TEL Chen
1. Selecting the right materials is essential not only to meet functional requirements but also to reduce costs effectively. Choosing an inappropriate material can lead to either over-specification, where performance exceeds needs and causes unnecessary waste, or under-specification, which may result in poor performance or even failure of the product. Therefore, the demand side should fully recognize the importance of rational material selection and, if needed, consult with experts to ensure the best choice.
2. The selection of color-coated materials primarily involves considering mechanical properties, substrate type, coating weight, front coating performance, and reverse coating performance. Factors such as the intended use, environmental corrosivity, expected service life, durability, processing methods, and deformation levels play a crucial role in determining the most suitable material.
3. Selection of Mechanical Properties, Substrate Type, and Plating Weight
3.1 Mechanical properties are typically chosen based on the application, processing methods, and degree of deformation. For applications that do not require high strength or complex forming, TDC51D and TDC52D series color-coated steel sheets are appropriate. When good formability is required, TDC53D and TDC54D series should be used. For load-bearing components, structural steels like TS280GD and TS350GD are recommended. Common processing methods include shearing, bending, and rolling. It's important to note that during actual production, the mechanical properties of the base metal may change due to the coating process, and these changes can affect the forming behavior of the sheet, potentially leading to defects like wrinkles or cracks. These factors must be carefully considered during material selection.
3.2 The choice of substrate type and plating weight depends on the environment’s corrosiveness, desired service life, and durability. Corrosion resistance is one of the main functions of color-coated panels. Hot-dip galvanized and hot-dip aluminum-zinc alloy substrates are commonly used for building applications due to their excellent corrosion resistance. The plating weight should be adjusted according to the severity of the environment—higher plating weights are necessary in more corrosive areas. Additionally, differences in corrosion resistance between various substrates should be taken into account during selection.
4. Selection of Front Coating Performance
4.1 The front coating performance includes aspects such as coating type, thickness, color, gloss, hardness, flexibility/adhesion, and durability. Each of these factors significantly influences the final performance and appearance of the coated panel.
4.2 Coating Type
4.2.1 Topcoat
Common topcoats include polyester, silicon-modified polyester, high-durability polyester, and polyvinylidene fluoride (PVDF). Polyester is widely used due to its moderate cost, good hardness, and flexibility. Silicon-modified polyesters offer better durability and color retention but have reduced flexibility. High-durability polyesters provide improved longevity at a higher cost. PVDF offers excellent weather resistance and flexibility but is more expensive and has fewer color options. The choice of topcoat should be based on the specific use, environmental conditions, and desired lifespan.
4.2.2 Primer
Epoxy, polyester, and polyurethane are common primer types. Epoxy provides strong adhesion and corrosion resistance, while polyester offers good flexibility. Polyurethane is known for its overall balanced performance. The primer is usually selected by the supplier based on the application, environment, and compatibility with the topcoat.
4.3 Coating Thickness
The thickness of the coating directly affects the corrosion resistance of the panel. Thicker coatings generally provide better protection. The appropriate thickness should be determined based on the environment’s corrosivity, expected service life, and other relevant factors.
4.4 Color Variation
Color variation can occur during production and use, influenced by factors such as production methods, color depth, exposure time, and environmental conditions. Both parties should negotiate to ensure consistent results.
4.5 Gloss Level
Gloss level is selected based on the application and user preferences. For example, building materials often use medium or low gloss, while household appliances may prefer high gloss.
4.6 Coating Hardness
Hardness refers to the coating's ability to resist scratches, abrasions, and impacts. It is critical for maintaining the appearance and integrity of the panel. The hardness should be chosen based on the intended use, processing methods, and storage conditions.
4.7 Flexibility/Adhesion
Flexibility and adhesion are closely related to the formability of the coated sheet. Materials with higher impact resistance and lower T-bend values are preferred for high-deformation applications.
4.8 Coating Durability
Durability is measured by how long the coating can maintain its performance. It is influenced by coating type, thickness, and environmental conditions. While atmospheric exposure tests are reliable, they are time-consuming and costly. Artificial aging tests, such as neutral salt spray and UV accelerated aging, are commonly used for practical evaluation. However, these tests may not fully replicate real-world conditions, so direct correlations between test results and actual service life are difficult to establish.
4.9 Additional Properties
In some cases, the coating may need to resist organic solvents, acids, alkalis, or pollution. Special attention should be given to these requirements to ensure the material meets all usage specifications.
5. Selection of Reverse Coating Performance
The reverse coating is typically chosen by the supplier based on the intended use and environment. In less corrosive environments, a single layer is usually sufficient for aesthetic purposes. If insulation materials are applied to the back, this should be specified during ordering. In highly corrosive environments, two layers are recommended to enhance protection.
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