FAQs

Are your applicators certified?

Yes we have certified applicators from both PCI (The Powder Coating Institute) and CCAI (Chemical Coaters Association). Our coaters have been trained on pretreatment applications, faraday cage coatings, powder application methods, cleaning, chemistry, color selections and more.

Information from PCI (powder coat institute; powdercoating.org)

Why is Pretreatment So Important?

99.9% of any successful coating requires excellent pretreatment. The cleaner the material, the better success you will have achieving adhesion, smoothness and longevity.

Powder coatings can provide improved performance over liquids when applied to a properly pretreated part. Solvent-borne paints are usually more forgiving of organic soils left on the work piece by sub-par cleaning. Because powder does not have solvents, you need to make sure the washer does a good cleaning job. This is just good operational practice and is not an unusual requirement. Iron phosphate is the most frequently encountered pretreatment used with powder coatings. However, if the highest level of performance is required, zinc phosphate will work admirably with powder as well.

What Type of Warranty Do You Offer?

AR’s powder coatings of parts include masking and plugging threaded holes. Custom masking is extra. All parts should be clean of any grease, rubber, gaskets, or plastic, and all grease fittings should be removed. Parts with grease, sludge, or oil will be charged a de-greasing fee. AR is not responsible for controlling “out gassing” of parts, a problem of internal gasses within a casting which when heated up can possibly come to the surface creating tiny pin holes. Cast aluminum, cast iron, wheels and parts may experience out-gassing and/or bubbling in the finished powder coating. AR will take every precaution to avoid out-gassing, however, we cannot guarantee that out-gassing will not occur in porous castings. Warranty Information: AR warrants against flaking & peeling only on new items for one year from date on sales slip. AR warrants against flaking & peeling only on used parts for six months from date on sales slip. AR assumes no responsibility for outside elements or damage.

Is Packaging Available?

AR includes protecting the parts with wrapping for the typical one two part runs. However for large quantities of parts it is recommended that you speak to one of our estimators for costs of professional packaging.

Is Pickup and Delivery Available?

Yes we offer pickup and delivery. AR has trucks ranging from 13′, 16′ and 20′ flat beds capable of pick up and delivery of any size part.

Can You Coat Thousands of Parts or Oversized Parts?

We offer both batch and conveyer coatings. Batch coatings are what is used for smaller part runs. AR’s Batch part capabilities are 12′ Wide x12′ Tall x 35′ Long booth and oven.

Conveyer coatings allow us to coat thousands of parts, and hundreds of feet per shift. Conveyer line part openings are 2′ Wide x 20′ Long x 8′ Tall. Coatings on our line go through stringent pretreatment process’s, dry off and automated guns on reciprocators to coat the parts. Line speeds of up to 10′ feet per minute. For instance 600′ linear feet of fence can be coated in less than 3 hours.

Is it Expensive to Powder Coat?

Powder coating has less expense in raw materials because there are no solvents that are needed to achieve the coatings. Also because the powder is electrostatically applied, more powder is attracted to the part, meaning less paint on the floor. Transfer efficiency also plays a roll in coatings. All of our hooks used for suspending the parts are stripped and old coatings are burned off for excellent grounding of the parts.

What Size Parts Can You Fit in Your Booth and Oven

We offer both batch and conveyer coatings. Batch coatings are what is used for smaller part runs. AR’s Batch part capabilities are 12′ Wide x12′ Tall x 35′ Long booth and oven.

Conveyer line part openings are 2′ Wide x 20′ Long x 8′ Tall.

What is Media Blasting?

Media Blast cleaning removes surface contaminants from the parts by the use of high-pressure air with a mechanical abrasive. Media blasting is the most superior way to prep a part for powder coatings. Soils, existing paints, and other contaminants are removed during the blasting process.

My Parts Have Slight Rust and Scale, Can You Coat Over Rust and Scale?

Coating over rust, scale (oxide layer formed on steel during the hot roll mill processing) or any corrosion can create future issues of delamination, peeling and flaking. Other issues caused by coating over rust are you will loose the smoothness of the coating. We recommend media blasting your parts that have rust and scale with garnet media that will not impinge the metals. Media blasting will remove soils and contaminants and prepare the parts with a sa2 white finish. Giving the parts the best adhesion for paint possible.

Is a Primer Base Coat Necessary?

