Paint defects blistering, swelling

 Defect case: Short oil Alkyd+ MF based paint. Applied a thin layer direct to MS metal  by heat curing at 180 degree C for 10 minutes ,paint is well, no swelling.

  After that,  when trying to cover uneven surface by making same paint putty(adding high mesh calcium 50/50 in same paint) for 60 minutes at same heat and occurs swelling that putty. 

That case which by?  Paint or surface or application procedure?

Problem identification : There should be moisture entrap when 2nd layer applied. Or uding unknown solvent. Or 1st layer does not dried well. Or putty PVC changed in alarming. Or MF grade varying. 

Solution: Should be confirmed 1st layer dried well. Use tru solvents. Use binder when adding CaCO3 powder. Check moisture  before and after of 1st coat application. Choose right grade of MF.

Top 10 paint manufacturing company in 2023(Global)

Top 10 paint manufacturing company worldwide in the year 2022

1. PPG(USA) : PPG is a global manufacturer of paints, coatings, and specialty materials and a Fortune 200 company with headquarters in Pittsburgh and operations in nearly 70 countries around the world.

Coating Sales: 17,700,000,000USD 

2. The Sherwin-Williams Co.(USA): Sherwin-Williams Company is an American company. It is primarily engaged in the manufacture, distribution, and sale of paints, coating, floorcoverings, and related products to professional, industrial, commercial, and retail customers, primarily in America and Europe. At the end of 2020, Sherwin-Willams had operations in over 120 countries.

Coating Sales: 16.600,000,000USD 

3.Akzo Nobel N.V.(Netherlands) stylized as AkzoNobel, is a Dutch  which creates paints and performance coatings for both industry and consumers worldwide. Headquartered in Amsterdam, the company has activities in more than 150 countries. 

Coating Sales: 11,650,000,000USD

4. Nippon Paints Holdings Co.(Japan) is a Japanese paint and paint products manufacturing company. It is the fourth largest paint manufacturer globally, based on revenue in 2022

Coating Sales: 9,980,000,000USD

5.  RPM International Inc.(USA) is an American multinational company with subsidiaries that manufacture and market specialty coatings. Industrial brands include Tremco, Carboline, Universal Sealants, Stonhard, RPM/Belgium, Euco, Day-Glo and Dryvit. RPM's consumer products are used by professionals and DIY for home maintenance and improvement and by hobbyists. Consumer brands include Zinsser,RUST Olium, DAF, Varathane, Mean Green, Krud Kutter, Concrobium, Moldex and Testtors. 

The company operates 122 manufacturing facilities around the world. Its products are sold in 170 countries and territories. 

Coating Sales: 6,700,000,000USD

6. Axalta Coating Systems(USA) is an American company specializing in coatings in a wide variety of industrial applications, materials and sectors, including automotive paints. Axalta develops and manufactures coatings for light and commercial vehicles, industrial, and refinish applications. The firm does business in 130 countries. 

Coating Sales: 4,900,000,000USD

7. BASF Coatings(Germany): BASF comprises subsidiaries and joint ventures in more than 80 countries, operating six integrated production sites and 390 other production sites across Europe, Australia, Asia, Africa and America. BASF has customers in over 190 countries and supplies products to a wide variety of industries.

Coating Sales: 4,550,000,000USD

8. Asian Paints Limited(India) is an Indian multinational paint company, headquartered in Mumbai. The company is engaged in the business of manufacturing, selling and distribution of paints, coatings, products related to home décor, bath fittings and providing related services.

Coating Sales: 4,110,000,000USD

9. Kansai Paint Co. Ltd.(Japan&India) is the largest industrial paint and third largest decorative paint company of India based in Mumbai. It is a subsidiary of Kansai Paint of Japan As of 2015, it has the third largest market share with 15.4% in the Indian paint industry. It is engaged in the industrial, automotive and powder coating business.

Coating Sales: 3,630,000,000USD

10. Masco(USA): is an American manufacturer of products for the home improvement and new home construction markets. Comprising more than 20 companies, the Masco conglomerate operates nearly 60 manufacturing facilities in the United States and over 20 in other parts of the world.

Coating Sales: 3,428,000,000USD

Thanks for reading.

Reference: https://en.wikipedia.org/wiki/Main_Page

https://www.pcimag.com/articles/110327-2022-global-top-10-top-paint-and-coatings-companies

https://www.coatingsworld.com/issues/2023-07-01/view_top-companies-report/top-companies-report-651116/

What is the impact hardness test? Why do we test for impact test? impact testing methods

 

What is impact test?

