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Coating Process Fundamentals Course Topics

Course Description

To coat is to replace gas at a solid surface by a layer of liquid, then to solidify the liquid by drying, chilling, or curing. Typically the coating must be thin, continuous, and, often, uniform and smooth. Usually the final microstructure is important; often it is critical. Coating processes are vital ingredients of modern technology in organic polymer photoresists in microelectronics and microphotonics; inorganic polymer sol-to-gel optical coatings; magnetic oxide suspensions for tapes and disks, adhesives and laminates; ubiquitous paints, enamels, and related protective and decorative coatings; photoreceptor suspensions for xerography; and multilayer photographic film, graphic arts products, liquid crystal, and light-emitting displays. Coating itself is fluid mechanics and interfacial phenomena, often delicate.

Drying involves mass and heat transfer, phase equilibria and colloid phenomena. Curing is chemical reaction and more. Drying and curing entail adhesion, shrinkage, stressing, and consequences. Coating processes consist of unit operations that can be understood scientifically. This continually evolving short course is based on research studies and is the first University course to cover coating process fundamentals. Comprehensive course notes are provided.

Course Topics Will Include

  • Elements of coating function and form
  • Basic phenomena of viscous flow, capillarity, and wetting; multilayer flow
  • Simple coating flows: knife, bar, dip, air-knife
  • Die flow and die design basics
  • Slot, extrusion and die coating; use of vacuum and tensioned web
  • Slide and curtain coating basics
  • Simultaneous multilayer coating
  • Rheology of coating liquids
  • Overview of computer modeling
  • Roll coating
  • Gravure coating and printing
  • Fundamentals of printing; lithographic printing
  • Flow instability and failure; flow defect mechanisms
  • Overview of coating process visualization
  • Blade coating basics
  • Colloidal phenomena and particulate coatings
  • Drying
  • Curing
  • Spray coating
  • Stress development and other defect mechanisms