Correlating Coating Quality of Coverage with Rheology for Mica-Based Paints

Abstract This paper examines the relationship between rheology and the qualitative appearance of dried, mica-based paint coatings used in the aerospace industry. The goal is to identify key rheological characteristics indicative of poor coating visual appearance, providing a screening tool to identify unsatisfactory paint formulations. Four mica paints were studied, having coating visual appearances ranging from very poor to very good. Strain sweeps indicated that the poor-quality paints have a smaller % strain midpoint in the linear visco-elastic range; while the good-quality paints have a lower G’/G” cross-over point in frequency sweeps. Thixotropy experiments utilizing single and multiple-loop hysteresis cycles plotting shear stress as a function of shear rate showed that the base mica paints with good appearance had nearly constant, reversible profiles in the forward and the backward directions; while the mica paints with poor appearance were irreversible with a noticeable gradual change in shear stress as more loops are run. The difference in area between the forward and the reverse curves was determined, leading to a quantifiable criterion that can differentiate good paints from poor paints with significance testing. This work would establish the first rheology model using hysteresis loops to predict the visual properties of mica-based paints.