The impact test involves subjecting a coated sample to controlled impacts and observing the resulting damage. The severity of the impact is gradually increased until visible damage, such as cracking, chipping, or detachment of the coating, occurs. The test can be conducted using different methods and equipment, such as pendulum impact testers or falling weight impact testers, depending on the testing standards and the specific requirements of the project.

Standards for Impact test?

The remaining impact test standards lay down the use of absolute units of energy:

kg m (ISO 6272, ASTM D 2794),

Joule (ASTM D 3029, ECCA T5),

inch lbs (ASTM D 2794 and ASTM D 3029).

1 (Joule) = 0.1 kg m = 8.8 inch lbs

 

 

 

Calculation

Impact Force calculation: If a weight (m) 1.5 kg falling from height (h) of 0.65m. So, what will be the force (lbs per square inch)?

 

Velocity (v)=√2gh= √2X9.81X0.65=3.57

So, 

                = ½ X1.5X(3.57)^2

                =9.558 Joule

We know, 1Joule=0.1kgm=8.8 lbs/ square inch

So. 9.558Joule= 8.8X9.558=84.1104 inch-lbs/square inch

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Pigment black for coating industries. Pigment black CI number, CAS No, Oil Absorption

 Carbon Black for Paints, Coatings and Inks

Carbon black is a highly engineered form of carbon widely used in paints, coatings and inks to achieve a spectrum ranging from gray to deep black. Over the time, the properties of carbon black pigment have been modified to achieve required properties in the final product, such as increased tinting strength, and improved the level of jet-ness or blue undertone and conductivity.

Cathodic protection of steel by Zinc Coating: What is the best anti-corrosive primer for steel? How does a Zinc coating works as anti-corrosive?

 

Cathodic protection of steel by Zinc Coating

SCOPE:   

Material: Stainless steel up to 120°C

Environment: Atmospheric

Exposure category C5 (high)

Standard ISO 12944 - 5

 

Abstract

According to AGA (American Galvanizers Association) explanation, Zinc is a natural, healthy and abundant element. Zinc metal has a number of characteristics that makes it a well suited corrosion protective coating for iron and steel products.

 

Zinc coating protect steel from corrosion due to it’s anodic properties where it will sacrificially corroded before the underlying steel.

 

Zinc Coating

The Film Galvanizing System ZINC coating contains 96% zinc in the dry film and provides cathodic protection of ferrous metals. Paint can be used as a unique system as an alternative to hot-dip galvanization or metallization, as primer in a duplex system (active + passive) or as a recharging system for hot-dip galvanization, metallization or zinced surfaces. Paint can be applied by brushing, rolling or spraying on a clean and rough substrate in a wide range of atmospheric circumstances.

 

Product physical & technical parameters

Components: - Zinc powder, Aromatic hydrocarbons, Binder

Density: 2.7kg/dm³

Volume Solids: 60 (±2%)

Solid content: 80% by weight (±2%) - 58% by volume (±2%) according to ASTM D2697

Color: Grey (color darkens after contact with humidity)

Zinc content: 96% (±1%) by weight, with a purity of 99,995%.

Special characteristics: Atmospheric temperature resistance of dry film

» Minimum: -40°C

» Maximum: 120°C with peaks up to 150°C

- pH resistance in immersion: 5,5 pH to 9,5 pH.

- pH resistance in atmospheric conditions: 3,5 pH to 12,5 pH.

- Excellent UV resistance

Non-toxicity:  A dry layer is not toxic. Have to test according to the standard AS/NSZ 4020.

Bellow table shows an overview of the steel preparation system

Step no.	Action	Method	Purpose
1	Pre-preparation	Visual inspection + wash down	Remove contamination
2	Salt Check	Conductivity Test	Check contamination
3	Preparation	Blast-clean all surfaces of the steelwork	Cleanliness / profile
4	De-dusting	By appropriate means	Cleanliness

 

Surface preparation

1.       Surface salt test: according with ISO 8502-6 and testing according to ISO 8502-9 (conductivity test).

2.       Blast cleaning:

Abrasive: all abrasives must comply with SSPC-AB1 grade 3

Abrasive salt contamination: test according with ISO 11127 or ASTM D 4940.

3.       Blast-profiles and cleanliness: All blast-profiles shall fall inside the range of 50 – 70 μm @110-130 PPI (peaks per inch) according to ISO 8503. Measurement according to ASTM 4417

The cleanliness of the overall surface must be in accordance with SA 2.5 standards - ISO 8501-1.

