Coating Explained

A coating is a covering that is applied to the surface of an object, or substrate.[1] The purpose of applying the coating may be decorative, functional, or both.[2] Coatings may be applied as liquids, gases or solids e.g. powder coatings.

Paints and lacquers are 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 to preventing corrosion. Along with corrosion resistance, functional coatings may also be applied to change the surface properties of the substrate, such as adhesion, wettability, or wear resistance.[3] In other cases the coating adds a completely new property, such as a magnetic response or electrical conductivity (as in semiconductor device fabrication, where the substrate is a wafer), 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 as printing.

"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. This continuous process is highly efficient for producing large volumes of coated materials, which are essential in various industries including printing, packaging, and electronics. The technology allows for consistent high-quality application of the coating material over large surface areas, enhancing productivity and uniformity.[6]

Applications

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] 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.[15] The body and underbody of automobiles receive some form of underbody coating.[16] Such anticorrosion coatings may use graphene in combination with water-based epoxies.[17]

Coatings are used to seal the surface of concrete, such as seamless polymer/resin flooring,[18] [19] [20] [21] [22] bund wall/containment lining, waterproofing and damp proofing concrete walls, and bridge decks.[23] [24] [25] [26]

Most roof coatings are designed primarily for waterproofing, though sun reflection (to reduce heating and cooling) may also be a consideration. They tend to be elastomeric to allow for movement of the roof without cracking within the coating membrane.[27] [28] [29]

Wood has been a key material in construction since ancient times, so its preservation by coating has received much attention.[30] Efforts to improve the performance of wood coatings continue.[31] [32] [33] [34] [35]

Coatings are used to alter tribological properties and wear characteristics.[36] [37] These include anti-friction, wear and scuffing resistance coatings for rolling-element bearings[38]

Other

Other functions of coatings include:

Analysis and characterization

Numerous destructive and non-destructive evaluation (NDE) methods exist for characterizing coatings.[54] [55] [56] [57] The most common destructive method is microscopy of a mounted cross-section of the coating and its substrate.[58] [59] [60] The most common non-destructive techniques include ultrasonic thickness measurement, X-ray fluorescence (XRF),[61] X-Ray diffraction (XRD)[62] and micro hardness indentation.[63] 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.[64] Scanning electron microscopy coupled with energy dispersive X-ray spectrometry (SEM-EDX, or SEM-EDS) allows to visualize the surface texture and to probe its elementary chemical composition.[65] Other characterization methods include transmission electron microscopy (TEM), atomic force microscopy (AFM), scanning tunneling microscope (STM), and Rutherford backscattering spectrometry (RBS). Various methods of Chromatography are also used,[66] as well as thermogravimetric analysis.[67]

Formulation

The formulation of a coating depends primarily on the function required of the coating and also on aesthetics required such as color and gloss.[68] The four primary ingredients are the resin (or binder), solvent which maybe water (or solventless), pigment(s) and additives.[69] [70] Research is ongoing to remove heavy metals from coating formulations completely.[71]

For example, on the basis of experimental and epidemiological evidence, it has been classified by the IARC (International Agency for Research on Cancer) as a human carcinogen by inhalation (class I) (ISPESL, 2008).[72]

Processes

Coating processes may be classified as follows:

Vapor deposition

Chemical vapor deposition

See main article: Chemical vapor deposition.

Physical vapor deposition

See main article: Physical vapor deposition.

Chemical and electrochemical techniques

Spraying

Roll-to-roll coating processes

Common roll-to-roll coating processes include:

