Compositions and methods for a high performance protective coating

A high performance protecting surface coating, and methods, is disclosed. The coating comprises a resin such as epoxy loaded with inert particles, preferably ceramic, a curing agent for hardening, and a selected additive such as a solvent. The protective coating of the present invention has adhesion strength of at least 2,000 psi and impact resistance of at least 90 inch-lbs.

FIELD OF THE INVENTION 
This invention relates generally to protective coatings and paints. More 
particularly this invention pertains to a coating system providing a tough 
wear and corrosion resistant material having extremely high adhesion to 
various metal, concrete, composite, or plastic substrates. 
BACKGROUND OF THE INVENTION 
Protective coatings are often used on many mechanical or protective 
surfaces to prevent corrosion, abrasion, and other wear on the surface. 
High performance coatings have been developed which exhibit high 
resistance to abrasion, corrosion, impact, and other characteristics of 
high performance. These coatings include powder comprising finally divided 
inert particles dispersed in a resin which is then mixed with a hardening 
catalyst and applied. 
The resin of the present coating should be selected for its wear resistant 
properties and by the strength of its adhesion to the surface being 
protected. Some commonly used resins include epoxy (e.g., Bisphenol A and 
Bisphenol F based epoxies), polyester, vinyl-ester, phenolic, novolac 
(phenol/novolac), and polyglycol resin. Epoxy resins are known to those 
skilled in the art to have the highest adhesion values of all resins. 
The adhesion strength of coatings is measured according to an international 
industry standard referred to as American Standard Testing Materials 
(ASTM). ASTM adhesion testing involves applying and curing a coating on to 
a surface substrate prepared according to National Association of 
Corrosion Engineers (NACE) specifications. For example, a steel test panel 
prepared to an anchor profile of 1 to 21/2 mils (white to near white 
metal) and cleaned of substantially all contaminates. The coating is 
applied and cured at room temperature (72.degree. F.). Adhesion is tested 
according to ASTM protocol by pulling off the cured coating and measuring 
the force required to pull the coating of the surface. Adhesion is 
measured under ASTM protocol in metric units known as Megapascals (Mpa). 
For convenience, Mpas are often converted herein to approximate English 
units of pounds per square inch (psi). 
In addition, or alternatively to ASTM testing, adhesion may also be 
measured by resistance to hydroblasting, i.e., measuring the force (in 
psi) of a pressurized stream of water to dislodge a coating from a 
standard prepared surface. Typically, adhesion strengths are the same 
whether measured by ASTM pulling or hydroblasting. One drawback of ASTM 
testing is that the surface substrate may fail by mechanical breakage or 
some other means before the coating being tested fails. 
Epoxy resins are known to those skilled in the art to have the highest 
adhesion strength of commonly available resins, epoxy having adhesion 
strength measured in the range of approximately 800 to 1,200 psi. 
Phenol/novolac resins are thermoset plastic materials offering alternatives 
to Bisphenol A-based epoxies and Phenolic resins, particularly when 
formulators and fabricators seek good strength and good chemical 
resistance at high temperatures. Phenol/novolac epoxy combines in one 
molecule the stability of a phenolic backbone with the reactivity and 
versatility of an epoxy resin. The resulting resins have multi-epoxy 
functionality. The additional reactive sites, as compared to a Bisphenol 
A-type resin, produce tightly cross-linked cured systems with improved 
resistance to acids, bases, and solvents; retention of good mechanical 
properties at high temperatures; minimal shrinkage for accurate 
reproduction; acceptance of a wide range of modifiers, fillers, and 
pigments; and improved high temperature adhesive properties. The 
phenol/novolac resin is usually received from the manufacturer dissolved 
in 15% acetone by weight of phenol/novolac. 
The resin carrying the inert particles must be mixed with an appropriate 
hardening catalyst or curing agent to form a base composition before 
application. Generally both the resin and catalyst are supplied from the 
coating manufacturer with instructions as to mixing. A coating 
commercially available is manufactured by Owens-Corning and marketed under 
the name Owens-Corning Abrasion Resistant Coating (ARC). The Owens-Corning 
coating contains finally divided ceramic particles dispersed in an epoxy 
resin, and a compound that adds flexibility to the coating. 
Another coating commercially available is manufactured by Freecom, Inc. 
under the name "Ceram-Kote 54." The Freecom product is sold with 
instructions that allow the user to dilute or thin the resin and catalyst 
mixture with an appropriate solvent to provide for ease of application and 
for various desired surface finishing and coating qualities. 
To the base composition mixture various additives may be combined to 
greatly enhance the qualities of the final product. Such additives may 
include pigments for color and thixatropes to inhibit running and sagging, 
a variety of inert ceramic powers added to enhance the abrasion resistant 
capabilities of the coating, and selected solvents to dilute the coating 
for enhanced uniformity of coverage of the surface being coated. The 
solvent or solvents should be selected on the basis of their lack of 
reactivity with any other components of the coating, particularly the base 
composition and any other additives. Isopropyl alcohol (isopropanol) and 
methyl-ethyl-ketone (MEK) have shown to be very good solvents in the 
present invention. 
