epoxy coating resin issues


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benet
benet
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I am having several issues using your epoxy coating resin as a top coat over a laminate  composite layup consisting of wood and glass fibre. The outer layer of the layup is .6mm veneer which has a thin coat of infusion resin applied to it at the layup stage in order to give an even colour when the laminate comes out of the press. (previously some infusion resin had soaked through the veneer and given a patchy look to the outer surface even after the coating resin had been applied.

The infusion resin is sanded with 120 wet paper and wiped clean with a clean damp microfiber cloth and allowed to dry before the coating resin is applied at an ambient temperature of 25 C.

The application of the coating resin at 2 parts res. to 1 part hard. is made with the resin largely bubble free, it is pored onto the surface and spread with mini foam rollers (held and gently dragged, not rolled).

I have tried  thin coats ( 36g. over 0.2m.sq) and experienced a lot of fish eye which i can only resolve by continuously spreading the resin as it thickens and eventually sticks with a less than smooth surface and still with fish eye in areas.

I have tried thicker coats ( 80g. over 0.2m.sq) and experieced very severe fisheye which can only be resolved by spraeding continuously as before in an attempt to make the resin stick. The result is a largely smooth surface but still with significant fish eye and a lot of milky whiteness due to the over agitation of the large amount of resin.

Both thick and thin require significant sanding back to get to a clear flat finish and in this process (starting 180 grit wet going to 1200wet ) i get 2 even bigger problems. 

1.  Is the appearance of white patches in the resin that appear to be leaching something onto the surface of the resin. They cannot be sanded away and do not go away with the application of heat. Also they cannot take a coat of resin on top of them as the problem persists through the new resin. i attach a picture for your examination.

2. Due to the thin wood veneer it is immensely difficult to judge at what point to stop sanding in the attempt to get a flat surface and any "rub through" is pretty much guaranteed to damage the veneer beneath, and anyway i cant work out an effective way of adding another coat of resin with any kind of decent finish on a surface that has uneven patches of wood and resin.



Any help would be greatly appreciated, at this point im thinking varnish ? or GC50 polyester gel coat ?

Thanks

ben
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benet
benet
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Hi Matt,

Thanks again.

By way of a recovery from my situation i proceeded to dry sand (not wanting to aggravate what seemed like a water ingress problem) . This reduced the white patches and revealed that they where indeed occurring (as you suggested) at the point where i had rubbed down through the coating epoxy to the infusion epoxy below. Perhaps the infusion epoxy was not completely cured and hence took on water from the wet sanding process. Anyway a the patches where considerably reduced and did not spread any further.

Following the dry sanding i thoroughly dusted the surface with a new ( ans as plain as i could find ) micro fiber cloth and wearing nitrile gloves to prevent grease contamination, proceeded to re apply 75g of coating epoxy to the surface. No fisheye, good thick glossy coating, popped bubbles with a  heat gun and im waiting for the cure now, but everything so far is looking good!

Looking forward to  my next build i shall be trying to use the coating epoxy direct at the laminating stage on the outside of the outer layers of veneer.

I am very pleased to have had your advice and it seems i am getting ever closer to an efficient way of getting to the results i want reducing the number of processes and man hours required.

One small thing, ive just contacted a old friend who has a paint shop and oven. If i give him my finished boards to sit in his oven for a while, how long? how hot? and what sort of effect will this have on the overall strength , impact resistance and flexibility of the epoxy used?

Maybe a new thread there?

Ben
Matt (Staff)
Matt (Staff)
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Hi Ben,

One small thing, ive just contacted a old friend who has a paint shop and oven. If i give him my finished boards to sit in his oven for a while, how long? how hot? and what sort of effect will this have on the overall strength , impact resistance and flexibility of the epoxy used?


Post-curing, if done properly, can only ever be a good thing for epoxy resin although, over enough time just at ambient temperature, the resin will naturally reach something very close to a post-cured resin (it will just take a huge amount longer). The exception is where resins will be used at high temperature - they should always be post-cured up to this operating temperature before use.

In terms of post-curing your boards, I would recommend a moderate post-cure as follows:

6hrs at 40'C
4hrs at 50'C
4hrs at 60'C

This steady ramp and not excessively hot post cure will ensure full cure of the resins without putting too much strain on them. The difference you would expect would be a harder feeling resin with more fully develped structural properties (and more of a 'ring' when you hit it, rather than the 'thud' of a resin that's not fully cured).

--Matt

Matt Statham
Easy Composites / Carbon Mods - Technical Sales
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