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A film applicator is a device used to evenly spread a substance, such as paint, ink, or cosmetics, over a substrate such as a drawdown card.
Applicators are usually metal bars that are manufactured to high tolerances to give consistent, repeatable results. Each bar will give a "theoretical wet film thickness" or, in other words, the thickness of the coating that should remain on the drawdown card after application. Even with high manufacturing tolerances, the actual wet film thickness can vary from 50% to 90% of the gap.
There are multiple types of bar applicators, their forms and uses are shown below. Film applicators follow the ASTM standard D823. [1] Applicators can be used either manually or automatically.
When using an applicator manually, small variations in speed and applied pressure are inevitable. These variations can affect the quality of the drawdown and thus the measurements of film properties such as abrasion resistance, hiding power and gloss.
The use of an automatic film applicator guarantees consistent speed and pressure, providing repeatable and high quality results.
Automatic film applicators vary in their construction. The most modern types of applicators use vacuum plates to hold the drawdown cards and allow a variety of application bars to be mounted. The speed and pressure of the bar can be adjusted to allow for customization of the final film thickness. The drawdown process is governed by ASTM standard D823. [1]
Used for high viscous coatings, this type of applicator has four different clearances built in, one on each horizontal surface.
Used for low viscous coatings, this applicator also has four different clearances built in. It is used for non-rigid substances and has a two sided opening in the center of the bar.
This applicator has one, two or four clearances and contains a slanted trailing edge, also used for high viscous coatings. This is the most common type of film applicator.
This is a wire wound bar at each end, the gap height is controlled by the wire diameter, very simple and very cost effective.
This applicator also has two clearances but features a U-shaped form instead of a straight bar.
The square applicator is the more versatile than previously mentioned applicators. It has 8 clearances in the form of a square frame. This tool combines the accuracy of fixed applicators with the versatility of adjustable applicators.
This adjustable applicator has a metal frame with an adjustable "knife" that acts as the gap clearance. These applicators are the most versatile manual applicator, but is also the least precise.
These applicators differ from the bar applicators as they consist of a metal rod wound with wire of varying thickness. The coating will pass through the gaps between the wires and level off at a uniform thickness. There are two main types of wire bars. Close wire wound bars will produce coating layers from 4 to 120μm. Higher coating thickness up to 500μm can be obtained using open wound bars.
A standard procedure for testing substances that are applied in a liquid form, and then dry to a solid film, is to create a controlled, standardized test film of the substance, usually on a standardized substrate, such as a metal, plastic or paper panel.
Paint is any pigmented liquid, liquefiable, or solid mastic composition that, after application to a substrate in a thin layer, converts to a solid film. It is most commonly used to protect, color, or provide texture to objects. Paint can be made or purchased in many colors—and in many different types, such as watercolor or synthetic. Paint is typically stored, sold, and applied as a liquid, but most types dry into a solid. Most paints are either oil-based or water-based and each have distinct characteristics. For one, it is illegal in most municipalities to discard oil based paint down household drains or sewers. Solvents for clean up are also different for water based paint than they are for oil based paint. Water-based paints and oil-based paints will cure differently based on the outside ambient temperature of the object being painted Usually the object being painted must be over 10 °C (50 °F), although some manufacturers of external paints/primers claim they can be applied when temperatures are as low as 2 °C (35 °F).
Electroplating is a process that uses an electric current to reduce dissolved metal cations so that they form a thin coherent metal coating on an electrode. The term is also used for electrical oxidation of anions on to a solid substrate, as in the formation of silver chloride on silver wire to make silver/silver-chloride electrodes. Electroplating is primarily used to change the surface properties of an object, but may also be used to build up thickness on undersized parts or to form objects by electroforming.
Fluid bearings are bearings in which the load is supported by a thin layer of rapidly moving pressurized liquid or gas between the bearing surfaces. Since there is no contact between the moving parts, there is no sliding friction, allowing fluid bearings to have lower friction, wear and vibration than many other types of bearings, it is possible for some such bearings to have near-zero wear if operated correctly.
Rebar, known when massed as reinforcing steel or reinforcement steel, is a steel bar or mesh of steel wires used as a tension device in reinforced concrete and reinforced masonry structures to strengthen and aid the concrete under tension. Concrete is strong under compression, but has weak tensile strength. Rebar significantly increases the tensile strength of the structure. Rebar's surface is often "deformed" with ribs, lugs or indentations to promote a better bond with the concrete and reduce the risk of slippage.
Cathodic protection (CP) is a technique used to control the corrosion of a metal surface by making it the cathode of an electrochemical cell. A simple method of protection connects the metal to be protected to a more easily corroded "sacrificial metal" to act as the anode. The sacrificial metal then corrodes instead of the protected metal. For structures such as long pipelines, where passive galvanic cathodic protection is not adequate, an external DC electrical power source is used to provide sufficient current.
