The Whitford

Engineering Design Guide

High-performance fluoropolymer coatings:
What they are,
how they function and
how to use them
to your best advantage

Makers of the world’s largest, most complete line of fluoropolymer coatings

 The purpose of this publication

Every day, one way or another, we at Whitford learn a little bit more about the
surprisingly complicated business of designing and making fluoropolymer coat-
ings perform to their maximum ability.
Typically, much of what we have learned comes from our mistakes.
It occurred to us that the information we have accumulated (and indeed
continue to accumulate as we learn) might prove as helpful to our customers as
it has to us. It is for that reason that we have assembled some of our basic
knowledge into this brochure.
We hope it will have been worth the effort.
The information included has many sources. Perhaps the most fruitful has
been the practical experience that comes from Whitford’s more than three
decades of working with and learning about these remarkable materials.
Some of the statements presented are the result of long and painstaking lab-
oratory tests and analyses, even if presented with the dogmatism of brevity.
Others are based on experimental work with specific products. Still others
are the opinions of people who have broad and deep experience in the field of
fluoropolymer coatings and are offered as the best recommendations under the
circumstances.
We invite you to read this document with some care.
We ask you to test your imagination as to how a coating might minimize —
or even eliminate — a design problem you’re facing.
Think of problems caused by friction, poor release, corrosion, wear, noise.
Think of other design and engineering problems for which a fluoropolymer coat-
ing may never have been tested.
You may join the growing list of designers and engineers who have opened
their minds to the surprising versatility of high-performance coatings — and
solved some difficult problems in the process.
If so, the purpose of this brochure will have been realized.

Activ8, Passiv8, Dykor, Eclipse, EterniTex, Excalibur, QuanTanium, Quantum, Quantum2,

RainCheck, Ravlex, SoilCheck, StainCheck, Suave, Superglide, Texcel, Ultralon, Whitford, Xylan,
Xylac, and Xylar are registered trademarks of the Whitford group of companies.
 What you’ll find

Chapter 1: The surprising success of high-performance coatings . . . . . . . . . . . . . 2

A. New options for designers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Components of Xylan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 2: High-performance coatings at work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A. Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Nonstick (release) properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
D. Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E. Noise reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F Temperature extremes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
G. Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
H. Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Chapter 3: Solving problems with Xylan coatings . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 4: Whitford primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 5: Applying Xylan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. Substrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C. Application techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
D. Flashing and curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
E. Surface considerations for maximum wear resistance . . . . . . . . . . . . . . . . . . . . . 22
F. Special cure and postcure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
G. Additional considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 6: Whitford flexible finishes and the automotive industry . . . . . . . . . . . . 25
Chapter 7: Whitford coatings and the textile industry . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 8: Calculating the real cost of a coating . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 9: Protecting the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Chapter 10: Whitford’s wide range of other products . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 11: Polymeric Systems, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 12: A word from our sponsor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Index and glossary (and more information). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1
 1. The surprising success of high-performance coatings
A. New options for designers coatings, “building” a coating to protect the soft
fluoropolymer from wear while taking advantage
High-performance fluoropolymer coatings of its low-friction property. On this concept,
are remarkable low-friction, dry-lubricant materi- Whitford was founded and Xylan fluoropolymer
als that combine the capabilities of two types of coatings became a reality.
“engineering plastics”. Fluoropolymers, with the
lowest coefficient of friction of any known solid, The first significant order for Xylan was for a
are combined with high-temperature organic brake adjustment mechanism for GM cars. This
polymers to provide a unique and highly versa- was followed by other applications: saw blades,
tile combination of properties. viscous fan drives, journal bearings, switch
detents, carburetor shafts, steam valve plugs, oil
These tough lubricating coatings can oper-
rig fasteners. The list grew quickly.
ate successfully at temperature extremes which,
at the low end, would render ordinary fluid lubri- Note: The full range of Xylan coatings has
cants too high in viscosity and, at the high end, become so extensive that properties vary widely.
would char them to ash. The coatings referred to in this brochure are
principally those designed for industrial applica-
Originally, low-friction solids were used for
tions, and the bulk of the data refers to them.
applications where sliding parts were heavily
loaded, infrequently lubricated or operated at Over the years, these self-lubricating materi-
high temperatures. This has been true since the als have been used to solve a growing range of
inception of dry lubricants, when ancient me- engineering and design problems.
chanics used graphite, talc, mica and other Today, Xylan is the largest, most complete
“slick” powders to reduce sliding friction. line of fluoropolymer coatings in the world. As
But, with the development of modern lubri- the materials have been tried on an ever-widen-
cating coatings, other properties have been ing spectrum of applications, we have learned a
designed in — including outstanding corrosion few things. For instance:
resistance. Today, when mechanical parts oper-
• A bonded, self-lubricating coating can last
ate under any of the above conditions, dry film
longer than hard chrome plating in certain high-
lubricants are often the only sensible, safe and
wear applications.
economical way to lubricate and protect them.
• Xylan can cut the cost of some pistons,
In the past, the only materials recognized as
dry lubricants for such applications were gra- plungers and splines by eliminating polishing
phite and molybdenum disulfide (MoS2 or Moly) and lapping processes.
or blends of both. While useful, these materials • Xylan can replace heavy metal platings on
solved only a limited range of problems. Moly engine journal bearings.
coatings were typically used in high-pressure
• Xylan can replace plating on hydraulic
applications; graphite coatings were generally
pistons and extend their lives in corrosive envi-
used in wet service or at elevated temperatures.
ronments.
Enter the matrix
Today’s fluoropolymer coatings are the result
B. Components of Xylan
of design engineering done several decades ago. The Xylan coating matrix is composed of
The first fluoropolymer coatings were rela- three basic ingredients:
tively soft films, the kind found on frying pans • A polymer binder for film strength, adhesion
and a few nonstick applications in industry. and protection of the softer lubricating particles.
Then, in 1969, a team of polymer chemists • A solid lubricant for low friction, release
and engineers devised the matrix concept for and resistance to wear.
2
 • Pigments, fillers and reinforcements for more than three decades, this binder is still
color and additional properties such as hardness. widely used for industrial applications in which
With the exception of Whitford’s Dykor pow- its superior properties and flexible cure sched-
ders, all materials are suspended in solvent or ule make it very adaptable. This class of binder
water, providing a compatible carrier so that, is found in the 1000, 1600, 1700 and 8110
together, they may be applied by conventional Series of Xylan coatings. (Ask for Whitford’s
“Introduction to the Xylan 1000 Series”.)
techniques such as spraying, dip/spinning, roller
coating, tumble coating, coil coating, curtain Another rugged polymer employed as a
coating, etc. binder in Xylan is a high-temperature-stable
thermoplastic. It is extremely resistant to abra-
The result is thin, continuous, protective film
sion and chemicals, and is a good choice for
barriers which resist chipping, spalling, abra-
components that operate in the presence of
sion, cold flow, temperature extremes, weather-
strong acids, bases or solvents. It is the binder
ing and a wide range of corrosive environments.
used in the Xylan 1300 and 8300 Series coatings.
Fluoropolymer-rich surface A third class of binder is a lower-temperature
Fluoropolymer and binder matrix thermoset. Although not as tough as some poly-
mers, it provides good corrosion protection, an
Molecular binder layer
exceptional array of colors, plus economy. It is
Substrate
a part of the Xylan 1400, 5200 and 5400 Series
coatings (used on fasteners and other industrial
hardware for corrosion protection).
2. Lubricants: Small particles of low-friction
materials such as polytetrafluoroethylene (PTFE),
molybdenum disulfide (Moly) and graphite, sus-
pended in the wear-resistant binder, reduce fric-
A matrix coating is one in which some soft tion at the surface. PTFE tends to be softer than
ingredients, such as the lubricant (PTFE), are the matrix, so when coated parts rub together,
enveloped in others (the matrix) such as harder, the lubricant smears along the surface of the
more wear-resistant binders.
coating and the mating surface, reducing friction.
If PTFE, for example, is used by itself (with-
out the matrix), and is exposed to a wear sur-
PTFE is most commonly used in Xylan be-
face, it quickly wears away. Combined with the cause it has the lowest coefficient of friction, is
matrix, however, the new structure solves the stable and effective at high and low tempera-
engineering problems as it protects itself. tures, and is inert to chemical attack. Also,
because of its low surface tension, it is an ex-
Matrix coatings are adjustable. The specific
properties of Xylan formulations depend on the cellent release agent.
materials used to form the total coating and their Other fluoropolymer lubricants include FEP
ratio to one another. By judicious selection of and PFA, which are less porous because of bet-
compounds, we can formulate a coating to have ter melt/flow characteristics, resulting in denser
superior release, wear resistance, chemical coatings that provide improved release. Both
resistance, high conductivity, etc.
have excellent nonstick and good low-friction
properties, and are stable in the presence of a
The basic elements wide range of solvents and corrosives.
1. Binders: Polymer binders hold the lubricat- Each fluoropolymer offers certain properties
ing particles and hard fillers in place and enable required in specific applications, such as FEP
them to adhere to a wide variety of substrates. for its release and PFA for its glass-like finish,
The coatings derive most of their corrosion and chemical resistance and ability to operate to
thermal characteristics from these materials. 260˚C/500˚F.
The first binder employed in Xylan was a Moly is preferred for high-load, low-speed
thermosetting alloy, which offers exceptional applications. It increases the load-bearing capa-
toughness and is stable to 315°C/600°F. After bility and the wear resistance of coatings that
3
are filled with other lubricants (notably PTFE).
Note: Encapsulating Moly in a matrix coating The 3 principal fluoropolymers
seems to eliminate its characteristic sensitivity to used in Xylan coatings
oxygen and moisture. That’s why Whitford uses
this lubricant in Xylan 1052 and 1425, which are PTFE (polytetrafluoroethylene): Has the low-
est coefficient of friction of any known solid and
designed for high-load applications.
is the fluoropolymer most widely used in coat-
Graphite is used for applications with tem- ings. It feels waxy to the touch. Also blends well
peratures in excess of 260°C/500°F, and in wet with engineering polymer binders. Is inert to
service at lower temperatures. Its drawback: a most chemicals and is approved for use in food
higher coefficient of friction than PTFE or Moly. applications.

3. Pigments/Fillers: Coatings are modified by FEP (fluorinated ethylene propylene): Has the
pigments and fillers to provide properties not best nonstick and non-wetting characteristics of
the three. It feels oily to the touch and lacks the
inherent in the primary ingredient, making them
high-temperature stability of PTFE. It is some-
harder, more corrosion-resistant or adding color.
what more resistant to corrosives than PTFE.
For example, Xylan can be made electrically Approved for use in food contact applications.
conductive by the addition of fillers such as car- Has excellent stability in waterborne coatings.
bon or metal particles.
PFA (perfluoroalkoxy): Has better release and
4. Carriers: Solid components of coatings are non-wetting properties than PTFE, but not quite
dissolved in solvent or suspended/emulsified in as good as FEP. Its wear characteristics are not
water, which enables them to be applied as a as good as PTFE. It has nearly the temperature
paint. The solvents used as carriers for Xylan capability of PTFE.
are chosen for ease of application, ease of
cleanup, economy and environmental safety. been achieved by Xylan:
Different application systems (conventional • First polymer coating to survive the rigors
air spray [siphon or gravity], electrostatic, HVLP, of internal diesel engine application on piston
airless, coil coating, curtain coating, dip/spin) skirts and journal bearings.
require different carrier combinations to achieve
optimum coating performance. For instance, • First tough PTFE coating with a flexible
conventional spray systems require relatively cure schedule (see chart, page 22). You can
slow (less volatile) carriers that enable coatings apply it to temperature-sensitive materials such
to level more uniformly on the substrate after as forged aluminum or tempered steel without
spraying. Other application techniques, such as reannealing the parts, or to many polymeric
dip/spin, may require fast (more volatile) carriers parts without thermally degrading and/or warp-
to “set” the coating film rapidly while parts are ing them, even to paper.
being processed. • First coating to be used by engine manu-
Because of the many formulation options facturers to achieve a boost in output power.
possible with Xylan matrix coatings, they can be • First coating to be used to dampen “piston
tailored to provide a wide and varied range of slap” and resultant wear in high-performance
properties — to solve different problems. If you motorcycle engines.
have unique requirements for lubricity, hardness, • First coating to be used as a dynamic seal
noise reduction, corrosion protection, environ- on air-conditioner rotor vanes.
mental compliance — even electrical conductivi-
ty or resistivity — these coatings may be modi- • First coating to achieve a wear rate equal
fied to meet your exact need. to bronze/steel bearings impregnated with PTFE-
Xylan “firsts” lead.
• First coating to replace cadmium and zinc
Whitford has frequently created special coat-
as a corrosion barrier on small fasteners.
ings to solve specific problems — leading to the
extensive range of Xylan coatings today. In this • First and only self-lubricating coating to be
process of solving problems, many “firsts” have used by NASA on a storage vault for moon rocks.
4
 2. High-performance coatings at work
rom the development of the first Xylan Xylan coatings are based on resin systems with

F product (1010), Whitford has modified the

basic formulation to solve specific problems.
This has led to new materials and combinations
a wide range of temperature capabilities, they
can be used from cryogenic levels to
260°C/500°F, with many being stable for brief
of materials so that, today, there are more than periods at 315°C/600°F.
3,000 different formulations of Xylan.
Where galling, abrasion, and high energy
Few products are as beneficial in so many loss due to friction are anticipated, consider
ways as the wide range of Xylan coatings. This applying coatings of 25 microns/0.001 inch or
very diversity, however, means that properties more to minimize friction and wear. (See page
can vary widely. 24 for this processing information.)
Xylan dry-film lubricants can solve numerous Potential applications include rotors for com-
problems, including friction/wear, corrosion, tem- pressors, air-cylinder pistons, hinges, sliding
perature extremes, sticking, vibration, galvanic bearings. The best coating choice is the one
activity, electrical insulation and conductivity. which provides the desired coefficient of friction
The selection of a coating depends on determin- and the maximum pressure/velocity (P/V) capa-
ing the problem of the application (wear, heat, bility (see sidebar, page 7).
corrosion, etc.) and matching it with the material
that most effectively solves the problem. Using a Xylan coating in a bearing cavity in
which a fluid lubricant is also used reduces fric-
A. Friction tion losses in the bearing to the lowest possible
Friction causes heat, wear and loss of ener- level because Xylan is oleophobic (it sheds oil).
gy in dynamic applications. In severe circum- During rotation, viscous shear forces within the
stances, friction can cause overheating and bearing are reduced slightly. Thus, instrument
seizure. bearings or other systems in which minimum
bearing friction is critical can benefit from a thin
Friction also causes brinelling, galling, scor-
ing, and underloading of fasteners. coating (7.5 microns/0.0003 inch).

