Preface xi
1. Introduction to Coatings 1
1.1 Definitions and Scope 1
1.2 Types of Coatings 3
1.3 Composition of Coatings 3
1.4 Coating History 4
1.5 Commercial Considerations 5
References 5
2. Polymerization and Film Formation 6
2.1 Polymers 6
2.2 Polymerization 13
2.3 Film Formation 19
References 27
3. Flow 29
3.1 Shear Flow 29
3.2 Types of Shear Flow 30
3.3 Determination of Shear Viscosity 32
3.4 Shear Viscosity of Resin Solutions 36
3.5 Viscosity of Liquids With Dispersed Phases 40
3.6 Other Modes of Flow 42
References 44
4. Mechanical Properties 46
4.1 Introduction 46
4.2 Basic Mechanical Properties 46
4.3 Fracture Mechanics 57
4.4 Abrasion, Scratch, and Mar Resistance 58
4.5 Measurement of Mechanical Properties 61
4.6 Tests of Coatings on Substrates 62
References 66
5. Exterior Durability 67
5.1 Photoinitiated Oxidative Degradation 67
5.2 Photostabilization 70
5.3 Degradation of Chlorinated Resins 75
5.4 Hydrolytic Degradation 75
5.5 Other Modes of Failure on Exterior Exposure 77
5.6 Testing for Exterior Durability 78
5.7 Service Life Prediction 84
References 84
6. Adhesion 86
6.1 Mechanisms of Adhesion 86
6.2 Mechanical Stresses and Adhesion 89
6.3 Adhesion to Metal Surfaces 90
6.4 Characterization of Surfaces 92
6.5 Organic Chemical Treatment of Substrates to Enhance Adhesion 93
6.6 Covalent Bonding to Glass and Metal Substrates 94
6.7 Adhesion to Plastics and to Coatings 95
6.8 Testing for Adhesion 96
References 98
7. Corrosion Protection by Coatings 99
7.1 Corrosion Basics 99
7.2 Corrosion of Uncoated Steel 100
7.3 Corrosion Protection of Metals 101
7.4 Corrosion Protection by Intact Coatings 103
7.5 Corrosion Protection by Nonintact Films 107
7.6 Evaluation and Testing 111
References 113
8. Acrylic Resins 115
8.1 Thermoplastic Acrylic Resins 115
8.2 Thermosetting Acrylic Resins 116
8.3 Water?Reducible Thermosetting Acrylic Resins 121
References 124
9. Latexes 125
9.1 Emulsion Polymerization 125
9.2 Acrylic Latexes 133
9.3 Vinyl Ester Latexes 135
9.4 Thermosetting Latexes 137
References 139
10. Polyester Resins 141
10.1 Hydroxy?Terminated Polyester Resins for Conventional Solids Coatings 142
10.2 Polyester Resins for High Solids Coatings 146
10.3 Carboxylic Acid?Terminated Polyester Resins 147
10.4 Carbamate?Functional Polyester Resins 148
10.5 Water?Reducible Polyester Resins 148
10.6 Polyester Resins for Powder Coatings 149
References 150
11. Amino Resins 151
11.1 Synthesis of Melamine–Formaldehyde Resins 151
11.2 Types of MF Resins 154
11.3 MF–Polyol Reactions in Coatings 155
11.4 Other Amino Resins 161
References 162
12. Polyurethanes and Polyisocyanates 163
12.1 Reactions of Isocyanates 164
12.2 Kinetics of Reactions of Isocyanates with Alcohols 165
12.3 Isocyanates Used in Coatings 170
12.4 Two?Package (2K) Solventborne Urethane Coatings 173
12.5 Blocked Isocyanates 176
12.6 Moisture?Curable Urethane Coatings 181
12.7 Waterborne Polyurethane Coatings 182
12.8 Hydroxy?Terminated Polyurethanes 185
References 186
13. Epoxy and Phenolic Resins 188
13.1 Epoxy Resins 188
13.2 Amine Cross?Linked Epoxy Resins 193
13.3 Other Cross?Linking Agents for Epoxy Resins 199
13.4 Water?Reducible Epoxy/Acrylic Graft Copolymers: Epoxy/Acrylic Hybrids 201
13.5 Epoxy Resin Phosphate Esters 202
13.6 Phenolic Resins 202
References 204
14. Drying Oils 205
14.1 Compositions of Natural Oils 205
14.2 Autoxidation and Cross?Linking 206
14.3 Synthetic and Modified Drying Oils 209
References 211
15. Alkyd Resins 213
15.1 Oxidizing Alkyds 214
15.2 High Solids Oxidizing Alkyds 217
15.3 Waterborne Oxidizing Alkyds 218
15.4 Nonoxidizing Alkyds 220
15.5 Synthetic Procedures for Alkyd Resins 220
15.6 Modified Alkyds 223
15.7 Uralkyds and Other Autoxidizable Urethanes 224
15.8 Epoxy Esters 225
References 226
16. Silicon Derivatives 228
16.1 Silicones 228
16.2 Reactive Silanes 232
16.3 Orthosilicates 233
References 234
17. Other Resins and Cross?Linkers 235
17.1 Halogenated Polymers 235
17.2 Cellulose Derivatives 237
17.3 Unsaturated Polyester Resins 238
17.4 (Meth)Acrylated Oligomers 240