Physical

See also

Further reading

Notes and References

  1. Carroll . Gregory T. . Turro . Nicholas J. . Mammana . Angela . Koberstein . Jeffrey T. . 2017 . Photochemical Immobilization of Polymers on a Surface: Controlling Film Thickness and Wettability . Photochemistry and Photobiology . en . 93 . 5 . 1165–1169 . 10.1111/php.12751 . 28295380 . 32105803 . 0031-8655.
  2. Howarth. G A. Manock. H L. July 1997. Water-borne polyurethane dispersions and their use in functional coatings. Surface Coatings International. 80. 7. 324–328. 10.1007/bf02692680. 137433262. 1356-0751.
  3. Howarth G.A "Synthesis of a legislation compliant corrosion protection coating system based on urethane, oxazolidine and waterborne epoxy technology" Master of Science Thesis April 1997 Imperial College London
  4. Wu . Kunjie . Li . Hongwei . Li . Liqiang . Zhang . Suna . Chen . Xiaosong . Xu . Zeyang . Zhang . Xi . Hu . Wenping . Chi . Lifeng . Gao . Xike . Meng . Yancheng . 2016-06-28 . Controlled Growth of Ultrathin Film of Organic Semiconductors by Balancing the Competitive Processes in Dip-Coating for Organic Transistors . Langmuir . en . 32 . 25 . 6246–6254 . 10.1021/acs.langmuir.6b01083 . 27267545 . 0743-7463.
  5. Campoy-Quiles . M. . Schmidt . M. . Nassyrov . D. . Peña . O. . Goñi . A. R. . Alonso . M. I. . Garriga . M. . 2011-02-28 . Real-time studies during coating and post-deposition annealing in organic semiconductors . Thin Solid Films . 5th International Conference on Spectroscopic Ellipsometry (ICSE-V) . en . 519 . 9 . 2678–2681 . 10.1016/j.tsf.2010.12.228 . 2011TSF...519.2678C . 0040-6090.
  6. Granqvist . Claes G. . Bayrak Pehlivan . İlknur . Niklasson . Gunnar A. . 2018-02-25 . Electrochromics on a roll: Web-coating and lamination for smart windows . Surface and Coatings Technology . Society of Vacuum Coaters Annual Technical Conference 2017 . en . 336 . 133–138 . 10.1016/j.surfcoat.2017.08.006 . 136248754 . 0257-8972.
  7. Howarth. G A. Manock. H L. July 1997. Water-borne polyurethane dispersions and their use in functional coatings. Surface Coatings International. 80. 7. 324–328. 10.1007/bf02692680. 137433262 . 1356-0751.
  8. Book: Howarth, G.A. Waterborne Maintenance Systems for Concrete and Metal Structures. The Royal Society of Chemistry. 1995. 0-85404-740-9. Karsa. D.R. 165. Cambridge, U.K. 5. Davies. W.D.
  9. Akram . Waseem . Farhan Rafique . Amer . Maqsood . Nabeel . Khan . Afzal . Badshah . Saeed . Khan . Rafi Ullah . 2020-01-14 . Characterization of PTFE Film on 316L Stainless Steel Deposited through Spin Coating and Its Anticorrosion Performance in Multi Acidic Mediums . Materials . en . 13 . 2 . 388 . 10.3390/ma13020388 . 1996-1944 . 7014069 . 31947700. 2020Mate...13..388A . free .
  10. Li . Jiao . Bai . Huanhuan . Feng . Zhiyuan . January 2023 . Advances in the Modification of Silane-Based Sol-Gel Coating to Improve the Corrosion Resistance of Magnesium Alloys . Molecules . en . 28 . 6 . 2563 . 10.3390/molecules28062563 . 36985537 . 10055842 . 1420-3049. free .
  11. S. Grainger and J. Blunt, Engineering Coatings: Design and Application, Woodhead Publishing Ltd, UK, 2nd ed., 1998,
  12. Ramakrishnan . T. . Raja Karthikeyan . K. . Tamilselvan . V. . Sivakumar . S. . Gangodkar . Durgaprasad . Radha . H. R. . Narain Singh . Anoop . Asrat Waji . Yosef . 2022-01-13 . Study of Various Epoxy-Based Surface Coating Techniques for Anticorrosion Properties . Advances in Materials Science and Engineering . en . 2022 . e5285919 . 10.1155/2022/5285919 . 1687-8434. free .
  13. Mutyala. Kalyan C.. Ghanbari. E.. Doll. G.L.. August 2017. Effect of deposition method on tribological performance and corrosion resistance characteristics of Cr x N coatings deposited by physical vapor deposition. Thin Solid Films. 636. 232–239. 10.1016/j.tsf.2017.06.013. 2017TSF...636..232M. 0040-6090. free.
  14. Gao . Mei-lian . Wu . Xiao-bo . Gao . Ping-ping . Lei . Ting . Liu . Chun-xuan . Xie . Zhi-yong . 2019-11-01 . Properties of hydrophobic carbon–PTFE composite coating with high corrosion resistance by facile preparation on pure Ti . Transactions of Nonferrous Metals Society of China . en . 29 . 11 . 2321–2330 . 10.1016/S1003-6326(19)65138-1 . 213902777 . 1003-6326.
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