Drive-line vibration and chatter result from Excessive friction is also detrimental to bolt-
friction. In these cases, stick/slip motion is usu- ed joints, in that much of the tightening torque is
ally the cause. This unstable sliding motion expended overcoming thread-to-thread and
occurs at very slow speeds, when friction bearing-face friction. In these situations, if the
increases above the force causing the move- bolt is not properly tensioned (preloaded), the
ment and motion stops, then drops below the joint can be unexpectedly weak in service.
moving force, at which point motion restarts. In addition, improperly fastened parts are
Deformation or destruction of delicate mech- subject to backout when vibration occurs.
anisms such as lock components can be Coating the threads reduces the makeup torque
caused by excessive friction. by as much as 65 percent.
Friction coefficients (measured by mating Because of its toughness and corrosion
surfaces rubbing against a coating) typically resistance, a PTFE-matrix in a thermosetting
vary from about 0.06 for PTFE materials to about binder is preferred for these applications.
0.15 for Moly coatings, although values as low
as 0.02 have been measured for some Xylan The oil embargo
coatings. The oil embargo of 1974 increased fuel costs
Xylan coatings are particularly useful when as much as 80 percent, catching America with
temperatures exceed the operating limits of con- cars that averaged 3.5 km per liter/13.3 mpg.
ventional mineral and synthetic oils. Because The situation for trucks was even worse.

5
 ed Xylan 1010 in the engine of a
Relationship of delivery unit, coating the pistons,
Load to Torque n bearings, connecting rods and crank-
yla shaft. Careful documentation proved
X
that, during 200,000 miles/322,000
km, the engine used almost 15 per-
x
Load / Wa cent less fuel.
d
increases Ca Over the past fifteen years,
il engine manufacturers have deter-
a ck/O mined that friction reduction has
Bl
resulted in increases in engine output
by as much as 16 percent.
In another example, a well known
manufacturer of diesel engines used
Torque increases Xylan instead of PTFE “buttons” on
piston skirts to reduce piston “slap”.
Other applications followed.
Whitford recommends the use of direct-tension indicators (DTI) to For viscous fan drives, a Xylan
determine proper make-up torque for each size or lot of fasteners coating proved to be the ideal way to
used on a given application. prevent the internal drive rotor from
The automotive industry responded by striking the drive housing. This elimi-
attacking the causes of inefficiency: weight, drag, nated the heat buildup that caused the drive
and friction. Weight and drag were reduced by fluid to gel.
successive generations of lighter and more
Many of the parking-brake actuators found
streamlined vehicles. Friction, however, was
on vehicles are
another matter, particularly on the internal com-
coated with Xylan
ponents of engines. Parts moving against each
— because it
other create friction. Even parts that are well
lubricated experience slight friction when sur- resists corrosion
face asperities (peaks) rub together (especially and the high
when an engine is started, or when it is cold). thread loads
(2,000 kg per
Previously, bonded dry-film lubricants had cm2/28,000 psi).
been used as insurance to back up fluid lubri-
Today, there
cants. However, the internal components of an
are hundreds of
engine operate in an environment that is hostile
different parts
to most low-friction coatings. It is hot (>205°C/
coated with Xylan
400°F), and many of the fluids encountered
in automobiles
(fuel, combustion vapors, battery acid, brake
around the world,
fluid, glycol) attack many polymer coatings.
many of them in
Also, wear rates on pistons, bearings, gears,
environments that
valve stems, and fan drives, are greater than
would melt or
most coatings can withstand.
degrade other
Several formulations of Xylan coatings coatings. From
worked well in this environment. Xylan 1010, clutch actuators
1014 and 1052 were tried and selected for sev- to air-conditioning
eral applications because they were hard, wear- compressors,
resistant, and stable at over 260°C/500°F. (Ask these coatings Most low-friction coatings can-
for Whitford’s “Introduction to the Xylan 1000 improve the not survive the hostile environ-
Series”.) mechanical per- ment of an engine’s interior.
In one early experiment, a trucking firm test- Xylan can — with ease.
formance of the

6
products by reducing friction, resisting corrosion
and withstanding wear. What “PV” means and how to use it
When two bearing surfaces rub against each
B. Wear other, wear is inevitable. The rate of wear is influ-
Initial contact between mating metal parts enced by the pressure they exert against each
results in momentary welding of asperities other (P), the velocity at which they move over
each other (V), the length of time they are in con-
(peaks) on each surface. As each part contin-
tact (T), and a wear factor constant (K) unique for
ues to move, the welded asperities are ripped
each combination of surfaces. K is a function of
off, leaving behind minute pits. the surface characteristics (roughness, coefficient
Every bearing and wear surface, no matter of friction [COF], hardness, ability to resist defor-
how smooth the finish, has these asperities. mation under load, etc.) and remains relatively
unchanged at various PV.
The problem is common to impellers and
The formula for calculating wear is:
housings, air-cylinder pistons, machine slides,
telescoping mechanisms, ball joints, plungers, W = KPVT
gear-teeth, hinges, journal bearings, valves, K: wear factor unique to surfaces in
power screws. contact, given in in3•min/ft•lb•hr or
mm3•min
Xylan coatings provide a thin layer of lubrica-
m•N•hr.
tion to prevent the asperities on mating surfaces
from making physical contact with each other. Wear: material (thickness) worn away in
The selection of the best dry lubricant (PTFE, inches or millimeters.
Moly, or graphite) for these applications de- Pressure: force between the surfaces in
pends primarily on the PV value (Pressure x lb/in2 or N/mm2.
Velocity), atmosphere, and temperature of the Velocity: rate of motion in ft/min or m/min.
application (see sidebar).
Time: duration of contact or operation in hr.
In many cases, a dry film provides enough
If K and the thickness or wear tolerance of the
lubrication to eliminate objectionable wear. For bearing surfaces is known, then the service life of
example, a molded nylon detent for an automo- the bearing may be calculated for various combi-
tive signal harness was failing prematurely due nations of Pressure and Velocity, or “PV factors”.
to heavy loads on the point of the detent. The
Wear life will be directly proportional to PV
sliding coefficient of friction between the detent factors below a certain limit. This “limiting PV fac-
and its mating cam was approximately 0.40, tor” is the point at which increasing P or V con-
which resulted in severe abrasive wear. verts normal wear into accelerated wear, often
When a 10 micron/0.0004 inch film of PTFE- leading to catastrophic failure of the bearing.
loaded Xylan was applied to the detent, the Several factors influence the limiting PV factor,
coefficient of friction dropped to 0.12, and including temperature. Surfaces moving in con-
detent life was multiplied by over 200 percent. tact generate heat which must be dissipated if the
bearing is to survive. Low COF materials (lubri-
Wear is often severe in bearing-type applica- cants, coatings) reduce the rate at which heat is
tions. Rods that slide through glands, rolling generated and help preserve the bearing. All
element bearings, slide assemblies, telescoping bearing materials, including fluoropolymer coat-
booms, ball reversers, rocker arms, ball joints, ings, must be used below their limiting PV factor
tracks, bushings, and thousands of other appli- to avoid failure.
cations are configured so that one part rolls or
slides over another part.
in a bearing is a function of the PV of the appli-
In most cases, friction and wear of the parts cation. As the PV increases, so do heat and
are reduced when one or both are coated with a wear on the bearing surfaces.
dry-film lubricant. Also, the coatings serve as a Dry lubricants have a “limiting PV value” that
thin cushion, spreading high point loads in bear- they can withstand for a reasonable wear life.
ings and reducing element fatigue. Typically, the highest limiting PV which a 25
The energy that is transmitted and dissipated micron/0.001 inch coating of Xylan can with-
7
stand is approximately 50,000 (PV). This limiting Shaft
value varies from coating to coating. Two fac- Cylinder Piston
tors to bear in mind:
First: the ability of a coating to bear loads
increases as thickness decreases. For instance,
while a 25 micron/0.001 inch film may be able to Swept
Swept area
bear PV of only 50,000, a 5 micron/0.0002 inch area
film (the practical lower limit using current appli-
cation techniques) may be able to bear PV of When specifying a coating for a bearing
application, we recommend that the coating be
150,000. For this reason, the PV tolerance of a
applied to the larger “swept” area. This will
coating may be modified by the film thickness. spread the wear over a larger area and provide
the greater amount of lubrication.

4 In general, a coating’s ability

to bear loads increases as wear to a moving mechanism is when it is new.
PV thickness factor

film thickness decreases Boundary lubrication failure

3
When equipment is started and stopped fre-
quently, lubricants are subjected to stress, which
2 can diminish their ability to lubricate. This can
bring sliding metal surfaces into virtual contact
(a condition known as “boundary lubrication”). If
1 metal-to-metal contact does occur, the boundary
0.2/5 0.4/10 0.6/15 0.8/20 1.0/25 lubrication can convert into actual failure as the
Film thickness (mils/microns) metal surfaces meet and begin to wear, which
can, in turn, lead to seizure.
Second: the lubricants themselves. PV limits A thin coating of Xylan reduces the chance
are not constant. They tend to increase with of failure and lengthens the life of such products
pressure and decrease with speed. as sprockets, seal plates for compressors, pump
This is particularly true with Moly coatings, pistons, cams, ball joints, conveyor trolleys,
which work better under high pressure and low gears, journal bearings.
speed, where galling is the principal reason for
These coatings solved wear problems under
failure.
start/stop conditions in reciprocating plungers in
The wear rates of many of the Xylan 1000, electrical solenoids. Typical plungers are
1420 and 1600 Series coatings are equal to that chrome-plated (and extremely hard). But the
of bronze/steel bearings impregnated with PTFE- starting and stopping at the end of each half-
lead when applied in thin films (17.5 microns/ cycle put the plunger into a boundary lubrication
0.0007 inch). condition, causing the plating to wear rapidly.
For break-in, frequent starts, and marginal When a matrix coating replaced chrome plating,
lubrication, remember: the period of greatest the boundary lubrication condition was overcome
and plunger life was extended by 90 percent.
A maker of chain saws uses Xylan 1010 as a
fail-safe lubricant on the cage of the saw’s main
bearing. Clearance between the cage and con-
necting rod is only 100 to 150 microns/0.004 to
0.006 inch. When the engine started, the bear-
ing was in boundary lubrication and, without the
coating, it tended to seize. As proof of the coat-
ing’s ruggedness, these engines run eight hours
per day and have a life expectancy of three
years.
8
 PTFE-type Xylan coatings are recommended
Do not confuse low friction
for applications where initial wear is anticipated
with release
to be light to moderate; Moly-type coatings are
recommended for conditions of heavy wear,
especially in high-load situations.
Fail-safe Low friction Release

In any circumstance in which a mechanism

In many applications, buildup of foreign par-
must function when needed, even if only once,
ticles is a far greater problem than high bearing
Xylan coatings provide a good margin of securi-
loads or corrosion. Examples: carburetor shafts,
ty, even under the most critical circumstances.
choke plungers, butterfly spindles, conveyor
This includes aircraft parts such as bearings parts, instrument probes, fluid injectors, copy
for turbine engines, solenoids, seat ejectors, and printer rollers.
actuators, door pins, and firing mechanisms for Buildup of dirt, ice, soot, scale, food and
ordnance. other foreign material can jam valve butterflies,
Another category is equipment that would be throttle shafts, float elements, orifices, plungers,
damaged were a component to fail. For exam- solenoids and other mechanisms.
ple, removing a frozen bolt from chemical pro- If contamination of a surface is anticipated, it
cessing equipment could cause damage cost- can be minimized with a thin coating of Xylan,
ing thousands of times more than the bolt. In which enables the part to shed the contami-
refinery equipment, the use of a wrench is
infinitely safer than the use of a cutting torch. Release and contact angle
A good rule of thumb: apply coatings of A drop of liquid on a coated surface forms a
bubble whose
approximately 25 microns/0.001 inch to the sur- shape is deter-
Contact angle
faces of these parts. This ensures that the com- mined by the rela- 75˚
ponent will function when required, and tionship between
provides good lubrication and excellent corro- the surface tension
sion protection. of the liquid and
the surface energy
of the surface on As coated @205˚C/400˚F
C. Nonstick (release) properties
which the liquid Contact angle
Nonstick should not be confused with low sits. 85˚
friction: the two are different. The closer the
Friction results from two surfaces sliding tension and the
across each other and is measured by a dimen- energy, the greater @345˚C/650˚F
sionless number that describes the reduction of the tendency of the
liquid to flow out Contact angle
drag (force) between the sliding parts. 94˚
and wet the sur-
Release is the property of a surface which face.
results in the inability of substances to adhere to A high-tempera-
it. It is a function of surface energy that can be ture cure, or buffing
measured by the angle of contact between the the Xylan coating, @205˚C/400˚F and buffed
surface and a drop of liquid (see diagram). The increases release
greater the contact angle, the lower the surface by spreading the fluoropolymer into a film, which
energy, and the greater release a coating has. decreases the surface energy of the plane. The
increased differential causes the surface tension of
Release is generally associated with cook- the bubble to draw itself up more into a sphere.
ware, coated to release food materials. But The contact angle is the tangent between the
release is equally vital to industrial processes plane and the drop of liquid. Therefore, the
such as thermoforming, rubber molding, auto- greater the contact angle, the greater the release
motive and adhesive assemblies, copy of the surface.
machines.
9
 D. Corrosion
The electrochemical process of corrosion is
complex, and can result from single or multiple
sources. Oxidizing fluids such as salt water,
electrolytes, under-hood chemicals, wetting
agents, by-products of combustion, acid fumes,
food materials, process chemicals, fuels, car
wash solutions, even high-performance synthetic
lubricants, can attack metal.
Dissimilar metal unions (galvanic corrosion)
and vibration between tightly joined components
(fretting) can also cause corrosion. The effects
range from catastrophic failure of studs/nuts on
compressors to seizure of door-lock components.
Xylan coatings, particularly the formulations
Eliminating ice buildup made with PTFE, offer a simple solution to the
problem. Xylan is an excellent corrosion barrier,
When air flows through a venturi, velocity
even if applied as a thin film. Most formulations
increases and temperature decreases. Thus,
form functional films at about 25 microns/0.001
when the ambient temperature is near freez-
inch. However, there may be microscopic pin
ing and moisture is in the air, the potential for
holes in the coating.
ice to build up is high.
When carburetors were common, ice Topcoat/
often formed at the throat in winter, causing Second coat Prime/
First coat Pin holes Substrate
the throttle butterfly to stick open or closed.
A large “doughnut” of ice was sometimes vis-
ible on the outside of the carburetor.
The problem was eliminated by coating
the throttle shaft and butterfly (shown here)
with a thin (17.5 micron/0.0007 inch) film of a Overlapping layers of the topcoat fill in and
high-release coating such as Xylan 1010. cover any minute pin holes in the prime coat.