U.S. Pat. No. 4,789,567, issued Dec. 6, 1988, to Freeman, hereinafter 
referred to as the '567 patent, and which is incorporated herein by 
reference, discloses a protective coating of finely divided abrasions 
resistant inerts carried in a corrosion resistant epoxy resin that is 
diluted with a solvent and applied to a surface. The coatings of the '567 
patent may be cured to achieve either a glossy or a mat finish. The '567 
patent, however, does not disclose nor teach the performance 
characteristics of the coating of the present invention. Nor does the '567 
patent teach the use of additives in the manufacture of the coating to 
achieve desired performance characteristics. 
U.S. Pat. No. 4,968,538, issued Nov. 6, 1990, to Freemen, a 
continuation-in-part of the '567 patent, hereinafter referred to as the 
'538 patent, and which is incorporated herein by reference, discloses a 
protective coating of finely divided abrasion resistant inerts in a 
corrosion resistant epoxy resin diluted with a solvent, and further 
disclosed the addition of novolac resin dissolved in methyl-ethyl-ketone 
(MEK) and polyglycol di-epoxide resin to the epoxy resin carrying inert 
particles. The '538 patent, however, the '567 patent, however, does not 
disclose nor teach the performance characteristics of the coating of the 
present invention. Nor does the '567 patent teach the use of additives in 
the manufacturer of the coating to achieve desired performance 
characteristics. 
SUMMARY OF THE INVENTION 
The coatings of the present invention comprise: a high performance surface 
coating, said coating comprising: at least one resin; inert particles 
loaded into said resin to form a mixture of resin and inert particles; a 
catalyst, wherein said mixture and said catalyst combine to form a base 
composition; and at least one additive added to said base composition to 
form a final coating composition having desired performance 
characteristics, and wherein said performance characteristics comprise 
adhesion strength of at least approximately 2,000 psi and impact 
resistance of at least 90-inch/lbs. 
The present invention also comprises a method of applying a high 
performance surface coating to a surface, said coating comprising: at 
least one resin; inert particles loaded into said resin to form a mixture 
of resin and inert particles; a catalyst, wherein said mixture and said 
catalyst combine to form a base composition; and at least one additive 
added to said base composition to form a final coating composition having 
desired performance characteristics, and wherein said performance 
characteristics comprise: adhesion strength of at least approximately 
2,000 psi and impact resistance of at least 90-inch/lbs, the method 
comprising: preparing the surface to be coated to achieve an appropriate 
anchor profile, re-suspending all said inert particles loaded in said 
resin, applying said additive and base composition mixture to said 
surface, and curing said coating to achieve a desired finish. 
The present invention further comprises a method of manufacturing a high 
performance surface coating, the method comprising: providing at least one 
resin, loading inert particles into said resin to form a mixture of resin 
and inert particles, adding a catalyst to mixture, wherein said mixture 
and said catalyst combine to form a base composition; and adding at least 
one additive to said base composition to form a final coating composition 
having desired performance characteristics of said coating, and wherein 
said performance characteristics comprise adhesion strength of at least 
approximately 2,000 psi and impact resistance of at least 90-inch/lbs. 
The coatings of the present invention are very high performance, having 
extremely high adhesion to carbon steel, stainless steel, aluminum, 
titanium, fiberglass, composite materials, plastics, and concrete, and 
having very high resistance to abrasion and corrosion. The coatings of the 
present invention are thin film and may be applied simply with a spray 
gun, brush, or roller, or by dipping the item to be coated into the 
coating of the present invention. The coatings of the present invention 
are flexible, machinable (when cured) and tolerate temperatures up to 
300.degree. F. (149.degree. C.) with no deterioration of performance. 
The coatings of the present invention comprise an inert particle loaded 
resin and a catalyst combined to form a base composition, together with 
any additives added to said base composition to achieve a final 
composition having desired performance characteristics. 
To load the resin with inert particles such as ceramic, the selected resin 
should be of such viscosity that the resin may be stirred or mixed with 
sufficient vigor to incorporate the solids. Usually this is accomplished 
by warming the resin. The temperature of the resin for mixing in the inert 
solids depends on the resin selected. For example, a good working 
temperature range for epoxy resin is in the range of approximately 
100.degree. F. to 120.degree. F. Resins that start out more viscous than 
epoxy may require higher temperatures. The resin should not be warmed to 
such temperatures, however, as to effect the coating properties of the 
resin. The resin is stirred or mixed and the inert solids are added to the 
resin gradually and combined with the resin by the mixing action. The 
inert solid particles are added to the resin until the mixture is in the 
range of approximately 60% to 90% solids by weight of the mixture. 
The coatings of the present invention are provided in two parts: the base, 
Part A, which is the inerts loaded resin composition, and a curing agent 
or catalyst, Part B. The base (Part A) is in two phases: one is solids 
(resin and inerts), the other phase is a small liquid layer on top. The 
base is mechanically shaken until all solids are in suspension, before the 
catalyst (Part B) is added. Shaking is renewed after catalyst addition 
until the batch is completely mixed. The standard ratio by volume is 13 
measures of the base and one measure of the catalyst. Should thinning be 
required to decrease the viscosity for spraying, isopropyl alcohol or 
methyl-ethyl-ketone (MEK) may be used sparingly. 
