Thesis (Ph. D.)--Lehigh University, 2004. / Includes vita. Includes bibliographical references (leaves 113-119).

Works created within the engineering studies in collaboration with IDEAL-Trade service discusses the influence of pickling acids on steel material and on the same material with powder coated . Based on the literature study and consultations with employees of the company were designed each experiment, investigators removal and acid corrosion attack , another verify adhesiveness powder coatings for various periods of exposure pickled material. Experiments and tests were carried out in companies ECOS , ITS and faculty FSI.

The choice of corrosion protection system depends on the environment and needed lifetime for the product. The right corrosion protection should be selected in a sustainable point of view, since a well-selected coating system can reduce the environmental and economical impact, by using less and better material. The systems used for classifying corrosion protection often give a passed/not passed result for the number of years it is expected to last in a specific corrosive environment. In the last decades, Electrochemical Impedance Spectroscopy (EIS) has become a popular method for evaluating corrosion protection for organic coatings. EIS can collect quantitative data by monitoring the coatings electrochemical behavior over time, which can be used for optimizing the coating system. The purpose of this thesis was to try to predict how different combinations of coating layers and substrates will perform as a corrosion protection, which could provide information that can optimize the coating process. In this thesis, EIS has been used as a test method to evaluate organic coating systems for corrosion protection, by looking at barrier properties and adhesion for powder coatings on aluminum substrates. The main part of the coatings were applied in the coating plant at Fagerhult AB, but an external supplier has been used as a reference. The powders used in the coating process were based on polyester resins and the substrates were different aluminum alloys. The EIS measurements were performed in the chemistry lab at the School of Engineering at Jönköping University and depending on the sample setup was each sample evaluated for two or four weeks of testing. Two groups of samples had intact coatings and a third group had samples with an applied defect in the coating. The analysis of sample setups with intact coatings showed that the topcoat absorbed water faster than the primer. The samples showed no significant degradation in corrosion protection for the evaluated period and could thereby not provide enough information to be able to conclude which setup give the best corrosion protection over time. The samples with a defect in the coating indicated that two of the substrates provided similar adhesion in the coating-substrate interface. The coating from the external supplier was also included in the test and it showed the best adhesion of the tested samples. The main conclusion is that the coating system used at Fagerhult AB provides a very good corrosion protection. Longer testing time with EIS measurements on intact coatings is needed to be able to rank the different sample setups by failure of corrosion protection.

The diploma thesis deals with the optimization of powder-coating process resulting in a reduction of labor intensity during finishing components in gas insulated switchgear (GIS). The thesis is divided into five main chapters that describe characteristic and function of gas insulated switchgear (GIS), the theory of powder-coating, including mechanical and chemical pretreatment of surfaces, the studies of contemporary quality of coating process in the company ABB s.r.o. with classification of components of GIS according to their function. This chapter also contains detailed analysis of section of coating process during the processing of selected parts (housing and conductor). The thesis also contains detailed studies of masking of surfaces at coating parts, specifies the most common defects and determines the main cause presented in a well-arranged chart, design, description and realization of optimization solutions with selection and evaluation of final version. An economic comparison of contemporary condition of powder-coating process with designed optimization solution is stated at the end of the thesis.

No description available.

Solution chemistry is a versatile and powerful tool in the synthesis of designed, complex nano-level high-tech materials. Normally, the technique is considered too expensive for large-scale production of complex multi-component ceramic materials. This thesis describes the expansion of the useful area of solution processing to multi-component bulk materials such as ZnO-based high-field varistors and WC–Co cutting tools, by developing novel techniques for solution-based coating of conventionally prepared metal and ceramic powders. The chemistry and microstructure development in the preparation of coatings, and the sintering of the coated powders to compacts, were studied in detail by SEM-EDS, TEM-EDS, XRD, IR-spectroscopy, dilatometry, TGA and DSC chemical analysis. ZnO powder with a ca 20 nm thick, homogeneous oxide coat of Bi–Sb–Ni–Co–Mn–Cr–Al oxide was prepared. After sintering to dense varistor bodies, much improved microstructures with much reduced ZnO-grain sizes were obtained. This shows that the oxides added as liquid sintering aid and grain-growth inhibitor become much more active when added homogeneously as a skin on the ZnO powder. After sintering of cobalt-coated WC, much improved micro-structures were obtained with a much more narrow WC grain-size distribution than that obtained from starting powders mixed by a conventional milling route. Coated powders also obviate the need for the extensive milling of WC and Co powders used in conventional mixing. The novel solution route was also applied to preparation of porous sponges and thin films on metal, glass and Al2O3 of sub 20 nm sized Co- or Ni-particles.

