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Abstract
Experimental analysis of the electrostatic fluidized bed coating process of carbon steel thin sheets was performed using two different
mesh-sized epoxy polyester powders. In particular, systematic analysis of the influence of the operative variables on coating and process
variability in the field of low film thickness (below 100 Am), was carried out, which for electrostatic fluidized beds has previously not been
considered feasible.
In this context, the effect of varying both the electrostatic and fluidized bed setting on the amount of the powder layer coating the workpiece surface was studied. In particular, exposure time, applied corona voltage, and airflow rate were found to influence the performance of
the coating process significantly.
Experimental results produced coating thickness trends consistent with theoretic expectations. In particular, effects on the coating process
of both electric and aerodynamic forces, which in turn affect the powder particles drawn up to the work-piece surface could largely be
predicted by examining experimental data. A set of 3D maps of the coating thickness achieved are also reported as they provide a useful tool
to monitor the process in a 5 15 s time range, applied voltage from 45 to 90 kV, and flow rate from 3 to 11 m3/h.
D 2005 Elsevier B.V. All rights reserved.
Keywords: Electrostatic fluidized bed; Coating process; Polymer powder; Electrostatic force; Aerodynamic force
1. Introduction
Growing concern for the environment nowadays and
particularly the need to reduce amounts of volatile organic
compound VOC emitted into the atmosphere are bringing
about increasing use of powder coating as an alternative
painting technology. This trend is driving the painting
industry to meet new demands by re-arranging existing
technologies. In this context, there is strong interest in any
environmentally sustainable painting technology such as the
electrostatic fluidized bed coating. Consequently, this paper
thoroughly examines the coating of metal thin sheets using
an electrostatic fluidized bed.
The electrostatic fluidized bed [1] coating process is
based on a very simple principle. It employs a remote
charging system to ionize dry air, which is forced out of a
* Corresponding author.
E-mail address: barletta@mail.mec.uniroma2.it (M. Barletta).
0257-8972/$ - see front matter D 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.surfcoat.2005.04.030
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M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
ment of a numeric model unaffected by unreliable experimental calibration. At the same time, an analytical model
based on both mathematical and physical considerations
was developed and validated which provides the first ever
reliable forecasts for electrostatic fluidized bed coating
process.
M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
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M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
Table 2
Reduced experimental plan (25 tests, replicated three times)
Levels
I
II
III
IV
V
Factors
Exposure time (s)
Airflow (m3/h)
5
8
10
12
15
3
5
7
9
11
50
60
70
80
90
After pre-treatments, surface preparations and dimensional controls performed by using a Mitutoyo Digital
Palmer (T1 mm as accuracy), workpieces were grounded.
They were then dipped in the free board zone [1] of the
electrostatic fluidized bed (i.e. the zone immediately above
the powder dense phase [1]) by using a pneumatic
movement system. The apparatus and coating procedure
was accurately described in a previous paper [10]. In this
context, it is important to note that work-pieces were
generally placed at a distance of 100 mm away from the
bed dense phase, whose height was kept fixed in minimum
fluidization at 230 mm. The environmental conditions
were always kept under firm control in order to avoid
systematic error affecting the experimental data. Consequently, all the experiments were carried out at a relative
humidity of less than 40% with an average temperature of
20 -C (accuracy T 0.2 -C). Once the exposure time elapsed,
the holder was removed from the column. Next, the
specimen was picked up from the holder and positioned in
the oven and cured at 170 -C for 11 min to establish the
full film properties the material was designed for. After the
cure, the specimens were examined by monitoring the
amount of deposited polymer using a coating thickness
gauge based on magnetic field, and a Mitutoyo Digital
Palmer was also used to perform a further check. The
Table 1
Material properties
Property
Weatherability
Corrosion resistance
Chemical resistance
Heat resistance
Impact resistance
Hardness
Flexibility
Adhesion
Polyurethane
Acrylic
Polyester
Hybrid fine
Hybrid coarse
Poor
Excellent
