Search results

The purpose of this paper is to demonstrate the processability of cohesive PE-HD particles in laser beam melting processes (LBM) of polymers. Furthermore, we present a characterization method for polymer particles, which can predict the quality of the powder deposition via LBM processes.

This study focuses on the application of dry particle coating processes to increase flowability and bulk density of PE-HD particles. Both has been measured and afterwards validated via powder deposition of PE-HD particles in a LBM machine.

For efficient coating in a dry particle coating process, the PE-HD particles and the attached nanoparticles need to show similar surface chemistry, i.e. both need to behave either hydrophobic or hydrophilic. It is demonstrated that dry particle coating is appropriate to enhance flowability and bulk density of PE-HD particles and hence considerably improves LBM processes and the resulting product quality.

At present, in LBM processes mainly polyamide (PA), 12 particles are used, which are so far quite expensive in comparison to, for example, PE-HD particles. This work provides a unique and versatile method for nanoparticulate surface modification which may be applied to a wide variety of materials. After the coating, the particles are applicable for the LBM process. Our results provide a correlation between flowability and bulk density and the resulting product quality.

This paper aims to express in detail the rheological, morphological and thermal properties of unpigmented and pigmented styrene-butadiene rubber composites with new prepared inorganic pigment based on kaolin covered with a thin layer of calcium and magnesium oxides or mixed oxide of both together. These new pigments combine the properties of both their constituents (kaolin and metal oxides), which are a new trend in inorganic pigments called core-shell pigments. The pigments used for comparison are kaolin (K), CaO/kaolin (CaO/K), MgO/kaolin (MgO/K) and CaO.MgO/kaolin (CaO.MgO/K).

The different pigments were characterized using different analytical and spectrophotometric techniques, such as X-ray diffraction, scanning electron microscopy/energy dispersive X-ray and transmission electron microscopy, while rubber vulcanizates' rheological, morphological, swelling and thermal properties were examined using different standard and instrumental testing and methods.

The study revealed that there is a significant effect of the new prepared pigments on SBR properties, where the optimum pigment loading was 40 phr for CaO/kaolin, while it was 2.5 phr for MgO/kaolin. Studying the effect of different ratios of oxides on kaolin (5, 10 and 20 per cent), different loadings of these pigments ranging between 2.5 and 40 phr were done for each pigment. These modified kaolin or core-shell metal oxide/kaolin pigments imparted new and improved reinforcing properties to SBR vulcanizates.

No research limitations were found.

Core-shell MgO/kaolin pigments are eco-friendly and can replace other expensive pigments that are usually used as fillers in the rubber industry with less expenses and comparable efficiency.

These new pigments are cheap and efficient and can be used in different fields other than rubber.

In part I of this study a new dry coating analysis was developed relating pigment cluster voids and pigment particle distribution to the pigment cluster dispersion coefficient, C_q, and the critical pigment volume concentration (CPVC). Part II of this study has addressed a wet coating analysis to relate pigment particle size distribution and viscosity in a coating formulation to the pigment cluster dispersion coefficient.

This study introduced the relationships for the wet coating by building on the dry coating evaluations introduced in part I of this study. Part II of this study showed that the CPVC for a solvent based coating can be significantly influenced by a change in the viscosity measured interaction coefficient, σ, as influenced by a change in an additive such as the surfactant concentration in the matrix or polymer phase of the coating. The CPVC was also shown to be strongly influenced by a separate analysis of the pigment particle size distribution to modify the coating viscosity.

It was pointed out recently that an increase in flow additive increased the CPVC but decreased viscosity. Consequently, it was shown theoretically in this study that viscosities compared at the same relative viscosity, η/η₀, and at the same filler composition, f_i, using the generalized viscosity model would require decrease in the interaction coefficient, σ, to increase the global volume fraction of filler or pigment, Φ_F. This implied that a measurement of the interaction coefficient, σ, should be a direct measure of the ability of the CPVC to be modified. A minimum viscosity from the generalised viscosity model also resulted at the maximum packing fraction, which in turn was found to increase the CPVC of the coating. Consequently, part II of this study has yielded a useful relationship between the cluster dispersion coefficient, C_q, and the interaction coefficient, σ, from the generalised viscosity model.

