THE COATINGS EXPERT YOUR BRAIN GAINER New solutions for your coating applications - Evonik Industries
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ISSUE 2019 THE COATINGS EXPERT YOUR BRAIN GAINER New solutions for your coating applications. DYNAPOL® polyesters for high-end packaging High-performance polymers coatings for demanding powder coating applications Meeting global regulatory drivers TEGO® Glide Promoting flow and Recoatable leveling with Evonik superwetters Cure-2-Go: Anquamine® 728 curing agent ACEMATT® 3400 New high-performance matting agent
THE COATINGS EXPERT 2019 EDITORIAL Dr. Claus Rettig Chairman of the Board of Management Evonik Resource Efficiency GmbH 2
Dear Readers, New market trends, the shift to digital We offer numerous solutions to meet technologies, and increasing demands existing and emerging environmental on products and applications – the regulations while boosting applicator coatings market constantly confronts productivity and coating performance. us with formidable new challenges. These include Anquamine® 728 At Evonik, we gladly accept those waterborne curing agent for epoxy challenges. flooring primers and topcoats, as well as Ancaminde® 2769 for excellent As a front runner in innovation, we corrosion resistance performance. know that the hunt for truly innovative Furthermore we offer TEGO® solutions is something like a brain AddBond LTW for additional adhesion teaser. Lateral thinking and per- in can coatings, VISIOMER® Methac- sistence help solve even the most rylates for crosslinking solutions, and daunting tasks. But thanks to our Direct-to-Metal (DTM) coatings for broad knowledge of the market and metals. In this issue you will learn close cooperation with our customers, more about these and many other we can help coatings manufacturers exciting topics for the global chal- enhance their formulations to improve lenges of our time. performance and effectiveness. We hope you enjoy reading the new Resource preservation, durability and journal! flexibility in coatings for metal objects, long-lasting protection against bio- Yours, logical growth, and new binders for Dr. Claus Rettig heat-seal applications are just a few of the issues we address. 3
THE COATINGS EXPERT 2019 CONTENTS 06 10 18 06 Cure-2-Go: Anquamine® 728 18 High-performance waterborne curing agent New epoxy floor epoxy formulation for self-level- coatings with unrivalled fast cure ing cementitious coating for and improved aesthetics concrete 10 ACEMATT® 3400 21 Improving adhesion: New high-performance matting A continuing challenge with agent with high transparency and modern, compliant coatings soft-touch properties for high-quality coating applications 26 High-performance polymers for demanding powder coating 12 Epoxy curing agents for applications chemical resistant applications 31 New additive to eliminate 16 Functional coatings R&D pinhole for water-based coating competence center established formulations 4
38 50 64 38 Meeting global regulatory 54 Innovation in the AEROSIL® drivers while boosting applicator process eliminates bead milling productivity 57 Promoting flow and leveling 40 Moisture mitigation solutions with Evonik superwetters for flooring systems using Evonik’s epoxy curing agents 62 DYNAPOL® polyesters for high-end packaging coatings 46 Smooth coating surfaces with superwetters 64 VESTAGON®: From high-perfor- mance solutions to future innovations 48 TEGO® Glide recoatable 68 A new class of binders for high-per- 50 Driving higher performance formance architectural Coil Coatings with ultra-high solids epoxy sys- tems for long-term asset protection 73 VISIOMER® HEMA-P 70M A new all-rounder 5
THE COATINGS EXPERT 2019 CURE-2-GO: ANQUAMINE® 728 CURING AGENT NEW EPOXY FLOOR COATINGS WITH UNRIVALLED FAST CURE AND IMPROVED AESTHETICS 6
“WHAT PROBLEMS KEEP YOU UP AT NIGHT?” A simple question to customers that displayed unmet needs in today’s industry floor coatings: – “I need to reduce my floor system cost … I want coatings with improved robustness under adverse cure condition … And also, I need good aesthetics and an epoxy system that meets stringent VOC/emission requirements”. In the application of epoxy industry floors, a maximum of four hours is acceptable to wait in between applying the primer and the topcoat, irrespective of cure conditions. Customers confirmed: “Anything longer than four hours and we will [have to] send the application team home, only to come back the next day again.” Challenging targets. Especially given the fact that fast-cure epoxy systems require 8-12 hours at low temperature cure (10 °C / 50 °F) before receiving a second coat and generally these systems suffer from carbamation. 7
THE COATINGS EXPERT 2019 Evonik Crosslinkers answers these lent aesthetics and good compatibility unmet needs with the commercializa- with pigment pastes. Anquamine® 728 tion of Anquamine® 728. The new based coatings have a low tendency to product is a waterborne amine curing carbamation and waterspotting and agent that offers fast cure and good can be applied up to 500 g/m2 / 20 mils aesthetics, for use in epoxy primers wet film thickness. Two coats per day and topcoats on concrete substrates. and next day back-in-service enables Combined with Ancarez® AR-555 applicators to improve productivity solid epoxy resin dispersion, it yields and save cost/m2. The end-user a primer with recoat times of less than receives a floor system that comes four hours at 10 °C / 50 °F and excel- with excellent aesthetics and has lent adhesion to damp concrete. potential to meet stringent emission Topcoats are best formulated with requirements. That’s Cure-2-Go with diluted liquid epoxy resins for excel- Anquamine® 728! 8
Figure 1 Recoat time of epoxy coatings to damp concrete at low tempera- ture cure condition. Comparison of Anquamine® 728 (Anq 728) versus a fast-cure mannich base epoxy system. Recoat time of epoxy coatings (h) Damp concrete, 9.5°C, 2–4% moisture 10 4 3 Anq 728 Anq 728 Mannich 400 g/m2 600 g/m2 base Figure 2 Comparison of Delta-E as a function of hours of UV-A exposure: White epoxy coating based on Anquamine® 728 versus an equivalent coating based on solvent-free epoxy technology. Delta E after hours of UV-A exposure Solvent-free epoxy Anquamine® 728 Time of exposure to UV-A light (h) CONTACT Robert Rasing robert.rasing@evonik.com 9
