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The purpose of this paper is to prepare heat insulating exterior emulsion coating and to study its heat insulating property along with mechanical, chemical and weathering resistance properties with varying amount of hollow glass microspheres and cenospheres.

For heat insulating effect, various compositions were made by incorporating different proportions of hollow glass microspheres (HGM) and cenospheres (C). The mechanical, chemical, morphological and optical properties of the coating films were studied and compared.

Addition of hollow glass microspheres and cenospheres enhanced heat insulating property of the coating, hardness, tensile strength and wet scrub resistance. It was evaluated that optimum loading for both cenospheres and hollow glass microspheres was 10 wt.% and both the systems showed good mechanical, chemical resistance and weathering properties.

Addition of hollow glass microspheres and cenospheres to acrylic emulsion coating is a simple and inexpensive method.

The new heat insulating coatings with good thermal insulation properties and improved weather resistance were prepared. These coatings could find applications in demanding fields such as exterior wall coatings and roof coatings.

The purpose of this paper is to formulate two component polyurethane coatings based on acrylic polyol, to study the effects of variable nanosilica loadings in these coatings on different morphological, optical, mechanical, corrosion resistance and weather resistance properties and to study the intercalation of acrylic polyol molecules into nanosilica crystals by XRD technique.

Two component polyurethane coatings were synthesised using acrylic polyol and isocyanate HDI. The nanosilica was incorporated in polyurethane formulation at the weight ratios of 1%, 3% and 5% based on total weight of polyol and isocyanate. The performance of nanocoatings was compared for variable loads of nanosilica for different properties such as morphological, optical, mechanical, corrosion resistance, weather resistance and were studied for intercalation of acrylic polyol into nanosilica crystals by XRD technique.

Improvement in the properties of polyurethane coatings is achieved with the incorporation of nanosilica. The improvement is the result of inherently high properties of inorganic nanosilica. Tensile strength, scratch hardness, abrasion resistance, corrosion and weathering resistance show significant improvement in performance with the incorporation of nanosilica. Properties are found to deteriorate beyond a certain loading of nanosilica; hence it is important to optimise loading level. The optimal range for high performance was found to be in the range of 1% to 3%. The improvement was a result of synergistic behaviour and good interfacial interaction between polyurethane and nanosilica at optimal levels.

The method used for incorporation of nanosilica into polyurethane was direct incorporation method. The other method of incorporation, i.e. in situ addition and its effect on properties can also be studied.

With the addition of optimal loading level of nanosilica to polyurethane coatings, properties can be enhanced up to the mark. The addition is relatively easy and cost effective.

The paper proves the significance of incorporation of nanosilica on original properties of polyurethane coatings and widens the area of applications of two component polyurethane coatings from acrylic polyol by strengthening them in their properties. The coatings can be applicable in high performance topcoats especially for automotive topcoats.

The paper's aim is to synthesise ultraviolet (UV) curable polyurethane acrylate based on polyester polyol and to study change in its mechanical, chemical, optical and weather resistance properties with varying amount of nanosilica. It also seeks to determine its optimum loading levels for property maximisation.

New UV curable polyurethane acrylate has been synthesised using polyester polyol, blend of isophorone diisocyanate and toluene diisocyanate and hydroxyl ethyl acrylate. This resin was incorporated with nanosilica (1‐3 per cent) on the basis of total solids. The newly synthesised material was characterised by fourier transform infrared spectroscopy, gel permeation chromatography, X‐ray diffraction and scanning electron microscopy. The mechanical, chemical and optical properties of the coating films were studied and compared.

The hardness, tensile strength and abrasion resistance show significant enhancement with increasing amount of nanosilica. It is also found that UV cured polyurethane acrylate nanocoating exhibited improved weather resistance. The optimum concentration of nanosilica for better performance is found to be 3 per cent of total solids. The improvement is the result of inherent nature of nanosilica.

Nanosilica used in present context is having 10 nm mean diameter and near about 600 m²/g surface area. Nanosilica having different particle size, surface area and surface modification can be used to improve more specific properties.

Addition of nanosilica particles to polyurethane acrylate coating is a simple and inexpensive method resulting in phenomenal increase in properties.

The new organic‐inorganic hybrid nanocoating with improved weather resistance was synthesised. These coatings could find applications in demanding fields such as automotive topcoats.

This study aims to construct a double layer heat insulation coating based on hollow glass microspheres (HGMs) and to investigate the effect of particle size on barrier property and heat insulation performance.

The waterborne double layer coating was composed of an anticorrosive epoxy ester primer and an HGM-containing silicone acrylic topcoat. With varied HGM sizes (20 μm, 40 μm, 60 μm and a 1:3 w/w mixture of 20 and 60 μm particles), the coating was immersed in 3.5 wt% NaCl solution for 28 days and was then subjected to a salt spray test for 450 h. The barrier properties of the coating were evaluated through electrochemical impedance spectroscopy. Heat insulation performance was examined using a self-made device.