In some instances, proper preparation of the surface may be useful to 
achieve maximum performance of the coatings of the present invention. For 
example, it is recommended that steel surfaces to which the coating is to 
be applied be prepared to white or near white metal (SSP-10 or NACE-2) 
with a blast ink or pattern profile of 1 mil to 21/2 mils maximum. 1 
mil=25 angstroms. Aluminum requires only a light blasting or an alodine 
wash before coating. Polyester, epoxy and other plastics should be wiped 
with solvent and slightly roughen for better adherence. For best results, 
substrates must be clean and clear of contaminants. 
The coatings of the present invention may be applied by brush, roller, 
standard air spray or airless spray equipment or by dipping the item to be 
coated into the coating of the present invention. Curing by air at room 
temperature occurs within six to eight hours for a standard finish. Curing 
may occur more rapidly or for different finishes by exposing the coating 
to elevated temperatures for varying periods of time. 
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
In the preferred embodiment of the present invention, a loaded resin is 
prepared by loading a wear resistant resin with particles of inert solids 
to form a mixture of inert particles suspended in resin. The inert 
particles may be in the form of irregularly shaped granules, spheres or 
platelets, depending upon the method of manufacturer, and may range in 
size from a few angstroms to several microns in size. Ceramic is the 
preferred inert, but any other abrasion resistant inert compound may be 
used. 
To load the resin with inert particles, the resin is stirred and inert 
solid particles are added gradually. The resin may need to be warmed first 
to achieve an adequate mixing viscosity. The temperature to which the 
resin is warmed will vary depending on the resin selected. For epoxy 
resin, for example, the epoxy is typically warmed to within approximately 
100.degree. F. to 120.degree. F. In the preferred embodiment, the resin is 
mixed with a high speed disperser. The disperser usually comprises a shaft 
with a mixing blade at the mixing end of the shaft, wherein the blade 
comprises sharp points to facilitate shearing of the mixtures, which 
results in more efficient dispersal of the components throughout the 
mixture. Particles are added to the resin until the mixture is in the 
range of approximately 60% to 90% inert solid particles by weight of the 
mixture. In the preferred embodiment, the range is approximately 75% to 
90% solids by weight. For purposes of the present invention, however, the 
precise ratio of resin to solids is less critical than the performance 
characteristics of the final coating composition. 
An appropriate catalyst such as diethylene triamine or cycloaliphatic amine 
solvent is added to the loaded resin to form a base composition and to 
initiate the curing process. The base composition is diluted with selected 
solvent additive such as isopropyl alcohol, methyl-ethyl-ketone (MEK), or 
both. Other additives such as inert particles, thixatropes (such as 
silica-hydrophilic or hydrophobic), and pigments, for example, may be 
added to the base composition to form a final coating composition having 
desired performance characteristics. The performance characteristics of 
the preferred embodiment comprise adhesion strength of at least 2,000 psi. 
The high performance coating of the present invention has a surprisingly 
high adhesion strength, as measured by ASTM or hydroblasting, of at least 
2,000 psi. This is stronger adhesion than is measured for ordinary epoxy. 
The adhesion strength of the coatings of the present invention come from 
the high solids content of the coating. The high solids content, or 
"ceramic particle loading," produces low shrinkage during curing and 
results in lower stress levels in the cured coatings. Less shrinkage and 
lower stress yields a longer-lasting coating. Another factor that 
contributes to the bonding strength of the coatings of the present 
invention is that during curing, no by-products are formed, thus volatile 
agents are not generated to act as plasticizers. 
The present invention comprises a higher inerts content in a resin than is 
achieved by those of ordinary skill in the art. The inert particles may be 
loaded into the resin of the present invention by any of a variety of 
mechanical means, including but not limited to, mixing, stirring, 
blending, folding, and the like. In the present invention, inert particles 
are loaded into the resin to form a resin/inert particle mixture 
comprising finely divided inert particles in suspension in a resin, 
wherein the inert particles comprise at least approximately 60% of the 
weight of the mixture. In the preferred embodiment, the inert particles 
comprise from approximately 75% to approximately 90% of the weight of the 
mixture, wherein the mixture is comprised almost entirely of inert 
particles and just enough resin to coat each such particle with a thin 
film of resin. 
The higher the content of inert particles in the present invention, the 
greater the wear resistance and overall toughness of the final coating 
composition. Ordinarily, the ease of application of the present coating 
may diminish with increased content of inerts. However, the present 
invention may be diluted with an amount of an appropriate solvent additive 
to improve the ease of application of the present invention comprising a 
high content of inert particles in the range of 80% to 90% of the weight 
of the is resin/particle mixture. 