THE COATINGS EXPERT 2019 ACEMATT® 3400 NEW HIGH-PERFORMANCE MATTING AGENT WITH HIGH TRANS- PARENCY AND SOFT-TOUCH PROPERTIES FOR HIGH-QUALITY COATING APPLICATIONS Evonik presents its new ACEMATT® In regards to rheology, the special 3400. It is the new matting agent in after-treatment of ACEMATT® 3300 the ACEMATT® product family of and ACEMATT® 3400 prevents the Evonik Resource Efficiency GmbH, adsorption of associative thickeners in specially developed for high-transpar- water-based systems. When formu- ency clear coatings and soft-touch lated with particular polyurethane coatings with smooth surfaces. binders, it can also improve the soft- touch feel. ACEMATT® 3400 is a surface-treated, thermal silica with medium particle ACEMATT® matting agents are size of 7.5 µm. The improved grind high-performance silica developed for performance results in a smooth sur- gloss reduction in a vast range of face finish with outstanding optical applications in the paints and coatings and haptic properties. industry. This highly efficient silica is intended Our best recommendations for for use in clear coatings, water-based high-quality coatings with excellent and solvent-based coatings. Typical transparency are the family of application fields include wood coat- thermal silica ACEMATT® TS 100, ings, plastics, and automotive coat- ACEMATT® 3300, and ACEMATT® ings. In addition, this new type of 3400. matting agent can be used in high solids and low-VOC formulations. 10
FAMILY OF EVONIK THERMAL SILICA MATTING AGENTS ACEMATT® TS 100 yy No surface treatment yy Particle size d50 = 9.5 µm yy Excellent matting efficiency yy Highest transparency ACEMATT® 3300 yy Organic surface treatment yy Particle size d50 = 10.0 µm yy Highest matting efficiency yy High transparency yy Soft-touch effect ACEMATT® 3400 yy Organic surface treatment yy Particle size d50 = 7.5 µm yy High matting efficiency yy High transparency yy Soft-touch effect yy Higher smoothness than ACEMATT® 3300 CONTACT Thomas Klotzbach thomas.klotzbach@evonik.com 11
THE COATINGS EXPERT 2019 EPOXY CURING AGENTS FOR CHEMICAL RESISTANT APPLICATIONS T wo-component epoxy systems pro- vide excellent mechanical properties, chemical resistance, and adhesion to a wide range of substrates. Therefore, they are frequently chosen over other technologies, especially when chemical resistance is an important attribute. Chemical resistance is required in a variety of applications from construction and infrastructure to protec- tive metal coatings. In the construction and infrastructure sector, epoxy systems are often utilized to improve chemical resis- tance in flooring, wastewater treatment plants, sewer, power plants, secondary containment, mortars, and grouts. For flooring applications, chemical resistance is critical in areas where the concrete flooring is regularly exposed to various chemicals, for example food and beverage preparation and service areas, meat packaging plants, dairy farms, paper and pulp plants, and chemical and pharmaceutical facilities. There are a number of key factors to be considered when selecting the right epoxy system for chemical resistance. These 12
factors encompass the type of appli- to help epoxy formulators meet their cation, substrate, classes of chemicals evolving needs for improved chemical to which resistance is required, dura- resistance epoxy systems. tion of resistance, degree of resis- tance, and processing and application For ambient-cure epoxy systems, requirements. In addition to chemical amine curing agents for chemical resistance, many applications require resistant applications can be separated other important attributes such as into two basic categories, aliphatic low-temperature cure, rapid develop- amine and cycloaliphatic amine curing ment of hardness, carbamation resis- agents. Cycloaliphatic amine-cured tance, or low color. Epoxy curing systems offer good resistance to agents impart significant influence on aqueous solutions, solvents, and inor- chemical resistance and other proper- ganic acids. Aliphatic amine curing ties of the cured epoxy systems. agents provide fast cure speed and Evonik offers a portfolio of products high crosslinking density. For grout 13
THE COATINGS EXPERT 2019 and mortar applications where water surfactants would negatively affect cleanability is needed, formulated the chemical resistance. Table 1 lists amidoamine curing agents are often the characteristics of selected amine selected. For instance, Ancamide® curing agents that offer good chemical 2886 curing agent is a newly devel- resistance. Each of these curing oped curing agent for tile grout agents offers distinct handling or application. It provides chemical performance advantages over the resistance to hot oleic acid in food others. In many cases, the optimal preparation areas where high-tem- performance advantages can be perature cooking oil is present. obtained by blending the curing Although cycloaliphatic amine curing agents. For example, a cycloaliphatic agents can also be used in combination amine can be blended with 10% to with external surfactants to achieve 30% by weight of a modified aliphatic water cleanability, the presence of amine, such as Ancamine® 2432 curing Table 1 Characteristics of the curing agents formulated with standard bisphenol-A based liquid epoxy resin at 25 °C. Curing agent Gel time (min.) Thin film set time1 Curing agent viscosity (cP) (150 g mass) (h) phr Ancamine® 1693 100 52 9 50 Ancamine® 2280 450 50 6 58 Ancamine® 2334 1180 42 2 50 Ancamine® 2422 2000 26 NA2 26 Ancamine® 2423 1200 17 3.5 60 Ancamine® 2432 300 46 2 46 Ancamine® 2748 2275 50 7 50 Ancamine® 2749 275 49 5 40 Ancamide® 2886 450 83 11 50 1 BK Drying Recorder, phase 3; 2. Not available. 14
agent, for faster cure and improved sol- vent resistance. Table 2 provides the examples of specific chemicals to which CONTACT the resistance is required and recom- Dr. Shiying Zheng mended curing agents. shiying.zheng@evonik.com Table 2 Specific chemicals to which resistance is required and corresponding curing agents. Specific chemicals Curing agents Aliphatic hydrocarbons, gasohol (10% ethanol) Ancamine® 2432, Ancamine® 1693 Aromatic hydrocarbons (toluene, xylene) Ancamine® 2422 Phenol Ancamine® 2422 Ethanol Ancamine® 2432 Methylene chloride Ancamine® 2422 Citric acid Ancamine® 2432, Ancamine® 2423 Lactic acid Ancamine® 2432, Ancamine® 2423 Acetic acid (low concentration) Ancamine® 2432 Acetic acid (high concentration) Ancamine® 2422 Hot oleic acid for coatings Ancamine® 2334 Hot oleic acid for grout Ancamide® 2886 Phosphoric acid (low and high concentration) Ancamine® 2432 Hydrochloric acid (low and high concentration) Ancamine® 2432 Nitric acid (low concentration) Ancamine® 2432 Nitric acid (high concentration) Ancamine® 2748, Ancamine® 2749 Sulfuric acid (low concentration) Ancamine® 2432 Sulfuric acid (high concentration) Ancamine® 2748, Ancamine® 2749 15