Ice continued to form, but was unable to

adhere to the shaft or the butterfly and was For even better protection, the coatings can
swept into the engine and converted to water be applied in two thin layers so that pin holes in
vapor. Thus, the dangers of losing power or one layer are covered by the second layer.
having a throttle stick were eliminated. Use of sacrificial primers increases the cor-
rosion resistance (in some cases to over 7,000
hours in ASTM B-117 salt fog with less than 15%
nants. If contamination is severe, buffing the
red rust). Certain Xylan coatings form excellent
coated surface will smear the fluoropolymer on
barriers to both acids and bases.
the surface of the coating and increase its
release property (see page 23, Part F). Even if corrosives eventually penetrate the
coating and attack the substrate, little or no
A thin coating of Xylan (17.5 microns/0.0007
underburrowing occurs, so the parts may still be
inch) is usually sufficient to eliminate the prob- easily disassembled for refurbishing.
lem.
This is particularly important for process
Most foreign matter is unable to cling to the equipment in extremely corrosive atmospheres,
waxy surface of the coating and falls off. What such as chemical mixers, pumps and marine
does not fall off is easily scraped off when the equipment. Even fasteners that normally suffer
component brushes against a mating surface. from heavy corrosion will remain functional if

10
they are coated prior to placing them in service. other more exotic and costly materials. They are
When ferrous, aluminum, or even galvanized applied by conventional spray and, when fully
parts are to be exposed to oxidizing fluids or cured, resist both corrosion and mechanical
fumes, Xylan coatings can help protect them. damage. Note: if multicoats are to be used,
oversize nuts may be required.
If corrosion is the dominant failure mode, The problem with automotive fasteners was
choose a coating that offers the best protection somewhat different. The typical automobile uses
from the specific environment. If the problem is about 2,000 small nuts and bolts on trim, acces-
a combination of corrosion and wear, a good sories, brake components and engine sub-
choice would be a coating that performs well in assemblies. Pressured by more and more con-
the presence of corrosive elements and has a sumers complaining that their new cars were
high nominal PV value. showing severe rust, automakers began a
For example, if corrosion is compounded by search for a better way to protect fasteners.
fretting (as found on compressor housings or
Previously, small fasteners were plated with
other components subject to cyclic stresses), a
cadmium. Corrosion resistance was about 96
hard, wear-resistant coating is the best choice.
hours as measured in a salt fog cabinet (ASTM
Fastener-class coatings B-117). Unfortunately, cadmium, a heavy metal,
One of the greatest contributions made by has serious environmental side effects and has
fluoropolymer coatings is increased resistance been severely regulated or banned in many
to corrosion. Xylan coatings designed for fas- countries. (The EU, for example, has banned
teners and other small parts have improved the disposal of cadmium and other heavy metals
corrosion resistance by a factor of five. in landfills.)
As the petrochemical industry developed, it The common replacement for cadmium is
began to demand better corrosion protection. zinc plating. This, in combination with Xylan,
Then came the automotive industry. But they provides the most cost-effective coating system
wanted corrosion protection and low friction. on the market today.
Specific formulations of Xylan were devel- The auto industry’s search for better fastener
oped to combat the severe corrosion that affects protection led to a new set of standards of coat-
the massive studs and nuts on oil drilling rigs ing performance. One of the first was issued by
and petrochemical processing equipment, as General Motors. It called for a coating that pro-
well as other items associated with the Chem- vided at least 336 hours of salt-fog protection on
ical Processing Industry (CPI). These coatings self-drilling and self-tapping screws — after the
also permit the use of less expensive (and screws have been driven through and removed
stronger) metals in place of stainless steel and from sheet-metal panels.
The Xylan 5000 Series was introduced to
meet this standard. These coatings and their
derivatives can be applied economically via the
dip/spin method. More recently, Xylan 5230 was
created, which offers the same performance
without the use of chrome (a heavy metal and
very unfriendly to the environment).
Testing this material, automakers and other
users of threaded fasteners found that salt fog
resistance increased to about 500 hours, more
than 5 times the previous “best”, with no danger
of hydrogen embrittlement.
A coating on threaded fasteners retards corrosion,
enables preloads to be set accurately and keeps Another advantage of the 5000 Series is that
fasteners functional even if they corrode. the torque required to preload coated fasteners

11
is more uniform than that for other fastener fin-
ishes. “Torque scatter” is narrowed, meaning
that preloads on fastened joints, made by
robots, tend to be more uniform and the joints
more secure (see chart, page 6).
Since the coatings permit the fastenings to
be tighter, back-out, or loosening from vibration,
is effectively eliminated.
Corrosion, as described above, does not in-
clude the severe chemical attack seen in chemi-
cal plants and refinery vessels. Ask Whitford for
information on Dykor products for these uses.
E. Noise reduction
Making cutting edges work better
Vibration generates noise. Vortices trailing Heat buildup from friction at the tips and
high-speed impeller blades, impacting gear flanks of saw blades leads to rapid loss of sharp-
teeth, bearings spinning in races, slapping pis- ness. A 25 micron/0.001 inch coating of Xylan
ton skirts, plungers sliding against the walls of reduces both friction and heat, extending the life
of blades by a factor of three or more. It also
actuators, reciprocating detents, and other reduces sap buildup. Similarly, a coating on
sources of vibration are dampened when treated hand pruners lowers friction to add power to the
with Xylan. Under impact, noise generation is cutting force, making cutting easier.
reduced.
In most cases, noise generation is effectively F. Temperature extremes
reduced by coatings of 25 to 40 microns/0.001
Few fluid lubricants are recommended for
to 0.0015 inch. When corrosion is not a consid-
use at cryogenic temperatures (most become
eration, these films may be applied in one coat,
solid) or above 205°C/400°F (they oxidize rapid-
although thicker coats may have greater energy-
ly). The Xylan 1000 Series dry-lubricant coat-
absorbing capacity.
ings, however, operate comfortably at both
If excessive noise is the primary problem, extremes.
multiple coats of Xylan (up to 60 microns/0.0025 They retain their hardness at high tempera-
inch) may be applied to achieve optimum tures because most binders for these coatings
results. Caution should be taken to avoid exces- are thermosetting resins. Although pigments
sive thickness, since the coating could be sub- and binders in some Xylan coatings may discol-
ject to delamination or tearing. or above 260°C/500°F, the coatings continue to
The choice of the best Xylan formulation for function. (For best results, coatings based on
noise reduction depends on the problem. If cor- thermosetting resins should be cured at
rosion is not a problem, apply a soft coating 30°C/50°F above the temperature at which they
such as Xylan 1006; otherwise use P-92 primer will be used.)
and a topcoat of Xylan 1014. Xylan 1000 series coatings are also useful for
A manufacturer of domestic dryers used a preventing damaging “hot spots” between two
bearing coated with Xylan 1010 to replace an rubbing parts, which enables some temperature-
oil-impregnated bearing. The problem with the sensitive materials to operate at conditions
under which they would otherwise fail.
old bearing was that, after approximately one
year of service, the oil migrated out of the bear- G. Sealing
ing and the dryer developed an annoying Very thin coatings of Xylan show little tendency
squeak. The coating not only provided the to cold flow (migrate under pressure), and thus
required lubrication, but also eliminated the are too hard to perform as conventional sealing
squeak. surfaces. Applied in thicker films, however,
12
these coatings will deform sufficiently under
pressure to form a tight thread-to-thread seal on
pressure plugs, fittings, valve stems and other
threaded fluid-power components. Tests of
coated pressure plugs have shown that they
resist leaking even when surge-tested repeated-
ly to 950 kg/cm2/13,500 psi.
The other characteristics of the coatings —
low friction, corrosion resistance and high-tem-
perature stability — are beneficial in these appli-
cations, too. The low coefficient of friction re-
sults in lower seating torques (as much as 60
percent). Because many Xylan coatings are
stable up to 315°C/ 600°F, they will not migrate Rollers live a longer, more productive life
from threads when equipment is operated at Xylan 1781 3-layer electrically conductive coat-
high temperatures. ing system gives end-users a smooth, coated
surface that provides excellent toner release and a
The coatings can be used as a dynamic toughness that extends in-service life for all
seal, too. For example: when applied to the aluminum and steel copier and printer rollers.
vanes of a powder metal rotor in an air-condi-
tioning compressor, Xylan seals the rotor/hous- In addition, the coating reduces the torque
ing interface, preventing leakage of the refriger- between the coated parts and similar but non-
ant past the rotor. To qualify for this application, primed fasteners in adjacent areas.
Xylan 1010 was tested for 150 million cycles at
8,000 RPM, at a temperature of 185°C/360°F. Conductive coatings, too
When formulated with such materials as
H. Electrical characteristics
carbon black, graphite, or metallic compounds,
Most of the resins and several of the lubricat- coatings can be used as conductors. These
ing materials used in Xylan dry-film lubricants formulations are preferred for static-sensitive
are excellent insulators, with dielectric strength systems such as computer printers and plastic
in the order of 2,000 V/mil (25 microns). web-handling equipment, or parts that operate
The very low dielectric constant and dissipa- in explosive atmospheres. Resistivity can range
tion factor, combined with the high dielectric from 10 to 1012 ohms/square, depending on the
strength and high-temperature capability of additives selected to make the coating conduc-
PTFE, FEP, PFA and the matrix resins, create tive. Whitford also offers a line of electrically
formulations that are excellent insulators. conductive coatings specially designed for copy
and printer rollers.
This insulating property renders a coated
An example: webs in paper and textile mills
surface a good capacitor. When there is particle
can be too dry to be conductive. This prevents
or air motion, or other static-charge-inducing
utilization of the outstanding release properties
systems, conventional Xylan coatings should be
of FEP heat-shrinkable tubing, because the
used with caution in the presence of static- static charge becomes a safety hazard. A
sensitive products such as integrated circuits. conductive coating of Xylan solves the problem
A fluoropolymer coating is called for on GM by providing the release while dissipating the
6076-M as a masking coat for threads, protect- static buildup.
ing them from the heavy buildup of today’s When coatings are used to insulate or con-
electrodeposited primers (a problem not only in duct, they should be applied in films of at least
automotive applications, but also in furniture, 25 microns/0.001 inch for maximum effective-
building equipment, etc.). The PTFE-based ness. Coatings of less than 25 microns tend to
coating “masks” the threads and provides easy be discontinuous, and therefore electrical prop-
removal of the primer by the mating nut or bolt. erties are compromised.

13
 3. Solving problems with Xylan coatings
he list of applications for these high-per- has been used on plug and ball valves for more

T formance coatings is almost without end

— and is growing. Here are a few exam-
ples of how various Xylan coatings have solved
than thirty-five years, to provide insurance that
the valve will work when it must.
Xylan improves
some interesting problems.
blow-out preventers (BOPs)
Xylan stops tapers jamming Hydril, a
CCL Systems makes equipment to prestress manufacturer
the steel strands that reinforce concrete struc- of BOPs
tures. One end of the (shown here),
strand is anchored; the was unable to
other is grasped by a use an estab-
three-part tapered lished plating
collet and collar held material for
in the jaws of an corrosion pro-
extremely heavy-duty tection and
jack. Loads as high as lubricity for
300kN (67,440 lbf) are its annular
applied until the concrete BOPs due to
is set, forcing the tapered environmental
parts together. controls. As a
result, the
Freeing the collet once company had
the tension was removed to find a re-
— without permanently placement surface-finishing technology for the
damaging the collet — was difficult. CCL internal surfaces which would facilitate quick
Systems discovered that coating the wedges sealing in the event of unexpected down-hole
with Xylan 1052 eliminated the jamming com- pressure spikes and have the ability to stand up
pletely and ensured reusability. to harsh, corrosive wellbore fluid conditions.
Xylan unsticks sticky valves Xylan 1052, a low-speed, high-pressure,
anti-galling, dry-film lubricant was tested. The
No one pays attention to ball and plug BOP bowl, piston and head were first coated
valves — until they stick, which can cause with a corrosion-resistant primer. Then Xylan
process fluids to be lost, product damage, 1052 was applied. The new coating system was
waste of energy, even dan- tested through 50 actuation cycles. Not only did
ger to personnel. Xylan 1052 pass the test, it also improved lubric-
Sticking valves are as ity and was placed in service. The BOPs are
common as the method gen- periodically pulled from the field for inspection
erally used to “fix” them: a and rework (remanufacture). Then they are
blow from a hammer, which recoated and returned to service to help protect
usually damages the valve in operating personnel and the environment.
the attempt to unstick it. Xylan lengthens life
A better solution is to pre- of sleeve bearing
vent the problem from occur-
ring in the first place — with A unique powder metal sleeve bearing
a thin coating of Xylan (25 (developed by Beemer Precision, Inc., of Fort
microns/0.001 inch). Xylan Washington, PA) uses Xylan 1052 to extend its

14
 service life in high-load, lubricant to provide low-friction movement until
low-speed applications the primary lubricant begins circulating.
with rotating and oscillat-
ing motions. Xylan quiets blower
The tough nonstick How much noise can a coating dampen?
coating virtually elimi- That depends on the application, but the results
nates the need for “break obtained in diesel engines are indicative.
in” because of its low By coating only the rotors of a supercharger,
coefficient of friction, a drop in noise emissions of 2.5 dbA was meas-
ideal for startup. ured and the efficiency of the blower was signifi-
After startup, the cantly improved.
coating continues to Another benefit: in the case of a bearing
function, helping lengthen the life of the bearing. malfunction, the Xylan coating would act as an
Xylan reduces wear on emergency lubricant to keep the blower from
self-destructing before it could be shut down.
air-cylinder pistons
In more and more applications, oil/air mix-
tures are either proving unsafe or are interfering
with process cleanliness.
In environments in which lubricated air is not
allowed by OSHA regulations or because of
other safety considerations, air-cylinder pistons
should be coated.
The easiest, most effective way to eliminate
the oil/air problem and provide proper lubrica-
tion for moving parts is to coat air-cylinder pis-
tons with 25 microns/0.001 inch of Xylan 1014 or
1424, which also extends the lives of the pistons. Xylan shows stability under fire
Xylan saves bearing cages Experiments conducted to reduce losses
as secondary lubricant caused by friction in diesel and spark-ignition
engines demonstrated that this environment was
When compressors are shut down, the pri-
difficult for any lubricant to endure. Matrix coat-
mary lubricant settles below the bearings. As a
ings, however, had proved their worth in other
result, startup can frequently be damaging to
hot-engine applications.
the bearings.
Xylan 1010 was
A coating of Xylan is used as a secondary
applied to pistons which
were operated for a quar-
ter of a million miles. The
coating showed some
signs of scorching — indi-
cating that the pistons ran
in excess of 260°C/500°F
— but it was still opera-
tional, and the pistons
showed little wear.
The scorching can be seen in the photo-
graph — as can the coating, still in place, ready
to perform and protect the piston.