Excellent
Very good
Excellent
HB-5H
Excellent
Excellent
Good
Very good
Very good
Very good
Very good
HB-3H
Very good
Very good
Excellent
Good
Very good
Good
Good Fair
HB-4H
Good Fair
Good Fair
Excellent
Very good
Very good Good
Good
Good
HB-4H
Very good
Excellent
Fair Poor
Excellent Very good
Very good
Very good Good
Very good
HB-3H
Very good
Excellent
Poor
Very good
Good
Very good Good
Very good
HB-3H
Very good
Excellent
M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
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Table 3
Full factorial experimental plan (50 tests, replicated four times)
Levels
I
II
III
IV
V
Three factors
Exposure time (s)
Airflow (m3/h)
7
14
3
5
7
9
11
50
60
70
80
90
Table 4
Verification experimental plan (20 tests, replicated four times)
Levels
I
II
III
IV
V
Two factors
Exposure time (s)
Airflow (m3/h)
4
7
11
14
3
5
7
9
11
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M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
Indexes
df
SS
MS
4
4
4
62
74
16,218.94
23,643.18
9333.92
17,434.72
66,630.76
4054.73
5910.80
2333.48
268.226
15.12
22.04
8.70
26.75%
39.20%
14%
20.05%
Table 6
Comparison between coating using finer and coarser powders
Surface status
Coating material
Finer powder
Coarser powder
Shrinkage
Voids
Pin holes
Orange peels
Edge cover
Minimized
Minimized
Minimized
Minimized
Minimized
Minimized
Present
Relevant
Relevant
Maximized
M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
4625
Fig. 5. Surface coating appearance (window paning and Forange peel_ effect).
A similar trend seems to characterize the coating thickness for both the exposure times (7 and 14 s) and all applied
voltages. Of relevance, an initial rise in coating thickness is
obtained from increasing the applied voltage. Then, after a
maximum value has been achieved, a strong decrease in
thickness clearly occurs. This trend is common to all the
investigated airflow levels, even if a top shift of curve is
clearly evident.
Once again, physics can interpret this phenomenon in
terms of a force system acting in the vicinity of and around
grounded targets. As previously stated, when moving
through the electric field established in fluidized bed,
powder particles are affected by aerodynamic, electric,
gravity, and frictional forces. Nevertheless, during the
coating process, there are only two forces playing a
fundamental role in determining coating thickness trends.
Firstly, the aerodynamic, which are very active all over the
fluidized bed, and secondly, electrical forces, whose
influence is very strong, very close to the grounded
substrate. The former exclusively depends on the superficial
speed, and as the latter are a function of the applied voltage,
they can be controlled accurately.
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M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
corona voltage in each case. Examination of the experimental data clearly shows growth in the thickness trend
when the exposure time between the two investigated levels
is varied. However, at the lowest level of exposure time (7
s), even if the coating thickness already suffers the effects of
electrostatic force, fewer electric phenomena occur compared with those affecting the deposition process after 14 s
as exposure time.
The 3D maps reported in Figs. 8 and 9 reveal the
complete trend in average roughness obtained by varying
both the applied voltage and the airflow. Three map
segments can be identified: a first zone, typical of low
airflow values (less than 7 m3/h), in which the low coating
thickness determine a poor surface finishing whichever the
voltage applied. A sort of incubation value of airflow can be
defined below which nothing happens in terms of the
influence of charge to mass ratio on average roughness. In
each case, the thickness of the polymer layer was very thin
indeed for practical purposes (less than 40 Am). A second
zone is formed where the applied voltage is lower than 70
kV but the airflow is faster than 7 m3/h. Here faint variations
in airflow determine relevant modifications (ranging from
30% to 80%) on attained average roughness. No back
ionization phenomenon seems to occur below 70 kV. In fact,
as previously seen in Fig. 7, increasing the exposure time
causes a further growth in coating thickness without any
deterioration of surface finishing (Fig. 9). Finally, a third
zone can be identified for higher applied voltages: strong
back ionization phenomena seem to characterize this map
segment. In fact, the merest slight variation of applied
voltage is enough to introduce a significant increase in
average roughness associated with a decreasing of coating
thickness (as seen in Figs. 6 and 7) and consequent
deterioration of surface finish with the occurrence of diffuse
grooves, pin holes, voids, and the Forange peel_ effect.