The addition of HGMs decreased the barrier properties of the coating by creating particle/resin interfaces for water penetration. In the HGMs-containing coatings, the use of larger HGMs showed relatively good barrier properties because of the lower particle density. The coating with smaller particles yielded a higher heat insulating capacity as indicated by lower equilibrium temperatures.

Future work will be focused on improving the barrier properties of the coating. Field exposure tests should also be performed to assess the long-term performance of the coating.

The mechanical properties of the coatings in this study also implied that HGMs can be used to develop scratch-resistant and impact-resistant coatings. Other potential applications for further studies include the uses of HGMs for coatings with improved fire retardancy and electromagnetic interference shielding.

A double layer coating was developed to provide balanced performance on both anticorrosion and heat insulation. The effects of HGM size were particularly highlighted.

To study the changes occurring in lac‐polyvinyl butyral (PVB) resin blends at molecular levels on baking the blends at 200°C for different intervals of time. It was also to ascertain the changes in key physico‐chemical parameters of these blends, before and after applying thermal stress on these blends.

Films of lac‐PVB blends, applied on tin panels were baked at 200°C for different time intervals. The FTIR spectra of the blends were recorded using specular reflectance spectroscopic techniques. The results obtained were compared and reported. The blends were also tested for different physico‐chemical parameters such as scratch hardness, flexibility, adhesion, acid resistance, etc.

On baking the blends of lac‐PVB resin at 200°C for different time intervals; fragmentation reaction, that is breakdown of products into small molecules, takes place in lac‐PVB blends. Side products such as acetic acid emerge on baking the blends. Probably hydrolysis of oxirane ring also takes place leading to the release of free alcoholic groups. The lac‐PVB blends do not show any improvement in scratch hardness and are also not resistant to the action of acids. The blends made by lac‐PVB resin baked at 200°C do not seem to be compatible as no improvement in any of the physico‐chemical parameters was seen.

Mixtures of solvents were tried for dissolving the PVB resin. In most of the solvent mixtures, PVB resin forms big lumps and is not soluble so there is a need for universal solvent for dissolving the PVB resin. The spectral studies on lac‐PVB blends were conducted qualitatively, although desirable, quantitative studies could not be carried out, due to the inherent difficulties in handling the resins.

The parent resins in lac‐PVB blends (baked at 200°C) do not seem to be compatible with one another as there was no improvement in any of the physico‐chemical parameters of the lac‐PVB blends. For making lac‐PVB blends, low range of baking temperature may be tried.

In literature, there is not much evidence of making lac‐PVB blends. This paper is the first one in attempting to obtain and correlate FTIR spectra of the lac‐PVB blends with physico‐chemical changes of the blends. This paper also highlights the convenience of the method and the scope of sophisticated data analysis such as derivative spectrometry.

This paper aims to prepare a new modified poly(ester amide) (PEA) resins and use it as a binder for anticorrosive and antimicrobial coatings.

New modified PEA compositions were prepared based on 4-amino-N, N-bis(2-hydroxyethyl) benzamide (AHEB) as the ingredient source of the polyol used and evaluated as vehicles for surface coating. The structure of the modifier and PEA resin was confirmed by FT-IR, H¹-NMR, MW, thermogravimetric analysis and scanning electron microscope studies. Coatings of 50±5 µm thickness were applied to the surface of glass panels and mild steel strips by means of a brush. The coating performance of the resins was evaluated using international standard test methods and involved the measurement of phyisco-mechanical properties and chemical resistance.

The tests carried out revealed that the modified PEA based on AHEB enhanced both phyisco-mechanical and chemical properties. Also, the resins were incorporated within primer formulations and evaluated as anti-corrosive and antimicrobial single coatings. The results illustrate that the introduction of AHEB, within the resin structure, improved the film performance and enhances the corrosion resistance and antimicrobial activity performance of PEA resins.

The modified PEA compounds can be used as binders in paint formulations to improve the chemical, physical, corrosion resistance and antimicrobial activity properties.

Modified PEA resins are cheaper and can be used to replace other more expensive binders. These modified PEA resins can compensate successfully for the presence of many the anticorrosive and antimicrobial paint formulations, and thus, lower the costs. The main advantage of these binders is that they combine the properties of both polyester and polyamide resins based on nitrogenous compound, are of lower cost and they also overcome the disadvantages of both its counterparts. Also, they can be applied in other industrial applications.

The purpose of this study is to highlight the direct fabrication of rapid tooling (RT) with desired mechanical, tribological and thermal properties using fused deposition modelling (FDM) process. Further, the review paper demonstrated development procedure of alternative feedstock filament of low-cost composite material for FDM to extend the range of RT applications.