While the experimental measurement of the parameters to isolate the clustering concepts introduced in this study may be difficult, it is expected that better quantitative measurement of clustering concepts will eventually prove to be very beneficial to providing improved suspension applications including coatings. The close relationship introduced in this study between clustering concepts and viscosity should provide an improved ability to measure the parameters to isolate clustering in coatings and other suspension applications.

The theoretical relationship developed in this study between the pigment cluster dispersion coefficient, C_q, and CPVC and the theoretical and experimental relationship between CPVC and the viscosity interaction coefficient, σ, inferred a direct relationship between C_q and the viscosity interaction coefficient, σ. Consequently, it was shown that the theoretical pigment cluster model developed in this study could be directly related to the experimental matrix additive composition controlling viscosity in a coating formulation. The practical implication is that the measurement tools introduced in this study should significantly influence future suspension formulations to provide better measurement and control of clustering and viscosity in coatings and other suspension applications.

Part II of this study has shown how a useful relationship can be generated between the interaction coefficient, σ, from the generalised viscosity model and the pigment cluster dispersion coefficient, C_q, developed in part I of this study. In addition, this study also showed that effective control of the CPVC of a coating can be modified by judicious control of the interaction coefficient using pigment particle size distribution and/or viscosity control additives in a wet coating analysis.

Carbon steel has a high application rate in modern industry, but this type of steel has the defect of high wear. This study aims to improve the surface friction and wear performance of carbon steel under such working conditions.

In this study, a dry film lubricant based on graphite powder was prepared by the ultrasonic dispersion method, and deposited on the surface of carbon steel specimens by the simple pressure spraying technology. At the same time, molybdenum disulfide and polytetrafluoroethylene dry film lubricants were developed by the same method, and the comparative experimental study on friction and wear was carried out in the end-face friction tester.

The results show that the deposition effect of graphite and molybdenum disulfide dry film lubricants on the surface of carbon steel is obviously better than that of polytetrafluoroethylene dry film lubricant. Compared with molybdenum disulfide and polytetrafluoroethylene dry film lubricant, graphite dry film lubricant has the best friction and wear performance on the surface of carbon steel. The working life of carbon steel specimens sprayed with graphite dry film lubricant decreases with the increase of pressure load and rotation speed. The combination of load and sliding speed will accelerate the transition of the coating to a stable direction. In addition, the micro lubricant particles formed in the wear process will form particle flow lubrication, and the appropriate addition of particle powder of the same material will also prolong the normal antifriction time of the lubricant.

These findings developed a dry film lubricant that can effectively improve the friction and wear properties of carbon steel surface.

This paper aims to investigate the effect of introducing nano-ceria (CeO₂) particles to the epoxy coatings on mild steel in natural seawater.

The epoxy–ceria nanoparticles were coated with mild steel using a wire-wound draw-down bar method. The effects of ceria nanoparticles on the corrosion resistance of epoxy-coated samples were analyzed using scanning electrochemical microscopy (SECM) and electrochemical impedance spectroscopy (EIS).

Localized measurements such as oxygen consumption and iron dissolution were observed using SECM in natural seawater in the epoxy-coated sample. The increase in film resistance (R_f) and charge transfer resistance (R_ct) values by the addition of nano-ceria particles in the epoxy coating was measured from EIS measurements after wet and dry cyclic corrosion test. Scanning electron microscope (SEM)/energy dispersive X-ray spectroscope (EDX) analysis showed that complex oxides of nano-ceria were enriched in corrosion products at a scratched area of the coated mild steel after corrosion testing. Focused ion beam-transmission electron microscope (FIB-TEM) analysis confirmed the presence of the nanoscale oxide layers of ceria in the rust of the steel.

The tip current at −0.70 V for the epoxy–CeO₂-coated sample decreased rapidly because of cathodic reduction of the dissolved oxygen. The increase in film resistance (R_f) and charge transfer resistance (R_ct) values by the addition of nano-ceria particles in the epoxy coating were measured from EIS measurements after wet and dry cyclic corrosion test.

The presence of complex oxide layers of nano-ceria layers protects the coated steel from rusting.

The use of this nano-ceria for corrosion protection is environment-friendly.