The finish of the coating of the present invention may be customized to the 
needs or desires of the user by vary the curing process of the present 
coating as described below. Curing the final coating composition slowly 
allows the inert particles to settle down, away from the surface of the 
coating, leaving a smooth outer surface of the coating, resulting in a 
glossy finish of the coating. More rapid curing causes the coating of the 
present invention to set-up before the inerts therein can settle 
significantly. The outer surface of the coating, therefore, is less smooth 
with rapid curing, resulting in a flat or mat finish of the present 
coating. 
While other coatings offer resistance to specific classes of chemicals, the 
coatings of the present invention resist caustics as well as most acids, 
petroleum distillates and solvents. The coatings of the present invention 
also provide excellent electrical insulating characteristics (di-electric 
and resistive properties), and retain these properties under severe 
operating conditions. The coatings of the present invention are Volatile 
Organic Content (VOC) compliant. The established VOC rating of the 
coatings is approximately 1.63 lbs/gal (196 g/l), which is well below the 
projected maximum VOC content for Industrial Maintenance Coatings expected 
to be promulgated by the U.S. Environmental Protection Agency. In 
addition, the coatings for the present invention are manufactured with 
epoxies and inert ceramic powders that are food grade when cured. 
The present coating comprises at least one resin, such as epoxy. Another 
embodiment of the present coating further comprises novolac resin 
dissolved in 15% MEK by weight of novolac and added in the range of from 
3.5% to 10% by weight of said base composition, polyglycol di-epoxide 
resin added in the range of from 0.7% to 2.7% by weight of said base 
composition, and silicon dioxide added in the range of from 4% to 20% 
based on the weight of the base composition. 
Prior to application of the coating to a surface, it may be helpful to 
prepare the surface. For optimal performance, steel surfaces must be 
prepared to white (NACE-1/SSPC-5) or near white (NACE-2/SSPC-10) finish by 
abrasive air blast cleaning or the like to achieve an anchor profile of 1 
mil to 21/2 mils maximum. Aluminum requires only a light blasting or an 
alanine wash before coating. Polyester, epoxy, and other plastics and 
composites should be wiped with solvent and slightly roughened for better 
adherence. For best results the substrates must be clean and free of 
contaminates. 
The coatings of the present invention require mixing before use. The base, 
Part A, is all solids (resin and inert particles) suspended in a small 
amount of solvent, and the solids settle during storage. The solids must 
be brought back into full suspension by vigorous mechanical shaking with a 
paint shaker for approximately five to ten minutes prior to adding 
catalyst. After adding catalyst into the base to form a base composition, 
shaking is continued for another five to ten minutes to complete the 
mixing. The length of time required for shaking or mixing depends on the 
ambient temperature. Higher temperatures require less shaking time and 
colder temperatures require longer shaking time. All inert solids must be 
in suspension prior to adding the catalyst (Part B). Mechanical mixing or 
shaking means may also be used to combine the catalyst with the loaded 
resin to form the base composition. After shaking or mixing the coatings 
of the present invention, it is recommended to strain the coating into a 
standard paint strainer and pour it into spray equipment or some other 
appropriate container. The pot life of the catalyzed coating at 72.degree. 
F. is approximately 4 to 6 hours. 
The viscosity of the base composition catalyst mixture is adjusted with 
small amounts of an additive comprising a selected solvent such as 
isopropanol (99% pure) or methyl-ethyl-ketone (MEK). Using a number 4 for 
viscosity cup, viscosity should be 34 to 38 seconds at 75.degree. F. to 
80.degree. F. (23.degree. C. to 26.degree. C.). The particular solvent 
used to dilute the coating may vary with the resin which carries the inert 
particles. The solvent selected should be mutually soluble with the base 
composition. The selected solvent should also flash readily. Where 
flexibility of the coating is a concern, and particularly where elastomers 
to enhance flexibility are included in the final coating composition, 
hospital grade Isopropyl alcohol (99% by volume alcohol) is the preferred 
solvent. Where flexibility is less of a concern, MEK is a suitable 
solvent, although both Isopropyl alcohol and MEK are generally 
satisfactory solvents for most uses. Another useful solvent for the 
present invention is HECTROLAX.RTM., manufactured by Ashland Chemical 
Company. In addition to being a useful solvent, HECTROLAX.RTM. also 
contains mica (a natural form of silica), which provides protection of the 
substrate from ultra-violet radiation. 
For best results, the coatings of the present invention should be applied 
by spraying. High volume, low pressure equipment is recommended as are 
tungston carbide needles and fluid nozzles for maximum life and to prevent 
damage to spray equipment. The compressed air source of the spray 
equipment should be outfitted with dryers as needed to supply moisture 
free air. Dry nitrogen may also be used as a pressure source. Airless 
equipment may also be used. 
The coatings of the present invention spray like automotive enamel paints. 
Apply a light first pass of 3 to 4 mils and allow the coating to sit until 
tacky. Normally 30 to 40 minutes is sufficient, but allow more time if the 
temperature is below 70.degree. F. Apply a second pass of 3 to 4 mils for 
a total dry film thickness (DFT) of 6 to 8 mils. Apply additional mils 
without occurring runs or sags if the finish product requires thicker 
coverage. Whenever impossible, always apply the second coat in a 
cross-coat method to the first coat. 
