粉末喷涂与应用课件.ppt

1、abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Introduction to Powder Coating粉末涂料介绍粉末涂料介绍abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Pretreatment for use withPowder Coatings金属前处理金属前处理abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Prep

2、aration金属的处理金属的处理Pretreatment is a process intended to prevent the corrosion of the painted metal.前处理是一种提高耐腐蚀的工艺前处理是一种提高耐腐蚀的工艺Fe2+O2+H2O=RUSTIron reacts with oxygen and water in the atmosphere creating a powdery brown mess,not very ornamental,and continuous until no solid metal remains.铁在空气中会与氧气和水反应

3、生成褐色的物质铁在空气中会与氧气和水反应生成褐色的物质abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation金属处理金属处理Several methods of corrosion prevention can be used几种防腐蚀的方法几种防腐蚀的方法For Steel:铁：铁：Automotive applications 汽车业汽车业 Primer:Underseals:Layers of Paint.abcd DONGGUAN JOINSHOW PRECISION HARDW

4、ARE MANUFACTURING CO.，LTD Several methods of corrosion prevention can be used几种防腐蚀的方法几种防腐蚀的方法For Steel:铁：铁：Architectural Applications 建筑业建筑业Galvanising:Anti Corrosive Primer*Galvanising covering with a layer of zinc.Metal Preparation金属处理金属处理abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.

5、，LTD Metal Preparation金属处理金属处理abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation金属处理金属处理Several methods of corrosion prevention can be used几种防腐蚀的方法几种防腐蚀的方法For Aluminium:铝：铝：Aluminium oxidises to form a white corrosion product铝被氧化后形成白色的物质铝被氧化后形成白色的物质Architectural Applic

6、ations 建筑业建筑业 Anodise:Acid Primersabcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation金属处理金属处理Why Pretreatment?为什么要前处理？为什么要前处理？Powder coatings are used to enhance the appearance of buildings,machines,furniture,appliances:粉末涂料用于改善建筑，机械设备，家具，以及其它器具的表粉末涂料用于改善建筑，机械设备，家具，以及其它

7、器具的表面：面：Designers and architects are searching to give distinction in terms of colour and effects.设计师和建筑师提供了包括颜色和效果在内的标准等级设计师和建筑师提供了包括颜色和效果在内的标准等级The problem is that all paints are porous：所有的涂料均不同程度的存在会渗水的小孔所有的涂料均不同程度的存在会渗水的小孔abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Prep

8、aration金属处理金属处理Molecules of water and salt can penetrate through the paint film.When they reach the metal surface the effect is worse than if the metal is uncoated.The answer=Pretreatment水和盐分子可以渗透漆膜，一旦它们与金属表面接触，产生水和盐分子可以渗透漆膜，一旦它们与金属表面接触，产生的影响甚至比没有喷涂还要糟糕。的影响甚至比没有喷涂还要糟糕。要解决这个问题就需要前处理。要解决这个问题就需要前处理。abc

9、d DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation金属处理金属处理Pretreatment:前处理前处理The chemical conversion of the metal surface before applying the powder coating.The metal then resists corrosion and the conversion permanently improves the adhesion of the coating.在使用粉末涂料以前用化学方法

10、对金属表面进行处理，可以在使用粉末涂料以前用化学方法对金属表面进行处理，可以改善耐腐蚀性和增加涂层的附着力。改善耐腐蚀性和增加涂层的附着力。abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation金属处理金属处理The performance of the powder coating is only going to be as good as the metal preparation.We will cover three types of metal treatment syste

11、ms粉末涂料的功能类似于金属处理，我们将介绍三种的金属粉末涂料的功能类似于金属处理，我们将介绍三种的金属处理方法处理方法 Iron Phosphate for Steel用于铁系的磷酸铁用于铁系的磷酸铁 Zinc Phosphate for Steel用于铁系的磷酸锌用于铁系的磷酸锌 Chromate for Aluminium用于铝的铬酸盐用于铝的铬酸盐Other systems can be used and information is available.当然还有其它处理方法当然还有其它处理方法abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANU

