The painting process

Paint can be applied as a solid, a gaseous suspension (aerosol) or a liquid. Techniques vary depending on the practical or artistic results desired.

As a solid (usually used in industrial and automotive applications), the paint is applied as a very fine powder, then baked at high temperature. This melts the powder and causes it to adhere to the surface. The reasons for doing this involve the chemistries of the paint, the surface itself, and perhaps even the chemistry of the substrate (the object being painted). This is called “powder coating” an object.

As a gas or as a gaseous suspension, the paint is suspended in solid or liquid form in a gas that is sprayed on an object. The paint sticks to the object. This is called “spray painting” an object. The reasons for doing this include

  • The application mechanism is air and thus no solid object touches the object being painted;
  • The distribution of the paint is uniform, so there are no sharp lines;
  • It is possible to deliver very small amounts of paint;
  • A chemical (typically a solvent) can be sprayed along with the paint to dissolve together both the delivered paint and the chemicals on the surface of the object being painted;
  • Some chemical reactions in paint involve the orientation of the paint molecules.

In the liquid application, paint can be applied by direct application using brushes, paint rollers, blades, other instruments, or body parts such as fingers and thumbs.

Rollers generally have a handle that allows for different lengths of poles to be attached, allowing painting at different heights. Generally, roller application requires two coats for even color. A roller with a thicker nap is used to apply paint on uneven surfaces. Edges are often finished with an angled brush.

  • Using the finish flat one would most likely use a 1/2″ nap roller
  • Using the finish eggshell one would most likely use a 3/8″ nap roller
  • Using the finish satin or pearl one would most likely use a 3/8″ nap roller
  • Using the finish semi-gloss or gloss one would most likely use a 3/16″ nap roller

After liquid paint is applied, there is an interval during which it can be blended with additional painted regions (at the “wet edge”) called “open time.” The open time of an oil or alkyd-based emulsion paint can be extended by adding white spirit, similar glycols such as Dowanol (propylene glycol ether) or open time prolongers. This can also facilitate the mixing of different wet paint layers for aesthetic effect. Latex and acrylic emulsions require the use of drying retardants suitable for water-based coatings.

Paint application by spray is the most popular method in industry. In this, paint is atomized by the force of compressed air or by the action of high pressure compression of the paint itself, and the paint is turned into small droplets that travel to the article to be painted. Alternate methods are airless spray, hot spray, hot airless spray, and any of these with an electrostatic spray included. There are numerous electrostatic methods available.

Dipping used to be the norm for objects such as filing cabinets, but this has been replaced by high speed air turbine driven bells with electrostatic spray. Car bodies are primed using cathodic electro phoretic primer, which is applied by charging the body depositing a layer of primer. The unchanged residue is rinsed off and the primer stoved.

Many paints tend to separate when stored, the heavier components settling to the bottom, and require mixing before use. Some paint outlets have machines for mixing the paint by shaking the can vigorously for a few minutes.

The opacity and the film thickness of paint may be measured using a drawdown card. Water-based paints tend to be the easiest to clean up after use; the brushes and rollers can be cleaned with soap and water.

Types of paints
Common painting defects and remedies,

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