Baigiamajame magistro darbe nagrinėjamos vibromechaniškai veikiamų perlydymo metu purkštinių NiCrBSi dangų savybės. Dangos pailgina mašinų, metalinių gaminių bei konstrukcijų eksploatacinį resursą, taupo medţiagas, apsaugo metalus nuo korozijos, agresyvios aplinkos poveikio. Terminis purškimas – vienas populiauriausių dangų dengimo būdų. Darbe pateikta terminio purškimo technologijų, purkštinių dangų savybių tyrimo metodų bei vibromechaninio apdorojimo taikymo apžvalga. Dangų purškimui bei perlydymui naudotas robotizuotas stendas. Atlikti dangos mikrostruktūros, porėtumo, kietumo, mikrokietumo bei atsparumo dilimui tyrimai, suformuluotos darbo išvados. Darbą sudaro šešios dalys: įvadas, literatūros analizė, eksperimentiniai tyrimai, tyrimų rezultatai, išvados, literatūros sąrašas. Darbo apimtis – 62 p. teksto be priedų, 24 iliustr., 15 lent., 35 bibliografiniai šaltiniai. / In the final master thesis the research of vibromechanical treatment of thermal sprayed NiCrBSi coatings during refuse process is completed. Coatings prolong machines, metal products and constructions worktime, save materials and protect metals from corrosion and impact of aggressive environment. Thermal spraying is one of the most common covering method. Review of thermal spraying techniques, methods of thermal sprayed coating properties analysis and application of vibromechanical treatment is given. Robot was used for covering and refusing the coating. Coatings microstructure, porosity, hardness, microhardness and wear test analysis were done. Conclusions are formulated. Structure: introduction, literature review, experimental researches, results, conclusions, references. Thesis consist of 62 p. text without appendixes, 31 pictures, 15 tables, 35 bibliographical entries.

<p>Solution chemistry is a versatile and powerful tool in the synthesis of designed, complex nano-level high-tech materials. Normally, the technique is considered too expensive for large-scale production of complex multi-component ceramic materials. This thesis describes the expansion of the useful area of solution processing to multi-component bulk materials such as ZnO-based high-field varistors and WC–Co cutting tools, by developing novel techniques for solution-based coating of conventionally prepared metal and ceramic powders. The chemistry and microstructure development in the preparation of coatings, and the sintering of the coated powders to compacts, were studied in detail by SEM-EDS, TEM-EDS, XRD, IR-spectroscopy, dilatometry, TGA and DSC chemical analysis. </p><p>ZnO powder with a ca 20 nm thick, homogeneous oxide coat of Bi–Sb–Ni–Co–Mn–Cr–Al oxide was prepared. After sintering to dense varistor bodies, much improved microstructures with much reduced ZnO-grain sizes were obtained. This shows that the oxides added as liquid sintering aid and grain-growth inhibitor become much more active when added homogeneously as a skin on the ZnO powder.</p><p>After sintering of cobalt-coated WC, much improved micro-structures were obtained with a much more narrow WC grain-size distribution than that obtained from starting powders mixed by a conventional milling route. Coated powders also obviate the need for the extensive milling of WC and Co powders used in conventional mixing.</p><p>The novel solution route was also applied to preparation of porous sponges and thin films on metal, glass and Al₂O₃ of sub 20 nm sized Co- or Ni-particles. </p>

