Functions and Applications of Brown Corundum Micropowder in the Coatings Industry
Speaking of the “tough guys” in the coatings industry, brown corundum micropowder is undoubtedly the top dog. Don’t be fooled by its dark appearance; it’s a versatile and capable material in the coatings world! Experienced paintmakers know that adding brown corundum micropowder is the key to achieving both wear-resistance and durability.
Brown corundum micropowder is simply micron-sized particles with an aluminum oxide content of approximately 95%. It’s refined in an electric arc furnace from raw materials like bauxite and coke at temperatures exceeding 2,000 degrees Celsius. The process is similar to cooking: only the right heat and the right balance of ingredients can produce a superior product. With a Mohs hardness of 9, second only to diamond, it’s considered the hardest material in the coatings industry.
I remember last year when we visited an industrial floor coating factory, the workshop manager pointed to the newly finished floor and boasted to us, “See? This floor is made with a coating infused with brown corundum powder. Forklifts run over it every day, and it hasn’t even scratched it in over three years!” Later, we learned that their coating incorporates 20% 325-mesh brown corundum powder, which has increased its wear resistance by more than three times that of ordinary coatings.
In the field of anti-corrosion coatings, brown corundum powder plays an indispensable role. Its sharp edges form a stable support structure within the coating, like a “skeleton” for the coating. Last year, an offshore platform project required a coating that was both resistant to seawater corrosion and able to withstand equipment friction. The winning formula used specially treated brown corundum powder, and I heard it lasted two years in seawater without any paint peeling.
The most challenging aspect of technology is the ratio of brown corundum powder added to the coating. Too much will make the paint too thick and difficult to apply; too little will make it ineffective. A seasoned craftsman uses a vivid analogy: “It’s like kneading dough. If there’s too much water, add flour; if there’s too much flour, add water. You have to find the perfect balance.” Generally speaking, the dosage ranges from 15% to 30% depending on the paint’s intended use. For example, floor paints can use more, while marine paints require less.
Brown corundum micropowder is available in a variety of sizes, ranging from 800 to 2000 mesh. The finer the mesh, the different the effects. Coarser particles are used for anti-slip applications, while finer particles are more suitable for topcoats. A sports field coating manufacturer shared their experience: they use 240 mesh for a base coat to enhance adhesion and 800 mesh for a topcoat to improve wear resistance. This combination yields surprisingly good results.
However, some precautions must be taken during application. Brown corundum micropowder has a relatively high specific gravity and is prone to settling, so an appropriate anti-settling agent must be added during the paint production process. Stirring is also crucial, as uneven distribution can affect the final effect. One factory experienced this loss. Due to insufficient mixing time, a batch of paint had inconsistent concentrations between the top and bottom coats, resulting in color differences after application and requiring rework.
With increasingly stringent environmental protection requirements, the production process of brown corundum powder is constantly improving. Many manufacturers are now promoting low-dust products to reduce dust pollution during the production process. Some companies are also researching surface modification technologies to enable brown corundum powder to better bond with resins and enhance the overall performance of coatings.
Overall, the application prospects of brown corundum powder in the coatings industry are vast. From floors to ships, from pipelines to storage tanks, it can be found everywhere. With the continuous emergence of new materials and new processes, this “old material” is also gaining new vitality.
So, next time you encounter an application that requires a particularly wear-resistant and durable coating, try adding some brown corundum powder. Perhaps this small change can significantly elevate your product’s performance! After all, in practice, many effective formulas are discovered through trial and error.
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