THE COATINGS EXPERT 2019 FUNCTIONAL COATINGS R&D COMPETENCE CENTER ESTABLISHED Evonik Resource Efficiency bundles its expertise in the Smart Surface Solutions R&D Competence Center, which focuses on unresolved questions in the paints and coatings industry. E vonik Resource Efficiency has established the Smart Surface Solutions R&D competence center in tise in the fields of coatings, particles, and specialty polymers in order to selectively improve surface proper- order to develop effective solutions ties. All opportunities share a common for previously unresolved issues in the holistic system approach, which is not paint industry. At several locations – limited to the development of new Essen (Germany) and Singapore – components for existing coating sys- more than 25 experts with diverse tems. education and industry backgrounds are working on the development of Technology-wise, the R&D compe- advanced corrosion protection coat- tence center has access to the full ings, anti-fouling concepts, anti-mi- spectrum of knowledge and technol- crobial surfaces, and coatings that ogy platforms of Resource Efficiency. repel dirt and ice. The internal experts are supported and broadened by external coopera- The Smart Surface Solutions R&D tion with customers, universities, competence center combines exper- research institutes, and start-ups. CONTACT Dr. Rüdiger Mertsch ruediger.mertsch@evonik.com 16
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THE COATINGS EXPERT 2019 HIGH-PERFORMANCE WATERBORNE EPOXY FORMULATION FOR SELF- LEVELING CEMENTITIOUS COATING FOR CONCRETE 18
S elf-leveling overlay systems for concrete floors offer numerous benefits. They can correct uneven floors, repair damaged concrete, and provide a smooth and durable new surface for decorative and functional treatments. Non-modified cement-based overlays typically used for this application can provide durability, long life, and low-mainte- nance cost coatings. Some of their disadvantages, however, include delayed hardening, low tensile strength, poor thermal shock and low chemical resistance. To mitigate these disad- vantages, the cement can be modified with various types of organic polymers. One such advanced composition is an epoxy modified cement (EMC), using Evonik’s waterborne epoxy thermoset technology based on Anquamine® 287 curing agent and an epoxy resin. Anquamine® 287-based EMC has a low odor and can be for- mulated free of volatile organic compounds (VOC), thus allowing for application in areas such as schools, offices or hospitals, that need to remain occupied during application. Table 1 Epoxy-modified cement formulation based on Anquamine® 287 curing agent and epoxy resin. 3K-Formulation Components Parts Part A Liquid epoxy resin/emulsion 5 - 15 Defoamer 0.05 - 0.10 Part B Anquamine® 287 17.0 Water 0 -10 Part C Portland cement 15 - 35 Quartz sand (various particle size) 15 - 35 Superplasticizer (powder) 0 - 0.20 19
THE COATINGS EXPERT 2019 A typical 3-component cementitious concrete formulation based on Anquamine® 287 is shown in Table 1. The extensive latitude with varying the binder levels in the formulation provides flexibility in tailoring the performance properties in terms of cure speed, thermal properties, chemical resis- tance, and tensile strength. Evonik’s EMC formu- CONTACT lation using Anquamine® 287 shows significant Shafiq Fazel performance benefits over standard polymer shafiq.fazel@evonik.com modified cements (PMC), including a much higher compressive strength and better adhesion to con- Svetlana Ivanova crete (Table 2). svetlana.ivanova@evonik.com Table 2 Epoxy modified cementitious coating (5% binder content) vs. commercial polymer modified cement self-leveler coatings. Test item Commercial PMC Commercial PMC EMC 5% (22℃/50% RH) self-leveler (1) self-leveler (2) organic binder Bond strength to concrete 502 psi 552 psi 651 psi (ASTM D7234), 7d (coating failure) (concrete failure) (Cohesive failure) 1 day 942 2,859 1,678 Compressive 3 days 1,105 3,144 6,700 strength – psi (ASTM C579) 7 days 1,246 3,146 10,200 28 days 2,214 5,037 13,600 Tensile strength 114 398 1,005 (ASTM C307), 28d - psi Flexural 311 1,145 2,337 (ASTM C580), 28d - psi Impact resistance 140 140 90 (ASTM D7294) (In.lbs) Abrasion resistance > 500 > 500 300 (ASTM D6037) (mg) 20
IMPROVING ADHESION: A CONTINUING CHALLENGE WITH MODERN, COMPLIANT COATINGS P aints and coatings continue to offer one of the most efficient and cost-effective means of protecting fusion, adsorption and/or mechanical interlocking – or chemical – through formation of chemical bonds between and decorating valuable property, the two interfaces. The latter mecha- equipment and structures, regardless nism is dependent on the chemical of end-use or environment. Formula- nature of both the coating material tors continue to innovate new ways to and substrate, but both mechanisms enhance coating properties while require intimate contact between the meeting increasing environmental and two layers to ensure maximum adhe- legislative demands. Adhesion failure sion. It is essential that the coating in continues to be one of the most com- its liquid or melt state can fully wet the mon reasons for the loss of coating substrate to ensure the maximum performance and some of the most contact; therefore, good cleaning and catastrophic coating failures. Adhe- surface preparation are essential steps sion failures can appear as blistering, to ensure good adhesion. Roughening flaking, scaling, peeling or delamina- the surface increases the surface area tion, but the consequence is inevitably available for adhesive interactions to damage to the substrate under protec- occur. tion. Evonik’s TEGO® AddBond adhesion Adhesion occurs at the interface of promoters are a family of modified two similar or dissimilar materials; in polyester resins that can partially coatings, this is the interface between replace the main coating binder in a the dried or cured coating and its formulation to enhance its adhesion to substrate. The main adhesive mecha- difficult substrates. These resins have nisms are either mechanical – via dif- multiple functional groups that can 21
THE COATINGS EXPERT 2019 Figure 1 Mechanism of polyester adhesion resins. Ability to covalently link to binder Interaction with binder Coordination to e.g. surface Interaction with substrate metal atoms interact with various surfaces, while ingly stringent environmental regula- the polyester binder is compatible tions limit the amount of volatile with many different resin chemistries solvents that can be used in coatings, to ensure good performance in many and this limits a formulator’s freedom different types of coatings (Figure 1). to use these adhesion promoters as TEGO® AddBond adhesion promoters low viscosity and low solvent content can also help improve the corrosion are typically mutually exclusive. resistance of coatings by preventing Evonik has developed two new sol- or slowing the adhesion failure that vent-free, liquid polyester adhesion leads to film delamination as corrosion resins that have been designed to develops. improve adhesion to critical substrates and between coating layers. These Typically, adhesion promoter resins adhesion resins can help decrease are relatively high in viscosity and formulation viscosity and provide require solvent dilution to achieve a excellent adhesion to various substrates workable viscosity. However, increas- in high solids, solvent-free, and UV 22