The results of this study indicated the significant effect of nano-ceria particles on the protective performance and corrosion resistance of the epoxy coating on mild steel. The dissolution of Fe²⁺ was lower in the epoxy–ceria nanoparticle-coated mild steel than that of the epoxy-coated mild steel resulting in a lower anodic current of steel. The increase in film resistance and the charge transfer resistance showed that the nano-ceria particles and the formation of complex oxides provide better barrier protection to the coating metal surfaces.

The purpose of this paper is to synthesize anticorrosion pigments ZnFe₂O₄ from diverse raw materials of various shapes and size of primary particles.

Anticorrosion pigments were synthesized through a high‐temperature process during a solid phase. Zinc ferrites were prepared from hematite (α‐Fe₂O₃), goethite (α‐FeO.OH), magnetite (Fe₃O₄), and specularite (Fe₂O₃) entering into reaction with zinc oxide at temperatures ranging from 600 up to 1,100°C. The nature of the initial raw material, primarily the shape of its particles, affects the shape of the particles of the synthesized zinc ferrite. The formulated zinc ferrites had a rod‐shape, lamellar, and/or isometric shape. The shape of the particles of synthesized zinc ferrites was studied with regard to its effects on the mechanical and corrosion resistance of organic coatings. The obtained pigments were characterized by means of X‐ray diffraction analysis and scanning electron microscopy. The synthesized anticorrosion pigments were used to prepare epoxy coatings and water‐borne styrene‐acrylate coatings that were subjected to post‐application tests for physical‐mechanical properties and anticorrosion properties.

The shape of the particles was identified in the synthesized pigments. X‐ray diffraction analysis revealed the degree of precipitation and lattice parameters. All of the synthesized pigments had good anticorrosion efficiency in an epoxy and in styrene‐acrylate coatings. Compared with a commercially used anticorrosion pigment, their protective power in coatings was demonstrably stronger.

The synthesized pigments can be used conveniently in coatings protecting metal bases against corrosion.

The synthesis of zinc ferrites with different particle shapes for applications in anticorrosion coatings provides a new way of protecting metals against corrosion. Of benefit is the fact that the synthesized pigments do not contain any environmentally harmful substances.

The primary objective of this two part study was to show theoretically how pigment cluster voids and pigment distribution can influence the critical pigment volume concentration (CPVC) and consequently the properties of a dry coating. In Part I of this study a pigment clustering model with an analytical solution has been developed that was a modification of an earlier model by Fishman, Kurtze, and Bierwagen that could only be solved numerically.

The original derivation of the clustering concept developed by Fishman et al. resulted in a mathematical analysis which was only able to be solved numerically and was found to be very tedious to utilize directly. In this study, a new successful derivation utilizing some of the original concepts of Fishman et al. was generated and shown to result in a practical and much more useable analytical analysis of the clustering concept. This new model was then applied directly to quantify the influence of flow agents or surfactants in a coating formulation on the CPVC as described by Asbeck.

It was found that the largest deviation from 100 per cent pigment dispersion with no pigment clusters occurred just before and just after the ultimate CPVC (UCPVC). A theoretical relationship was also found between the pigment cluster dispersion coefficient, C_q, and CPVC. This result was consistent with the experimental relationship between CPVC and the per cent flow additive as found by Asbeck. The density ratio of overall coating to the pigment density was found to go through a maximum at a global volume fraction of pigment that was slightly greater than the UCPVC as expected for a mechanical property. It was also identified that mechanical failure of most coating formulations should be apparent at either the “Lower Zero Limit” or the “Upper Zero Limit” global volume fraction pigment as defined in this study.

While the experimental measurement of the parameters to isolate the clustering concepts introduced in this study may be difficult, it is expected that better quantitative measurement of clustering concepts will eventually prove to be very beneficial to providing improved suspension applications including coatings.

The theoretical relationship developed in this study between the pigment cluster dispersion coefficient, C_q, and CPVC and the experimental relationship between CPVC and the per cent flow additive found by Asbeck inferred a direct relationship between C_q and the per cent flow additive. Consequently, it was shown that the theoretical pigment cluster model developed in this study could be directly related to the experimental matrix additive composition in a coating formulation. The implication is that the measurement tool introduced in this study can provide better measurement and control of clustering in coatings and other suspension applications.