The alternative materials for FDM and their processing requirements for fabrication in filament form as reported by various researchers have been summarized. The literature demonstrates the role of various post-processing techniques on surface finish of FDM prints. Further, low-cost materials for feedstock filament have been investigated experimentally to check their adaptability/suitability for commercial FDM setup. The approach was to realize the requirements of FDM (melt flow rate, flexibility, stiffness, glass transition temperature and mechanical strength), necessary for the successful run of an alternative filament. The effect of constituents (additives, plasticizers, surfactants and fillers) in polymeric matrix on mechanical, tribological and thermal properties has been investigated.

It is possible to develop composite material feedstock as filament for commercial FDM setup without changing its hardware and software. Surface finish of the parts can further be improved by applying various post-processing techniques. Most of the composite parts have high mechanical strength, hardness, thermal stability, wear resistant and better bond formation than standard material parts.

Future research may be focused on improving the surface quality of parts fabricated with composite feedstock, solving issues related to the uniform distribution of filled materials during the fabrication of feedstock filament which in turns further increases mechanical strength, high dimensional stability of composite filament and transferring the technology from laboratory scale to various industrial applications.

Potential applications of direct fabrication with RT includes rapid manufacturing (RM) of metal-filled parts and ceramic-filled parts (which have complex shape and cannot be rapidly made by any other manufacturing techniques) in the field of biomedical and dentistry.

This new manufacturing methodology is based on the proper selection and processing of various materials and additives to form high-performance, low-cost composite material feedstock filament (which fulfil the necessary requirements of FDM process). Finally, newly developed feedstock filament material has both quantitative and qualitative advantage in RT and RM applications as compared to standard material filament.

Silane cross-linkers have been used to strengthen the mechanical stabilities and friction resistance of plastic products. Therefore, the effect of silane cross-linkers on latex has been studied through preparing modified self-cross-linking long fluorocarbon polyacrylate latex. In this paper, nonionic surfactant alcohol ether glycoside (AEG1000) and anionic polymerizable surfactant 1-allyloxy-3-(4-nonylphenol)-2-propanol polyoxyethylene (10) ether ammonium sulfate (DNS-86) acted as mixed emulsifier and 3-(methacryloyloxy) propyltrimethoxysilane (KH-570) and bis (2-ethylhexyl) maleate (DOM) were used as functional monomers.

The modified acrylate polymer latex was synthesized through the semi-continuous seeded emulsion polymerization with methyl methacrylate (MMA), butyl acrylate (BA), dodecafluoroheptyl methacrylate (DFMA) and hydroxypropyl methacrylate (HPMA) as main monomers. Potassium persulfate (KPS) was applied to initiate polymerization reaction, nonionic surfactant AEG1000 and DNS-86 acted as emulsifier, KH-570 and DOM were used as functional monomers, respectively.

The optimum conditions of synthesizing the modified latex were the following. The mass ratio of monomers containing MMA, BA, DFMA, HPMA, KH-570 and DOM was 13.58:13.58:0.90:1.20:0.15:0.60, the usage of initiator KPS was 0.5% of the total weight of monomers and the amount of emulsifier was 7% of all monomers with AEG1000:DNS-86 = 1:1. The results indicated that the conversion of monomer was 99% and the coagulation was about 2.0%.

The resultant latex was modified silane cross-linker KH-570 and DOM, which positively affected the comprehensive properties of latex and its film. Apart from this, the novel mixed emulsifier was used to improve the size and distribution of latex particles and reduce environmental problems caused by the use of emulsifiers.

This paper aims to discuss the use of the sensor material in coating to detect defects which can cause corrosion on metal substrate. This coating consists of sodium polyacrylate (SP) to detect the presence of water and fluorescence substance 2-[4-(piperidin-1-yl)-5H-chromeno-[2,3-d]pyrimidin-2-yl]phenol [benzopyranopyrimidine (BPP)] to detect crack formation.

The coating resin is a mixture of poly(methyl methacrylate) (PMMA) and poly (methyl vinyl ether-alt-maleic anhydride). The additives are used to provide a visual indicator to the observer for when the coating exhibits any defects, so that quick action can be taken before corrosion develops further. SP has absorbent properties and expand when in contact with water, while BPP exhibits high luminous intensity in its solid form that is easily perceivable when exposed to UV. PVM/MA was used as the binder with ethanol as the solvent. The resistance of this coating towards water penetration was investigated using electrochemical impedance spectroscopy (EIS). The coating’s performance was observed in terms of visible optical appearance.

The sensor coating developed in this project serves as visual aid to the observer through the expansion of SP and high fluorescence of BPP material after the top coat is physically damaged. These findings are in provision of preventive measures that can be taken in case of top coat failure.

The resistance of the coating that contained SP could not be investigated with EIS due to its ability to expand immediately when in contact with liquids.

The coating developed in this study may be to detect corrosion.

The sensor material used has not been previously studied in applications to detect the presence of water or used to detect crack formation.

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process.

PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles.

PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one.

The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.