Unlike liquid coatings, powder coatings are more corrosion resistant to the elements. Pretreatment is vital to any coating process. Our coatings go through many different process’s that include degreasing, di rinsing, iron phosphate (etches the metals) and sealers. Also we offer media blasting to remove scale and rust before coatings. Powder coating primers such as our zinc rich primer offer the best corrosion resistance to the products. By adding a powder coating primer, you are adding additional coating life to the part. Areas with exposure to the elements such as sprinklers and pools (chemicals that are in pools can cause corrosion) and high traffic areas can benefit from zinc rich primers by adding more film build thickness and salt spray resistance to the parts.

Are There Many Color Choices?

We carry over 300 stock colors that are stored in our environmentally protected room. We keep our powder stored at 72 degrees with 50%-60% relative humidity per the manufactured recommendation. Typically powders have a one-year shelf life. There are thousands of colors available in today’s marketplace. For examples of some custom colors, check out www.prismaticpowders.com

What Type of Finishes are Available?

Smooth, textured, wrinkle, hammered, vein, transparent, and candies are available. We also carry food and beverage powder coatings for ant-microbial applications.

What is Outgassing in Powder Coating?

Powder coating requires an object to be heated. When it is, impurities or gases can rise to the surface and create a cosmetic defect in the part. These rising gases cause pinholes in the coating that can also result in damage to the coating as moisture can get in them and allow for corrosion. These gases can come from a number of different sources so a number of different techniques are utilized to eliminate them from the process and craft a flawless powder coat.

In this post, we’ll break down the cause of outgassing while powder coating and go over some of the ways that we combat this phenomenon so we can ensure that your parts come out not only appealing to the eye, but free from damage.

What Causes Outgassing?

Before we can talk about how to go about preventing the negative effects of outgassing, we must discuss the circumstances that allow it to occur. The four most common causes of outgassing are listed below. We’ll start with how human error can cause outgassing and then discuss the ways that the properties of the object itself can cause the problem.

  1. Surface Contamination – Oil, dirt, grease and other forms of contamination on the surface of the object can vaporize while the piece is being heated and cause gas to bubble to the surface. Surface contamination can cause other problems with the powder coating process as well and is such an easily avoided human error that it is not generally thought of as a cause of outgassing. It is mentioned here for the sake of completeness.
  2. Coating Thickness – If too thick of a film coating is used during the process then it can cause gases to be given off during the curing process which make their way to the top of the surface and cause imperfections. Some powder coating materials are more likely than others to cause this problem, so knowledge of the materials used is an important factor when powder coating.
  3. Castings – We are done discussing the ways that human error can cause outgassing and are now going to move on to the aspects of the object itself that can cause the problem. Cast metal is a common material used as a base for powder coating. The problem with cast metal is that gases can become trapped in the metal during the casting process. When heated, these gases will be released and cause outgassing.
  4. Galvanization – Steel is highly susceptible to corrosion. One of the best ways to combat corrosion on steel is to coat it with a layer of metallic zinc using a process known as galvanization. This is great for the steel but can cause problems during powder coating. This is because gases can become trapped during the galvanization process in the same way that they do during metal casting. For that reason, powder coating galvanized steel can be just as tricky as powder coating cast metal items.

How is Outgassing Prevented?

Now you know how gases, or substances that can become vaporized into gases at high temperatures, can get trapped and cause outgassing. Next, we can discuss ways to prevent problems from arising so you are always happy with the final results.

  1. Clean Contamination – Before powder coating can begin, objects should be thoroughly cleaned and degreased so that any contaminants which may vaporize during the process are removed from the equation. This not only eliminates a cause of gas-related problems but ensures the best adhesion of the powder to the material.
  2. Control Thickness – Some jobs require a heavy film, but this does not mean that it must be applied in one coat. By understanding the materials used in coating and making sure to use multiple coats of necessary, outgassing caused by applying too heavy of a film coat can be avoided.
  3. Add a Primer – Applying a sealant as a primer coat before powder coating can ensure that any gases that may be released during the heating process are contained and unable to bubble up into the coating. It is important to note that this is not a replacement for thorough cleaning in the pre-treatment phase.
  4. Powder Additives – The real problem with outgassing is that the gases are escaping as the powder is hardening. This is what causes the pinholes on the surface. For certain powder materials, additives can be used that will cause the powder to remain in liquid form for longer. This will give the gas extra time to escape before the powder hardens around the bubbles.
  5. Preheat the Part – Since outgassing is caused by gas bubbles being released when the object is heated during the powder coating process, it can be avoided by heating the object before the coating process begins. This will cause all of the gas bubbles to expel themselves from the material before the powder coating even begins.

