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Syllabus
Powder Coating Application
1. INTRODUCTION TO THE MODULE
1.1 Outline the chemistry of formation of a simple polymer such as polyethylene.
1.2 Outline bonding mechanisms between polymer chains.
1.3 Distinguish between thermosetting and thermoplastic polymers.
1.4 Explain the term copolymer.
2. PRETREATMENT
2.1 Identify the substrates that can be powder coated.
2.2 Describe the processes that can be used to pretreat substrates.
2.3 Discuss methods of mechanical cleaning and preparation.
2.4 Discuss processes for effective cleaning prior to chemical or coating processes.
2.5 Define the purpose of conversion coatings.
2.6 Discuss the chemistry of phosphating on steel.
2.7 Discuss the different types of phosphate coatings; explain their uses and be able to select the correct one for various products under different environmental conditions of use.
2.8 Describe the layout of a typical phosphating plant.
2.9 Discuss the use of chromate conversion coatings on different metals.
2.10 Discuss some basic theories of adhesion that apply to powder coating.
2.11 Discuss some of the problems that occur at a substrate/coating interface.
2.12 Assess the effectiveness of different cleaning treatments.
3. POWDER APPLICATION
3.1 Describe powder application processes that use fluidised bed techniques.
3.2 Outline the principles of powder application by electrostatic processes.
3.3 Describe the elements of electrostatic application process.
3.4 Understand the function and importance of ‘Venturi’ powder-feed devices.
3.5 Describe the types of powder booths in use.
3.6 Describe the methods and equipment needed to recover powder.
3.7 Discuss the issues relating to colour change requirements for manual and automatic application methods.
4. METHODS OF MELTING, INCLUDING FLOW AND/OR CURE
4.1 Describe types of oven in use.
4.2 Understand temperature/time parameters.
5. TESTING APPLIED COATINGS
5.1 Describe standard methods of ensuring that powder coatings meet quality standards.
5.2 Use selected test methods to assess the properties of powder coatings.
6. SOLVING POWDER COATING PROBLEMS
6.1 Identify causes of problems in fluidised bed applications and suggest solutions.
6.2 Identify causes of problems in electrostatic applications and suggest solutions.
7. HEALTH, SAFETY AND THE ENVIRONMENT.
7.1 Understand the risks and legislation involved in working with and applying powder coatings.
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