Table 7-a and -b, and Fig. 10, respectively report the
ANOVA table and the analysis of mean for the full factorial
M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
4627
Table 7
a: Results of ANOVA table on full factorial experimental investigation
by considering interactions between investigated factors
Interactions
Source
Factors
df
Time
Voltage
Airflow
Time * Voltage
Time * Airflow
Voltage * Airflow
Time * Voltage *
Airflow
Error
Total
Seq SS
Adj MS
C (%)
1
4
4
4
4
16
16
13,945.6
24,074.8
23,543.8
4205.2
2308.3
3837
502.8
13,945.6
6018.7
5886
1051.3
577.1
239.8
31.4
1233.46
532.3
520.6
92.98
51.04
21.21
2.78
18.96
32.73
32.01
5.71
3.13
5.21
0.68
100
149
1130.6
73,548.1
11.3
1.53
Source
Factors
df
Applied
Voltage (kV)
Airflow (m3/h)
Exposure
time (s)
Residual
Total
Seq SS
Adj MS
24,074.8
6018.61
4
1
23,543.8
13,945.6
5886.0
13,945.6
140
149
11,983.9
73,548.1
85.6
C (%)
70.31
32.73
68.76
162.92
32.01
18.96
16.29
Fig. 11. Residuals analysis for the full factorial experimental design.
experimental investigation. Examination of the data collected reveals the significance of both the applied voltage
and airflow, in agreement with previous observations. By
disregarding all the interactions, a contribution percentage
C (%) for residuals, set at about 15% with a MS w of 85.6
(Table 7-b), confirms the significantly improved reliability
of experimental plan compared with the Taguchi design,
even though less df are engaged in full factorial design (over
9 against 16 df). The reduction in film thickness due to the
strong effect of back ionization phenomenon can be readily
seen in the trends shown in Fig. 10.
Figs. 11 and 12 report the analysis of residuals performed
on full factorial experimental design. Probability plot,
normality test (Shapiro Wilk), and residuals histogram
Fig. 10. Analysis of means for the full factorial experimental design.
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Fig. 12. Residuals model diagnostic for the full factorial experimental design.
M. Barletta, V. Tagliaferri / Surface & Coatings Technology 200 (2006) 4619 4629
4. Conclusions
Detailed experimental investigation supported by a
rigorous statistical analysis aimed at quantifying the
influence of process parameters and fluidized bed hydrodynamic on electrostatic fluidized bed coating process on
thin films (below 100 Am).
The relative influence of exposure time, airflow, and
applied voltage on achievable coating thickness was
measured. The statistical approach of the first Taguchi
experimental design revealed the relevance of all the factors
except for the powder typology. In addition, the slight
impact of exposure time on coating thickness was found.
The experimental results of the next full factorial design
showed the ability of fluidized bed to apply films under 100
Am thick and to manage the process accurately. Four process
maps were drawn in which the influence of each process
variable can be seen on coating thickness and average
roughness. In particular, the voltage level (70 kV) producing
the highest coating thickness in the shortest possible time
and without any deterioration in surface finish was
discovered. The highest voltage levels resulted in electrical
problems, that is to say, back ionization phenomena which
produced a decrease in coating thickness and a related
deterioration of surface aesthetic aspect (presence of voids,
pin holes, craters, and Forange peel_ effect). The lowest
4629
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