The finished application of the material appears glossy when wet. It gels 
at room temperature (72.degree. F.) in approximately 3 hours. Longer gel 
times occur at colder temperatures and shorter gel times occur at higher 
than room temperature. An 80% cure is achieved within 12 hours, and full 
cure is achieved within 48 hours at room temperature. Elevated 
temperatures produce full cures in shorter times. It is possible to place 
material into service after 12 hours at room temperature or earlier if the 
temperature is above 72.degree. F. Room temperature curing typically 
yields a glossy appearance to the finish of the coating by allowing the 
inert particles to settle away from the surface of the coating. 
Should a more rapid cure be desired, the coatings of the present invention 
cures in 1 hour if the temperature is elevated to 150.degree. F. If this 
method is used, the finish appears flat (mat) to semi-gloss depending on 
the amount of time the coating air dried prior to rapid curing; by causing 
the coating to setup or gel before the inert particles settle away from 
the surface of the coating. Some flexibility, however, is lost by rapid 
curing. 
Should a glossy finish be desired with rapid curing, spray and air dry the 
coating for 15 to 30 minutes. Then, place the coated part in an oven at a 
temperature at approximately 110.degree. F. to 120.degree. F. However, 
some loss of gloss and flexibility can be expected. If allowed to air cure 
prior to heating, the product maintains its glossy finish. 
The coatings of the present invention, when applied and cured as described 
above, achieve the characteristics detailed in Table I. 
TABLE I 
______________________________________ 
Adhesion &gt;2,000 psi (15.17 Mpa) 
(ASTM 4541, elcometer pull-off) 
The failure made was a 
fracturing through the glue 
Adhesion &gt;4,000 psi (27.98 Mpa) 
(ISO 4624, using hydraulic test 
equipment type P.A.T. Model GM01) 
Abrasion Resistance 
10.9 Miligrams loss 
(ASTM D 4060, Tabor Test 1,000 
cycles, CS 17 wheel, 1 kg) 
Flexibility &gt;30% elongation 
(ASTM D 522, Conical Mandrel Bend 
at 75.degree. F.) 
Impact Resistance 30 inch-pounds 
(ASTM G 14) Impact Strength 
Static Coefficient of 
0.152 mean static friction value 
Friction 
(ASTM D 4518-90) 
Dielectric Strength 
1,435 volts/mil 
(ASTM D 149) 
Spray Salt (Fog), 5% 
No distress observed 
solution, &gt;1500 hours (ASTM B 
117) 
Continuous-Use Temperature 
300.degree. F. (149.degree. C.) 
Fire Rating over Steel 
Smoke Density-Class 1 
(ASTM E84-91a) Flame Spread-Class 1 
VOC (Volatile Organic 
1.63 lb/gal (196 g/lit) 
Compounds) 
______________________________________ 
The adhesion strength of the coating of the present invention is measured 
to be at least 2,000 psi, which is stronger than one would expect from 
epoxy alone. The upper limit of the adhesion strength of the present 
coating is not known although it has been measured as high as 5,000 psi.

The performance characteristics summarized in Table I are illustrated in 
the following examples of performance testing: 
EXAMPLE 1 
Adhesion Testing 
Test #1 
a. Procedure: Measurements were made in compliance with ISO 4624. Adhesion 
was controlled using hydraulic test equipment, types P.A.T. Model GM01 
connected to a data logger. Scotch Weld 3M DP460 adhesive was used, 
thermally cured at 50.degree. C. for 10 hours prior to testing. 
b. Prepared by: Hydro Research Centre 
Porsgrunn, Norway 
Thor H. Jahnsen 
c. Date: Sep. 18, 1994 
d. Test Panels: Carbon steel test plate coated with the present invention, 
test area 1.57 cm.sup.2 
e. Results: Test 1 27.62 Mpa 
Test 2 25.58 Mpa 
Test 3 27.67 Mpa 
Test 4 27.98 Mpa (&gt;4,000 psi) 
Standard deviation 1.10 
Average 27.21 Mpa 
Adhesion of the Present Invention on Other Metals and Varying Surface 
Preparations: 
Test #1A Adhesion of the present invention on Titanium Plate 
Prepared by: Norcoat A. S. 
Date: Sep. 20, 1994 
Titanium plate: 25 Mpa (3,625 psi) 
Test #2A Adhesion of the present invention on Stainless Steel 
Prepared by: Ceram-Coat Scandinavia AS 
Date: Jan. 1, 1995 
Stainless steel: 24.94 Mpa (3,616 psi) 
Test #3A Adhesion of the present invention on Aluminum 
Prepared by: Cream-Coat Scandinavia AS 
Date: Jan. 1, 1995 
Aluminum: 26.18 Mpa (3,796 psi) 
Test #4A Prepared by: Norsk Hydro Research Centre 
Date: Mar. 15, 1996 
1) Surface Preparation:(UHPW)Ultra High Pressure Water 125 mm pipe, Grade 
HB2 29.49 Mpa (4,277 psi) 
2) Surface Preparation: (UHPW) and Blast Cleaning to SA-21/2 125 mm pipe, 
34.44 Mpa (4,994 psi) 
Test #2 
a. Procedure: ASTM D4541 Adhesion Elcometer Pull-off 
b. Prepared by: Technical Inspections Services, Inc. 