Conclusion

Knowing all of the ways that problems like outgassing can pop up is key to a successful powder coat. Someone who doesn’t know what they are doing could very easily end up with a botched job. At AR Powder Coating, we have years of experience that allows us to foresee problems not only with outgassing, but the many other issues that can crop up during a powder coating job.

Our pre-treatment process for powder coating involves a DI rinse, degreaser, iron phosphate, and a sealer and our experience working with a variety of powder coating materials means we’ll always get the right thickness the first time. Our high degree of professionalism, therefore, eliminates the potential for human error caused outgassing. You can also trust us to know what to do if you bring in a cast metal or galvanized steel object so that you get that object back with the exceptional quality that you expect from a team of professionals.

If you are looking to have a powder coating job complete, please feel free to contact us today with any question you have. We’ll be glad to help and look forward to doing business with you.

Are All Powders the Same?

Two categories of powder coating materials include thermoset and thermoplastics.

There are different chemistries of powder coatings available. These include Epoxy’s, Hybrid, Urethane, Polyester and TGIC Polyesters. Each chemistry serves a different purpose. For instance:

Epoxy coatings offer higher mechanical strength and corrosion resistance. However epoxy coatings must have a topcoat applied as epoxies are not resistant to UV light and can be limited in gloss retention when exposed to sunlight.

Hybrid coatings are an epoxy-modified polyester that has good over bake and application properties such as impact resistance and hardness.

Urethane coatings have excellent uv exposure resistance, excellent impact flexibility and hardness.

Polyester coatings have four excellent properties that include chemical resistance, uv exposure, impact and flexibility resistance and hardness.

How is Powder Applied?

A process called electrostatic spray deposition (ESD) is typically used to achieve the application of the powder coating to a metal substrate.  This application method uses a spray gun, which applies an electrostatic charge to the powder particles, which are then attracted to the grounded part.  After application of the powder coating, the parts enter a curing oven where, with the addition of heat, the coating chemically reacts to produce long molecular chains, resulting in high cross-link density. These molecular chains are very resistant to breakdown.  This type of application is the most common method of applying powders.  Powder coatings can also be applied to non-metallic substrates such as plastics and medium density fiberboard (MDF).

Sometimes a powder coating is applied during a fluidized bed application.  Preheated parts are dipped in a hopper of fluidizing powder and the coating melts, and flows out on the part.  Post cure may be needed depending on the mass and temperature of the part and the type of powder used.  No matter which application process is utilized, powder coatings are easy to use, environmentally friendly, cost effective, and tough!

 

Are There Different Finishes Available?

We carry many different varietys of powder coatings. Coatings come in wrinkled, hammered, textured, vein, transparant and smooth finishes. AR also has different levels of gloss finishes available. AR has the ability to take any high gloss color and turn it into matt or flat gloss levels.

 

Why Should I Powder Coat My Parts Instead of Spray or Liquid Coating?

Powder coating is a high-quality finish found on thousands of products you come in contact with each day.  Powder coating protects the roughest, toughest machinery as well as the household items you depend on daily.  It provides a more durable finish than liquid paints can offer, while still providing an attractive finish.  Powder coated products are more resistant to diminished coating quality as a result of impact, moisture, chemicals, ultraviolet light, and other extreme weather conditions. In turn, this reduces the risk of scratches, chipping, abrasions, corrosion, fading, and other wear issues.

It’s tough. It looks great. And it lasts a long, long time.  In addition to being durable, powder coating is an attractive choice due to environmental advantages.

PCI (powder coat institute; powdercoating.org)

 

What Types of Parts Can Be Powder Coated?

Metals such as steel, aluminum, stainless steel can be powder coated. Typically parts that can withstand the oven curing temperatures of 400+ degrees can be powder coated.

 

What is Powder Coating?

Powder Coatings are made up of dry resins used to add protection, functionality and decorative finishes to metal substrates. Powder coatings are made up of different resins or polymers that are bonded together when heat or radiant energy is applied.