Chrome plating, often referred to simply as chrome, is a technique of electroplating a thin layer of chromium onto a metal object. The chromed layer can be decorative, provide corrosion resistance, ease cleaning procedures, or increase surface hardness. Sometimes, a less expensive imitator of chrome may be used for aesthetic purposes.
A bandsaw is a power saw with a long, sharp blade consisting of a continuous band of toothed metal stretched between two or more wheels to cut material. They are used principally in woodworking, metalworking, and lumbering, but may cut a variety of materials. Advantages include uniform cutting action as a result of an evenly distributed tooth load, and the ability to cut irregular or curved shapes like a jigsaw. The minimum radius of a curve is determined by the width of the band and its kerf. Most bandsaws have two wheels rotating in the same plane, one of which is powered, although some may have three or four to distribute the load. The blade itself can come in a variety of sizes and tooth pitches, which enables the machine to be highly versatile and able to cut a wide variety of materials including wood, metal and plastic.
Anodizing is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts.
A shim is a thin and often tapered or wedged piece of material, used to fill small gaps or spaces between objects. Shims are typically used in order to support, adjust for better fit, or provide a level surface. Shims may also be used as spacers to fill gaps between parts subject to wear.
A coating is a covering that is applied to the surface of an object, usually referred to as the substrate. The purpose of applying the coating may be decorative, functional, or both. The coating itself may be an all-over coating, completely covering the substrate, or it may only cover parts of the substrate. An example of all of these types of coating is a product label on many drinks bottles- one side has an all-over functional coating and the other side has one or more decorative coatings in an appropriate pattern to form the words and images.
Electrical tape is a type of pressure-sensitive tape used to insulate electrical wires and other materials that conduct electricity. It can be made of many plastics, but vinyl is most popular, as it stretches well and gives an effective and long lasting insulation. Electrical tape for class H insulation is made of fiberglass cloth.
Conformal coating material is a thin polymeric film which conforms to the contours of a printed circuit board to protect the board's components. Typically applied at 25-250 μm(micrometers) thickness, it is applied to electronic circuitry to protect against moisture, dust, chemicals, and temperature extremes.
Electroless nickel plating is a chemical process that deposits an even layer of nickel-phosphorus or nickel-boron alloy on the surface of a solid substrate, like metal or plastic. The process involves dipping the substrate in a water solution containing nickel salt and a suitable reducing agent.
Geotechnical investigations are performed by geotechnical engineers or engineering geologists to obtain information on the physical properties of soil earthworks and foundations for proposed structures and for repair of distress to earthworks and structures caused by subsurface conditions. This type of investigation is called a site investigation. Additionally, geotechnical investigations are also used to measure the thermal resistivity of soils or backfill materials required for underground transmission lines, oil and gas pipelines, radioactive waste disposal, and solar thermal storage facilities. A geotechnical investigation will include surface exploration and subsurface exploration of a site. Sometimes, geophysical methods are used to obtain data about sites. Subsurface exploration usually involves soil sampling and laboratory tests of the soil samples retrieved.
Aluminium conductor steel-reinforced cable (ACSR) is a type of high-capacity, high-strength stranded conductor typically used in overhead power lines. The outer strands are high-purity aluminium, chosen for its good conductivity, low weight and low cost. The center strand is steel for additional strength to help support the weight of the conductor. Steel is higher strength than aluminium which allows for increased mechanical tension to be applied on the conductor. Steel also has lower elastic and inelastic deformation due to mechanical loading as well as a lower coefficient of thermal expansion under current loading. These properties allow ACSR to sag significantly less than all-aluminium conductors. As per the International Electrotechnical Commission (IEC) and The CSA Group naming convention, ACSR is designated A1/S1A.
Paint and other coatings that are on slanted or vertical surfaces tend to sag when first applied. The thickness of the coating as well as the composition and viscosity will affect the overall sagging and conversely the sag resistance. In order to find the sag resistance of a coating a simple test is used. A metal applicator bar is used along with a Drawdown card.
Drawdown charts are rectangular pieces of non-fluorescent paper which are used to test a variety of coating properties. These properties include opacity, spreading rate, penetration, and flow & leveling behavior. This non-fluorescent material has to be especially rugged in order to maintain its structure and give reliable readings, as the coatings tested are often corrosive or abrasive. These charts are necessary in the testing of any coating as they give reliable and accurate readings for any type of coating before the coating is applied to the intended material.
Pressure-sensitive tape, known also in various countries as PSA tape, adhesive tape, self-stick tape, sticky tape, Sellotape, or just tape, is an adhesive tape that will stick with application of pressure, without the need for a solvent or heat for activation. It can be used in the home, office, industry, and institutions for a wide variety of purposes.
A die in polymer processing is a metal restrictor or channel capable of providing a constant cross sectional profile to a stream of liquid polymer. This allows for continuous processing of shapes such as sheets, films, pipes, rods, and other more complex profiles. This is a continuous process, allowing for constant production, as opposed to a sequential (non-constant) process such as injection molding.