formulations. TEGO® AddBond primer. Improvements in adhesion LP 1600 gives the best flowability were demonstrated by replacing 5% and strongest reduction of formulation of the main binder in each formulation VOC content, while LP 1611 has neg- with the new adhesion promoters and ligible impact on film hardness and good applying the formulation on various reduction of formulation VOC content. substrates, curing the coating for The performance of these new prod- seven days and then measuring the ucts was demonstrated in four differ- cross-cut adhesion (0 – 5 scale where ent, high solids formulations – a 1K 0 is best). The improvements with the alkyd metal topcoat, a 1K melamine 1K alkyd topcoat are shown in Table cured polyester stoving enamel, a 2K 1, but similar results were also seen in white PU topcoat, and a 2K epoxy the other formulations. Table 1 Adhesion of alkyd metal topcoats to various substrates. All data measured using 5 % (by solids content) liquid adhesion resin in place of main resin except where stated. Without adhesion With TEGO® With TEGO® Substrate promoter AddBond LP 1600 AddBond LP 1611 Aluminum GT 4 GT 3 GT 3-4 Al-Alloy GT 1 GT 1 GT 1 Steel GT 1 GT 1 GT 1 Phosphated GT 1 GT 1 GT 1 Zinc GT 4-5 GT 3 GT 3 EDC GT 1 GT 1 GT 1 ABS GT 5 GT 0 (3%) GT 0 (3%) PA GT 5 GT 1 (10%) GT 1 (10%) AlMn1Cu GT 4 GT 4 GT 2 Steel GT 2 GT 1 GT 0-1 23
THE COATINGS EXPERT 2019 Improvements in adhesion also cor- light stable and do not affect the color relate with improvements in corrosion and gloss stability of the final coating, resistance, where film delamination in both QUV and oven stability tests. after salt spray testing was significantly reduced. Polyester adhesion resins Chemists developing environmentally also impart excellent elasticity that friendly, high solids coatings often results in superior deformability and struggle with obtaining a suitable impact resistance. VOC-compliant application viscosity while simultane- coatings are often sensitive to raw ously meeting Volatile Organic Con- material incompatibilities and this can tent (VOC) limitations. These new often reduce optical appearance. liquid adhesion resins reduce viscosity These new liquid adhesion resins are without changing the rheological very compatible with most binders behavior of the coating, so leveling, and solvents, ensuring consistent and sag control, and application properties attractive finishes. The resins are also are not affected. This effect is more Figure 2 Viscosity reduction in high solids, 2K polyurethane topcoat formulations. Viscosity at different NVC 2000 1800 1600 1400 1200 [mPas] 1000 800 600 400 200 0 78.8% 76.8% 75.0% blank with LP 1600 with LP 1611 control 24
visibly evident as the solids content of the formulation increases. Figure 2 shows how the new adhesion resins lower the viscosity of a 2K polyurethane topcoat with 5% replacement of main binder. Similar results are seen in the other formulations tested. The new TEGO® AddBond LP 1600 and LP 1611 adhesion resins are soluble in most common solvents and provide benefits in many water-based formulations when they are formulated with wetting agents in order to ensure consistent substrate wet-out. Ensuring excellent coating adhesion to an increasing number of difficult substrates while meeting modern VOC requirements remains a challenge for many coatings formulators. Polyester adhesion resins are a valuable formulation tool for improving both adhesion and inter-coat adhesion of many different coatings. TEGO® AddBond LP 1600 and LP 1611 are new generation, liquid polyester adhesion resins that are suitable for ultra high-solids and water-based formu- lations without compromising other critical perfor- mance attributes of the coating. CONTACT Jim Reader jim.reader@evonik.com 25
THE COATINGS EXPERT 2019 HIGH-PERFORMANCE POLYMERS FOR DEMANDING POWDER COATING APPLICATIONS Recent material developments in long-chain polyamide and PEEK powders as well as in novel coating technologies could open up new opportunities for protective or tribological coating applications. In addition to offering the well-known properties of polyamide 12, which include excellent durability and chemical resistance, Evonik’s new long-chain polymer powders also provide increased temperature resistance. Improving performance in this way could help fulfill unmet coating needs in various industrial applications. L ong-chain polyamides such as polyamide 12 (PA 12) powders have been used in applications such as unique ability to resist abrasion and chemicals. wire and pipe coatings for many years, A trend has recently emerged toward where they deliver valuable physical long-chain polyamides with increased and chemical protection for metal. temperature resistance –and Evonik is Besides long-chain polyamides Evonik responding to that trend by introduc- offers polyether ether ketone (PEEK) ing newly developed polyamide powders that are particularly suitable powders for applications with higher for coating applications that are sub- temperature requirements. Coatings ject to extreme mechanical, thermal, based on high-performance polymer and chemical demands. The coating powders could optimize the efficiency material can withstand consistent and service life of engines, bearings, operating temperatures of up to and gears, as well as protect pipes and 250 °C and is characterized by its wind turbines from corrosion. 26
Coatings made of VESTAKEEP® PEEK PRETREATING THE STEEL could reduce friction in the planetary SUBSTRATES gearbox of a wind turbine, transferring Pretreating parts before coating is power even more efficiently and absolutely essential for removing any extending the life of the gearbox. adhering grease, oxide layers, and dust particles. Grease residues can Evonik coated steel substrates using crack during preheating and contami- two long-chain polyamide powder nate the surface of the part and grades (VESTOSINT® 1111 polyamide therefore the coating. Oxide layers 12 powder and a development grade and dust particles result in poor adhe- with increased temperature resis- sion. We therefore subjected the parts tance) and two PEEK powder grades to alkaline degreasing, roughened the (VESTAKEEP® 2000 UFP20 and a parts by sandblasting them with clean development grade for tribological grit, and then performed an additional coatings). degreasing step. 27
