Optimization of Teflon Spraying Process for Non-stick Coating Application

Spray coating process is a simple technique to develop a thin and uniform coating layer on a substrate, where the atomized coating material is transferred to the target surface for deposition by the assist of pressurized air flow. However, the utilization of coating material and deposition rate associated with this technique can be extremely low under the improper setup of spraying conditions. The process study and optimization of spray coating were experimentally examined in this paper to provide an insight into the process. Teflon was employed as the coating material due to its renowned on the non-stick feature. Air pressure, spray time, nozzle size and spray distance were optimized with regard to the material consumption and coating layer thickness. As per the experimental results, the small nozzle size of spray gun should be applied together with the low air pressure, low spray time and short spray distance from the target to minimize the Teflon consumption and to accurately control the dry film thickness obtained. The predictive models for these two responses were also presented in this research.