Flash IR pre-curing of the decorative layer in metal-flake powder coatings

Metal-flake powder coatings are a special class of metallic paint finishes composed of two superimposed layers: a pigmented decorative base coat and an overlaying transparent protective top coat. In the present investigation, a novel curing procedure for such bilayer coatings is proposed. Flash IR pre-curing of the base coat promotes the formation of a surface diffusion barrier and limits movement of the decorative pigments and metal flakes around their initial positions. Oven baking after deposition of the top coat then completes curing of the bilayer coating. The influence of the IR intensity and irradiation time on the final properties of bilayer coatings was investigated. The visual appearance, surface morphology and scratch resistance were evaluated. Experimental findings revealed that the hybrid IR/oven baking curing procedure is a viable method for obtaining bilayer powder coatings with outstanding properties in a shorter processing time and with considerable energy savings. © 2011 Elsevier B.V.