Will Powder Coating Prevent Rust

When it comes to finishing a surface, we are all looking for that “magic” product that is easy to apply, looks beautiful and lasts forever.

It is true that there is no such thing as magic, or the illusion of "forever." That being said, there is such a thing as a really, really long time, which is what powder coating is all about.

Rust is a form of iron oxide. It occurs when iron combines with the oxygen in the air causing it to corrode. Rust is the orange-brown discoloration that builds up on metal. Rust can affect iron and its alloys, including steel. Whenever you have iron, water, and oxygen together, you get rust. The main catalyst for rust to occur is water. Although iron and steel structures seem solid to the eye, water molecules are able to penetrate microscopic gaps in the metal. This starts the process of corrosion. If salt is present, for example in seawater, the corrosion will be more rapid. Exposure to sulfur dioxide and carbon dioxide will also hasten the corrosion process. To avoid rust and corrosion, Powder coatings can be applied to the metal.

Powder coatings are designed to prevent oxidation by keeping the part from exposure to oxygen and water. It is a type of coating that is applied as a free-flowing, dry powder. Unlike conventional liquid paint which is delivered via an evaporating solvent, powder coating is typically applied electrostatically and then cured under heat or with ultraviolet light. The powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher than conventional paint. Powder coating is mainly used for coating of metals, such as household appliances, aluminium extrusions, drum hardware, automobile, motorcycle, and bicycle parts. More advanced technologies allow other materials, such as plastics, composites, carbon fiber, and MDF (medium-density fibreboard), to be powder coated using different methods that require less heat and time.

Powder coating offers benefits such as superior durability, scratch resistance, gloss retention and resistance to chalking. It is mainly used for applications on metal parts exposed to extreme weather conditions. Powder coatings are cost efficient, as they do not contain solvents and volatile organic compounds. Furthermore, over-sprayed powder coating can be retrieved and recycled for use, thereby reducing cost.

Benefits of Powder Coating

Efficiency

Because of the electromagnetic energy used to apply the powder to parts, there is almost no waste in the powder coating process. Additionally, an expert can apply as much (or as little) powder as necessary in one application. Rather than allowing the parts to dry between coats, everything is done at once, which saves money and time.

Low Cost

Along with the money you’ll save by eliminating extra steps, powder coating is cost-efficient in a few other ways. The materials used are bought according to the job’s specifications. The powder is less costly than paint, and it takes up less space when stored.

Durability

As far as the finish is concerned, powder coating is more durable than most other options. When it cures, the powder will form chemical bonds in the process and create a flexible, durable finish. Powder coated parts are highly resistant to corrosion, flaking, and scratching.

Variety

While mil spec powder coating has a few common finishes and colors, one of the biggest benefits of the method is the potential for customization. Powder manufacturers will create unique blends to match any color, texture, and finish. There are few competitive options in terms of versatility and range.

Environmental Safety

Because the powder is free of toxic chemicals and solvents, it is regarded as safe for usage and disposal. The processes release no harmful chemicals into the air, and they produce less waste. However, expert painters know to avoid inhaling the powder and to wear safety gear that minimizes skin contact.

Quality

The powder coating application and drying processes create a finish not found in any other paint product. Because the powder melts and reforms as a solid, it creates a smooth surface without drips or runs. Therefore, there is no need to sand or refinish if mistakes are made.

Maintenance

Powder coating is easy to maintain; no special solvents or cleaners are required. Because these coatings are so resistant to corrosion and damage, there is no concern over rust and other cleaning-related damage. In most applications, an occasional wipe with soapy water is enough to keep parts clean and useful for years into the future.

The global powder coatings market size is expected to reach USD 19.9 billion by 2027, at a revenue-based CAGR of 7.0% from 2020 to 2027, according to a report by Grand View Research, Inc. The market is expected to witness significant growth over the forecast period primarily owing to superior properties of powder coatings over conventional paints including high resistance to corrosion, chipping, and abrasion, durability, cost-effectiveness, excellent finishing, and reduced processing time.

Frequently Asked Questions about Powder Coating

How many coats are applied with powder coating?

Powder coatings are generally a one coat finish, applied to suitably cleaned and pre-treated substrates. Some coatings such as metallics may require a clear coat to protect the metallic effect.

Can powder coatings be applied on site?

Powder coatings are a factory applied finish using specialised equipment. The equipment includes an electrostatic spray gun, spray booth and an oven to bake (or cure) the coating. On site application is not possible given the hot curing cycle required to fuse the coating.

Are powder coatings suitable for use on surfaces which come into contact with food?

Some powder coatings can be designed specifically for contact with food but this is a specialised application that could be developed on a Made To Order basis. If this feature is required, you should contact GZ Industrial Supplies for further information as the standard ranges of powder coatings are not suitable for contact with food.

How do I maintain and refurbish a powder coated surface?

The effects of pollution, dirt, grime and salt deposits can all accumulate on a powder coated surface over time. To extend the effective life of powder coatings and fulfil any warranty requirements that may exist, a simple regular maintenance program should be implemented for the removal of residues. As a general rule, all powder coated surfaces should be cleaned every twelve months.

However in areas where pollutants are more prevalent, especially in coastal or industrial regions, a cleaning program should be carried out on a more frequent basis. To clean a powder coated surface, customers should carefully remove any loose deposits with a wet sponge and then use a soft non-abrasive brush or cloth in combination with a mild household detergent solution to remove dust, salt and other residues. Finally rinse all powder coated surfaces with clean water.

Conclusion:

Rust can compromise your metals’ strength, making them fragile and shortening their lifespan. When it comes to keeping your metals looking their best while also maintaining durability, preventing rust in the first place is key. Exposure to outdoor conditions will increase the risk of rust, especially if the climate is rainy or humid.

Powder coating is resistant to cracking, peeling, chipping, abrasion, rust and damage due to chemical exposure. While it is not indestructible, it is highly durable, retains colour and gloss, goes on uniformly, has excellent UV stability and is a far more environmentally friendly option than traditional liquid paint. Powder coating provides a protective barrier that helps prevent rust. Powders are applied using an electrostatic spray process. The electrically conductive object is sprayed with a charged, non-conducting powder.

It is important to clean the metal part or surface, by removing any dirt or corrosion before applying any rust-preventative coating. Make sure the part is clean and dry.

Will Powder Coating Prevent Rust is one question many people have yearned to know, having read through this article I believe you are now well informed.

Are you in need of Powder coating service? Look no further than the professionals at GZ Industrial Supplies. We stock an extensive grade of Powder coating equipment for whatever project you need to tackle. We are proud to have served our customers over the years and are ready to assist you with your requests. Have questions? Contact us today to learn more.