15
 Xylan coating prevents hostile environment of heat, oil and friction.
leaks past threads • Cosworth replaced steel throttle plates with
aluminum, which is lighter, but running between
Pressure vessels, valves, pipe unions, stor- aluminum guides soon caused scuffing. So they
age tanks, reactors, pipe lines, and other fluid- coated the throttle plate and the guides with
containment equipment are often fitted with Xylan, solving the scuffing problem and provid-
threaded plugs for inspection, pressure relief, ing permanent dry lubrication, even in the pres-
filling, or tapping. ence of gasoline vapor.
Coatings on pipe plugs not only improve • Magnesium castings are lighter, but con-
their performance and reliability but also make tact with harder materials (such as the sintered
them easier to use. A thin film of Xylan elimi- iron rotor in Cosworth's oil scavenger pump)
nates the PTFE tape normally wrapped around caused wear, rendering the castings unservice-
the threads to seal them. able. A coating of Xylan 1010 completely
solved the problem. Even after extensive racing
trials, no appreciable wear was evident.
Having proved itself on the race track, Xylan
is now enabling production car designers to cut
weight and wear as they improve performance
— all at a lower cost.

In addition, the corrosion protection and low-

friction properties of the coating greatly reduce
break-out torques, enabling users to remove the
plugs at a later date without destroying them.
In most instances, the pipe plugs may be
reused without difficulty.
Xylan coatings are also available in many
colors, enabling users to color-code particular
plug sizes and different alloys.
Xylan proves a winner
on the track
Reducing weight and minimizing wear are
two major objectives of car designers around
the world — especially in car racing. But there
is a problem: the lighter the material, the greater
the tendency to wear.
Cosworth Engineering, internationally re-
nowned designers of high-performance en-
gines, has solved many design problems with
Xylan coatings on engine components:
• Aluminum cylinder liners save weight, but
they suffer from scuffing. A collar of Xylan
sprayed around the base of the cylinder liner
eliminates the problem, even in the engine's

16
 4. Whitford primers
ost Xylan coatings are formulated to

M function as single-coat materials. There

are times, however, when a primer will
provide significantly improved performance, and
therefore more than justify any additional cost.
Note: There is a difference between “primers”
and “basecoats”, and the two should not be
confused. Whitford defines the terms as follows:
• Primer: a coating designed to stand
alone and function by itself, but that can
also be used to enhance the performance
of a different topcoat.
• Basecoat: a coating designed to be part
of a specific system, without which the
system will not perform as specified. Base- Xylan, when combined with a zinc-rich sacrificial
coats generally will not function properly primer, can withstand 1,080 hours of exposure in the
alone. salt-fog cabinet. Rust is minimal, the coating is still
functional and the fasteners are fully serviceable.
Primers can be organic or inorganic, metallic
rode more readily than the base metal. The by-
or non-metallic. The selection of which primer is
products of this sacrificial corrosion then fill pores
most suitable for an application depends largely
within the coating, further reducing the corrosion
on the desired performance enhancement, the
process. The third is the use of inert fillers,
environment in which the coating system will
which can increase the length of the diffusion
operate, and to a lesser degree on the topcoat path of the necessary components of corrosion.
to be used. By providing a barrier to oxygen and moisture,
The mechanisms of corrosion control are the corrosion reaction is greatly reduced.
quite complex. However, as a general principle, Regardless of the primer selection or the
Xylan primers improve corrosion resistance by environment to which the coating system is
one of three methods. The first is inhibition. The exposed, a primer will only offer enhanced per-
use of select pigments inhibits the corrosion formance if applied to a properly prepared sur-
reaction and promotes the formation of a stable, face. This is so important to developing the full
passive oxide layer on the metal surface. potential of high-performance coatings that the
The second is sacrificial protection. Primers next chapter is dedicated to proper surface
highly filled with anodic metallic pigments cor- preparation and application conditions.

Left: Coated bolt but with no primer in ASTM B117 after 500 hours. Right: Same conditions but with a primer.
What a difference the use of the right primer can make!

17
 5. Applying Xylan
pplying coatings is more complicated than Plastics

A it appears, and unfortunately space pre-

vents us from covering all the finer points.
For a complete evaluation of your application,
Many plastics can be coated with Xylan.
Note: vinyl products containing a high content of
plasticizer can cause adhesion problems.
consult a Whitford Quality Approved Applicator
Nylon, PEEK, PEK, PPS, ABS, polycarbonate,
early in the design process (for a list of these,
epoxy, polyester, phenolic — all can be coated.
please call your Whitford representative).
Parts made of these materials must be cured
A. Substrates at temperatures well below the softening temper-
Xylan can be applied to almost any clean, ature of the substrate to avoid distortion and
dry, oil-free surface. The only materials to which polymer degradation.
it will not adhere are those with inherent release Elastomers
characteristics such as polyolefins and similar
Some Xylan coatings may be applied to
fluoropolymers (although, with special surface elastomeric parts not expected to elongate more
preparation, Xylan will adhere to these as well). than about 30 percent in service. Greater elon-
Virtually all metals gation may cause these coatings to crack. If a
Almost every structural metal can be coated discontinuous coating is not objectionable, elon-
gation greater than 30 percent is permissible.
with Xylan, including steel (carbon and stain-
(Note: Whitford has developed flexible finishes
less), aluminum (wrought and cast), copper (and
that can be elongated to 150 percent or greater
alloys), and titanium. Note: high nickel- and
with no cracking of the coating. Ask for
chrome-bearing alloys, and some platings of
Whitford’s “Flexible Finishes” brochure.)
nickel, can also be coated if abrasive blasting is
used and the coatings are applied within an Elastomeric parts successfully coated with
hour or two of blasting. Xylan include bushings, mounts, automotive
door and window seals, vibration dampeners.
Special precautions must be taken with pow- Substrates include natural rubber, EPDM, SBR,
dered-metal parts. These parts appear ideal for butadiene and its derivatives, and silicones.
coating: their surface is porous and provides
good “tooth” to which a coating can cling. Glass and ceramics
However, since many of these parts have been Fluoropolymer coatings will adhere to clean
treated with resinous impregnants, oils are ceramic and glass surfaces, but curing the coat-
trapped within the porosity. To coat them, bake ing without cracking the substrate can be diffi-
the parts at a temperature higher than the cure cult. (If possible, use glass or ceramic intended
temperature. Any contaminants which bleed to for high temperatures.) In most cases, a low-
the surface during the bake must be thoroughly temperature cure (below 150°C/300°F), followed
removed. Then, the parts can be coated. by a slow cool-down period, will not crack the
substrate. For glass parts, coating adhesion
Die-cast parts can be a problem. They are
may be improved by a fluorine etch or the use of
typically cast using aluminum, zinc and magne-
a primer.
sium alloys that can be “gassy” and porous.
When coated parts are cured, the gas trapped Fabrics and composites
in internal cavities expands and erupts. When Xylan coatings are increasingly being used
cured at over 235°C/450°F, these parts may (for low friction and release at elevated tempera-
have numerous eruptions on the coated surface. tures) on woven and nonwoven industrial textiles
To evaluate whether the substrate can withstand made from such modern materials as carbon
the cure temperature, prebake a part to 10-15˚C/ fiber. One of the most successful applications of
20-25˚F higher than the anticipated cure. Xylan involves a fabric bearing which is woven

18
from a nylon/glass blend, then coated and as effective as vapor degreasing. Parts which
cured. should not be alkaline-washed are those which
These composite bearings are used under may be adversely affected by the chemistry
the compressor blades of large bypass fanjet involved (such as aluminum and magnesium).
engines. The natural porosity of fabrics forms Grit blasting with aluminum oxide or car-
sponge-like “wells” into which the coating pene- borundum particles is a common cleaning tech-
trates. In service, this extra supply can continue nique, preferred for parts whose surface con-
to provide PTFE to a wear surface long after the taminants — rust, scale, corrosion, old coatings
coating is worn away from a smooth substrate. — must be attacked physically to be removed.
Xylan adheres well to other composites, too, It is not, however, the most effective technique
provided release agents have not been applied for removing oily or fluid contaminants. When
to the material. parts are particularly oily, alkaline cleaning or
pre-baking them before blasting will improve the
Paper and wood effectiveness of the blast and reduce contamina-
Xylan adheres well to uncoated or unvar- tion of the blast medium.
nished paper products as well as wood. As Grit blasting does more than clean; it rough-
unlikely as it may seem, the coatings perform ens the surface and enhances mechanical
every bit as well as they do on metal and other adhesion by increasing the surface area to
substrates. Cure temperatures should not which the coating can cling. A grit medium from
exceed 180°C/350°F. 36 to 220 mesh/250 to 70 microns is recom-
B. Preparation mended for blasting most metal parts. (Note:
the particle size quoted above runs from larger
Cleaning and pretreatment are important.
to smaller.) Steel grit is generally avoided
Every surface to be coated must be clean, since
because minute particles may be left behind
few coatings adhere to dirty or oily substrates.
and become starting points for oxidation.
Note: The second-best coating over the best
Shot blasting is similar to grit blasting, but
surface preparation is likely to perform better
employs metal or other “shot” as the blast medi-
than the best coating over the second-best
um. For parts which will be used in fatigue/fret-
surface preparation.
ting applications, this process can be beneficial
There are many ways to clean a part, each because it imparts residual compressive stress-
with advantages and disadvantages. Some es on the surface of the parts, thus lengthening
techniques go beyond cleaning and create sur- their lives under cyclic loads.
face “structures” that enable a coating to cling Tumble blasting is another variation in which
better. It is often desirable to use a combination parts — usually small parts — are placed into a
of cleaning methods to achieve optimum adhe- rotating cylinder along with an abrasive medium
sion. The more common methods are: which abrades the part surfaces. The effect
Vapor degreasing used to be the most widely varies with the medium employed, but is much
used cleaning technique, but fell into disfavor the same as grit blasting. This technique is less
because of regulatory restrictions on the use of effective than fluid cleaners for removing
cleaning solvents. machine oils and other similar contaminants.
Where permitted, degreasing remains an Acid or alkaline etching is an excellent tech-
excellent technique for removing foreign materi- nique both for cleaning and roughening the sur-
als from fingerprints to machine oils. It is an face of aluminum parts. Because the size of the
economical technique for cleaning small batch- equipment is considerable, it is usually reserved
es. Avoid using it on parts that may be attacked for high-volume production parts.
by the solvent, such as plastics, composite Pickling is common for removing rust/scale
parts, or metal parts with organic inserts. from ferrous parts after cleaning. It should not
Alkaline washing involves cleaning parts with be used on parts that will be highly loaded,
moderate- or high-pH cleaners. This is pre- since it can cause hydrogen embrittlement.
ferred for high volumes of parts and is generally Phosphating is a secondary surface prepa-

19
ration for steel which is generally used after shipment of each Whitford product.
vapor degreasing, alkaline washing or grit blast- Preheating: Preheating parts prior to coating is
ing. Whitford normally recommends a modified recommended when parts are in humid atmos-
zinc or manganese phosphate with a fine crys- pheres because condensate on cool parts can
talline structure. Zinc phosphate is used for cause defects. Preheating is also useful when
static applications, and manganese phosphate parts of great mass are coated and oven dwell
for dynamic and higher-temperature applications. times to bring them up to temperature would be
A thin layer (15-25 gms/m2) of zinc phosphate uneconomical, or when films that are thicker
on the surface promotes better adhesion and than normal are required.
dramatically increases corrosion resistance and We recommend that preheating at the time of
chemical protection. A good alternative: Xylan coating be limited to no more than 65°C/130°F to
4070 Primers, which outperform conventional avoid solvent or water “boiling” on the surface of
phosphating. the parts. Thin or light-gauge parts may require
Iron phosphate may be less expensive, but greater temperatures because of their tendency
zinc phosphate has superior corrosion resist- to lose heat rapidly during transfer from the heat
ance and better protection from corrosive creep. source to the coating area. Note: Preheating is
Whitford prefers zinc phosphate. Note: Manga- not recommended with Xylan 5000 Series coatings.
nese phosphate has better corrosion resistance C. Application techniques
and thermal stability than zinc, but can be more
difficult to apply, especially to high-alloy steel. The techniques used for applying Xylan
depend on the shape of the part, the number of
Anodizing: An electrochemical treatment of parts, the desired transfer efficiency, the appli-
primarily aluminum which can greatly increase cation rate and the type of carrier used in the
hardness. It creates a porous, corrosion-resist- Xylan formulation. Here is a brief guide:
ant surface that is excellent for coating, provid-
Spraying: By far the most versatile and wide-
ed it has not been sealed. (Other metals, such
ly used technique to apply Xylan is spraying.
as manganese and titanium, although much less
There are five basic types: conventional (also
common, may be anodized.)
known as siphon or gravity), HVLP, airless,
Conversion coating: Normally applied in a pressure pot, and electrostatic.
bath to create an “active” surface to promote
• Conventional: The choice for small num-
adhesion of the coatings. Specially formulated
bers of parts, where considerable manual work
phosphates are available for use on aluminum.
is required. Almost any Xylan formulation can
Ask about Whitford’s Activ8/Passiv8.
be applied by this technique.
Other factors • HVLP (high volume, low pressure): A varia-
Combinations of pretreatments: These are tion that reduces air pressure and increases
required for the best overall coating adhesion liquid volume. Its greater efficiency reduces the
and corrosion protection. For common sub- number of Volatile Organic Compounds re-
strates, industry practice has been to use the leased (see Chapter 9, page 30) and can
following pretreatments or combinations: increase transfer efficiency.
• Carbon steel: vapor degrease/ • Airless: Similar to the siphon system but
gritblast/phosphate or plate. uses hydraulic pressure to move and atomize
the liquid instead of air.
• Aluminum: alkaline wash/etch or grit blast.
• Pressure pot: Similar to conventional
• Stainless steel: heat oxidize/grit blast. spraying, except the coating is under positive
• Chrome and nickel plate: vapor degrease/ pressure. This technique moves more coating
pre-bake/grit blast. than a conventional system and is recommend-
Coating material preparation: It’s important ed for larger production runs. Almost any Xylan
to mix or roll all ingredients according to the formulation can be applied by this system.
Product Data Sheet which accompanies the first • Electrostatic: The recommended process

