Evaluation of characteristics for microwave-assisted polymer coating of the steel substrate
-
Praveen Kumar Loharkar
and
Asha Ingle
Abstract
Polymeric barrier coatings are one of the most sought-after methods for protecting metallic parts from corrosion and for ensuring a glossy appearance. In this work, pure polyester barrier coating was applied on a steel substrate using a microwave-assisted curing process with an experimental design based on L9 Taguchi orthogonal array. It included three key factors, viz. voltage, powder output from the spray gun and microwave power with three levels of each. The heat required for curing was achieved through electromagnetic-thermal energy conversion with the aid of a graphite susceptor. A multi-physics numerical study was carried out to identify the magnitude of temperature attained at different levels of microwave power and irradiation time. This was used to build the microwave curing set-up. The impact of parametric variation of the microwave-assisted process on the gloss was quantified. In addition, an assessment of dry film thickness, corrosion resistance, and impact strength was performed. Taguchi analysis reveals that out of three factors used, microwave power has the most significant impact on the gloss units. The desired level of impact strength was achieved for all samples, with the exception of the one coated with the factor combination of the least levels. Corrosion resistance for specimens was measured to be 240 h using a standard salt spray test. Specimen prepared with larger power input showed lesser blistering. The results substantiate the feasibility of a microwave-assisted process route for the industrial coating process.
Acknowledgments
The authors would like to thank M/s Manish Engineering Works, Aurangabad for providing the opportunity and resources to implement a microwave-assisted coating process at their facility.
-
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
-
Research funding: None declared.
-
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
References
1. Loharkar, P. K., Ingle, A. Microwave-assisted corrosion resistant pure polyester coating of cold rolled closed annealed steel. Mater. Today Proc. 2021, 44, 1676–1680. https://doi.org/10.1016/j.matpr.2020.11.839.Search in Google Scholar
2. Yong, Q., Chang, J., Liu, Q., Jiang, F., Wei, D., Li, H. Matt polyurethane coating: correlation of surface roughness on measurement length and gloss. Polymers 2020, 12, 326. https://doi.org/10.3390/polym12020326.Search in Google Scholar PubMed PubMed Central
3. Yang, Q., Ma, Y., Zhu, J., Chow, K., Shi, K. An update on electrostatic powder coating for pharmaceuticals. Particuology 2017, 31, 1–7. https://doi.org/10.1016/j.partic.2016.10.001.Search in Google Scholar
4. Wang, W., Zhao, C., Sun, J., Wang, X., Zhao, X., Mao, Y., Li, X., Song, Z. Quantitative measurement of energy utilization efficiency and study of influence factors in typical microwave heating process. Energy 2015, 87, 678–685. https://doi.org/10.1016/j.energy.2015.05.036.Search in Google Scholar
5. Loharkar, P. K., Ingle, A., Jhavar, S. Parametric review of microwave-based materials processing and its applications. J. Mater. Res. Technol. 2019, 8, 3306–3326. https://doi.org/10.1016/j.jmrt.2019.04.004.Search in Google Scholar
6. Mishra, R. R., Sharma, A. K. Microwave-material interaction phenomena: heating mechanisms, challenges and opportunities in material processing. Composer Part A Appl. Sci. Manuf. 2016, 81, 78–97. https://doi.org/10.1016/j.compositesa.2015.10.035.Search in Google Scholar
7. Maeng, H. Y., Lee, M. A study on the exploration of electrostatic powder coating materials suitable for 3D scanning. MATEC Web Conf. 2016, 40, 1–5. https://doi.org/10.1051/matecconf/20164001004.Search in Google Scholar
8. Mishra, R. R., Sharma, A. K. A review of research trends in microwave processing of metal-based materials and opportunities in microwave metal casting. Crit. Rev. Solid State Mater. Sci. 2016, 41, 217–255. https://doi.org/10.1080/10408436.2016.1142421.Search in Google Scholar
9. Singh, S., Gupta, D., Jain, V., Sharma, A. K. Microwave processing of materials and applications in manufacturing industries: a review. Mater. Manuf. Process. 2015, 30, 1–29. https://doi.org/10.1080/10426914.2014.952028.Search in Google Scholar
10. Wahed, M. A., Gupta, A. K., Gadi, V. S. R., Supradeepan, K., Singh, S. K., Kotkunde, N. Parameter optimisation in V-bending process at elevated temperatures to minimise spring back in Ti-6Al-4V alloy. Adv. Mater. Process. Technol. 2020, 6, 430–444. https://doi.org/10.1080/2374068X.2020.1728651.Search in Google Scholar
11. Gupta, D., Bhovi, P. M., Sharma, A. K., Dutta, S. Development and characterization of microwave composite cladding. J. Manuf. Process. 2012, 14, 243–249. https://doi.org/10.1016/j.jmapro.2012.05.007.Search in Google Scholar
12. Singhal, C., Murtaza, Q., Alam, P., Hasan, F. Structural and mechanical properties of microwave hybrid sintered aluminium silicon carbide composite. Adv. Mater. Process. Technol. 2019, 5, 559–567. https://doi.org/10.1080/2374068X.2019.1636188.Search in Google Scholar
13. Yahaya, B., Izman, S., Konneh, M., Redzuan, N. Microwave hybrid heating of materials using susceptors - a brief review. Adv. Mater. Res. 2013, 845, 426–430. https://doi.org/10.4028/www.scientific.net/AMR.845.426.Search in Google Scholar
14. Loharkar, P. K., Ingle, A. Numerical analysis of microwave heating: fundamentals and applications. IOP Conf. Ser. Mater. Sci. Eng. 2020, 810, 012061. https://doi.org/10.1088/1757-899X/810/1/012061.Search in Google Scholar
15. Mishra, R. R., Sharma, A. K. On melting characteristics of bulk Al-7039 alloy during in-situ microwave casting. Appl. Therm. Eng. 2017, 111, 660–675. https://doi.org/10.1016/j.applthermaleng.2016.09.122.Search in Google Scholar