12、FACTURING CO.，LTD Metal Preparation Iron Phosphate金属处理金属处理 磷酸铁磷酸铁Metal pretreatment can be applied by spray or dipping.金属前处理可以借助喷淋或浸渍金属前处理可以借助喷淋或浸渍In the case of iron phosphate the process could look like this:下面是磷酸铁的工艺流程下面是磷酸铁的工艺流程Stages 1,2 and 3 can be either spray or dip步骤步骤1，2和和3均可采用喷淋或浸渍均可采用喷淋

13、或浸渍DRAINDRAINStage 1Clean&PhosphateStage 2RinseStage 3Rinse&SealWorkFlowabcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation Iron Phosphate金属处理金属处理 磷酸铁磷酸铁Typical 3 Stage System典型的典型的3步骤流程步骤流程Metal SubstrateSteel Phosphatising System金属基材金属基材None Ferrous Clean and EtchStag

14、e time duration1 90 seconds不同步骤所需的时间不同步骤所需的时间2 45 seconds3 30 secondsStage temperature 1，2和和3步骤所需的温度步骤所需的温度40 60oCDrying/干燥温度干燥温度100 120oCTypical concentration 2 3%by volume典型的浓度典型的浓度Typical acidity典型的酸值典型的酸值pH 3.5 5.5Typical coating weight典型的膜重典型的膜重20 40 mg/ft.abcd DONGGUAN JOINSHOW PRECISION HARDW

15、ARE MANUFACTURING CO.，LTD Metal Preparation Zinc Phosphate金属处理金属处理 磷酸锌磷酸锌Zinc Phosphate process for steel tends to be more complicated磷酸锌的工艺流程复杂一些磷酸锌的工艺流程复杂一些Stage 1CleanStage 2RinseStage 3Phos-phateStage 4RinseStage 5RinseDRAINDRAINDRAINDRAINabcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING C

16、O.，LTD Metal Preparation金属处理金属处理Dwell Time:Each stage depends on:各阶段所需的时间，受下面的因素控制各阶段所需的时间，受下面的因素控制 The amount of pretreatment chemical dissolved in water溶于水的前处理化学药品的浓度溶于水的前处理化学药品的浓度 The age of the chemical化学药品的有效时间化学药品的有效时间Regular checking is required to give consistent good results at least twice

17、per shift.通常要经常检查前处理的状态通常要经常检查前处理的状态一个班至少两次一个班至少两次abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation Zinc Phosphate金属处理金属处理 磷酸锌磷酸锌Typical 5 Stage System典型典型5步骤流程步骤流程Metal SubstrateSteel Phosphatising System金属基材金属基材None Ferrous Clean and EtchStage time duration1 90 seco

18、nds不同步骤所需的时间不同步骤所需的时间2 45 seconds3 60 seconds4 30 seconds5 30 secondsStage temperature温度温度40 60oCDrying干燥温度干燥温度100 120oCTypical concentration典型浓度典型浓度2 4%by volumeTypical acidity1=alkaline酸碱性酸碱性2=acidicTypical coating weight40 70 mg/ft.典型的膜重典型的膜重abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING

19、 CO.，LTD Metal Pretreatment-BS 3189 Type 3Spray Phosphate Plant 9 stage pretreatment九步法九步法 Degrease脱脂脱脂 Rinse水洗水洗 Rinse水洗水洗 Rinse水洗水洗Acid Etch(phosphoric acid)表调表调Zinc Phosphate磷酸锌磷化磷酸锌磷化 Rinse水洗水洗 Rinse水洗水洗 De-ionised water去离子水水洗去离子水水洗 Dry 干燥干燥Quality Standard BS6497参考英国标准参考英国标准BS6497abcd DONGGUAN