20
for very high production conditions or when an to create striations in the coating which are visible
electrostatic “wrap” is needed to coat complex in the finished and pressed piece. These stria-
shapes efficiently. Rods, wires, outdoor furniture tions are often referred to as “chicken tracks”.
and other parts that require a 360-degree coating • Pad or screen printing: Adding a patterned
are examples. Not all formulations lend them- or decorative coating over standard coatings
selves to electrostatic spraying with conventional using a pad or a silk screen.
equipment. Some (such as water-based prod-
ucts) may require special electrostatic systems. Coating fabrics
The application techniques by which fluoro-
Bulk techniques: These are the most eco-
polymer finishes and coatings are applied to
nomical methods of applying coatings to small
textiles may differ significantly from those utilized
and intricate parts such as fasteners, clips and
for applying coatings to metal, rubber or plastic
other irregularly shaped pieces. Transfer effi-
substrates.
ciency is exceptionally high: as much as 95
percent of the coating is applied to parts. Bulk Application can be accomplished by pad-
coating techniques operate in two basic ways: ding, in which the greige (pronounced "grey" and
meaning "untreated") fabric is immersed in a
• Dip/spin coating: This is just what the
bath of the finish and the excess is removed by
name implies. A basket filled with parts is
passing the wet fabric through padded rollers.
immersed in a reservoir half-filled with coating,
Padding spreads the finish evenly over both
raised out of the coating but still within the
sides of the fabric, minimizing application time
reservoir and spun to carry off excess fluid by
and effort.
centrifugal force. Following that, the parts are
cured. Because parts are in contact with each Textiles can also be coated or impregnated
other, which can prevent complete coverage of by "knife over roller". This method uses a vis-
the coating, at least two passes through this cous coating that is metered onto a rotating
process are required to ensure total coverage. roller, which supports the entire web of the
• Barrel/tumble coating: This technique in- fabric. As the fabric passes over the roller, the
volves tumbling parts and spraying them while forward motion produces a well of coating, also
hot air passes over them. This method is pre- known as a rolling bank, behind a stationary
ferred for extremely lightweight or flat parts knife. The gap between the knife and the roller
(such as washers or small O-rings) which tend is the primary determinant of the amount of coat-
to “nest” together. ing deposited onto the fabric. Variants of the
knife-over-roller method include knife-over-table,
Four other methods are: knife-over-air, and knife-over-gap. Knife coating
• Coil coating: This uses high-speed rollers is used for single-side application of the coating
to apply precise film thicknesses to wide, contin- onto the fabric.
uous sheets of metal, which are subsequently Similar in popularity to knife coating is roll
drawn or stamped. This process is used very coating of fabrics. All variants, such as direct
successfully for high-volume coating of cook- roll, kiss coating, gravure, and reverse roll, utilize
ware, bakeware and small appliances. a rigid roller partially immersed in the coating
• Curtain coating: A high-volume application solution. The coating is either directly applied to
technique in which parts are passed through a the fabric or is transferred to other rollers prior to
falling curtain of the liquid coating. It’s fast, eco- deposition onto the fabric. Each variant affords
nomical and highly efficient (virtually no waste). different levels of efficiency, flexibility and preci-
sion of deposition weight.
• Roller coating: Similar to coil coating in that
it uses rollers to apply the coating to the surface. Other possible application techniques for
In the case of roller coating, however, the coat- fabric coatings may include transfer coating,
ing is applied to metal blanks rather than contin- rotary screen printing, or simply spraying.
uous rolls of metal. The process is used for
high-volume applications like cookware and D. Flashing and curing
bakeware. One of its drawbacks is that it tends Achieving a tough, continuous film requires a

21
flashing process, in which the carrier is vapor- Curing schedules: These vary for different
ized by brief exposure to an elevated tempera- Xylan formulations. However, some Xylan coat-
ture (but lower than the cure temperature), and a ings permit wide latitude in the selection of cure
curing process, in which the coating resins link temperatures so that cure can be compatible
into a continuous film. with the part. For instance, you may want to
Most Xylan coatings can be cured via con- limit the cure temperature of a die-cast part to
vection ovens and infrared (IR) ovens. Some 380°C/715°F, or for a formed aluminum part to
special formulations can be cured with exposure less than 235°C/450°F.
to ultraviolet (UV) light. Only a few formulations Note: Cure time is the period that begins
are suitable for cure at ambient temperature. when parts reach and remain at cure tempera-
The curing process is a time/temperature rela- ture, not oven dwell time (the entire period dur-
tionship. In all cases, the higher the tempera- ing which the parts are in the oven).
ture, the shorter the curing time (see chart).
Note: altering the time/temperature relationship CAUTION: Entrapped air in such parts as
will affect performance (see F, next page). rollers or insulated/jacketed vessels may become
a “bomb” and explode when heated to cure tem-
Convection systems: These use heated air to peratures. An air-relief hole or pressure-relief
cure the coatings. They are, by far, the most valve must be a part of the assembly.
common type used to cure Xylan. Sophisticated
production ovens, which employ conveyors to E. Surface considerations for
move parts, usually have at least three heat maximum wear resistance
zones within them: a warm-up zone, a bake
zone, and a heat-extraction zone. Should the coating be applied to both sur-
faces of the mating parts?
Infrared systems: A line-of-sight process that
allows fast heating of the surface of the coated The answer is generally no, for reasons of
substrate (as opposed to other, slower systems, cost. Only a small increase in lubricity is gained
which must heat the total part). Efficient, but by coating both surfaces. However, part life may
must be controlled carefully to avoid overheat- be doubled because of the greater thickness.
ing. Very effective for flat or shallow parts. Remember: in most cases, it is easier and more
economical to coat the exterior of a part rather
UV systems: These initiate a photochemical
than the interior (a shaft instead of a bearing).
reaction that is far faster and uses far less ener-
gy than thermal systems. UV also reduces the When there is a difference in mating materi-
footprint of the curing line significantly. als, it is preferable to coat the softer of the two

˚C
Curing temperature related to curing time: Xylan 1000 Series
˚F
426 800
398 750
371 700
343 650
315 600
287 550
260 500
232 450
204 400
176 350
148 300
121 250
093 200
065 150
5 10 15 20 25 30 35 40 45 50 55 60
Minutes
22
surfaces (the one which, in boundary-lubrication (See PDS for more specific instructions.)
conditions, could suffer the greater damage). G. Additional considerations
The mating surface affects the wear rate of a • Postforming: Some Xylan formulations may
coating. For instance, the wear rate on a coated be stamped, deep-drawn, bent, punched,
journal that supports an aluminum shaft is as drilled, machined, and otherwise manipulated
much as 50 times that of an identical bearing without damaging the coating — provided that
that supports a carbon steel shaft. (See “What the part is properly pretreated before coating.
‘PV’ means and how to use it”, page 7.)
• Controlled removal for precision sizing:
The roughness of a mating surface also has Many Xylan coatings may be applied in thick
an effect on coating wear. The optimum surface films and then machined, buffed, centerless
has 8-12 micro-inches/0.2-0.3 microns (RMS). ground, sanded, etc., to achieve a very high
Surprisingly, hyper-smooth surfaces (less than gloss and an extremely close tolerance.
4 micro-inches/0.1 microns (RMS) produce high-
er wear rates than those with a finish between • Higher builds: Thicker films may be
15-30 micro-inches/0.375-.75 microns (RMS). achieved by preheating the substrate as previ-
ously mentioned or by using formulations with
A smoother surface permits less transfer of higher solids, which are available in most, but
PTFE to the mating surface and friction increas- not all, Whitford products.
es — causing wear. Surfaces which are rougher
than 30 micro-inches/.75 microns (RMS) also • Coating removal: Once applied and cured,
result in high rates of abrasive wear, increasing fluoropolymer coatings can be removed from
as the roughness increases. a part mechanically by sand/grit blasting, or
thermally by degrading the coating (at 480°C/
Caution must be used with coatings in 900°F). Use caution when degrading thermally.
cathodically/anodically protected assemblies
(contact your Whitford representative). Important: At temperatures >300°C/>575˚F,
fluoropolymer coatings give off fumes which can
F. Special cure and postcure cause “polymer fume fever”, a condition not
unlike a mild, 24-hour case of flu (there are no
Some Xylan coatings can be processed to
known long-term effects). If you take fluoropoly-
improve performance for specific applications.
mers to these high temperatures, be sure that
For instance, cure affects adhesion, release,
the work area is well ventilated.
hardness, corrosion resistance, friction proper-
ties, wear rate, and flexibility. Here are some Substrate removal:
suggestions for enhancing coating performance: when to make room for a coating
• Curing for maximum hardness and chemi- Coatings are generally applied to parts with-
cal resistance: For applications in which coat- out any provision for the thickness that they add
ings will be subjected to extreme wear, we rec- (coatings are not included in the original
ommend that they be cured at the upper (hot) design). This is particularly true when coatings
end of their cure schedule. This results in maxi- are used as corrosion barriers (within some lim-
mum crosslinking of the binder. its, the thicker they are, the better). This is also
• Curing for nonstick/release: Release can true of parts that are stamped or deep-drawn.
be increased by post-curing at elevated temper- In many bearing applications, however, toler-
atures or by buffing the surface after it has been ances are too tight to add another 17.5 microns/
thoroughly cured. 0.0007 inch of material without any provision for
• Curing for multiple coats: If applying multi- it. For these situations, use this guide: where
ple coats to a part, in most cases the first and parts form an interference fit, remove an amount
intermediate coats should be flashed but not of substrate material that is equal to half the
fully cured prior to the application of subsequent thickness added by the dry coating film. In all
coats. This increases the bond between each cases, parts treated in this manner should be
layer and results in a stronger, denser coating. thoroughly performance tested.

23
 Guide to application and processing techniques
Application Substrate Pretreatment Post treatment

Friction/wear Steel (ferrous) Degrease, grit blast to 100 µin/2.5 µm. Can be polished

Steel (stainless) Degrease, grit blast to 100 µin/2.5 µm. Can be polished

Aluminum Degrease or alkaline wash, grit blast to 40 Can be polished

(die-cast) µin/1 µm.

Aluminum (wrought- Degrease or alkaline wash, grit blast to 80- Can be polished
bare metal) 120 µin/2-3 µm.

Aluminum (anodized) Degrease or alkaline wash. Can be polished

Babbitt metal Degrease. Can be polished

Bronze (sintered) Bake to 260˚C/ 500˚F, degrease or alkaline Can be polished

wash.

Cast iron Degrease, grit blast to 60 µin/1.5 µm. Can be polished

Non-metallic Clean nondestructively. Can be polished

Corrosion barrier

• Fasteners Steel (ferrous) Degrease, grit blast to 120 µin/3 µm, phos- None required
phate and/or plate, apply primer/topcoats.

• Other Steel (ferrous) Degrease, grit blast to 120 µin/3 µm, None required
phosphate, apply primer & topcoats.

Iron (cast) Degrease, grit blast to 120 µin/3 µm, apply None required
primer & topcoats.

Aluminum (cast) Alkaline wash, grit blast to 120 µin/ None required
3 µm, apply primer and topcoats.

Aluminum (wrought) Degrease, grit blast to 120 µin/3 µm, ano- None required
dize if practical, apply primer and topcoats.

Brass, bronze Degrease, grit blast to 120 µin/3 µm, apply None required
primer and topcoats immediately following
blasting.

Electrical Steel Degrease, grit blast to 60 µin/1.5 µm, apply Spark test (if insulating), ohms
applications two 0.0007 in/17.5µm coats with intermedi- per square (if conductive)
ate cure at 120˚C/250˚F.

Aluminum Alkaline wash, grit blast to 60 µin/1.5 µm, Spark test (if insulating), ohms
apply two 0.0007 in/17.5µm coats with per square (if conductive)
intermediate cure at 120˚C/250˚F.

Copper Degrease, grit blast to 60 µin/1.5 µm, apply Spark test (if insulating), ohms
two 0.0007 in/17.5µm coats with intermedi- per square (if conductive)
ate cure at 120˚C/250˚F.

