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Industrial coatings are barriers that are typically sprayed and fused to a substrate, yet they still offer the same benefits of a traditional film. Industrial coatings are differentiated from other types of aesthetic coatings in that they are designed to protect a substrate from its environment. Industrial coatings are commonly applied to protect steel or concrete from corrosion, but often times high performance coatings are used to enhance and improve the properties for Release, Non-Stick, Low Friction, Abrasion and Wear Resistance, Corrosion Resistance, Lubrication, Galling, Noise Reduction, High Temperature and electrical insulation.

High performance coatings can be applied to steel and steel alloys, aluminum, brass, magnesium, glass, fiberglass, and even some types of rubber. Most high performance coating “systems” require that the substrate being coated be roughened (typically sand or bead blasted), pre-heated, a primer applied, and then topcoats that are fused at high temperature.

The benefits of traditional coatings can be enhanced by certain additives. For instance, the addition of ceramics increases both abrasion and thermal properties of coatings, while the addition of Carbon enhances the conductivity of a coating.

Types of High Performance Coatings:

FLUOROPOLYMER COATINGS:
Fluoropolymer coatings offer all of the benefits of traditional fluoropolymer films in an extremely thin conformal “Skin”

NON-STICK / RELEASE: Most substances do not stick to fluoropolymer coatings making clean up very easy.

LOW COEFFICIENT OF FRICTION: Fluoropolymers have a low coefficient of friction, and are used when sliding is required between coated parts.

NON-WETTING: Fluoropolymer coatings are hydrophobic and as a result, do not “Wet” In many cases FEP and PFA are used in applications where self cleaning is required.

WIDE THERMAL OPERATING RANGE: PTFE, FEP, and PFA fluoropolymer coatings have a continuous operating temperatures of over 400 degrees F, and will operate successfully at cryogenic temps as well (-450 deg F).

ELECTRICAL INSULATION: Fluoropolymers have very high dielectric strength and a low dissipation factor and make excellect electrical insulators when applied in a continuous coating. The quality of the coating application has a direct reflection on the coatings electrical insulation properties….If the coating is not continuous (Pinhole free) then the electrical properties will not be of any use. Most companies have methods for testing for pinhles, and one should make sure they specify “continuous, or Pinhole free” when they order coatings for electrical insulation.

CHEMICAL RESISTANCE Thermoplastic Fluoropolymer coatings (FEP, PFA, ETFE) are often used for chemical resistance when continuous exposure to harsh chemicals is required. Exposure to alkali metals is not recommended for fluoropolymer coatings.

PTFE:
PTFE (polytetrafluoroethylene) nonstick coatings are two-coat (primer/topcoat) systems. These products have the highest operating temperature of any fluoropolymer (260°C/500°F), an extremely low coefficient of friction, good abrasion resistance, and good chemical resistance. PTFE is available only in water-based liquid form. Depending on the supplier, PTFE coatings are bio-compatible. They are also available in a handful of colors.

FEP:
FEP (fluorinated ethylene propylene copolymer) nonstick coatings melt and flow during baking to provide nonporous films. These coatings provide excellent chemical resistance. In addition to low friction, FEP coatings have excellent nonstick properties. Maximum use temperature is 204°C/400°F. FEP is available in water-based liquid and powder forms.

PFA:
Like FEP, PFA (perfluoroalkoxy) nonstick coatings melt and flow during baking to provide nonporous films. PFA offers the additional benefits of higher continuous use temperature (260°C/500°F), film thicknesses up to 1,000 micrometers (40 mils), and greater toughness than PTFE or FEP. PFA is an excellent choice for a wide variety of uses, especially those involving chemical resistance and release. PFA is available in both water-based liquid and powder forms. When used as a top coat over


ETFE:
ETFE is a copolymer of ethylene and tetrafluoroethylene and is also sold under the Tefzel® trademark. Although not fully fluorinated, ETFE has excellent chemical resistance and can operate continuously at 149°C/300°F. This resin is the toughest of the fluoropolymers and can be applied at film builds up to 1,000 micrometers (40 mils) to provide a highly durable finish. ETFE is available in powder form.

TEFLON-S®: Is a coating that was developed by DuPont that has increased hardness and better abrasion resistance. When combined with an FEP ort PFA top coat, one gets the benefits of release as well. This system is very durable.