Houston, Tex. 
Paul E. Partridge 
c. Date: May 8, 1995 
d. Test Panels: Steel test panels with a blast profile of 2.5 mils coated 
with 4 to 10 mils of the present invention using conventional spray 
equipment 
e. Results: Adhesive strength greater than 2,220 psi. 
On all three pulls, the primary failure mode was a fracturing of the glue. 
EXAMPLE 2 
Abrasion/Tabor Test 
a. Procedure: ASTM D4060, Tabor abraser using a load of 1,000 grams on CS 
17 wheels 
b. Prepared by: Technical Inspection Services, Inc. 
Houston, Tex. 
Paul E. Partridge 
c. Date: May 8, 1995 
d. Test Panels: Steel test panel with a blast profile of 25 mils coated 
with 4 to 10 mils of the present invention using a conventional spray 
equipment. 
e. Results: Average mass loss after 1,000 cycles 10.9 mg/0.0109 g 
Average mass loss after 5,000 cycles 64.7 mg/0.0647 g 
EXAMPLE 3 
Flexibility/Mandrel Bend 
a. Procedure: ASTM D522, Air-dry specimens applied to 0.032" thick plates 
were bent over a conical mandrel. 
b. Prepared by: Technical Inspection Services, Inc. 
Houston, Tex. 
Paul E. Partridge 
c. Date: May 8, 1995 
d. Test Panels: Steel test panels with a blast profile of 2.5 mils coated 
with 4 to 10 mils of the present invention using a conventional spray 
equipment. 
e. Results: No visible cracking observed at 1/8" diameter. 
Percent elongation greater than 30%. 
EXAMPLE 4 
Static Coefficient of Friction 
a. Procedure: ASTM D4518-90 
Method A: Inclined Plane Test 
Method E: Horizontal Pull Test 
b. Prepared by: Technical Inspection Services, Inc. 
Houston, Tex. 
Paul E. Partridge 
C. Date: May 4, 1995 
d. Test Panels: Steel test panels with a blast profile of 2.5 mils coated 
with 4 to 10 mils of the present invention using a conventional spray 
equipment. 
e. Results: Polished stainless steel facing 
Method A--Mean static friction value 0.152 
Method B--Mean static friction value 0.133 
EXAMPLE 5 
Differential Flow Characteristics of the Present Invention Internally 
Coated Pipe 
a. Procedure: This test determines the fluid friction coefficient for pipe 
internally coated with the present invention. To calculate the friction 
factor coefficients for each piece, a standard pressure head loss test was 
carried out using water flow over an appropriate range of Reynolds numbers 
in the turbulent range. 
b. Prepared by: National Engineering Laboratory 
East Kilbride, UK 
c. Date: September 1995 
d. Test Panels: Two (2) pieces of 23/8", 4.6 lb/ft tubing. One piece was 
internally coated with the present invention and the other was internally 
shot blasted clean. 
e. Results: 
______________________________________ 
Friction Factor 
Friction Factor 
Present Invention 
Flow Rate 
Coefficient 
Coefficient Percentage 
Liters/Sec 
"Shot Blast 
Present Invention 
Improvement on 
gal/min! 
Test Piece" 
Test Piece Friction Factor 
______________________________________ 
750 0.0233 0.0201 15.9% 
47.31! 
2750 0.0218 0.0158 38.0% 
173.47! 
3800 0.0236 0.0149 58.4% 
239.70! 
4450 0.0243 0.0145 67.6% 
280.71! 
______________________________________ 
Surface Roughness Measurement: 
Shot Blast Cleaned Test Piece Ra=7 micro meters 300 micro inches! 
Present Invention Test Piece Ra=0.4 micro meters 16 micro inches! 
EXAMPLE 6 
Cathodic Disbonding 
a. Procedure: ASTM G8/G42 
Duration: 30 days 
Temperature: 23.degree. C. and 70.degree. C. 
Electrical Current: -1.5 V 
b. Prepared by: Raychem Ultratec Division 
Kessel-Lo, Belgium 
c. Date: Sep. 19, 1995 
d. Test Panels: Segments of 2" pipe coated with the present invention 
e. Results: In combination with cathodic protection systems, the coating 
performs well at ambient temperatures. 
______________________________________ 
Increase in 
Thickness Temperature 
disbonding 
Coating (Um) (.degree. C.) 
radius (mm) 
______________________________________ 
Present Invention 
425 23 8 mm, OK 
Present Invention 
360 70 blisters 
______________________________________ 
EXAMPLE 7 
Autoclave Testing of Several Samples of the Present Invention: Hydrostatic 
Seawater Test, Report #05-1648-2 
a. Procedure: Temperature: 90.degree. C./194.degree. F. 
Pressure: 5,000 psi 
Liquid Phase 1 
Aqueous: Synthetic Seawater 
Liquid Phase 
Hydrocarbon: None 
Gas Phase: None 
Duration: 24 Hours 
Release Temp: Less than 65.degree. C./150.degree. F. 