17.5 2?Hydroxyalkylamide Cross?Linkers 240
17.6 Acetoacetate Cross?Linking Systems 241
17.7 Polyaziridine Cross?Linkers 242
17.8 Polycarbodiimide Cross?Linkers 242
17.9 Polycarbonates 243
17.10 Non?Isocyanate Two?Package Binders 243
17.11 Dihydrazides 244
References 244
18. Solvents 246
18.1 Solvent Composition 246
18.2 Solubility 247
18.3 Solvent Evaporation Rates 251
18.4 Viscosity Effects 257
18.5 Flammability 258
18.6 Other Physical Properties 259
18.7 Toxic Hazards 259
18.8 Atmospheric Photochemical Effects 260
18.9 Regulation of Solvent Emissions from Coatings 262
References 265
19. Color and Appearance 267
19.1 Light 267
19.2 Light–Object Interactions 268
19.3 Hiding 274
19.4 Metallic and Interference Colors 275
19.5 The Observer 276
19.6 Interactions of Light Source, Object, and Observer 277
19.7 Color Systems 277
19.8 Color Mixing 281
19.9 Color Matching 281
19.10 Gloss 286
References 292
20. Pigments 293
20.1 White Pigments 293
20.2 Color Pigments 296
20.3 Inert Pigments 302
20.4 Functional Pigments 303
20.5 Nano?Pigments 304
References 305
21. Pigment Dispersion 307
21.1 Dispersion in Organic Media 307
21.2 Formulation of Nonaqueous Mill Bases 311
21.3 Dispersion in Aqueous Media 313
21.4 Dispersion Equipment and Processes 315
21.5 Evaluation of Dispersions 320
References 322
22. Effect of Pigments on Coating Properties 323
22.1 PVC and CPVC 323
22.2 Relationships Between Film Properties and PVC 326
References 330
23. Application Methods 331
23.1 Brushes, Pads, and Hand Rollers 331
23.2 Spray Application 332
23.3 Dip and Flow Coating 338
23.4 Roll Coating 339
23.5 Curtain Coating 340
References 341
24. Film Defects 342
24.1 Surface Tension 342
24.2 Leveling 344
24.3 Sagging and Drip Marks 346
24.4 Crawling, Cratering, and Related Defects 348
24.5 Floating and Flooding: Hammer Finishes 351
24.6 Wrinkling: Wrinkle Finishes 352
24.7 Bubbling and Popping 353
24.8 Foaming 354
24.9 Dirt 355
References 355
25. Solventborne and High Solids Coatings 357
25.1 Primers 358
25.2 Top Coats 360
References 365
26. Waterborne Coatings 366
26.1 Water?Reducible Coatings 367
26.2 Latex?based Coatings 369
26.3 Emulsion Coatings 371
References 372
27. Electrodeposition Coatings 374
27.1 Anionic Electrodeposition Coatings 375
27.2 Cationic Electrodeposition Coatings 376
27.3 Effect of Variables on Electrodeposition 378
27.4 Application of Electrodeposition Coatings 380
27.5 Advantages and Disadvantages of Electrodeposition 381
27.6 Autodeposition Coatings 383
References 383
28. Powder Coatings 385
28.1 Binders for Thermosetting Powder Coatings 385
28.2 Binders for Thermoplastic Powder Coatings 390
28.3 Formulation of Thermosetting Powder Coatings 391
28.4 Manufacture of Powder Coatings 394
28.5 Application Methods 396
28.6 Advantages and Limitations 400
References 401
29. Radiation Cure Coatings 403
29.1 UV Curing 404
29.2 Free Radical?Initiated UV Cure 406
29.3 Cationic UV Cure 412
29.4 Hybrid Free Radical/Cationic Polymerization 413
29.5 Effects of Pigmentation 414
29.6 Electron Beam Cure Coatings 415
29.7 Dual UV/Thermal Cure 415
29.8 Selected Applications 416
29.9 Advantages, Disadvantages, and Selected Advances 416
References 418
30. Product Coatings for Metal Substrates 419
30.1 OEM Automotive Coatings 419
30.2 Appliance Coatings 427
30.3 Container Coatings 427
30.4 Coil Coating 431
30.5 Coatings for Aircraft 435
References 436
31. Product Coatings for Nonmetallic Substrates 438
31.1 Coatings for Wood 438
31.2 Coating of Plastics 444
References 448
32. Architectural Coatings 449
32.1 Exterior House Paints and Primers 450
32.2 Flat and Semigloss Interior Paints 455
32.3 Gloss Enamels 459
References 463
33. Special Purpose Coatings 464
33.1 Maintenance Paints 464
33.2 Marine Coatings 471
33.3 Automobile Refinish Paints 474
33.4 Traffic Striping Paints 477
References 478
34. Functional Coatings 480
34.1 Superhydrophobic and Superhydrophilic Coatings 480
34.2 Ice?Phobic Coatings 483
34.3 Self?Healing Coatings 484
34.4 Environmentally Sensing Coatings 485
34.5 Antimicrobial Coatings 486
References 486
Index 488