4.       De-dusting: The cleanliness should be class 1 (according to ISO 8502-3)

Surface Pre-preparation	Steam Clean @ 150 bar (min) @ 80°C or High Pressure Fresh Water Wash @ 150 bar (min)
Surface Preparation	Sa 2.5 (ISO 8501-1) SSPC-SP10 (Grit-blast or slurry blast. Also UHPAB to SSPC-SP12
Surface Profile	Rz 50 – 70µm (ISO 8503-2)
Surface Roughness	Ra 12.5 – 15µm (ISO 8503-1)

 

Application:

Brush / Roller	Dilution is not required. Only when the product thickens, use thinner within 5% of paint weight.
Conventional spray	Use Gravity feed spray gun. Nozzle size: 1.5 ~ 2.0 mm, Pressure: 0.3 MPa Dilution: 0 ~ 5%, Paint strainer: #100
Air-less spray	Tip size: above 0.017 inches (e.g. 517) Pressure: above 20 MPa, Gun filter: #50 ~ 60 Dilution: 0 ~ 5%

 Application system:

Coats	Product	Application Type	Application Method	Required DRY Film Thickness (µm)
Coat-1	Zinc Coating	Full coat	Airless Spray, Conventional Spray & Brush	(60-120) µm
Coat-2	Zinc Coating	Full coat	Airless Spray, Conventional Spray & Brush	(60-120) µm

 

Properties

Test item	Methods	Result should be
Hardness	Pencil scratching (ISO/DIS 15184:1996)	Pencil B (minimum)
Adhesion	Peel off a sticky tape on 25 cells check pattern (square: 2mm x 25)- (ISO 2409:1992)	No abnormality
Heat resistance	Electrical constant temp. drier 170 °C, 24 hours	No abnormality
Cold resistance	Low temp. cycle test for 72 cycles <1 cycle>Left at -30 °C for 5 hours and Left at +10°C for 1 hour	No abnormality

 

 

Anti-corrosion performance

 

Test item	Testing method	Duration	Result Should be
Water immersion	Immersed in ion exchanged water	3 months	No abnormality other than white rust
Salt water immersion	Immersed in 3% salt water	3 months	No abnormality other than white rust
Salt spray	5% NaCl (pH6.5~7.2) Temp of spray chamber: 35±1°C (ISO 7253:1984)	1440 hours	No abnormality other than white rust

 

Image: Anti-corrosive Zinc Primer

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What is the surface preparation standards? ISO 8501-1, Blast cleaning to standards Sa1, Sa2, Sa2.5, Sa3

ISO 8501-1 Pictorial Standards of Cleanliness

ISO 8501-1 is a pictorial standard relating to surface cleanliness, amongst other methods, though abrasive blasting. The original condition of steel surfaces prior to blasting are depicted in various stages of corrosion as follows:

Grade A         Steel surface largely covered with adhering mill scale but little, if any rust

Grade B         Steel surface which has begun to rust and from which the mill scale has begun to flake

Grade C          Steel surface on which the mill scale has ruted away or from which it can be scraped, but with slight pitting visible under normal vision.

Grade D          Steel surface on which the mill scale has rusted away and on which general pitting is visible under normal vision

 

Standard notation usually, but not always, includes the original condition of steel before blasting i.e. “B Sa3”. Pictorial standards of cleanliness (Sa1, Sa2, Sa2.5 and Sa3) are depicted overleaf.

Blast-cleaning to Sa Standards

Blast cleaning to ISO 8501-1 Sa standards is a commonly used specification with pictorial and written guidelines as follows:

·         Sa 1 Light blast -cleaning When viewed without magnification, the surface shall be free from visible oil, grease and dirt. And from poorly adhering mill scale, rust, paint coatings and foreign matter.

·         Sa 2 Thorough blast-cleaning    When viewed without magnification, the surface shall be free from visible oil, grease and dirt and from most of the mill scale, rust, paint coatings and foreign matter. Any residual contamination shall be firmly adhering.

·         Sa 2½ Very thorough blast-cleaning    When viewed without magnification, the surface shall be free from visible oil, grease and dirt and from mill scale, rust, paint coatings and foreign matter. Any remaining traces of contamination shall show only as slight stains in the form of spots or stripes.

·         Sa 3 Blast-cleaning to visually clean steel When viewed without magnification, the surface shall be free from visible oil, grease and dirt and from mill scale, rust, paint coatings and foreign matter. It shall have a uniform metallic color.

Reference: www.satactics.com