THE COATINGS EXPERT 2019 parts for 3–5 seconds before allowing them to cool to room temperature under air exposure. Electrostatic spraying technology was employed for coating parts with PEEK. Using an Optiflex 2S system from the GEMA company of Switzerland, we electrostatically charged the powder by applying a voltage of 100 kV and then placed the powder-coated parts in an oven for 10 minutes to generate a dense and adherent coating. We then allowed the parts to cool. PREHEATING THE STEEL Laser-based technology for coating SUBSTRATES parts with PEEK* was also applied by Evonik preheated the parts in an oven, our partner Fraunhofer-Institut für maintaining a uniform temperature Lasertechnik in Aachen (Germany). profile and varying oven temperatures between 360°C and 400°C for poly- TESTING amide coatings and between 380°C Polyamide coatings peeled off of the and 450°C for PEEK coatings. steel substrate underwent a tensile test to determine their mechanical COATING THE STEEL SUBSTRATES properties. The melting point of the Evonik used the fluidized bed coating polyamide coatings was determined process for coating parts with long- by DSC as directed in DIN EN ISO chain polyamides, dipping the pre- 11357. A Taber test (CS17, 500 g) for heated parts into the fluidized bed performing tribological tests on the basin with little heat loss. The coating polyamide coatings was used, and a powder in the basin was uniformly pin-on-disc setup for the PEEK coat- fluidized with air from the air chamber ings (8 MPa, 0.5 m/s, 5000 m). through the fine-pored base plate. We Adhesion of the PEEK coatings was used oil-free air (humidity between determined by a cross-cut test accord- 50% and 70%) for fluidizing, dipping ing to DIN EN ISO 2409. 28
RESULTS FOR LONG-CHAIN RESULTS FOR PEEK COATINGS POLYAMIDE COATINGS Evonik was able to apply both PEEK The melting point of the coatings powder grades easily via electrostatic made with the new long chain spray coating to yield coating thick- powder was 195°C; 20°C higher than nesses in the range of 60 µm. The that of coatings made from polyamide coefficients of friction of both PEEK 12. Despite the higher melting point coatings were in the range of 0.28; of the new long-chain polyamide the wear coefficients were in the powder, the processing parameters range of 5.8 x 10-7 mm3/Nm. for fluidized bed coating were similar to those used for PA 12, and the fluid- Using laser melting technology izing behavior of the new powder was allowed to generate dense, adherent as good as that of polyamide 12. PEEK coatings in a very short time Evonik was able to generate coatings period: the minimum laser interaction with thicknesses in the range of 250 time for generating dense coatings is µm. The results of the tensile test approximately 7 seconds. The coating show that that the novel coatings are thickness was adjusted to 30, 45, and also highly durable, with yield stress 60 µm, achieving excellent adhesion and strain values of 37 MPa and 15%, to the substrate with a cross-cut clas- respectively. The abrasion resistance sification of 0, depending on substrate of the new long-chain polyamide pretreatment and laser-melting coatings determined by the Taber test parameters. was comparable to that of polyamide 12, and weight loss was less than 1 mg/100 cycles. 29
THE COATINGS EXPERT 2019 Evonik’s recent material develop- higher turbine speeds. These special ments in novel coating technologies VESTAKEEP® coatings also allow and in long-chain polyamide and PEEK manufacturers to employ more powders could open up new opportu- cost-efficient substrate materials for nities in demanding coating applica- components used in applications with tions in the oil and gas, industrial, and sliding friction. automotive sectors. The latter market seems to be very promising, especially H. Sändker, J. Stollenwerk, P. Loosen, * for tribological coatings. The excellent Laser-based Process for Polymeric tribological performance of coatings Tribological Coatings on Lightweight made from specially developed Components, Surface and Coatings VESTAKEEP® powders significantly Technology, vol. 332, 2017, pp. 391-398 reduces the friction between sliding surfaces, which in turn makes opera- tion more efficient and economical. Examples of the benefits include lower fuel consumption and lower CONTACT CO2 emissions in combustion engines, Holger Renners extended service life for bearings, and holger.renners@evonik.com 30
NEW ADDITIVE TO ELIMINATE PINHOLING IN WATER-BASED COATING FORMULATIONS C onsumers are becoming increas- ingly aware of the importance of protecting our environment. This performance; water replaces typical organic solvents. Water has a drying speed that is usually much slower than has had a major impact on the coatings organic solvents. However, end-users industry, with the demand for low- to still require quick drying speed and no-VOC coatings increasing. To meet film formation in their water-based this demand, those who formulate formulations. The drying speed can be these low-VOC products have amended by using modified resin invested considerable resources into systems, compact printing processes, developing their waterborne technol- and other methods. However, these ogies. From a technical perspective, methods can still display pinholing many waterborne formulations still issues; these issues are especially suffer from application limitations – in evident in formulations with the fol- particular, poor substrate wetting, lowing characteristics / properties: edge retraction, pinholing, and other defects – that result in high product yy High temperature baking process failure rates, which can be costly to yy Wet-on-wet process the manufacturer. Fortunately, yy High wet film thickness, e.g. for high-performance wetting agents, mono coat defoamers, and other additives can solve these issues and produce consis- To address this issue, strong defoam- tently flawless waterborne coatings. ers and deaerators – e.g. hydrocar- bon-based – have been used to Waterborne coatings use a combina- eliminate pinholes within the dried tion of water-based resins and addi- film. There may be compatibility tives to achieve the desired coating issues due to the nature of hydrocar- 31
THE COATINGS EXPERT 2019 Figure 1 Molecular defoamers displace foam stabiliz- ing surfactants but are unable to stabilize the bubble wall. bon-based chemicals in water-based stabilize foam and allow normal liquid formulations, which results in lower flow so the bubbles can break natu- gloss, poor leveling and DOI, and rally. even sometimes cratering issues. This paper describes a new additive based Molecular defoamers are also effec- on a new pinhole elimination mecha- tive at controlling micro-foam, small nism; the additive also shows excellent bubbles trapped within the liquid, compatibility in water-based formula- which will result in pinhole issue tions. especially after baking process. Molecular defoamers are partly solu- MOLECULAR DEFOAMER FOR ble in water and are able to move to MICRO-FOAM IN WATER-BASED bubbles below the liquid surface to FORMULATIONS de-stabilize micro-foam. This leads to Molecular defoamers are surfactants the coalescence of micro-foam into with specific Gemini structures that larger bubbles which rise to the sur- are designed to compete with and face much faster and burst more easily. replace foam-stabilizing surfactants at Many conventional defoamers, e.g. oil the surface of the foam bubble. These based defoamers, are not effective at specially designed surfactants do not controlling micro-foam because the 32