© 2023 Walter de Gruyter GmbH, Berlin/Boston
Articles in the same Issue
- Frontmatter
- Editorial
- Editorial ICPCM 2021
- Original Papers
- Developing easy-to-use, cost-effective wound dressing material by coating commercial cotton bandages with nanomaterials
- Temperature and magnetic field controlled dielectric relaxation and magnetodielectric response in KBiFe1.9Co0.1O5 polycrystalline
- Influence of thermo-mechanical treatment in austenitic and ferritic field condition on microstructural and mechanical properties of reduced activation ferritic-martensitic steel
- Effect of nanoparticle on mechanical properties of activated tungsten gas welding of austenite stainless steel 316L and optimization of process parameters
- Flexural behavior of carbon/glass inter-ply hybrid FRP composites under elevated temperature environments
- Surfactant assisted single step electrodeposition of CuInSe2 thin films with rich indium selenide surface over layer
- Optimization of hot rolling parameters of CRNO steel with the aid of hot compression test and deformation map
- Reduced graphene oxide synthesis by dry planetary ball milling followed by arc plasma treatment of high pure graphite
- Influence of interphase characteristics on the elastic modulus of unidirectional glass-reinforced epoxy composites: a computational micromechanics study
- Investigation of dielectric, impedance, and magnetodielectric behavior in Bi5Ti3FeO15–Bi2Fe4O9 composites prepared by sol–gel modified method
- Effect of spheroidization annealing on low cycle fatigue (LCF) characteristics of cold forged steel components
- Growth of CuO nanoparticles using one step chemical bath deposition under microwave heating and their characterizations
- Phase formation and electrical properties study of PVDF thick films synthesized by solution casting method
- Generation of microchannels on PMMA using an in-house fabricated μ-ECDM system
- Temperature dependent constitutive plastic flow behaviour of titanium alloy Ti6Al4V
- Production and characterization of Al–Cu binary alloy produced by using novel continuous casting process
- Synthesis of Al–Sn alloys by direct chill casting under the effect of mechanical stirring: an experimental and simulation optimization study
- Evaluation of characteristics for microwave-assisted polymer coating of the steel substrate
- Synthesis and fabrication of acrylic acid treated rattan fiber epoxy composite
- Development of superhydrophobic hybrid silica-cellulose aerogel as promising thermal insulation and sound absorption
- Effect of thermal annealing on structure and magnetic properties in a Ni–Cr multilayer
- Effect of heat input on corrosion behavior of automotive zinc-coated steel joint
- Development of Al–SiC–TiO2 hybrid composite using powder metallurgy route and the influence of TiO2 content variation on microstructure and mechanical properties
- News
- DGM – Deutsche Gesellschaft für Materialkunde
Articles in the same Issue
- Frontmatter
- Editorial
- Editorial ICPCM 2021
- Original Papers
- Developing easy-to-use, cost-effective wound dressing material by coating commercial cotton bandages with nanomaterials
- Temperature and magnetic field controlled dielectric relaxation and magnetodielectric response in KBiFe1.9Co0.1O5 polycrystalline
- Influence of thermo-mechanical treatment in austenitic and ferritic field condition on microstructural and mechanical properties of reduced activation ferritic-martensitic steel
- Effect of nanoparticle on mechanical properties of activated tungsten gas welding of austenite stainless steel 316L and optimization of process parameters
- Flexural behavior of carbon/glass inter-ply hybrid FRP composites under elevated temperature environments
- Surfactant assisted single step electrodeposition of CuInSe2 thin films with rich indium selenide surface over layer
- Optimization of hot rolling parameters of CRNO steel with the aid of hot compression test and deformation map
- Reduced graphene oxide synthesis by dry planetary ball milling followed by arc plasma treatment of high pure graphite
- Influence of interphase characteristics on the elastic modulus of unidirectional glass-reinforced epoxy composites: a computational micromechanics study
- Investigation of dielectric, impedance, and magnetodielectric behavior in Bi5Ti3FeO15–Bi2Fe4O9 composites prepared by sol–gel modified method
- Effect of spheroidization annealing on low cycle fatigue (LCF) characteristics of cold forged steel components
- Growth of CuO nanoparticles using one step chemical bath deposition under microwave heating and their characterizations
- Phase formation and electrical properties study of PVDF thick films synthesized by solution casting method
- Generation of microchannels on PMMA using an in-house fabricated μ-ECDM system
- Temperature dependent constitutive plastic flow behaviour of titanium alloy Ti6Al4V
- Production and characterization of Al–Cu binary alloy produced by using novel continuous casting process
- Synthesis of Al–Sn alloys by direct chill casting under the effect of mechanical stirring: an experimental and simulation optimization study
- Evaluation of characteristics for microwave-assisted polymer coating of the steel substrate
- Synthesis and fabrication of acrylic acid treated rattan fiber epoxy composite
- Development of superhydrophobic hybrid silica-cellulose aerogel as promising thermal insulation and sound absorption
- Effect of thermal annealing on structure and magnetic properties in a Ni–Cr multilayer
- Effect of heat input on corrosion behavior of automotive zinc-coated steel joint
- Development of Al–SiC–TiO2 hybrid composite using powder metallurgy route and the influence of TiO2 content variation on microstructure and mechanical properties
- News
- DGM – Deutsche Gesellschaft für Materialkunde