24
 6. Whitford flexible finishes and the automotive industry
n 1986, Whitford identified a need for alternative

I products to traditional methods of post-treating

elastomeric seals and moldings. These con-
ventional treatments included polyamide and
polyester flocking agents, silicone solutions, fine
particle chalks, and specialty greases.
Whitford’s R&D technicians set a high priority
on these new products, and within months had
the first product developed and tested. The
products have evolved over the years, and
today are better than ever.
Whitford’s new products were designed to
meet increasing performance demands of auto-
motive manufacturers including:
1. Reduction of coefficient of friction.
Whitford’s flexible finishes are used by major auto-
2. Suppression of noise generated by seals motive manufacturers all over the world.
due to micromovement between the car
doors and the car body. Who’s using Xylan?
3. Elimination of sticking of seals to car doors. Xylan coatings for flexible finishes have been
tested and approved and are used by more than
4. Protection of rubber and thermoplastics
30 automotive manufacturers around the world.
against the effects of weathering.
As more and better coatings for flexible fin-
5. Offering of novel colors, appearances, and
ishes are developed by Whitford (a never-ending
textures.
project), more manufacturers are taking advan-
In addition to these attributes, the new prod- tage of their benefits.
ucts (marketed under Whitford’s “Xylan” trade
name) are cost-effective, easy to apply through A variety of substrates
a variety of spray and brush techniques, and are EPDM (ethylene-propylene-diene monomer)
available in waterborne, VOC-compliant forms rubber is one of the most common substrates on
engineered to meet the most vigorous environ- which Xylan flexible finishes are used. Never-
mental regulations in the world. theless these coatings are also being used on
many other surfaces, including NBR, PVC, TPEs,
TPOs, acrylics, ABS, and polyesters.
Pretreatment
Depending on the quality of the substrate
and the performance requirements of the coat-
ing, substrate pretreatment may be required.
Adhesion of Xylan products can be optimized by
solvent degreasing, priming, corona discharge,
plasma treatment, flame treatment, or through
mechanical abrasion.
Curing
Xylan flexible finishes are ideal for applications such
as EPDM weatherstripping. Xylan coatings are easily cured by conven-

25
tional methods, although the fastest, most effi- to provide outstanding release characteristics,
cient, least expensive of all is by ultraviolet light. as well as to eliminate the “stick-slip” effect,
Whitford was the first coating company to devel- which reduces noise attributed to the micro-
op UV-curable coatings for flexible substrates. movement of seals against glass and painted
body panels.
Quality standards
Whitford is one of a select group of compa-
nies which have achieved and maintained the
highest quality standards in the industry.
This commitment to the most exacting stan-
dards is carried out by quality assurance teams
at each of Whitford’s worldwide facilities where
these products are manufactured.
Choosing the right coating
Whitford supplies coatings which have been
Xylan flexible finishes are designed to withstand the formulated to solve specific problems on a vari-
most demanding climatic conditions that vehicles
can encounter, from blistering heat to sub-zero freez- ety of substrates. The coatings are classified
ing, and still perform. into the following categories:
The UV cure has these advantages: 1. Glass-Run Applications: These products
are designed to withstand the abrasive forces
• Uses a fraction of the energy of conven-
associated with the movement of glass windows
tional ovens.
along seals during operation.
• Once powered up, the UV-cure equipment
2. Weatherstrip Applications: These include
stabilizes in minutes, saving hours of time
coatings for primary and secondary door seals,
a conventional oven takes to reach full heat.
trunk (boot) seals, and hood (bonnet) seals.
• Saves space by replacing the many feet of These coatings ensure freeze-release, weather-
a curing oven with a cabinet not much ing resistance, and noise suppression.
larger than an office desk. 3. Appearance Applications: These coatings
• Does not impart heat to the substrate, are generally recommended for decorative
allowing temperature-sensitive materials to effects, and have excellent weathering resist-
be used. ance. They are used for a colored, textured
(soft feel), or metallic effect.
Typical applications
Note: Many Xylan coatings for flexible sub-
Xylan flexible finishes have an exceptional strates have found use outside the auto industry.
track record in a diverse array of automotive
applications. In glass-run channels, Xylan’s
remarkable abrasion resistance ensures long-
lasting, smooth, silent window operation com-
bined with consistently low levels of friction.
When used on trunk (boot) seals, this versatile
material provides excellent release even in the
most adverse conditions.
Additionally, Xylan protects door seals, body
seals, and drip rails by providing superior exteri-
or durability. These products have surpassed
the most rigorous automotive specifications for
resistance to accelerated weathering and water Thanks to Xylan, the absence of itch and squeak lets
immersion. Further, they have been engineered the beauty of nature speak in its own quiet way.

26
 7. Whitford coatings and the textile industry
erhaps the most revolutionary change in

P the world of textiles in several thousand

years was the invention of synthetic fibers.
The next most revolutionary change was the
introduction of surface treatments to enhance the
performance of textiles in many ways, such as
water repellency, release, strength, resistance to
chemicals, etc. Whitford has been a leader in
the development of special coatings and finish-
es for the textile industry (such as EterniTex®).
EterniTex coatings are typically a blend of
PTFE and other fluoropolymers reinforced by a
matrix, designed to provide a wide range of
benefits. Belts coated with EterniTex, for exam-
ple, last up to ten times longer than the same
belts coated with PTFE.
Superb resistance to UV has been designed into
Superior water repellency EterniTex to prolong fabric life as well as protect
fabric color.
There are many different treatments to help
prevent the passage of water through fabric. EterniTex also offers maximum release on high-
Some repel moisture better than others. Some temperature textiles. Typical application: high-
last longer. EterniTex offers a treatment that temperature belting. EterniTex provides release
works better than most other treatments avail- up to 240˚C/465˚F and dramatically extends
able. It offers additional benefits, too: service life on a woven Kevlar® laminating belt
compared to the same belt treated with silicone.
• Increased, longer-lasting water repellency.
Other formulations, designed for low-temper-
• Increased fabric strength.
ature belt applications, provide outstanding
• Outstanding protection against ultra- resistance to abrasion and wear as belts bend
violet damage. around rollers and rub against the deck.

Coating “A” EterniTex

Coating “A” at 600 mm of hydrostatic head: the EterniTex, with its superior water repellency, shows
moisture penetrates from below and shows clearly no signs of water penetration, even at 2,000 mm of
on the top of the fabric. hydrostatic head (more than 3 times as much).

27
Service life is extended by at least several times.
Another benefit: controlled friction, which con-
tributes to longer life. And EterniTex can be
made conductive to dissipate static discharge,
always a threat to the workplace.

1.2 Coefficient of friction comparison

1.0
Coefficient of friction

0.8
Uncoated textile belt
0.6

0.4
Belt coated with EterniTex A laminating belt coated with EterniTex for excellent
0.2 release properties and longer belt life.

0
ishes are well understood, and it is generally a
0 20 40 60 80 100 120 140 160 question of finding the material that provides the
Extension (mm) best solution for a particular application.
As new versions of EterniTex are developed,
Superior belting reinforcement pioneering minds are taking these treated fab-
rics into entirely new areas, where they are hav-
Textiles coated with EterniTex are also used
ing a significant impact. For example:
as a reinforcing component to add strength to
conveyor and power-transmission belts. The • Reprographic textiles
EterniTex coating creates an internal lubricating • Gasket materials
system within the weave of the fabric. This
• Filtration textiles
allows the fibers to move easily against each
other as the belt is subjected to stress and • “Quiet” textiles
strain, rather than to abrade each other. It also • Anti-wicking fabrics (lighter, more efficient
enables far greater capacity to absorb shock sails for racing boats)
under tension — without damage to the textile.
• Breathable waterproof fabrics (tents, tar-
paulins).
Comparison of shock resistance
of reinforcing textiles These
Increasing resistance to shock

used in elastomeric belting superior coat-

ings of Eterni-
EterniTex-co Tex are easily
ated textile
applied by all
conventional
methods used
Uncoated te
in the textile
xtile
industry. And
they are virtual-
Increasing stress ly all VOC-
compliant.
Uncoated textile versus same textile coated with
EterniTex. The uncoated version tolerates only limit- Note:
ed deformation, while the coated version tolerates Please see
more, easily doubling the life of the belt. page 21 for
application
Superior thinking EterniTex prevents wicking, reduc-
methods related ing the weight of sails (and its UV
The classic uses for textile coatings and fin- to fabrics. resistance protects colors, too).

28
 8. Calculating the real cost of a coating
hat may sound like a simple task, but the uration of the part and the skill of the applicator.

T answer is more complicated*. If you judge

price by the cost of a gallon, liter or kilo,
you will not only be wrong but may wind up pay-
2. The pretreatment you select can have a
significant effect on cost. And it will affect per-
formance of the part.
ing far more than you think. That’s because a
lower price for a given quantity or weight may Calculating coverage and cost
mean a higher price per unit area of coverage.
The volume of one U.S. gallon represents 1604
The only valid way to compare the cost of a square feet of liquid at a thickness of 25 microns/
coating is to compare the cost of coverage of a 0.001 inch. The liter represents 1000 square
given area at a specific film thickness (normally meters at one micron (or 40 square meters at 25
25 microns/0.001 inch). microns). Obviously, these coverage figures
change proportionally with coating thickness. With
What gives a coating its coverage? The coatings that are less than 100 percent solids (all
answer is the amount of solids by volume** it liquid coatings), these figures decrease propor-
contains (not solids by weight). And few coat- tionally. Use the following formulae to calculate
ings contain the same amount of solids. A coverage:
typical (and real) example: Coverage/US gallon (in sq. ft.) =
• Coating “T” costs $80.00 per gallon. (1604 ft2/mil) x (% solids by volume)
Coating “X” costs $88.00 per gallon, or 10 per- film thickness in mils
cent more per gallon. Coverage/liter (in sq. mtrs.) =
• Coating “T” has 13 percent volume solids. (1000 m2/micron) x (% solids by volume)
Coating “X” has 20 percent volume solids. film thickness in microns
• 20 divided by 13 gives 1.54, so the gallon Finally, cost per unit of area =
of Coating “X” has 54 percent more volume Cost/gallon or liter
solids, which means that “X” covers 54 percent coverage/gallon or liter
more square feet or meters than “T.”
• Coating “T” gives 209 square feet of cover- *In some industrial applications, the coating may
age. Since Coating “X” gives 54 percent more, be only a small part of the total cost because of the
it covers 321 square feet. cost of the labor needed to mask, rack, multicoat and
package (as well as the cost of packaging materials).
• $80 (the cost of “T”) divided by 209 gives
**Volume solids: all liquid coatings contain a vari-
a theoretical cost*** of 38.3 cents per square
ety of solid materials. When the coating is cured and
foot. $88 (the cost of “X”) divided by 321 gives the liquids driven off, only the solids remain. Weight
a theoretical cost of 27.4 cents per square foot. solids are different, so don’t be confused. Some
• You pay 10 percent “more” per gallon for solid ingredients weigh more than others, but don’t
cover as much area. Coverage depends on the
Coating “X.” Yet, in terms of coverage (actual
thickness of the coating and the area covered, which
cost), Coating “T” is really 40 percent more is volume, not weight.
expensive than Coating “X.”
***Theoretical cost assumes 100 percent transfer
There are a few other factors worth mention- efficiency in application of the coating.
ing that are not directly related to cost/coverage:
1. Cost also depends on transfer efficiency, Ask for a copy of Whitford’s Cost Calcu-
the percentage of coating that actually reaches lator, which comes as an Excel spreadsheet
and remains on the part. And transfer efficiency and automatically calculates everything you
depends on several factors, including the formu- might want to know about a coating’s coverage
lation, the method of application used, the config- with the simple click of the mouse.

29
 9. Protecting the environment
he so-called “Green Movement” is here to that period does not exceed the local limits.

T stay. And well it should be. Most of us

have ignored the environment and con-
tributed to the contamination of the world in
There is little question that present VOC lim-
its will be tightened as time goes by.
Southern California, with severe air quality
which we live. One of the manifestations is the
emphasis on VOCs — Volatile Organic Com- problems, has led the way to more stringent reg-
pounds* — and the need to lower and control ulations. Recently, the state raised the transfer
emission of these chemicals. efficiency requirement for wood-spray equip-
ment from 40 percent to 65 percent. And legis-
Whitford supports this and presents the fol- lation now limits VOCs for the “extreme perform-
lowing to help you understand the restrictions ance” category for coating metal parts and
and measure the VOCs you may be emitting. products as follows:
What are VOCs? Air-dried Baked
VOCs are those ingredients in a paint or lbs/gal gms/ltr lbs/gal gms/ltr
coating, defined as photochemically reactive by 3.5 420 3.0 360
the USA’s Environmental Protection Agency, that
The calculations for these VOCs, of course,
escape into the atmosphere during the drying or
exclude the water and other exempt compounds.
curing process. With some exceptions, organic
solvents are classified as VOCs. Not all the news is bad
In general, Whitford coatings come under Whitford has spent considerable time (and
the “Extreme Performance” industry guideline. funds) engineering new coatings that conform
(“Extreme Performance” includes coatings to, and surpass, the most stringent regulations in
exposed to any of the following: the weather all the world. Many of our coatings are low-VOC
of the time, temperature consistently above and/or waterborne. We’re developing more
95°C/205°F, detergents, abrasive and scouring products of this type, which will be announced
agents, solvents, corrosive atmospheres or simi- as they come on stream.
lar environmental conditions.) This guideline If you’d like information on any of these prod-
calls for the following limits on VOCs: ucts, or have questions regarding VOCs, please
• Pigmented coatings: normal use . 3.0 lb/gal. contact your Whitford representative.
• Pigmented coatings: How to measure VOCs
extreme performance. . . . . . . . . . . 3.5 lb/gal.
There is a simple formula for calculating the
• Clear coatings: . . . . . . . . . . . . . . . . 4.3 lb/gal.
amount of volatile organic compounds in any
Note: some countries measure VOC limits in solvent-based coating:
metrics (grams per liter). To make the conver-
VOCs =
sion, simply multiply the lb/gal by 120. For ex-
Density (lb/gal) x (1 - % solids by weight)
ample: 3.5 lb/gal x 120 = 420 gms/ltr.
The following examples show how the formu-
A few more things to remember la works in several types of coatings. (Note:
In most of the United States, regulations per- these are white coatings with the ratio of Ti02 to
mit the averaging of VOCs emitted during a 24- resin at 1 to 1; the assumed density of the
hour period. If you use a low-VOC material, you organic solvent at 7.5 lb/gal; the density of the
can also use the same amount of a high-VOC resin solids at 9.5 lb/gal.)
material (as high as the other was low) — pro- *Since “VOC” is an American term, the formulae are
expressed in the units of measurement used by US regula-
vided the total amount of VOCs produced during tory authorities.