20、JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Pretreatment Quality Control金属前处理金属前处理 质量控制质量控制Titration Checks:检测项目：检测项目：1.Cleaner2.Rinses3.Acid Concentration4.Rinse5.Phosphate Concentration and coating weight7.Rinse8.ObservationsChecked at regular intervals during normal production and bef

21、ore production commences以上项目应在生产过程中定时和生产前进行检验以上项目应在生产过程中定时和生产前进行检验abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal PretreatmentDry金属前处理金属前处理干燥干燥To ensure metal surface is dry ready for powder coating.在喷涂粉末涂料前必须保证在喷涂粉末涂料前必须保证金属工件已经完全干燥金属工件已经完全干燥Drying oven-Phosphate Plantabcd DON

22、GGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation Chromate金属处理金属处理鉻酸盐鉻酸盐For aluminium chromate conversion铝铝铬酸盐处理铬酸盐处理British Standards exist for the conversion of aluminium BS 6496适用于铝的英国标准适用于铝的英国标准BS6496The same conversion can be used for Galvanised steel-BS 6497适用于电镀铁的英国标准适

23、用于电镀铁的英国标准BS6497Stage 1CleanStage 2RinseStage 3EtchStage 4RinseStage 5Chrom-ateStage6 7RinseStage 8DeminRinseDRAINDRAINDRAINDRAINDRAINDRAINabcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Metal Preparation Chromate金属处理金属处理鉻酸盐鉻酸盐Typical 7 Stage System七步法七步法Metal SubstrateAluminium/Alum

24、inium Alloys金属基材金属基材Galvanised Steel Clean and EtchStage 1CleaningStage 2RinseStage 3Deoxidise metal surfaceStage 4RinseStage 5ChromateStage 6RinseStage 7Acidulated RinseStage Temperature80 100oCDrying90 95oCDo not overheat at the dry off stage干燥温度不能过高干燥温度不能过高abcd DONGGUAN JOINSHOW PRECISION HARDWAR

25、E MANUFACTURING CO.，LTD Metal Preparation Chromate金属处理金属处理鉻酸盐鉻酸盐Chromate conversion to Aluminium and Galvanised steel鉻酸盐处理完铝和电镀铁后的变化鉻酸盐处理完铝和电镀铁后的变化Yellow Chromate ConversionTypical Coating黄色鉻酸盐的变化黄色鉻酸盐的变化Weight(g/m2)Pale Yellow0.2 0.7Gold0.7 1.6Brown1.6 3.5Green mix chromate/phosphate0.5 2.0 For Pow

26、der Coating a lightweight coating is recommended In the range 0.2 2.0 g/m2 应用于粉末涂料，膜重一般在应用于粉末涂料，膜重一般在0.22.00.22.0g/m2g/m2abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Spraying and ApplicationofPowder Coatings粉末涂料的喷涂与应用粉末涂料的喷涂与应用abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURIN

27、G CO.，LTD abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Application Systems粉末涂料的应用系统粉末涂料的应用系统abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Application SystemsFeed Systems粉末涂料应用系统粉末涂料应用系统

28、供粉系统供粉系统Direct feed system from Drum to Gun.粉末涂料直接从粉桶粉末涂料直接从粉桶送至喷枪送至喷枪The system shown feeds 1 gun右图是只供一个喷枪右图是只供一个喷枪的直接供粉系统的直接供粉系统abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Application SystemsFeed Systems粉末涂料应用系统粉末涂料应用系统供粉系统供粉系统Direct feed system directly from a 25 kilo b

29、ox.This system is set up to feed 2 guns.Used mainly in manual operations.右图为直接从粉末涂右图为直接从粉末涂料的包装箱至喷枪的料的包装箱至喷枪的供粉系统。图中的设供粉系统。图中的设备适用于两把喷枪，备适用于两把喷枪，通常用于人工喷涂。通常用于人工喷涂。abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Application SystemsFeed Systems粉末涂料应用系统粉末涂料应用系统供粉系统供粉系统Bulk feed s

