Comparative Study of the Performances of Al(OH)3 and BaSO4 in Ultrafine Powder Coatings

A Mechanistic Study on the Anti-Corrosive Performance of Zinc-Rich Polyester/TGIC Powder Coatings

Powder coatings represent an environmentally friendly VOC-free alternative to widely used solvent-borne zinc-rich coatings, with economic and ecological benefits. In particular, powder coatings have several advantageous properties, such as chemical resistance and mechanical strength. However, the performance and characteristics of polyester-based zinc-containing powder coatings remain unknown. In this study, the corrosion performance of polyester powder coatings containing up to 80% zinc is compared. Electrochemical and salt-spray testing results indicate that coatings formulated with 80% zinc demonstrate superior anti-corrosive properties than coatings with lower zinc dosages. Two distinct behavioral phases of the coating with 80% zinc were observed by measurements of open circuit potential (OCP) and polarization resistance (Rp) during immersion tests—a phase indicative of a barrier effect and a phase consistent with galvanic protection. The evolution of the coating was further characterized and interpreted as five stages by electrochemical impedance spectroscopy (EIS), and the mechanistic details were discussed. This UV-resistant single-layer powder coating has the potential to replace the commonly used high-VOC multi-layer liquid coating systems at a significantly lower cost.

Modified chemical mineralization-alkali neutralization technology: Mineralization behavior at high iron concentrations and its application in sulfur acid spent pickling solution

Mineralization coupled with neutralization is a dual-function technology for disposing acidic iron-rich waters, which can recover the valuable iron in the form of secondary mineral and concurrently purify the wastewater. In this study, a modified technology for treating high Fe wastewater (sulfur acid spent pickling liquor, 62 g Fe/L) was proposed based on the specific investigation of the mineralization behaviors in Fe concentration range of 20-70 g/L. Results showed that high SO₄^2-/Fe²⁺ molar ratio (> 2.0) tended to trigger gelation phenomena at Fe concentrations above 30 g/L. Fe specie distribution suggested that the insufficient polymerization among Fe-OH complexes might be responsible for the gelation phenomena, since the strong Fe-SO₄ coordination almost completely suppressed the Fe_x(OH)_y^(3x-y)+ form (a general terms of Fe³⁺ hydrolysates and their polymers). Modified mineralization strategies were proposed, including pretreatment with dilution or BaCl₂/CaCl₂ precipitation, of which CaCl₂ pretreatment was a versatile and low-cost method. Following CaCl₂ pretreatment, chemical mineralization converted above 90% of iron into secondary mineral, which therefore drastically reduced the alkali consumption (from 164.2 g/L to 1.4 g/L) and sludge yield (from 328.1 g/L to 2.4 g/L) in subsequent neutralization treatment. The resultant mineral was identified as schwertmannite, and exhibited efficient adsorption capacity toward arsenite (364.2 mg/g). The modified chemical mineralization-alkaline neutralization is a cost-effective technology for the treatment of the acidic iron-rich waters. In practical applications, several regulating strategies should be further explored to improve the mineral purity, and the mineralization conditions must be optimized according to the Fe and SO₄^2- concentrations in wastewater.

A Comparative Study on the Anti-Corrosive Performance of Zinc Phosphate in Powder Coatings

Powder coatings are gaining popularity for their economic and environmental benefits. Additives (pigments) such as zinc phosphate enhance the anti-corrosive properties of coatings, but their behavior in powder coatings has not been extensively studied. In this study, zinc phosphate was incorporated into three powder coating systems: polyester clearcoat, polyester and epoxy coatings with filler BaSO4. Neutral salt spray and electrochemical tests (OCP, LPR, and EIS) confirmed that the anti-corrosive performance improved with the addition of zinc phosphate. The optimal additive dosage was determined to be 2% for all of the coating systems studied here, based on salt spray tests. Here, the time until failure increased by 1.5 to 2 times. Using electrochemical tests, an optimal additive dosage of 8% was found for the polyester clearcoat, while the other coating systems maintained an optimal additive dosage of 2%. Performance increased by as much as one order of magnitude based on resistance/impedance measurements. This suggested a synergistic effect between the additive and the filler. The passivation layer was confirmed by both X-ray diffraction and Raman spectroscopy. Based on the results and discussion presented in this article, the discrepancy was caused by different features of the two tests, such that the electrochemical tests probe the function of intact coatings, whereas salt spray measures only the corrosion spreading from the scribe. It is proposed that the two test methods characterize different aspects of the coatings, corresponding to their service conditions. This has theoretical and practical significance in the evaluation of anti-corrosive coatings. Other properties of the coatings, including adhesion, gloss, distinctness-of-image, and pencil hardness, were measured as per applicable standards and the conformance was verified.

Investigation of the Performance of Fumed Silica as Flow Additive in Polyester Powder Coatings

Fumed silica is one of the most commonly used flow additives in the powder coating industry. To investigate the influence of the properties of fumed silica on powder coatings, three different types of fumed silica, Aerosil R812, R972, and R8200, were selected and introduced to an ultra-high-gloss powder paint by the dry-blending method with preset mixing conditions and times. Their effect on the powder flowability, coating application related properties and film properties were carefully studied. The angle of repose (AOR) and bed expansion height data, which represent the semi-dynamic and dynamic flowability of powders respectively, show a strong flowability enhancement for the powders with additives, and R812 exhibits the best performance compared to 8200 and R972, mainly due to its high hydrophobicity and specific surface area. For the ultra-high-gloss powder paint, all the flow additives cause slight gloss reductions, surface roughness increase and a significant effect on the distinctness of image (DOI). The addition of R972 is beneficial to the transfer efficiency of powders compared with the other two, while the additives impose only a minor influence in the Faraday cage effect. The melting and curing dynamics, i.e., gel time, and inclined plate flow, are not affected by the flow additives.

Special Issue on "Thin Film Processes"

Thin film processes are significantly incorporated in manufacturing display panels, secondary batteries, fuel/solar cells, catalytic films, membranes, adhesives, and other commodity films [...]