This manual is designed to assist the applicator with industry trends and best practices. The information included provides a summation of known technology and processing techniques that are used in liquid finishing. It contains the fundamental information needed to operate a liquid coating system and efficiently manage this process, with emphasis on the practical issues that affect the daily operation.

The information included will prove useful to those new to liquid coatings as well as those already experienced with liquid paint application. This manual can be used for training purposes as well as a reference.  

Discount pricing is available for orders of 10 or more handbooks (15% discount).  Please contact CCAI at 859-356-1030 to purchase at the quantity discount pricing.

TABLE OF CONTENTS

Chapter 1        INTRODUCTION TO LIQUID COATINGS

• Paints Classifications
• Liquid Application Overview

Chapter 2         SUBSTRATE MATERIAL

• Metal Substrates
• Non-Ferrous Substrates

Chapter 3         LIQUID ORGANIC COATINGS

• Coating Selection
• Paint Classifications
• Liquid Coating Preparation

Chapter 4         FORMULATING LIQUID COATINGS

• Resins
• Pigments
• Extender Pigments
• Solvents
• Additives

Chapter 5         THE ART OF FORMULATING LIQUID COATINGS

• Appearance
• Color, Gloss and Texture
• Hiding and Coverage
• Viscosity

Chapter 6         LIQUID FILM BUILDS

• Film Build Measurement
• Percent Solids
• Coverage and Mileage

Chapter 7         PAINT MANUFACTURING PROCESS

Chapter 8         TESTING LIQUID PAINTS

• Wet Test Methods
• Dry Test Methods
• Test Panels

Chapter 9         PAINT LINE OVERVIEW

• Conveyors
• Pretreatment
• Liquid Application
• Cure

Chapter 10      CONVEYORS

• General Design
• Design Centers
• Drive Design
• Lubrication
• Preventive Maintenance and Inspection
• Sanitary Pan
• Inverted Box Track
• Power and Free Conveyors
• Friction Drive Conveyors
• Fixed Angle Friction Drive Wheel
• Trolleys
• Friction Belt Drive
• Control System for Finishing Application Conveyors

Chapter 11      CLEANING AND PRETREATMENT PRIOR TO LIQUID COATING

• Basics of Cleaning – Soils, Cleaners, and Cleaning Processes
• Phosphates and Non- or Low-Phosphorus Approaches
• Basics of Iron and Zinc Phosphatizing
• A Comparison of Iron and Zinc Phosphate Conversion Coatings
• Pretreatment Strategies for Multiple Metals
• Mixed Metal Pretreatment Strategies
• Aluminum Pretreatment
• Preparation of Plastics for Painting
• Structure of a Modern Automotive Paint System for Exterior Plastics

Chapter 12      PRETREATMENT WASH EQUIPMENT

• Typical Washer Processes
• Spray Washer Components
• Pretreatment Maintenance and Control

Chapter 13      INTRODUCTION TO LIQUID APPLICATION

Chapter 14      LIQUID COATING METHODS

• Coil Coating
• Air Spray Application
• Spray Patterns, Controls, and Adjustments
• Spray Gun Cleaning & Maintenance
• Airless & Air Assisted Spray Guns
• Electrostatic Application
• Robotic Liquid Application
• High Speed Bell Atomization Systems

Chapter 15      LIQUID SPRAY BOOTHS

• Fundamental Design Considerations
• Spray Booth Sizing
• Air Flow Design
• Spray Booth Exhaust Sizing
• Overspray Recovery

Chapter 16      AIR MANAGEMENT

• Air Control Equipment
• Air Filter Operation
• Air Pressure Regulators
• Supply Air, Filtration & Installation
• Air Supply Moisture
• Air Pressure and Volume

Chapter 17      WET ON WET APPLICATION PROCESS

• Process Overview
• Flash Times – Flash Zones
• Advantages and Disadvantages

Chapter 18      TRANSFER EFFICIENCY

• Spray Techniques
• Troubleshooting Air Atomizing Spray Guns

Chapter 19      AUTOMATIC APPLICATION EQUIPMENT

• Types of Automatic Application Equipment
• Automatic Spray Equipment for Moldings
• Automatic Equipment Operation
• Automatic Equipment Limitations
• Automatic Equipment Controls

Chapter 20      FLUID DELIVERY SYSTEMS (FDS)

• Methods for Feeding Material to Spray Gun
• Circulating Systems
• Plural Component Mixing Equipment

Chapter 21      CATALYSTS IN LIQUID INDUSTRIAL FINISHES

• Types of Catalysts
• Acid Catalysts for Melamine Baking
• Metal Catalysts for Urethanes
• Siloxane Crosslinking
• Driers for Air Dry Oxidation Polymerization

Chapter 22      OVENS AND CURING EQUIPMENT

• Convection
• Infrared
• Convection/IR combination
• Ultraviolet
• Low Cure Coatings
• Oven Profiling
• Convection Oven Construction
• Dry Off/Cure/Combination Ovens

Chapter 23      HOOKS, RACKING AND PART TRANSPORTATION

Chapter 24      MASKING

• What are Masks?
• Different Types of Masks
• Resolving Common Issues with Masking
• How to Clean Masking for Reuse

Chapter 25      APPLICATION PROCESS CONTROL FOR A QUALITY FINISH

• Process Control
• Paint Material
• Paint Application
• Flash-Off
• Curing
• Record Keeping

Chapter 26      PREVENTATIVE MAINTENANCE OF A LIQUID LINE

• Types of Maintenance Plans Devising a Preventative Maintenance Plan
• Preventative Maintenance of a Typical System

Chapter 27      DEFECT ANALYSIS & TROUBLESHOOTING LIQUID PAINT FINISHES

• Paint Film Defects & Wear-Out
• Production Defects Causes of Dirt
• Basic Rules for Avoiding Finishing Problems

Chapter 28      LIQUID COATINGS REMOVAL AND RE-WORK

• Methods of Coating Removal
• Selection of Coating Removal Method
• Repair of Cured Liquid Coating Defects
• Part Stripping Methods

Chapter 29      SPOT REPAIR & SURFACE FINESSING

• Introduction
• Spot Repair Methods Cosmetic Finessing of Surface Defects
• Summary

Chapter 30     ENVIRONMENTAL REGULATIONS & CONSIDERATIONS FOR A
LIQUID FINISHING SYSTEM

• Air Rules
• Employee Health and Safety
• Hazardous and Non- Hazardous Wastes
• Pretreatment and Cleaning
• Best Practices and Recommendations

APPENDIX I    CALCULATING & CONTROLLING LIQUID PAINT OPERATIONAL COSTS

APPENDIX II   UNDERSTANDING SUBSTRATE COMPOSITION 291 GLOSSARY OF TERMS