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Coating

From Wikipedia, the free encyclopedia
Lacquerbeing sprayed onto acabinet

Acoatingis a covering that is applied to the surface of an object, orsubstrate.[1]The purpose of applying the coating may be decorative, functional, or both.[2]Coatings may be applied asliquids,gasesorsolidse.g.powder coatings.

Paintsandlacquersare coatings that mostly have dual uses, which are protecting the substrate and being decorative, although some artists paints are only for decoration, and the paint on large industrial pipes is for identification (e.g. blue for process water, red for fire-fighting control) in addition topreventing corrosion.Along with corrosion resistance, functional coatings may also be applied to change the surface properties of the substrate, such asadhesion,wettability,or wear resistance.[3]In other cases the coating adds a completely new property, such as a magnetic response or electrical conductivity (as insemiconductor device fabrication,where the substrate is awafer), and forms an essential part of the finished product.[4][5]

A major consideration for most coating processes is controlling coating thickness. Methods of achieving this range from a simple brush to expensive precision machinery in the electronics industry. Limiting coating area is crucial in some applications, such asprinting.

"roll-to-roll"or "web-based" coating is the process of applying a thin film of functional material to a substrate on a roll, such as paper,fabric,film, foil, or sheet stock.[6]

Applications[edit]

Coatings can be both decorative and have other functions.[3][7]A pipe carrying water for a fire suppression system can be coated with a red (for identification) anticorrosion paint. Most coatings to some extent protect the substrate, such as maintenance coatings for metals and concrete.[8]A decorative coating can offer a particular reflective property, such as high gloss, satin, matte, or flat appearance.[9]

A major coating application is to protect metal from corrosion.[10][11][12][13][14][15]Automotive coatings are used to enhance the appearance and durability of vehicles. These include primers, basecoats, and clearcoats, primarily applied with spray guns and electrostatically.[16] The body and underbody of automobiles receive some form ofunderbody coating.[17]Such anticorrosion coatings may usegraphenein combination with water-basedepoxies.[18]

Coatings are used to seal the surface of concrete, such asseamless polymer/resin flooring,[19][20][21][22][23]bund wall/containment lining,waterproofinganddamp proofingconcrete walls, andbridge decks.[24][25][26][27]

Mostroof coatingsare designed primarily for waterproofing, though sun reflection (to reduce heating and cooling) may also be a consideration. They tend to beelastomericto allow for movement of the roof without cracking within the coating membrane.[28][29][30]

Wood has been a key material in construction since ancient times, so its preservation by coating has received much attention.[31]Efforts to improve the performance of wood coatings continue.[32][33][34][35][36]

Coatings are used to altertribologicalproperties and wear characteristics.[37][38]These include anti-friction, wear and scuffing resistance coatings forrolling-element bearings[39]

Other[edit]

Other functions of coatings include:

Analysis and characterization[edit]

Numerous destructive and non-destructive evaluation (NDE) methods exist for characterizing coatings.[56][57][58][59]The most common destructive method ismicroscopyof a mountedcross-sectionof the coating and its substrate.[60][61][62]The most common non-destructive techniques includeultrasonicthickness measurement,X-ray fluorescence(XRF),[63]X-Ray diffraction(XRD)[64]andmicro hardness indentation.[65]X-ray photoelectron spectroscopy(XPS) is also a classical characterization method to investigate the chemical composition of the nanometer thick surface layer of a material.[66]Scanning electron microscopycoupled with energy dispersive X-ray spectrometry (SEM-EDX,or SEM-EDS) allows to visualize the surface texture and to probe its elementary chemical composition.[67]Other characterization methods includetransmission electron microscopy(TEM),atomic force microscopy(AFM),scanning tunneling microscope(STM), andRutherford backscattering spectrometry(RBS). Various methods ofChromatographyare also used,[68]as well as thermogravimetric analysis.[69]

Formulation[edit]

Theformulationof a coating depends primarily on the function required of the coating and also on aesthetics required such as color and gloss.[70]The four primary ingredients are theresin(or binder),solventwhich maybewater(or solventless),pigment(s) and additives.[example needed][71][72]Research is ongoing to removeheavy metalsfrom coating formulations completely.[73]

For example on the basis of experimental and epidemiological evidence, it has been classified by theIARC(International Agency for Research on Cancer) as a human carcinogen by inhalation (class I) (ISPESL,2008).[74]

Processes[edit]

Coating processes may be classified as follows:

Vapor deposition[edit]

Chemical vapor deposition[edit]

Main article:Chemical vapor deposition

Physical vapor deposition[edit]

Main article:Physical vapor deposition

Chemical and electrochemical techniques[edit]

Spraying[edit]

Roll-to-roll coating processes[edit]

Commonroll-to-rollcoating processes include:

  • Air knifecoating
  • Aniloxcoater
  • Flexocoater
  • Gap Coating
    • Knife-over-roll coating
  • Gravurecoating
  • Hot melt coating- when the necessary coating viscosity is achieved by temperature rather than solution of the polymers etc. This method commonly implies slot-die coating above room temperature, but it also is possible to have hot-melt roller coating; hot-melt metering-rod coating, etc.
  • Immersiondip coating
  • Kiss coating
  • Metering rod (Meyer bar) coating
  • Roller coating
  • Silk Screencoater
    • Rotary screen
  • Slot Die coating- Slot die coating was originally developed in the 1950s.[77]Slot die coating has a low operational cost and is an easily scaled processing technique for depositing thin and uniform films rapidly, while minimizing material waste.[78]Slot die coating technology is used to deposit a variety of liquid chemistries onto substrates of various materials such asglass,metal,andpolymersby precisely metering the processfluidand dispensing it at a controlled rate while the coating die is precisely moved relative to the substrate.[79]The complex inner geometry of conventional slot dies requiremachiningor can be accomplished with3-D printing.[80]
  • Extrusion coating- generally high pressure, often high temperature, and with the web travelling much faster than the speed of the extruded polymer
    • Curtain coating- low viscosity, with the slot vertically above the web and a gap between slot-die and web.
    • Slide coating- bead coating with an angled slide between the slot-die and the bead. Commonly used for multilayer coating in the photographic industry.
    • Slot die bead coating- typically with the web backed by a roller and a very small gap between slot-die and web.
    • Tensioned-web slot-die coating- with no backing for the web.
  • Inkjetprinting
  • Lithography
  • Flexography

Physical[edit]

See also[edit]

Look upcoatingin Wiktionary, the free dictionary.

References[edit]

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Further reading[edit]

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