Best Practices for Applying Functional Industrial Coatings

In the world of functional industrial applications, coatings play a critical role in enhancing the performance and durability of different products. Functional industrial coatings, designed for specific purposes such as reduced friction, corrosion resistance, chemical resistance, or anti-abrasion, are essential for extending the lifespan of the products. Proper application of these coatings is key to achieving their intended benefits. Here are some best practices to ensure optimal results when applying functional industrial coatings.

1. Surface Preparation

Surface preparation is the cornerstone of a successful coating application. The surface must be clean, dry, and free of contaminants such as rust, grease, and old paint. For metal surfaces, this often involves abrasive blasting or sanding to remove oxidation and create a rough surface profile that promotes better adhesion.

2. Choosing the Right Coating

Selecting the appropriate coating for the intended function is crucial. Different coatings offer varying properties. Some coatings, such as Halar® ECTFE, provide superior resistance to chemicals, corrosion, or high temperatures. Other coatings, such as Teflon® PTFE offer very good low friction and non-stick properties. It’s essential to understand the specific environmental conditions and performance requirements of the application. For example, a marine environment may necessitate a coating with exceptional saltwater corrosion resistance, wheras an automotive application would require protection from repeated use.

3. Applying Coating in Optimal Conditions

Different conditions can significantly impact the effectiveness of functional industrial coatings. Factors such as temperature, humidity, and airflow should be considered before application. Most coatings have recommended application ranges for temperature and humidity. Applying coatings outside these ranges can lead to issues like poor curing, uneven application, or compromised adhesion.

4. Proper Application Techniques

Following the manufacturer’s guidelines for application is vital. Application techniques vary based on the coating type and the surface being coated. Common methods include spraying, dipping or wiping, depending on the type of coating and desired thickness on the substrate. Each technique has its advantages and should be chosen based on the coating’s characteristics and the geometric size and shape of the product or part being coated.

5. Thickness and Coverage

Achieving the correct film thickness is essential for the coating to perform its intended function. Too thin a layer may not provide adequate protection or coverage, while too thick a layer can lead to issues like sagging, cracking, or improper curing. It’s also important to apply multiple coats if required, allowing each layer to cure properly before applying the next. For applications that require an extremely thin layer of coating, with precise and repeatable application, it’s best to use controlled, automated robotic spraying.

6. Drying and Curing

Proper drying and curing are critical for the coating’s performance. The curing process allows the coating to develop its full strength and protective properties. This process can vary depending on the type of coating and the substrate being coated. Follow the manufacturer’s recommendations for curing times and conditions. It is critical to handle the coated surface with care when transferring the product or part for curing. Avoid exposing the coated surface to potentially damaging conditions before the coating has fully cured.

7. Inspection and Quality Control

Regular inspection during and after the application and curing process helps identify potential issues early. Check for defects such as bubbles, runs, scratches or uneven coverage. Conduct adhesion tests to ensure the coating adheres properly to the substrate. Implementing a quality control process helps maintain high quality standards and ensures that the coating performs as expected.

8. Maintenance and Recoating

For certain coated parts or products, routine maintenance is essential to prolong the lifespan of the coating and the underlying substrate. Regular inspections help identify areas where repairs may be needed. Addressing minor issues promptly can prevent them from escalating into more significant problems. Some products that are exposed to high-use and wear environments, such as compressor rotors and commercial waffle grids, can be refurbished and recoated to extend the product’s useful life.

9. Documentation and Record-Keeping

Maintaining detailed records of the coating application process, including surface preparation, coating types, application methods, and curing process, is valuable for future reference and quality assurance. Documenting these processes helps in troubleshooting issues and ensures that best practices are consistently followed.

Applying functional industrial coatings effectively requires careful attention to detail and adherence to best practices. From thorough surface preparation to selecting the right coating and ensuring proper application techniques, each step plays a vital role in achieving optimal performance and durability. By following these best practices, you can ensure that your functional industrial coatings provide the protection and functionality needed to enhance the lifespan and performance of your products.

Scott Yoder, Regional Manager

Scott Yoder is a Regional Sales Manager at Orion Industries, Ltd., the leader in functional industrial coatings and applications. He provides technical consulting and support to Orion’s manufacturing customers to improve the performance and functionality of their products and components. Scott draws from his 10 years of functional coatings industry experience combined with 25 years as a physician and educator to offer optimal coating solutions to customers.