Effect of Powder Particle Size and Charging Efficiency on Film Build and Surface Finish
Keywords
Abstract
Powder coating, a solvent-free technique, is influenced heavily by powder particle size and electrostatic charging efficiency. This study investigates how these two factors affect film build and surface finish using epoxy-polyester hybrid powders categorized into fine (<20 µm), medium (20–40 µm), and coarse (>40 µm) sizes. Coatings were applied to steel panels using a corona-type spray gun under consistent voltage and flow conditions. Post-application, panels were cured and evaluated for film thickness and surface roughness. Fine powders yielded the smoothest surface (Ra = 0.8 µm) but had the lowest film build (35 µm) due to reduced charging efficiency (55%). Coarse powders achieved higher film build (65 µm) but resulted in rougher finishes (Ra = 2.0 µm). Medium particles offered a balanced performance with adequate surface finish (Ra = 1.2 µm) and film build (50 µm). Charging efficiency increased with particle size, highlighting the trade-off between deposition and surface quality. This study suggests that optimizing powder distribution and charging parameters can significantly enhance coating outcomes.
Copyright & License
Copyright © 2025 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0/) which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Cite this Article
Mr. Swapnil Sanju Bhalerao, Mr. Navnath Chandrakant Palve (2025). Effect of Powder Particle Size and Charging Efficiency on Film Build and Surface Finish. International Journal of Technology & Emerging Research (IJTER), 1(1), 32 - 34
BibTeX
@article{ijter2025212505136328,
author = {Mr. Swapnil Sanju Bhalerao and Mr. Navnath Chandrakant Palve},
title = {Effect of Powder Particle Size and Charging Efficiency on Film Build and Surface Finish},
journal = {International Journal of Technology & Emerging Research },
year = {2025},
volume = {1},
number = {1},
pages = {32 - 34},
issn = {3068-109X},
url = {https://www.ijter.org/article/212505136328/effect-of-powder-particle-size-and-charging-efficiency-on-film-build-and-surface-finish},
abstract = {Powder coating, a solvent-free technique, is influenced heavily by powder particle size and electrostatic charging efficiency. This study investigates how these two factors affect film build and surface finish using epoxy-polyester hybrid powders categorized into fine (<20 µm), medium (20–40 µm), and coarse (>40 µm) sizes. Coatings were applied to steel panels using a corona-type spray gun under consistent voltage and flow conditions. Post-application, panels were cured and evaluated for film thickness and surface roughness. Fine powders yielded the smoothest surface (Ra = 0.8 µm) but had the lowest film build (35 µm) due to reduced charging efficiency (55%). Coarse powders achieved higher film build (65 µm) but resulted in rougher finishes (Ra = 2.0 µm). Medium particles offered a balanced performance with adequate surface finish (Ra = 1.2 µm) and film build (50 µm). Charging efficiency increased with particle size, highlighting the trade-off between deposition and surface quality. This study suggests that optimizing powder distribution and charging parameters can significantly enhance coating outcomes.},
keywords = {Powder coating, Particle size, Electrostatic charging, Film build, Surface roughness, Epoxy-polyester},
month = {May},
}