oil is insoluble and remains at the liq- defoamers will not migrate to the uid surface. Molecular defoamers are surface of the cured coating film and also more dynamic than most foam will not cause issues associated with stabilizing surfactants; therefore, they this, such as poor recoatability (espe- can reach new bubble surfaces more cially after high-temperature baking quickly and prevent new foam bubbles processes). Molecular defoamers can forming. As surfactants, molecular also provide additional dynamic wet- defoamers are compatible with most ting properties to the formulation. systems and do not cause incompati- “Gemini” based surfactants simultane- bility problems like oil-based defoam- ously act as surfactants (and thus ers. Due to their excellent compati- enhance compatibility) and defoamers; bility in both liquid paints and also they have been used for many years by cured coating films, molecular the paint and coatings industry. Figure 2 Film formation mechanism in 4 stages of water-based coatings, and T2 shows the packing time of solid particles within wet paint. 10 Fluidity factor (Hz) – Log scale 1 T2 10-1 water evaporation deformation and compactification of particles 10-2 formation of a homogeneus film 10-3 I II III IV 10-4 0 20 min 40 min 1h 1 h 20 min 1 h 40 min 2h 2 h 20 min Time 33
THE COATINGS EXPERT 2019 Figure 3 Effect of additive containing different number of EO on the time of T2 during drying process. (Temperature: 24 °C, Humidity: 32%, Wet film thickness: 60um) 1 T2=13'23'' T2=14'23'' Fluidity factor, Hz, log 0.1 T2=15'8'' 0.01 1E – 3 0 200 400 600 800 1000 1200 Time,s Blank (Bayhydrol A2601) Blank + Surfactant with 3EO Blank + Surfactant with 10EO USE OF HYDROPHILIC SURFAC- philic surfactants will show balanced TANTS TO LOWER DRYING performances, including pinhole SPEED eliminations, drying speed, water Although fast drying water-based resistance, and so on. It is well known formulations are required by end that humectants can capture moisture coating process, sometimes having very well; a humectant is a substance slower drying speeds help give micro- with several hydrophilic groups, most foam more time to move out of water- often hydroxyl groups, and also, based paints and break, thus ethoxylates, amines, carboxyl groups, eliminating pinholes. Proper hydro- or it is esterified. 34
These groups show excellent affinity impact on water resistance (here to form hydrogen bonds with mole- focusing on alkoxylates as hydrophilic cules of water and keep things moist. group), and the effect of number of However, water-based coatings, alkoxylate on drying speed is illus- especially for those coatings with trated in Fig. 2 and Fig. 3. The drying requirement of water and corrosion speed is evaluated by “Diffusing-Wave resistance, can not use traditional the Spectroscopy”. “Speckle Rate” is rec- humectant; otherwise the water ognized as particle moving rate in wet resistance will be drastically affected. paint; faster the drying speed, the Experiments shows that hydrophilic quick the particle’s movement rate. surfactants containing less than 10 Pinhole elimination will be affected by alkoxylates will show very limited Stage II shown in Fig. 2, during which Figure 4 Minimum film thickness (um) when pinhole appears in water-based mono coat for truck coating. Hydrophilic surfactant + molecular defoamer Molecular defoamer Hydrophilic surfactant 48 50 52 54 56 58 60 62 64 66 35
THE COATINGS EXPERT 2019 the high concentration in solid induces COMBINATION OF MOLECULAR a packing process. This stage appears DEFOAMER AND HYDROPHILIC as a disturbed area on the drying SURFACTANT FOR PINHOLE kinetics, showing accelerations and ELIMINATION decelerations of the particles as they Water-based one-coat formulations get in contact together around time for truck coatings have been selected T2. It is believed that before T2, solid for evaluation of pinhole elimination particles can move in wet paint and using different additives. The wedge micro-foam can also move freely up to spray has been applied with gradient wet paint surface and break. If an wet film thickness, checking the film additive can prolong T2 during drying thickness when the pinhole appears process, the pinhole will be easily after baking. As indicated in Fig. 4, the eliminated. Fig. 3 shows the effect on purely hydrophilic surfactant actually the T2 of hydrophilic surfactant con- shows negative for the pinhole elimi- taining different number of ethoxyl- nation. However, when combining the ates. The result shows that additive molecular defoamer and the hydro- containing ethoxylate will get T2 little philic surfactant (which provide signif- prolonged, and when the number of icant synergy for pinhole elimination), ethoxylate increased to 10, the T2 has the formulation benefits from the been prolonged about 105s, which faster movement of micro-foam to the will get pinhole having longer time to wet film surface (by molecular move out. defoamer) and still little wet paint film (by hydrophilic surfactant). Compared When the longer or stronger hydro- to the conventional additives based on philic group is attached to the surfac- low-compatibility chemicals for pin- tant, benefits for pinhole elimination hole elimination, the additives with will be evident; however, there will new mechanism show excellent com- also be a higher tendency for foam to patibility in water-based formulations. appear in the paint. Therefore, the As shown in Fig. 5, a perfect coating hydrophobic part of the surfactant film appearance can be achieved with needs to be paired with a structure the new additives, while there will be that will compromise the issue caused poor leveling, lower DOI, and lower by foam tendency. gloss using the conventional additives. 36
Figure 5 Compatibility comparison between new additive and conventional one. New Additive Benchmark CONCLUSION With the increasing demanding for water-based coating formulation development, pinholing issues are always of importance to formulators, especially those with specific require- ments for compatibility, wet-on-wet processes, fast-dry baking systems, and high wet film thickness. This paper describes a new additive mech- anism for elimination of pinholes, CONTACT combined with excellent compatibility Dai Ye in water-based formulations. ye.dai@evonik.com 37
THE COATINGS EXPERT 2019 MEETING GLOBAL REGULATORY DRIVERS WHILE BOOSTING APPLICATOR PRODUCTIVITY 38