30
 Solvent-borne coatings Waterborne coatings
By weight Volatile Organic Compounds are now
calculated in terms of pounds per gallon of
coating less water and less exempt com-
pounds (of which there are few).
40% solvent
After removing any water and exempt
60% solids compounds, the material remaining is
expanded to the gallon equivalent — giving
a VOC reading higher than the actual VOCs
for that gallon.
In this example, the formula becomes
slightly more complicated:
Specifications VOCs = Density x (1 - %solids by weight
% solids by weight . . . . 60 -%water by weight)
% solids by volume . . . . 43.1 (1 - % water by volume)
Density. . . . . . . . . . . . . . 10.67 lb/gal
Coverage. . . . . . . . . . . . 691 sqft/gal @1.0 mil By weight
To calculate the VOCs in this coating, substi-
tute the correct numbers in this formula: 20% water
VOCs = 10.67 lb/gal x (1 - 0.60) 20% solvent
or
VOCs = 10.67 lb/gal x 0.4 = 4.28 lb/gal 60% solids

High-solids coatings
By weight

Specifications
25% solvent % solids by weight . . . . 60
75% solids % solids by volume . . . . 44.4
Density. . . . . . . . . . . . . . 10.98 lb/gal
Coverage. . . . . . . . . . . . 712 sqft/gal @1.0 mil
Water weight @20% . . . 2.20 lb
% water volume
@8.33 lb/gal . . . . . . . . .0.26 (2.20/8.33)
As before, substitute the values in the formula
as we do here:
Specifications
% solids by weight . . . . 75 VOCs = 10.98 lb/gal x (1 - 0.6 - 0.2)
% solids by volume . . . . 60.3 (1 - 0.26)
Density. . . . . . . . . . . . . . 11.93 lb/gal or
Coverage. . . . . . . . . . . . 691 sqft/gal @1.0 mil VOCs = 10.98 lb/gal x 0.2 = 2.97 lb/gal
0.74
The formula remains the same:
VOCs = 11.93 lb/gal x (1 - 0.75) If you’d like information on low-VOC products, or
or have questions regarding VOCs, please contact
VOCs = 11.93 lb/gal x 0.25 = 2.98 lb/gal your Whitford representative.

31
 10. Whitford’s wide range of other products
hitford manufactures the largest, most

W complete line of fluoropolymer coatings

in the world — as well as a group of
inorganic coatings.
Fluoropolymer coatings first became known
as cookware coatings for their release and easy
cleanup properties. They were not uniform and
suffered from poor adhesion and durability.
Over time, and especially within the past few
years, cookware coatings have evolved into
increasingly sophisticated systems.
Here is a simplified list of Whitford products.

Xylan on the inside, Xylac on the outside. Whitford

coatings are used on cookware and bakeware in
countries all around the world.
similar regulatory authorities serve essentially
Xylan: one-coat products. the same purpose. While a complicated issue, it
is worthwhile mentioning that any coating sold
by Whitford for use in food applications meets
the most stringent requirements of authorities
throughout the world.
For answers to any questions in this compli-
Xylan Plus: two-coat products. cated area, please contact Whitford’s Regulatory
Affairs Department.

Xylan Eterna: three-coat products.

Quantum2 is Whitford’s nonstick “doubly
Xylan is Whitford’s brand name for a wide reinforced to outlast all conventional nonsticks”.
range of one-, two- and three-coat conventional Reinforced internally with hard ceramic particles,
and reinforced nonsticks. These coatings come it has twice the durability of other reinforced
in many different variations that offer a wide vari- nonsticks (that’s why the “2” in “Quantum2”). It
ety of performance levels at remarkably low is ideal for cookware and bakeware.
prices.
Whitford uses the 7000 and 8000 designa-
tions for all Xylan coatings used for food contact
or food-associated applications.
In the United States, the Food & Drug QuanTanium is “reinforced with titanium to
Administration (FDA) regulates coatings that stand up to almost anything”. That’s because
come into contact with food. In other countries, certain alloys of titanium, the lightest, toughest

32
metal known, are many times harder than the A first coat of tough nonstick is applied, set-
aluminum and steel used in the pots and pans tling down into the valleys. Then, a second and
themselves. While not as resistant to wear and third coat are applied, filling in all the valleys
abrasion as Eclipse, it consistently outperforms and covering the peaks. The coatings are now
other internally reinforced cookware coatings. bonded to the surface for extra durability.
Excalibur combines the strength of stainless
steel with the low friction and release character-
istics of nonsticks.

Tests show that Eclipse outlasts other inter-

nally reinforced coatings by a significant factor.
The reason: a unique primer reinforced with a
high percentage of materials virtually as hard as The Suave line includes Whitford’s “soft-
diamonds. The midcoat also contains the rein- touch” and “silk-touch” coatings. Suave offers
forcing materials, leaving the topcoat dedicated new dimensions to the aesthetic and tactile pos-
entirely to “release”. sibilities of design. The soft-to-the-touch texture
Eclipse is ideal for all types of aluminum provides a firm, comfortable grip to help prevent
cookware and bakeware, from smooth to grit- slipping. Suave comes in an unlimited range of
blasted to hard-anodized. colors (color-matching is easy) and has good
resistance to wear.
Suave is user-friendly, easily applied to
phenolic, ABS, melamine, PVC, methacrylates,
nylon, aluminum, iron, stainless steel, and cures
It was Excalibur that took nonstick coatings at low temperatures.
to the top end of the cookware market. That’s
because Excalibur is far more than a nonstick
coating. It is a unique system. What makes it
different from — and superior to — all other non-
sticks is that it is externally reinforced.
The substrate is blasted with an abrasive.
Then, white-hot particles of stainless steel are
sprayed onto the surface. Welded to it, they
form permanent “peaks and valleys” that pro-
vide a tough base for the nonstick coatings.

A Suave coating on many items provides a hand-

some, matte, rubber-like surface that improves grip
and helps prevent things from slipping. And Suave
comes in many eye-catching colors!

Acquired from ICI, Ultralon products come in

The secret of Excalibur’s durability: a patented stain- one- and two-coat systems for industrial applica-
less-steel alloy that forms a hard matrix into which tions such as conductive multicoats for fuser
three coats of tough nonstick are sprayed. and release rollers on photocopiers.

33
 Xylac coatings are high-temperature decora-
tive finishes for cookware and associated prod-
ucts, bridging the gap between acrylic paints
and more expensive porcelain coatings while
maintaining resistance to all household cleaning
and dishwashing compounds.

Dykor protects against many hostile environments. It

comes in both liquid and powder forms.

Xylar coatings are thin-film surface-protec-

tion finishes, ideal for extending the lives of
parts where environments are extremely hot,
corrosive and/or abrasive.
Xylac decorative exterior coatings offer many options Based on an alloy of ceramic and metallic
to add eye appeal to products, from high-gloss clear
coats to colorful hammertone finishes. materials, Xylar forms a thin, hard, high-tempera-
ture-stable, sacrificial ceramic metallic barrier.
All are based on organic polymers with out- In many cases, these coatings enable parts to
standing high-temperature properties, unlimited be used in environments that would normally
colors, one-coat coverage, excellent gloss reten- preclude their use. In others, they enable
tion at elevated temperatures, adhesion to all designers to replace expensive super alloys with
metallics, flexible cure schedule(s), minimal sur- less costly metals coated with Xylar. Topcoats
face preparation, and high impact resistance. may be added to modify or improve the properties
of the basecoats (such as increasing corrosion
resistance or decreasing coefficients of friction).

Dykor 200s and 600s are combinations of

resins from the polyvinylidene (PVDF) family and
appropriate fillers, typically graphite and mica.
When combined and applied at 0.6 mm/25 mils,
the system provides outstanding chemical, cor-
rosion and UV resistance.
Dykor 700s are attractive, functional powder
coatings often used for wire goods and small
electric appliances. A range of formulations is
available offering various colors, levels of easy-
clean, and operating temperatures. Dykor 800s Xylar 2 Silver protects against high-temperature oxida-
are high-build fluoropolymer powder coatings for tion, provides sacrificial corrosion protection and
chemical resistance and high release. resists atmospheric and salt-water corrosion.

34
 11. Polymeric Systems, Inc.
ate in 2003, Whitford reached an agreement technology, with additional patents obtained for

L with the shareholders of Polymeric Systems,

Inc. (PSI), to purchase the company. Poly-
meric Systems, Inc. develops and manufactures
improvements incorporated into the expanding
product line. The company experienced steady
growth through its sale in 2003.
high-performance sealants, caulks, and epoxy The company was merged into Whitford and
adhesives. Its leading product line is a 2-part is now housed in Whitford’s headquarters in
epoxy putty stick, offered in a range of formula- Pennsylvania, due west of Philadelphia. Poly-
tions, each for specific applications. meric Systems’ operations occupy 80,000
The origins of PSI date from 1959, when Ted square feet in Whitford’s multi-story building on
Flint, a chemical engineer, and a partner started sixty-three acres of property (which allows sub-
a business to manufacture adhesives and stantial room for expansion).
sealants. That business was sold to Teledyne While PSI does private-label and toll manu-
Corporation in 1967. facturing, it also markets its own products.
Ted Flint then formed Polymeric Systems in PSI-labeled products include a range of con-
1969. Its first product was a line of sealants for struction sealants and epoxy putties, pastes and
the insulating glass industry. gels (all of which are available for private label).
In 1972, Mr. Flint developed a 2-part epoxy PSI’s entire product line is either low in solvents
putty product with an innovative core/shell (cylin- or solvent-free. A new line of non-irritating
der form) for easy user application. Strong epoxy adhesives has just been introduced and
patent protection was secured for the product patents filed on this unique material.

One of PSI’s leading product lines is a series of 9 patented Epoxy Putty Sticks, each custom-formulated to pro-
vide fast, easy and permanent repairs to a series of materials from concrete to wood to plastic to metal.

35
 In 1995, PSI brought to market a new pack-
aging system called SUM PAK.® This is a single-
use pack of a two-component reactive adhesive
or sealant. The package holds the two compo-
nents in separate pouches until pressure is
applied (such as with a pencil or pen pressing
over them), at which point the components are
released into a series of chambers connected
with mixing holes. The top is cut with scissors,
and the same pencil or pen moves up the pack-
age, forcing the two components through the
QuikWood® epoxy patches wood easily and quickly. mixing holes until they reach the top, thoroughly
It can be sanded, stained and painted. mixed (actually achieving molecular mixing).
PSI’s epoxy putty sticks consist of pre-meas- The glue is applied as needed. The remarkable
ured components (an activator and base) in pack is easy to use, with no mess, and offers an
cylinder form, allowing the required portion to be extended shelf life.
cut, then mixed and molded by hand prior to
use. This line has evolved into a family of nine
products specifically formulated to adhere to a
variety of surfaces — including metals, wood,
plastic, fiberglass and concrete — and for a
range of temperature and moisture conditions.
There is even a version that can be mixed and
applied under water for plumbing or marine use.
In recent years, the Company has developed
some PSI-branded sales of epoxy sticks through
do-it-yourself (“DIY”) retail channels.
PSI has two other major product-line offerings:
urethane- and silicone-based elastomeric seal-
PSI’s SUM PAK®: The patented package uses up-
ants. These are reactive products of single, ward pressure to burst the two pouches holding sep-
2-part, and multi-part components, packaged in arate ingredients, which are then mixed — perfectly
liquid or paste form in containers from tubes to — by the channels through which they pass on the
drums. The primary markets for these elasto- way to the top. “Molecular” mixing in a matter of a
meric sealants are the construction, marine, few seconds!
automotive, and wood construction industries. PSI's production is geared to accommodate
varying batch sizes to increase flexibility — a
requirement for most private-label manufacturers.
Many of these systems have been custom-
designed for the PSI products, particularly the
epoxy putty sticks. Its packaging systems
capabilities include tube and cartridge filling
systems, pail filling, labeling and capping, blister
packs, as well as a custom-designed form, fill
and seal machine for their SUM PAK products.
To no small extent, the products produced
by PSI overlap those produced by Whitford
Sili-Thane 801 offers all the benefits of silicone and
(especially in terms of raw materials), so the
polyurethane-type sealants with none of the disadvan-
tages. There are no solvents or isocyanates. VOCs coming together of the two companies made
are less than 1%. 801 adheres well to a wide range good sense from every perspective — and from
of substrates, resists discoloration and is paintable. the very beginning.

36
 12. A word from our sponsor
hitford Corporation was founded in West It is this approach to the business that has

W Chester, Pennsylvania, in 1969. Six

months later, Whitford Plastics Limited
was founded in Runcorn, England. From the
led Whitford to have the largest, most complete
line of fluoropolymer coatings in the world —
despite the fact that one of our competitors is
start, Whitford has taken a global approach to its larger than we are in terms of annual turnover.
business. Our worldwide mission statement summa-
Since then, Whitford has grown into a world- rizes what we do:
wide organization with manufacturing facilities in “We provide attentive, innovative solutions
seven countries, direct employees in eight more, to our customers’ problems via
and agents in an additional 25. We operate in our products and related technology.”
more than fifty countries.
This philosophy, of course, demands a seri-
ous commitment to research and development.
One advantage that Whitford enjoys is that
we are a private company, so we can allocate
our funds as we see fit. As a result, we commit
an annual average of at least six percent of our
sales to R&D, something disinterested share-
holders of a public company (who expect larger
dividends every quarter) would be unlikely to
permit.
May we help?
You may have a design problem that a fluo-
ropolymer coating could solve. If so, we’d like
to hear from you. Please tell us about the prob-
lem in sufficient detail so we can determine if we
have the precise product to solve it.
Whitford suggests that customers send samples of If we don’t, we’ll create one.
their finished products for laboratory testing to assure
maximum coating performance.

What business are we in?

Some companies develop products in the
abstract — and then bend problems to fit the
products. At Whitford we take the opposite
point of view.
We believe that we are in the business of
solving problems more than the business of sell-
ing products. The coatings we engineer are
simply the vehicles by which we solve problems
for our customers.
We believe that the way to a better product Whitford’s Rheometer measures the flow and deforma-
is to start with a specific problem, then create a tion of component materials in a coating formula, key
product specifically designed to solve it. to film formation, curing and aging.