Release Time: 30 minutes 
b. Prepared by: Technical Inspection Services, Inc. 
Houston, Tex. 
c. Date: Jul. 12, 1995 
d. Test Panels: Twenty-two (22) coupons measuring about 1.5".times.3" were 
cut from the larger samples using a bandsaw. The coupons were coated with 
the present invention at Big Spring, Tex. and TISI. The samples designed 
with a "PC" suffix were post-cured at 140.degree. F. for two (2) hours, 
room temperature for one (1) hour and then 300.degree. F. for one (1) 
hour. The samples were tested for performance in a one-phase hydrostatic 
autoclave test. 
e. Results: 
Sample #5 23/8" O.D. Gray OD, Med. Gray I.D. No Blisters O.D.: No Blisters 
Sample #5PC 23/8" O.D. Gray OD, Med. Gray I.D. No Blisters O.D.: No 
Blisters 
Sample #6 23/8" O.D. Gray-Brown I.D., Bare O.D. #3: Not Tested 
Sample #7 23/8" O.D. Gray-Brown I.D., Bare O.D. #4: No Blisters 
Sample #7PC 23/8" O.D. Gray-Brown I.D., Bare O.D. #4: No Blisters 
Sample #8 Q-Panel 1/32".times.3".times.5": Coated at Big Spring: No 
Blisters 
Sample 8PC Q-Panel 1/32".times.3".times.5": Coated at Big Spring: No 
Blisters 
Sample 9 Q-Panel coated at TISI, 10 mils: No Blisters 
Sample 9PC Q-Panel coated at TISI, 10 mils: No Blisters 
*Experimental coupons #1 through #4 not reported. 
EXAMPLE 8 
Corrosion, Chemical Test 
a. Procedure: Testing was completed in accordance with ANSI 124.1 on fully 
cured samples with various exposed regions. 
1. Immersion Test . . . Liquids at room temperature for: 
.box-solid. 1-A=16 hours 
.box-solid. 1-B=24 hours 
.box-solid. 1-C=168 hours 
2. Immersion test . . . Boiling liquid for 24 hours. 
3. Rub test . . . 100 cycles with a saturated cloth. 
b. Prepared by: Owens-Corning Fiberglass Corp. 
Technical Center 
Granville, Ohio 
c. Date: September 1985 
d. Results: 
______________________________________ 
Chemical Method Effect 
______________________________________ 
Acids Hydrochloric Acid 10% 
1B, 1C None to Slight 
Acetic Acid 10% 1B, 1C Slight 
Sulfuric Acid 1B, 1C None to Slight 
Nitric Acid 10% 1B, 1C Moderate 
Bases Ammonium Hydroxide 20% 
1B, 1C No Effect 
Sodium Hydroxide 50% 
1B, 1C No Effect 
Sodium Hydroxide 30% 
2 No Effect 
Detergents and 
Spray & Wash 1A None 
Bleaches Wisk 1A None 
Clorox 1A Slight 
Solvents Acetone 1A None to Slight 
Methanol 1A None to Slight 
Ethanol 1A None to Slight 
Methyl-Ethyl-Ketone 
1B, 1C None to Slight 
Stoddard Solvent 3 No Effect 
Toluene 3 No Effect 
Gasoline 3 No Effect 
Other Hydraulic Fluid 1C None 
(Skydrol) 
______________________________________ 
NOTE: Slight=Discoloration; Moderate Chalking; Severe=Blistering 
EXAMPLE 9 
Dielectric Strength Test 
a. Procedure: ASTM D149 dielectric strength in air or oil 
b. Prepared by: Owens-Corning Fiberglass Corp. 
Granville, Ohio 
George W. Ritter, Ph.D. 
c. Date: Aug. 21, 1986 
d. Test Panels: Steel test panels coated with the present invention at a 
dry film thickness of 4 mils 
e. Results: In Air=Approximately 7,000 volts at 7 mil 
In Oil=Approximately 10,000 volts at 7 mil 
EXAMPLE 10 
Impact Test 
a. Procedure: ASTM D2794--Intrusion Direct Impact 
b. Prepared by: Technical Inspection Services, Inc. 
Houston, Tex. 
Paul E. Partridge 
c. Date: May 8, 1995 
d. Test Panels: Steel test panels with a blast profile of 2.5 mils coated 
with 4 to 10 mils of the present invention using a conventional spray 
equipment. 
e. Results: Impact resistance . . . 90 inch-pounds 
EXAMPLE 11 
Humidity Test 
a. Procedure: Specimens were exposed to 100% condensing humidity at 
140.degree. F./60.degree. C. for two weeks (336 hours) 
b. Prepared by: Boeing Materials Technology 
Renton, Wash. 
c. Test Panels: Two (2) stainless (301) window clips coated with white 
gloss present invention 
d. Results: No loss of coating adhesion, blistering or other visible 
defects were observed on the window clips. 