D emands within the global coatings market are always increasing. The performance envelope is expanding, while the need to improve worker safety and minimize environmental impact is at the forefront of new developments. Ancamine® 2878 epoxy curing agent has recently been developed to meet the requirement for fast return to service, offering safer handling and regu- latory compliance in most global regions. The key properties of fast cure at both ambient and low temperature with excellent carbamation and high-corrosion resistance makes Ancamine® 2878 ideally suited to meet performance demands within the protective coating and marine markets. Systems based on Ancamine® 2878 can also be formulated into high- build coatings offering fast property development for quicker turnaround of applications. Ancamine® 2878 has been formulated to be low-vis- cosity and highly reactive without the use of alkyl phenols or solvents, providing an improved EH&S profile and safer handling. It has been specifically developed to meet performance requirements for medium-duty corrosion-resistance application within the marine and protective coating markets and due to the fast-cure properties can also find further applica- tions in other areas including civil engineering. The combination of high-performance and a good EH&S profile means Ancamine® 2878 will continue to meet the emerging demands within the coatings market for years to come. CONTACT Marina-Elena Schmidt marina.schmidt@evonik.com 39
THE COATINGS EXPERT 2019 MOISTURE MITIGATION SOLUTIONS FOR FLOORING SYSTEMS USING EVONIK’S EPOXY CURING AGENTS M oisture related problems with floor coverings and coatings applied over concrete slabs have cre- concrete in new and existing con- struction. One of the methods includes the use of vapor retarder ated significant problems over the films under the concrete to prevent years for formulators, specifiers, moisture migration from the soil. This contractors, and owners in the con- approach is only effective, however, in struction industry. Concrete is one of new construction jobs as the film the most commonly used materials in needs to be laid down before the the construction industry due to its concrete is poured. It also does not strength, durability, resilience, safety, address any migration from moisture and low cost. However, concrete is a contained within the concrete itself. permeable material and allows mois- Another technique is to use reactive ture contained below the slab, or silicates to reduce moisture and solu- trapped in the concrete itself, to ble alkali transfer to the concrete migrate as a vapor phase to the con- surface by combining them with crete surface. This moisture transfer hydroxides within the cement paste. phenomenon accounts for many When used properly and in the right flooring failures with millions of dol- amounts, reactive silicates can be lars lost annually; and, the construc- beneficial to concrete, improving its tion team from manufacturers, density and reducing permeability. installers and project architects have Nonetheless, if these materials are to bear the liability. over-applied, they can be more dele- terious to concrete as water soluble Over the years, there have been vari- cations (K+, Li+, Na+) from the silicates ous methods that the industry can promote salt formation in the top employed to mitigate moisture prob- layer of the concrete. This formed lems when installing flooring over layer can cause osmotic pressure to 40
occur which could potentially lead to both existing and new construction blistering or disbondment of the sur- jobs since it is the final step before face coating or floor covering. applying the floor covering, such as tile, wood, carpet, laminate etc. or a The most common means to address seamless flooring system consisting of flooring failures due to moisture vapor multiple coating layers such as broad- is to apply moisture mitigation coat- cast floors, Terrazzo, etc. ings on the surface of the concrete slab. A moisture mitigating coating There are two types of moisture mit- can be a very effective solution to igation coatings; (1) moisture vapor address moisture vapor originating permeable or “breathable” (MVP) and from either the ground soil or concrete (2) moisture vapor blocking or barrier itself as water is one of its ingredients. coatings (MVB). A MVP coating Applicators can use this method for system is typically preferred where 41
THE COATINGS EXPERT 2019 there is a significant possibility of Evonik offers products for both MVP osmosis to occur due to high alkaline and MVB applications. Evonik can salts and moisture presence in the provide curing agents to formulate a concrete. As the osmotic pressure is complete breathable flooring system considered to be more severe, com- including primers, self-leveling floors pared to other moisture transmittance and cementitious concrete floors. Our mechanisms such as hydrostatic and waterborne curing agents such as capillary pressure, a moisture breath- Anquamine® 701 and 731 can be able system could be the best choice formulated as overlays which cure at assuming that the top layer is also > 3 mm thickness to give a porous breathable. A MVB prevents a mois- morphology that allows moisture ture vapor from migrating to the sur- vapor to transmit while preventing face of the concrete slab due to soluble salts within a concrete layer to hydrostatic pressure or capillary flow move to the surface and therefore and is preferred when a non–perme- avoid osmotic blistering or delamina- able floor covering or seamless coating tion (Figure 2). Another Evonk curing is applied on top of the moisture miti- agent, Anquamine® 287 can be for- gating layer. If no MVB is applied, over mulated with cement, aggregates and time even a small amount of moisture additives in a low binder-to-cement collected under the non-permeable ratio to provide a high-performance, floor covering can lead to adhesive breathable coating that can avoid floor failures between concrete and a top failures due to moisture. floor coating or covering. The mois- ture vapor transmission difference For MVB applications, Evonik pro- between moisture vapor permeable vides a number of curing agents, coating systems such as Anquamine® including Ancamine® 2739 and 2800. 701 and moisture vapor barrier system The MVB coatings are 100% solids such as Ancamine® 2800 is shown in epoxy systems applied directly to Figure 1. These results were obtained surface of prepared concrete at >10 by ASTM E96 wet cup method and mils (0.25 mm) to suppress moisture demonstrate well a significant differ- transmission down to ≤ 0.1 perms. ence in the rate of moisture migration Ancamine® 2739 and 2800 employ through the different type of moisture Evonik’s patented “very low emission mitigating coatings. technology” that allows the coating to 42
