A Plethora of Finishes Reshape Possibilities for Fabricators and Designers
There are numerous methods available for painting metal. On-site, spray or brush applications are common; in factory settings, techniques such as spray painting, powder coating, or coil coating are utilized. For modern metal architecture, especially with products like metal composite materials, the coil coating process is preferred to achieve nearly flawless, long-lasting finishes.
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Coil coating involves a continuous process where a metal coil is coated before fabrication. The coil unwinds from an uncoiler, passes through a series of accumulators, gets processed and painted, and finally rewound on a recoiler. This process ensures a finished, cured product. Traditionally applied to aluminum, this technique can also be used on other metals like steel.
According to the National Coil Coating Association, prepainted metal maintains its appearance better over time compared to post-painted surfaces. The consistency achieved through rigorous quality control and continuous manufacturing provides cost benefits and eco-friendly outcomes, reducing waste and improving efficiency while capturing volatile organic compounds (VOCs).
Advanced Metal Paint Application Techniques
Traditional methods like spray systems, typically used for single-sheet batches, have evolved. Continuous coil coating processes now employ roll coating or die coating methods. Reverse roll coating, a common approach, uses two rolls in opposing directions. An applicator roll then applies the paint to the metal substrate, ensuring controlled paint thickness, though it risks "roping" marks.
Die coating, however, affords even greater control and precision. This method applies paint through a slot die extrusion system, achieving a seamless layer that minimizes waste and maximizes sustainability.
Evolution of Paint Systems: From Polyester and Urethane to Fluoropolymers
As industry demands have grown, paint systems have evolved beyond polyester and urethane options. Fluoropolymer paint systems, adhering to AAMA 2605 specifications, offer unparalleled weatherability and durability.
Polyvinylidene fluoride (PVDF), introduced in 1948, marked the first generation of fluoropolymer paints. Its formulation requires an acrylic resin, achieving optimal performance at a 70% PVDF and 30% acrylic ratio. Though PVDF is susceptible to remelt and offers limited color palettes, its durability is highly regarded.
In 1982, fluoroethylene-vinyl ether (FEVE) emerged as the second generation, featuring chemical cross-linking that prevents remelt under high conditions. FEVE, being a clear resin, enables vibrant finishes with gloss levels up to 70. Its resilience and color versatility have made it a game-changer in the market.
Thanks to advancements in coil coatings and paint systems, an extensive array of durable finishes is now available. Metal composite material (MCM) has further revolutionized architectural designs by offering lightweight, easily fabricated solutions without compromising aesthetics or structural integrity.
Jim Moses, Technical Services Manager at Mitsubishi Chemical Composites America's ALPOLIC MCM division, brings over four decades of experience in construction manufacturing, engineering, and operations.
This article was featured in Metal Construction News.
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Brushed aluminium sheets and mill finish sheets serve overlapping applications in areas like furniture, interior decor, and vehicles. However, brushed aluminium is typically more favored in these sectors. So, what sets them apart?
Surface Quality
Mill finish aluminum plates are prone to surface irregularities from casual handling, whereas brushed aluminum plates exhibit superior flatness and smoothness due to their refined production processes.
Decorative Appeal
Mill finish sheets display aluminum's natural gray tone, while brushed aluminum sheets offer a broader color range, achieved through the coating of colored aluminium coils, making them suitable for various aesthetic requirements, particularly in architectural exteriors.
Service Life
The protective coating on brushed aluminum enhances its durability, resulting in a longer service life compared to mill finish plates.
Processing Characteristics
Brushed sheets can be bent and cut to size, reducing waste and improving weather resistance, even in harsh conditions such as saline-alkali acid rain environments.
Price Considerations
Despite their advantages, brushed aluminum sheets are costlier. Therefore, selection should be based on your specific needs and budget constraints. Mill finish sheets can often be a more economical choice.
These distinctions between brushed and mill finish aluminum sheets aim to help you make an informed decision.
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