Air-suspension particle coating is a process by which thin coatings are applied to powder particles. The coatings can be formulated to act as permeable barriers to increase powder shelf-life or to impart controlled release character. The ultimate objective of a coating operation is to produce individual particles, each with a well-controlled, even coating. This project was focused on the air-suspension coating of fine powders of ~100 µm in diameter for the dairy industry. Despite the widespread use of the technology in the pharmaceutical industry, its use in the food industry has been limited. Little is known about the fundamental mechanisms, and so published work to date is product and equipment specific and is statistical in the way the experimental design and analysis has been approached. This 'black box' approach is time consuming and costly. Better methods based on an understanding of the physical and chemical mechanisms are needed to deal with the numerous products and constantly changing formulations typical of the dairy industry. This thesis proposes a new approach to air-suspension particle coating research. The basis of this 'micro-level process approach', is to deconvolute the complex coating process into smaller manageable parts based on classical physical phenomena for which descriptions already exist. The thesis identifies and develops an understanding of the key micro-level processes controlling coated product quality and process performance. Four were selected for further study: drying, droplet impact and spreading, and stickiness which encompasses the two key micro-level processes of droplet impact and adherence and inter-particle agglomeration. They were studied separately to deconvolute the variable effects and interactions. Kinetic data were collected for the drying droplets containing maltodextrins, whey protein isolate and gum arabic. A mathematical model, based on 'ideal shrinkage' was developed to predict the drying kinetics of single droplets with particular interest in the development of the surface glass transition temperature. The model accurately predicted the kinetics until significant morphological changes occurred in the droplet. To better predict the kinetics late in the drying process, the droplet radius was set to be constant at a time based on the surface proximity to the surface glass transition temperature (critical X concept). This was done to arrest droplet shrinkage in line with experimental observations and to more accurately depict the drying of high molecular weight, amorphous glass forming polymers. After this point, a new flexible calculation scheme was used to better predict the variation in internal droplet structure as either a dense, 'collapsed shell' structure or a 'dense skin-porous crumb' structure. Further study should focus on the surface and internal droplet structure (porosity and mechanical integrity) development during drying, particularly the conditions leading to the arresting of the droplet radius and the subsequent rate of skin thickness progression. The critical X concept was used to make industrial-scale predictions of the optimum drying conditions that ensure maximum droplet impact and adherence efficiency and minimum inter-particle agglomeration in a Würster-style coating operation. This enabled the prediction of two key design parameters, the nozzle distance from the powder impact point and the Würster insert height. The span in design parameters showed that there is significant opportunity for design optimisation based on the critical X concept. A probe tack test was used to map the level of stickiness of droplets of different coating materials as they dried. As skin formation progressed, the stickiness passed through a maximum, in most cases to arrive at a point at which the droplet was no longer sticky at all (non-adhesive state). The maximum point of stickiness represents the ideal state to ensure successful droplet-substrate impact and adherence. The minimum point of stickiness represents the ideal state to prevent unwanted inter-particle agglomeration. The time interval between the onset of stickiness and the non-adhesive state was particularly dependent on the addition of plasticisers, but also on the formulation and the drying air conditions. Future work should look to establish a possible relationship between the surface glass transition temperature and the probe tack test stickiness measurements. The impact and spreading of droplets containing maltodextrin DE5 on to solid anhydrous milkfat was studied using a high speed video camera. It was found that the final spread diameter was able to be fixed close to the maximum spread diameter by using surfactants, thus avoiding significant recoil. Because existing literature focuses on predicting the maximum spread diameter, this work defines a need for adequate prediction methods for the final spread diameter, as this is the significant parameter in coating applications. Formulation and operating guidelines were established to independently optimise each micro-level process. These were used in a series of population based coating experiments in a pilot-scale Würster coater. This study highlighted the limited flexibility of the standard 'off-the-shelf' Würster coating apparatus for the coating of fine sized dairy powders. Because of this, the validation of the guidelines were inconclusive and optimisation could not be carried out. Further validation work is required on a custom-built apparatus for dairy powders. This work has advanced the fundamental knowledge of the coating process and is independent of material, equipment and scale. This knowledge, based on physical and chemical mechanisms, can be used to develop coating formulations and identify optimum process conditions for successful coating in less time and at less expense than is current practice. The next step is to put the guidelines into practice and craft the engineering of a continuous coating apparatus for dairy powder applications.

En raison de leur Tf très élevée, les polyamides ne sont pas exploités comme revêtements poudre UV. Dans ce travail, de nouveaux revêtements poudre UV, à base de copolyamides de type AA,BB/ AB, de faible masse molaire et porteurs de groupements réactifs sous UV, ont été élaborés en vue d’une application sur supports sensibles aux hautes températures. En variant la composition relative en co-monomères dérivés d’acides gras(synthétisé ou commerciaux) et la teneur en ramifications et doubles liaisons carbone-carbone,des copolyamides renfermant de 63 à 100% de carbone biosourcé, présentant des Tg de -31 à 3°C et des Tf de 60 à 143°C, ont été développés. L’irradiation sous UV d’un copolyamide linéaire (Tf = 114°C) et de son analogue ramifié (Tf = 96°C), en présence de benzophénone et à T≥Tf, a permis de trouver un bon compromis entre la perte de cristallinité et la réticulation. En effet, les revêtements obtenus ont montré des propriétés très intéressantes pour l’application visée. / Because of their high melting temperature, polyamides are not employed in the UV powder field. In this work, powder coatings based on novel biosourced AA,BB/AB type copolyamides, exhibiting low molecular weights and bearing photocurable groups, were elaborated for application on heat sensitive substrates. By varying the co-monomers (synthesized or commercially available) relative composition as well as the dangling chain and the carbon-carbon double bond amounts, copolyamides with biosourced carbon ranging from 63 to 100%, glass transition temperatures ranging from -31 to 3°C and melting temperatures ranging from 60 to 143°C were obtained. The UV irradiation of a linear copolyamide (Tf = 114°C) and of its branched analogue (Tf = 96°C), at T≥Tf, and in presence of benzophenone, has been the best solution to compensate the lost of cristallinity through photocrosslinking. Indeed, the obtained coatings exhibited very interesting properties for the expected application.