>Physical Testing </li></ul><ul><li>Exit End </li></ul>
    25. 25. Coil Coating: The Process Exit End <ul><li>Recoil </li></ul><ul><li>Coil Tipper - Coils Eye to the Sky </li></ul><ul><li>Package - Paper Wrap & Skid </li></ul><ul><li>Tag/Record </li></ul><ul><li>Store or Ship </li></ul>

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