30、ystem,powder is supplied in a fibre bag.Weight of powder up to 1,000 kilos per bag.Used mainly on automatic plants where colour change is limited.大型供粉系统，粉末涂料一大型供粉系统，粉末涂料一般般1吨一个包装，用于自动吨一个包装，用于自动喷涂系统，限于换色较少的喷涂系统，限于换色较少的场合。场合。abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Fluidi

31、sation Systems粉末涂料流化系统粉末涂料流化系统Dry air passes through a membrane giving the powder liquid qualities.干燥的空气通过微孔板，使粉末涂干燥的空气通过微孔板，使粉末涂料象水一样流动。料象水一样流动。The air must be dry and free from water and oil.空气必须除水和油空气必须除水和油abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Delivery Systems粉末涂料

32、的传送系统粉末涂料的传送系统abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Delivery Systems粉末涂料的传送系统粉末涂料的传送系统Actual powder feed systemVenturi feed from fluid bed.右图是用文氏管从流化右图是用文氏管从流化床吸取粉末的送粉系统床吸取粉末的送粉系统abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Forces at work on the Po

33、wder ParticlesAt any one time 4 forces are at work on the powder particle as it travels from the gun to the earthed work-piece.粉末在离开喷枪到达工粉末在离开喷枪到达工件时受件时受4种力的影响种力的影响-Air Resistance-Electrostatic Attraction-Weight(Gravity)-Aerodynamic Force abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，L

34、TD Powder Charging SystemsThere are 2 major categories in charging of powder coating corona and tribo:粉末涂料主要有两种带电方法粉末涂料主要有两种带电方法静电静电/摩擦摩擦 Gun TypeCharge Location充电位置充电位置InternalExternalRemotePowder SupplyXXCorona静电法静电法Integrated GunPowder SupplyXXTribo摩擦带电法摩擦带电法Xabcd DONGGUAN JOINSHOW PRECISION HARD

35、WARE MANUFACTURING CO.，LTD Corona Charging Systems静电带电系统静电带电系统In this method,a high voltage generator is used to charge an electrode at the tip which creates an electrostatic field(or corona)between the gun and the work-piece.利用高压电极使粉末带电，并在喷枪与工件间形成电场利用高压电极使粉末带电，并在喷枪与工件间形成电场External Charging System/外

36、充电系统外充电系统abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Corona Charging Systems静电带电系统静电带电系统Corona charging-manual system/手动枪手动枪-automatic system/自动枪自动枪abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Corona Charging Systems静电带电系统静电带电系统Internal Charging System内充电系统内充电系

37、统abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Corona Nozzle Systems静电枪的喷嘴静电枪的喷嘴The type of product toBe coated will influence The nozzle to be used on theSpray gun,two types are shownabcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Corona Nozzle Systems静电枪的喷嘴静电枪的喷嘴C

38、onical Spray Nozzles used to give an evenly distributed film thickness over flat panels.圆锥型的喷嘴一般用于喷涂平圆锥型的喷嘴一般用于喷涂平面，并得到膜厚均匀的涂层。面，并得到膜厚均匀的涂层。Interpon AF particle managed powder being applied on domestic appliances.右图为右图为Interpon AF粉末涂料用粉末涂料用于家用设备于家用设备abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACT

39、URING CO.，LTD Corona Charging Systems静电带电法静电带电法v The high voltage power supply charges the electrodev高压发生器使喷枪电极带电高压发生器使喷枪电极带电v The concentrated charge creates an electrostatic fieldv带上电荷后形成静电场带上电荷后形成静电场v The electrostatic field causes the air to ionize and generate a coronav静电场使空气电离形成电晕静电场使空气电离形成电晕v

40、 The corona emits electronsv电晕放射出电子电晕放射出电子v The electrons are picked up by oxygen molecules forming negative ionsv这些电子借助氧分子形成负离子这些电子借助氧分子形成负离子abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Corona Charging Systems cont.静电带电法静电带电法v The ions follow the field linesv负离子沿着电力线移动负离子沿着电力线移动v