37
 Index and glossary

hese definitions are given primarily in their Binder: Tough polymer that acts as an adhe-

T relation to high-performance fluoropolymer

coatings and their use in this publication.
Abrasion: A wearing, grinding, or rubbing
sive to join elements of matrix coatings. Pages
2, 3, 4, 5, 12, 23, 39, 40.
Boundary lubrication: Condition in which a
away by friction. Pages 3, 5, 25, 26, 27, 33. lubricating film between sliding surfaces has lost
its hydrodynamic property due to heat, pressure
or low speed. As a result, the surfaces are virtu-
ally touching, separated only by a layer of lubri-
cant too thin to be effective. Potential for metal-
to-metal contact and damage to surfaces is
great. Page 8.
Break in: Initial wear of mechanical compo-
nents when large surface asperities (peaks) can
cause high friction and wear rates. Page 15.
Brinelling: Surface fatigue of steel compo-
nents that undergo cyclic stress, which causes
minute flexing resulting in work-hardening of the
surface. Eventually, brinelling may cause sur-
face cracking or spalling. Page 5.
Buffing/Burnishing: Process of polishing a
cured coating to enhance release and low fric-
tion properties. Pages 9, 10, 23.
Carrier: Liquid portion of a coating in which
solids are dissolved or suspended. Pages 3, 4,
20, 22.
Cold flow: Tendency of plastic materials to
migrate slowly under heavy loads and/or over
Whitford‘s unique Gyrograph provides a sensitive
measure of abrasion and coating adhesion, especial- time. Pages 3, 12.
ly of intercoat adhesion (a common source of failure). Conductor: Material that can support flow of
Additives: Materials added to coatings to electrical current. Coatings are normally insula-
enhance certain properties. Page 13. tors, but can be modified with certain fillers and
pigments to make them conductive. Page 13.
Alkaline wash: Cleaning process that
employs a high pH solution (caustic). A good Corrosion: Process of metal decomposition
choice for parts with little buildup of contami- (oxidation) in which metal ions are united with
nants. Pages 19, 20, 24. oxygen to form metal oxides. Fluoropolymer
coatings provide excellent barriers against most
Aluminum oxide: Hard particulate medium corrosives. Pages 1, 2, 3, 4, 5, 6, 7, 9, 11, 12, 14,
used in grit blasting to clean and roughen sur- 16, 17, 19, 20, 23, 24, 34.
faces that are to be coated. Pages 19, 41.
Crosslinking: Quality of thermosetting plastic
Anodizing: Creating a hard oxide layer on resins in which polymer chains combine during
aluminum parts via an electrolytic process. curing process. In general, the greater the
Unsealed hard anodized surfaces have a porosi- crosslinking, the tougher and more chemically
ty that makes them excellent substrates for coat- resistant the coating. Page 23.
ings. Page 20. Cryogenic: Temperatures less than -130°C/
Babbitt metal: a soft alloy of tin, copper and -200°F. Bonded dry-film lubricants continue to
antimony. Page 24. perform at these temperatures. Pages 5, 12.

38
 Curing: Process of bonding or fusing a coat- chiefly in coatings and adhesives. Pages 18, 35.
ing to a substrate. Pages 1, 4, 18, 21, 22, 25 Fabrics: Woven or nonwoven materials that
26, 30, 37. can be impregnated with fluoropolymer coatings
Dielectric strength: Ability of a coating to to impart low friction, improve chemical resist-
resist the passage of direct electric current. ance, and increase strength. Pages 18, 19, 21,
Page 13. 28.
Dip/spin: Coating application technique in FEP (fluorinated ethylene propylene): A ther-
which small parts are placed in a basket that is moplastic member of the fluoropolymer family of
lowered into a coating bath, then raised and plastics. FEP has the best nonstick and nonwet-
spun to remove excess coating. An economical ting properties of these materials. Pages 3, 4,
system for coating high volumes of small parts. 13.
Pages 3, 4, 11, 20, 21. Fillers: Pigments and other solids used to
alter properties of coatings. Pages 3, 4, 17, 34.
Flashing: A brief subcure (at lower tempera-
tures than the final cure) to drive off solvents/
carriers prior to full cure. This helps prevent
bubbling. See “Partial cure.” Pages 1, 21, 22.
Fluoropolymers: Family of engineering plas-
tics containing fluorine, characterized by high
thermal stability, almost universal chemical resis-
tance and low friction. Pages 2, 4,18, 23, 27.
Fretting: Wear phenomenon caused by vibra-
tion among tightly clamped or fastened sur-
faces. Pages 10, 11, 19.
Friction (dynamic): Resistance to continued
motion between two surfaces; also known as
sliding friction. Pages 1, 2, 3, 4, 5, 6, 7, 9, 11,
12, 13, 15, 16, 18, 23, 24, 25, 26, 28, 33, 34.
Dip/spinning is ideal for small, complicated parts.
Friction (static): Resistance to initial motion
Dry (solid) lubricants: Solid materials such as between two surfaces. Pages 1, 2, 3, 4, 5, 6, 7,
PTFE, Molybdenum Disulfide (MoS2) and graphite 9, 11, 12, 13, 15, 16, 18, 23, 24, 25, 26, 28, 33,
that have low coefficients of friction. Pages 2, 7. 34.
Elastomers: Any of various elastic sub- Graphite: Carbon-based dry lubricant that is
stances resembling rubber. Page 18. preferred for high-temperature applications.
Electrostatic spray: Spray application Pages 2, 3, 4, 7, 13, 34.
process in which the coating and part to be Hot hardness: Ability of a coating to retain
coated are oppositely charged; process pro- hardness and wear resistance at elevated tem-
vides excellent “wrap” of coating around the peratures. Usually a characteristic of coatings
part, even on sides opposite the spray gun. based on thermosetting resin binders. Page 38.
Page 21. HVLP (high volume, low pressure): A type of
Engineering plastics: Plastic resins that have spray gun utilizing high pressure in combination
high-performance properties such as high tem- with low air velocity to increase transfer efficien-
perature stability, hot hardness, abrasion resist- cy and reduce air pollution. Pages 4, 20.
ance, and corrosion resistance. Page 2. Hydrogen embrittlement: Embrittlement of
EPDM: Ethylene-propylene-diene monomer, carbon steel caused by absorption of atomic
an elastomeric substitute for rubber used exten- hydrogen in plating, pickling or acid cleaning
sively in the automotive industry. Pages 18, 25. processes. Pages 11, 19.
Epoxy: A flexible resin, usually thermosetting, Kesternich: German scientist who developed
made by polymerization of an epoxide and used the Kesternich Cabinet and test method used for

39
 PFA (perfluoroalkoxy): Thermoplastic mem-
ber of fluoropolymer family of engineering plas-
tics, characterized by excellent release and low
friction. Pages 3, 4, 13.
Phenolic: A resin or plastic, usually thermo-
setting, made by condensation of a phenol with
an aldehyde and used for molding, insulating,
coatings and adhesives. Pages 18, 33.
Phosphating: Surface pretreatment used on
ferrous parts that provides a very thin crystalline
film that enhances both corrosion resistance and
adhesion. Pages 19, 20.
Polymer fume fever: 24-hour flu-like symp-
toms (with no known long-term effects) caused
by inhaling the gases released during fluo-
ropolymer decomposition. Page 23.
Post cure: A second cure at high tempera-
ture to enhance specific properties such as
release and nonwetting. Page 23.
Whitford keeps Kesternich cabinets running virtually Postforming: Process of shaping parts after a
all the time at several of its research laboratories coating has been applied and cured, a tech-
around the world.
nique commonly used with stamped, blanked, or
acid-rain simulation (DIN 50018). Page 39, 40. spun parts. Page 23.
kN: Kilo-Newton, a measure of force, also Powder metal: Material formed by compres-
expressed as “pounds force” (lbf). Page 14. sing metal particles and heating (sintering) to
lbf: Pounds force, a measure of force, also solidify and strengthen them. Pages 13, 14.
expressed as “kilo-Newtons” (kN). Page 14. PPS (Polyphenylene sulfide): A thermoplastic
µ: One micron, a millionth of a meter. Also engineering polymer second only to PTFE in
expressed as µM, or micro-meter. Page 24. chemical resistance. In fact, PPS is unaffected
by any solvent to 400˚F/205˚C. Page 18.
µ inch: One micro-inch, a millionth of an
inch. Page 24. Preheating: Warming of parts prior to appli-
cation of coating, recommended when adhesion
Matrix coating: One in which some ingredi- is critical and when parts are being coated in
ents, such as the lubricant (PTFE), which is soft, humid atmospheres. In some cases, this tech-
are enveloped in others (the matrix, such as nique can be used to achieve higher-than-nor-
harder, more wear-resistant binders). Pages 3, mal film builds. Pages 20, 23.
4, 8, 15.
Preloads (for fasteners): The “tightness” of a
Moly, moly disulfide, molybdenum disulfide, fastener equals the make-up energy applied
MoS2: Four names for the same naturally occur- minus the energy required to overcome friction
ring substance that has good low-friction and at the fastener’s bearing surfaces and threads.
high load-bearing properties. Pages 2, 3, 4. Page 11.
Noise dampening: The absorption of sound Pressure spraying: Coating technique similar
vibrations. Xylan coatings form good noise- to siphon spraying, except that the coating is
reducing surfaces. Page 12. delivered from a pressurized pot to the spray
Oleophobic: Oil-shedding. Page 5. nozzle under positive pressure. Generally used
Partial cure: A process sometimes utilized for high-volume production. Page 24.
when multiple layers of fluoropolymer coatings Pretreatment: Processes for cleaning and
are to be applied. The first coat is incompletely conditioning a substrate to be coated. Next to
cured. The second coat is applied and both are the choice of coating, this may be the most
fully cured together. See “Flashing”. Page 39. important factor in the use of high-performance

40
coatings. Pages 19, 20, 25, 29. eign material on the substrate to be removed.
PTFE (polytetrafluoroethylene): A thermo- Pages 19, 20, 23.
plastic member of the fluoropolymer family of Static electricity: An imbalance of positive
plastics. PTFE has the lowest coefficient of fric- and negative charges usually associated with
tion of any known solid and the highest tempera- two nonconductors rubbing together. Page 5.
ture resistance of the fluoropolymers. Pages 3, Stick-slip (chatter): Unstable sliding condition
4, 5, 6, 7, 8, 9, 10, 13, 16, 19, 23, 27, 28. in which movement of one part over another
PV, limiting PV (LPV) factor: Mathematical starts and stops, caused by temporary overcom-
limit of a coating’s load-carrying ability and wear ing of static coefficient of friction. Page 26.
resistance under bearing conditions. Pages 7, Substrate: Any surface to be coated. This
8, 11, 23, 25, 33, 34. can include metals such as steel, cast iron,
PVDF (Polyvinylidene fluoride): High-molecu- bronze, brass, aluminum, stainless steel, chro-
lar-weight thermoplastic of vinylidene fluoride mium, and (with special precautions) nickel.
with greater strength, wear resistance and creep Paper, most plastics, wood, leather, fabrics, and
resistance than FEP, PFA or PTFE. Page 34. glass can also be coated. Pages 1, 3, 4, 10, 18,
Resistance (electrical): The opposition 19, 20, 21, 22, 23, 24, 25, 26, 27, 33, 36.
offered by a coating to the passage through it Thermoplastic: Plastic resin that softens
of an electric current. Pages 1, 2, 3, 5, 10, 11, when reheated. Pages 3, 25.
12, 17, 20, 22, 23, 26, 27, 28, 33, 34. Thermoset: Plastic resin that crosslinks dur-
ing cure so that it does not soften when reheat-
ed. Pages 3, 5, 12.
Transfer efficiency: The amount (percentage)
of a coating that actually reaches and stays on
the part being coated. Some coating methods
give far higher transfer efficiency than others.
Pages 20, 21, 29, 30.
Volatile organic compounds (VOCs): The
ingredients in a paint or coating, defined as pho-
tochemically reactive by the USA’s Environmen-
tal Protection Agency, that escape into the
atmosphere during the drying or curing process.
Pages 20, 30, 31.
Wear: Deterioration by friction (abrasion,
spalling, cutting, fretting). Pages 1, 2, 3, 4, 5, 6,
7, 8, 9, 11, 15, 16, 19, 22, 23, 24, 27, 33.

For more information...

Salt-fog cabinets perform an ongoing and important
role at Whitford in the development of fastener-class While this document may seem
coatings with better resistance to corrosion. lengthy, it is only scratching the sur-
face of the knowledge that we have
Salt fog: ASTM B-117 test procedure that acquired over the years.
simulates the corrosive environment caused by
road salt and marine spray. Pages 10, 11. Whitford offers many brochures, flyers
and the like with far greater detail on
Sand blasting (also grit blasting): Surface specific subjects.
cleaning and roughening process that provides
If you’d like more information on a
a mechanical “tooth” to aid coating adhesion.
given subject, please contact us.
Media include aluminum oxide, carborundum,
even crushed walnut shells. The medium must
be chosen to match the substrate and the for-

41
 How to contact Whitford
Whitford manufactures in 7 countries, has em-
ployees in 8 more and agents in an additional 25.
To find the office nearest you, please visit our
website: www.whitfordww.com or email us at
sales@whitfordww.com.

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WHITFORD. NO REPRESENTATION OR WARRANTY IS MADE, HOWEVER, CONCERNING THE ACCURACY OR COMPLETENESS OF
THE INFORMATION PRESENTED IN THIS PUBLICATION. WHITFORD MAKES NO WARRANTY OR REPRESENTATION OF ANY KIND,
EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTIC-
ULAR PURPOSE, AND NO WARRANTY OR REPRESENTATION SHALL BE IMPLIED BY LAW OR OTHERWISE. ANY PRODUCTS SOLD
BY WHITFORD ARE NOT WARRANTED AS SUITABLE FOR ANY PARTICULAR PURPOSE TO THE BUYER. THE SUITABILITY OF ANY
PRODUCTS FOR ANY PURPOSE PARTICULAR TO THE BUYER IS FOR THE BUYER TO DETERMINE. WHITFORD ASSUMES NO
RESPONSIBILITY FOR THE SELECTION OF PRODUCTS SUITABLE TO THE PARTICULAR PURPOSES OF ANY PARTICULAR BUYER.
WHITFORD SHALL IN NO EVENT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. WC1/06