Figure 1 Moisture vapor transmission of Anquamine® 701 (moisture vapor permeable) and Ancamine® 2800 (moisture vapor barrier) coating as tested using ASTM E96 wet cup method. Moisture Vapor Transmission (MVT) ASTM E96 (wet cup) 3,0 2,5 2,0 Change in Mass (g) 1,5 1,0 0,5 0 0 2 4 6 8 10 12 14 16 18 Elapsed Time (days) Anquamine® 701 Ancamine® 2800 Figure 2 Blister formation in coatings due to osmotic pressure from the concrete slab. Blister Water Vapour Self-leveller Primer Partially-sealed Concrete Water-saturated concrete Water 43
THE COATINGS EXPERT 2019 cure without the use of non-reactive certified by third party testing. This is a diluent such as benzyl alcohol. Benzyl standard practice for two-component alcohol, a common diluent used in resin based membrane-forming mois- most conventional epoxy floor coat- ture mitigation systems for use under ings, emits out of the coating over resilient floor coverings. One of the time leaving voids in the film. This main requirements to meet the compli- could allow moisture vapor to pass ance is that MVB coating should not through, or if the voids occurs at the exceed permeance greater than 0.1 interface of the coating-concrete grains/h/ft2/in. Hg (perm) when tested layer, it could cause blistering or in accordance with Test Method ASTM delamination as the epoxy coating E96 when applied at the recommended would start peeling off from the sub- thickness designated by its manufac- strate. Ancamine® 2739 and 2800 do turer. The handling properties and third exceed the new moisture mitigation party testing results of Ancamine® 2739 systems standard ASTM F3010 -13 as and 2800 are shown in Table 1. Table 1 The handling properties and third parting testing results of Ancamine® 2739 and 2800. Ancamine® 2739* Ancamine® 2800* Curing agent viscosity @25 °C (cPs) 350 500 Mix viscosity @25 °C; (cPs) 500 594 Gel time, 150 g mass @25 °C ; (min) 85 41 Thin film set time, phase 3 (hr) 11 6 ASTM D5895 Adhesion to concrete** 360 psi 380 psi ASTM D7234 Bulk concrete failure Bulk concrete failure Permeance; (grains/hr/ft2/in.Hg) 0.051 (16 mils) ASTM E96 wet method at specified 0.064 (16 mils) 0.062 (14 mils) thickness (mils)** 0.10 (10 mils) * Used with resin blend consisting of liquid epoxy resin (LER), Epodil® 748 and Epodil® 749 (80:10:10) ** Results from third party testing (CTL Group) 44
Figure 3 Adhesion testing of Ancamine® 2800 and Anquamine® 287 cementitious coating using ASTM D7234 method on damp concrete. Ancamine® 2800 Anquamine® 287 In summary, preventing moisture mentioned epoxy curing agents are related failures is becoming one of the eco-friendly and do not use volatile most critical demands in the flooring organic components (VOC), or other industry and Evonik’s epoxy curing harmful materials such as nonyl phe- agents can help to mitigate these nol. They are proven technology that problems. Anquamine® 701, 731 and has been used in the construction 287 are excellent choices for a mois- industry for quite some time and ture mitigation system where there is continues to grow due to the new a need for permeability. Ancamine® requirements and market drivers. 2739 and 2800 would be the prod- ucts of choice when a moisture barrier is required. All these curing agents have outstanding adhesion to dry and CONTACT damp concrete which is also an Shafiq Fazel important requirement for this type of shafiq.fazel@evonik.com application (Figure 3). In addition to having excellent performance in Svetlana Ivanova moisture mitigation application, all the svetlana.ivanova@evonik.com 45
THE COATINGS EXPERT 2019 SMOOTH COATING SURFACES WITH SUPERWETTERS E vonik presents two optimised siloxane superwetting surfac- tants – DYNOL™ 960 and DYNOL™ in eliminating marks left by brush or roller. The figure below shows a comparison of the performance 980 – based on unique chemistry to obtained with DYNOL™ 980 com- meet the growing need for high-per- pared to modified siloxane surfactants formance waterborne coatings. in an acrylic water-based wood coat- ing. DYNOL™ 980 works to smooth DYNOL™ superwetters are designed the surface of the spray applied coat- to achieve exceptional wetting of ing, helps wetting the pores of the difficult-to wet substrates by providing wood, leaves no surface defects and a superior balance of properties, no foam (Figure 1). including both equilibrium and dynamic wetting, system compatibil- Both DYNOL™ products improve the ity and low foam. DYNOL™ 960 and overall performances of waterborne DYNOL™ 980 especially enhance coatings and present multiple benefits flow and levelling properties and help to wood coating formulators. 46
Figure 1 Comparison of superwetters in an acrylic water-based wood coating applied by spray. Blank Polyether modified siloxane 1 Polyether modified DYNOL™ 980 siloxane 2 CONTACT Christine Louis christine.louis@evonik.com 47
THE COATINGS EXPERT 2019 TEGO® GLIDE RECOATABLE E vonik has a long-standing history as a supplier of glide additives to improve the flow / leveling and oped a product to meet this demand: TEGO® Glide 496 satisfies the need for advanced solutions (see Figure 1 surface properties of various coating and Table 1). systems. For solvent-based wood coatings for kitchen cabinets or furni- Table 1 shows that the blank formula- ture, the challenge is that additives tion has not only a poor appearance which provide good haptic (feel/ but also a very high slip value and touch) properties are not recoatable corresponding poor touch (hand – and vice versa. Being able to use feeling). All of the benchmark addi- one additive that provides both of tives provide an improved slip and these properties is desirable in these touch but their recoatability is defi- situations. Through comparison with cient. The new TEGO® Glide 496 commercial benchmarks, Evonik improves all performance attributes. Resource Efficiency GmbH has devel- Figure 1 TEGO® Glide 496 provides excellent recoatability in a 2K solvent-based polyester clear lacquer. Benchmark TEGO® Glide 496 48
Table 1 Application testing results for 2K solvent-based polyester clear lacquer on cherry wood. Visual appearance Adhesion Slip [cN] Touch After 7 days Blank Turbulent GT 0 182 - Benchmark A Good GT 5 45 + Benchmark B Good GT 1 55 + Benchmark C Craters GT 5 48 + TEGO® Glide Good GT 0 47 + 496 Adhesion: Cross-cutting test according to DIN EN ISO 2409 Slip: Measured with Instron, Bluehill, 500 g, felt coated, 12 mm/sec Touch: Hand-feel Application work has shown that the Besides wood lacquers, the coatings new TEGO® Glide 496 is suitable for industry has a growing interest for both solvent- and water-based formu- such a new additive in plastic, indus- lations, has excellent compatibility, trial, and transportation coatings as and demonstrated scratch-resistance well as printing inks. improvement in various systems. Furthermore the additive is globally registered and complies with various food contact regulations. CONTACT Roger Reinartz Heike Semmler roger.reinartz@evonik.com heike.semmler@evonik.com 49
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