41、 The powder particles distort the field around themv粉末涂料粒子使周围的电力线产生扭曲粉末涂料粒子使周围的电力线产生扭曲v The distorted field lines direct ions to the powder particlesv扭曲后的电力线引导离子被粉末涂料粒子吸附扭曲后的电力线引导离子被粉末涂料粒子吸附v The ions bombard the powder particles and transfer the electrons giving the particles a negative chargev吸附的离

42、子轰击粉末粒子，并使其带上负电，形成负极吸附的离子轰击粉末粒子，并使其带上负电，形成负极abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Tribo Charging Systems摩擦带电法摩擦带电法Tribo electricity is generated by the friction of one material on another.In Tribo charged spray guns,the powder rubs on a specially formulated and shaped surfa

43、ce which allows charge to transfer.摩擦带电是通过不同物质摩擦形成的，摩擦枪可以使粉末与特殊摩擦带电是通过不同物质摩擦形成的，摩擦枪可以使粉末与特殊设计并有特殊结构的表面摩擦而带电设计并有特殊结构的表面摩擦而带电abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Tribo Charging Systems摩擦带电法摩擦带电法abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Tribo Charging Sy

44、stems摩擦带电法摩擦带电法Tribo nozzles in different configurations.不同结构的摩擦枪喷嘴不同结构的摩擦枪喷嘴abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Electrostatic Fluid Bed Systems静电流化床法静电流化床法abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Penetration粉末的吸附粉末的吸附The picture shows the de

45、velopment of the corona(red dotted area).Articles passing through are charged with the negative ions(-).The charged powder particles are attracted to the earthed substrate.右图显示了电场，电右图显示了电场，电力线，粉末的充电及力线，粉末的充电及被接地的工件吸附过被接地的工件吸附过程。程。abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder

46、 Penetration粉末的穿透粉末的穿透Achieving penetration into deep recesses in most important when applying powder coating.粉末涂料能否到达死角这对粉末涂粉末涂料能否到达死角这对粉末涂料的应用来说很重要料的应用来说很重要The most effective controls are the nozzle patternAnd air assistance.有效的控制方法是选择合适外形的喷嘴及调整辅助空气有效的控制方法是选择合适外形的喷嘴及调整辅助空气It is possible to overcom

47、e the“Faraday Cage Effect”现在，克服现在，克服“法拉第法拉第”效应已成为一种可能效应已成为一种可能abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Powder Penetration粉末的穿透粉末的穿透Reducing the“Faraday Cage”Effect减弱减弱“法拉第法拉第”效应效应To reduce the effect it is necessaryTo assist in the creation of charged airParticles inside the r

48、ecess.This should be彻彻achieved by increasing the air stream.可以借助加大传送空气的压力来减弱可以借助加大传送空气的压力来减弱“法拉第法拉第”效应效应abcd DONGGUAN JOINSHOW PRECISION HARDWARE MANUFACTURING CO.，LTD Faraday Cage Effect“法拉第法拉第”效应效应A Faraday cage can technically be defined as an area within which there is no electrostatic field.In

49、finishing,this term is applied more loosely,and generally refers to an area such as inside corners or cavities that are difficult to coat.The reason why these areas are difficult to coat is that the adjacent surfaces to the inside of the corner attract the electrostatic filed,therefore deflecting th

50、e powder from penetrating into the recessed areas.At the same time,this recessed area is difficult for the aerodynamic forces to penetrate into without blowing powder off already coated areas.法拉第区域可以被认为是静电屏蔽区。实际应用中定义法拉第区域可以被认为是静电屏蔽区。实际应用中定义更宽松，通常是指死角和洞等难喷涂区域。难喷涂的原因是这更宽松，通常是指死角和洞等难喷涂区域。难喷涂的原因是这些区域的外围