EXAMPLE 12 
Salt Fog Chamber Test (336) 
Test #1 
a. Procedure: Specimens were exposed to a 5% salt spray solution at 
95.degree. F./35.degree. C. for two (2) weeks (336 hours). 
b. Prepared by: Boeing Materials Technology 
Renton, Wash. 
C. Date: Nov. 30, 1988 
d. Test Panels: Stainless steel (301) coupons coated with white gloss 
present invention 
e. Results: The stainless steel revealed no signs of coating deterioration. 
Test #2 
a. Procedure: ASTM B117, 5% salt spray solution 
b. Prepared by: Southwestern Laboratories 
Ft. Worth, Tex. 
Kemp E. Akeman, P.E. 
c. Date: May 23, 1994 
d. Test Panels: 3".times.6" steel panels coated with the present invention 
e. Results: After 1,667 hours of exposure, no distress of coated body was 
observed. Test was terminated at 1,667 hours. 
EXAMPLE 13 
Surface Burning Characteristics of the Present Invention Applied to 16 
Gauge Sand Blasted Carbon Steel 
a. Procedure: ASTM E84-91a 
b. Prepared by: Southwest Research Institute 
San Antonio, Tex. 
c. Date: Jul. 6, 1995 
d. Test Panels: Ceramic/epoxy coating (present invention) was applied with 
a conventional spray gun to ten (10) sections of 24'.times.24' square 16 
gauge carbon steel, which was blasted to a NACE I (SSPC=SP5, Swedish=SA-3) 
white metal finish. Two passes at 30 minutes apart for a total D.F.T. of 
7-10 mils. (Sample was prepared by the client). 
e. Results: Flame Spread Index: 20 (Class I Fire Rating) 
Smoke Developed Index: 40 (Class I Fire Rating 
EXAMPLE 14 
Fire Resistant Hydraulic Fluid (Skydrol) Special Test (BMS 3-11) 
a. Procedure: One half of aluminum sample coated with the present invention 
immersed in BSM 3-11 (Skydrol Hydraulic Fluid) for 13 days. 
b. Prepared by: Boeing Materials Technology 
Renton, Wash. 
Sisty Cortner, Material Engineer 
c. Date: Nov. 30, 1988 
d. Test Panels: Aluminum 2024-T3 
e. Results: One half of each specimen was immersed in BSM 3-11 for 13 days. 
Pencil hardness tests were then prepared per BSS 7263 to determine of 
coating had softened. Coating was examined for blistering, loss of 
adhesion or other deterioration. There was no noticeable softening of the 
coating after 13 days exposure to Skydrol. There was no apparent 
blistering or other signs of coating deterioration. 
EXAMPLE 15 
Rain Erosion Test--Naval Air Development Center 
"Unclassified summary of test results from classified report containing 
testing results on the present invention." 
Date: Jun. 15, 1989 
"The Naval Air Development Center conducted test in Code 5021 on unprimed 
aluminum disks protected with the present invention to standard rain-field 
conditions specified in Mil-R-7705B at its Rain Erosion Test Facility. The 
samples survived ten minutes exposure to the simulated rain-field at which 
time small pits had developed exposing approximately 20% of the aluminum 
surface. Although raid correlated with normal fleet maintenance schedules 
instead of depot schedules. In considering the difficulty involved when 
bonding to aluminum substrate outside the facet that no primer nor etching 
process was employed, the present invention is superior over all paint 
systems currently used by the fleet in respect to adhesion and erosion 
resistance. Besides the qualities, the present invention can withstand 
maximum temperatures created during "dash" conditions of 750.degree. F. 
(not to exceed fifteen minutes) without degradation of physical 
properties. In the past, other epoxies had been much lower in dielectric, 
loss and VOC than their polyurethane counterparts. Code 5021 has conducted 
preliminary test on the present invention and determined dielectric 
constant and loss tangent to be 4.51 and 0.061 respectively which is 
better than polyurethane products currently used. The Material Safety Data 
Sheet for the present invention (required by the Federal Government) and 
gives a very low VOC value of 1.89 lb/gal and no apparent toxicity 
threshold." 
EXAMPLE 16 
Coating Stripping Feasibility Test (for Aircraft) 
a. Procedure: Abrasive blast with PM (plastic media) to determine if the 
present invention can be removed from F-4 aircraft and if possible at what 
rate of removal as compared to existing systems. 
b. Prepared by: United States Air Force 
Hill AFB, Utah 
Maintenance Division 
c. Date: Oct. 16, 1987 
d. Test Panels: Six (6) steel panels coated with the present invention to a 
thickness of 8 mils 
e. Results: Stripping is feasible. Rate of coating removal was 0.7 square 
feet per minute, which can be compared to the present average removal rate 
of 2.6 square feet per minute on an F-4 aircraft. The paint most commonly 
found on F-4 is gun ship quality polyurethane (Mil-83286). In summary, 
even though the paint on the panels was more difficult to strip than 
polyurethane, it can be stripped with relative ease using the PMB 
stripping pioneered at Hill Air Force Base. 
The above description is not intended to limit the scope of the invention 
to that described, since different additives, catalysts and curing 
processes may be used as experimentation would lead a person of ordinary 
skill in the art to practice.