In this study, a new successful derivation utilizing some of the original concepts of Fishman et al. was generated and shown to result in a practical and much more useable analytical analysis of the clustering concept. This new model was then applied directly to quantify the influence of flow agents or surfactants in a coating formulation on the CPVC as described by Asbeck.

Mechanical and chemical properties of acrylic-melamine automotive clear coat in the presence of different percentages of well dispersed nano-layered sodium montmorillonite (Na-MMT) silicate particles were investigated. For this purpose, prepared dry clear coat film samples were subjected to the entire standard test series, usually carried out in automotive coating industry.

Effects of adding different percentages of nano-layered silicate on mechanical and chemical properties of acrylic-melamine automotive clear coat were investigated. To increase the compatibility of nanoclays with polymer matrix of clear coat, the surface of nanoclays was modified by benzalkonium chloride as a cationic surfactant. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) were used for characterization and comparison between clays before and after modification, and also after dispersion in coating. Prepared dry clear coat film samples subjected to the test series are usually carried out in automotive coating industry.

The results indicated that incorporation of 1 and 2 Wt.% of nano-layered silicate caused desired improvement in chemical and physical properties of the acrylic-melamine clear coat. Increasing the percentage of nanoclay to over 2 Wt.% caused damage in some properties such as hardness, cupping and gloss.

All materials and methods were used in this research are industrial grade. Therefore, the introduced modified clear coat sample has potential for commercial production as an automotive clear coat.

As far as it was searched in the literature, effects of adding nanoclay particles on mechanical and physical properties of different clear coats, such as epoxy clear coat, have been investigated in a few researches, but in this research, common and special tests which are necessary in automotive coating industry have been ignored. In the present study for the first time, acrylic-melamine clear coat was subjected to modification using nano-clay, and also, the most common industrial test methods were used for investigation of mechanical and chemical properties.

This paper aims to disclose the evolution of pendulum hardness of two-component acrylic polyurethane coatings during the cure process and attempts to describe the quantitative relationship between pendulum hardness and curing time. These findings are helpful for the study of fast curing acrylic polyurethane coatings.

The pendulum hardness method was used to monitor the hardness of two-component acrylic polyurethane coatings during curing. The quantitative relationship between pendulum hardness and curing time can be obtained with Avrami equation.

The evolution of coating pendulum hardness can be divided into three stages. By using the Avrami equation that explained the influence of both the acid value and the curing temperature on the drying speed of hydroxyl acrylic resin, the evolution of coating pendulum hardness during curing can also be accurately described.

It should be noted that the physical meaning of the Avrami exponent, n, is not yet clear.

The results are of great significance for the development of fast-curing hydroxyl-functional acrylic resins, with the potential to improve the drying speed of the coatings used in automotive refinish.

It is novel to divide the pendulum hardness into three stages, and, for the first time, the Avrami equation is utilized to describe the evolution of coating pendulum hardness during curing.

The purpose of this paper is to investigate the effects of reinforcing particles (B₄C, TiB₂ and TiC) on the physical, corrosion and wear behaviour of copper matrix composite coatings.

Coatings were produced by cold gas dynamic spraying process, and the contribution of reinforcements (B₄C, TiB₂ and TiC) to the coating characteristics was detected through microstructural examinations (scanning electron microscope examinations and X-ray diffraction analyses), hardness and electrical conductivity measurements, corrosion tests in Cl⁻ environment with potentiostat/galvonostat apparatus and wear tests which were performed under dry conditions by reciprocating wear tester.

Coatings with high density, good bonding at the coating and substrate interface were obtained by cold gas dynamic spray process. The electrochemical polarisation test in a Cl⁻ environment clearly indicated that the type of reinforcing particles did not significantly affect the corrosion performances of pure copper coating. In terms of the wear performances of the coatings, the best wear performance has been obtained for pure copper coating. Wear performance reduction of the composite coatings was related to the inhibition of continuous oxide layer formation on the worn surfaces due to third-body abrasion mechanism and delamination of oxide layer during wear tests.

Contrary to expectations, wear tests results of the study revealed the inverse effect of ceramic particle addition to the copper matrix in cold spray coating applications due to poor bonding between matrix and reinforcing particles.