| Summary: | Ultrafine powder coatings are one of the development directions in the powder coating industry, as they can achieve thin coatings with good leveling and high surface smoothness comparable to liquid coatings. Compared to regular coatings, they experience a higher sensitivity to any incompatibilities, e.g., filler from coating components. The properties of fillers play a great role in the performance of coating films. Aluminum trihydrate (Al(OH)<sub>3</sub>) is a well-known filler in solvent-based coatings and other polymer industries. To study and evaluate the performances of Al(OH)<sub>3</sub> in ultrafine powder coatings, a popular filler, barium sulfate (BaSO<sub>4</sub>) is used for comparison. Both fillers are added in ultrafine powder coatings based on two of the most commonly used resin systems (polyester-epoxy and polyester). The differences of physical and chemical properties between both fillers have significant influences on several properties of powder paints and coating films. The polar groups (hydrogen bond) in Al(OH)<sub>3</sub> result in the strong interaction between inorganic filler and organic polymer matrix, thus decreasing the molecular network mobility and influencing the chain formation, which is verified by differential scanning calorimetric (DSC). The bed expansion ratio (BERs) of powder paints incorporated with Al(OH)<sub>3</sub> are much higher than those with BaSO<sub>4</sub>, which indicate more uniform gas-solid contact during the spraying process. Samples with Al(OH)<sub>3</sub> exhibit much lower specular gloss at 60°, which are expected to achieve remarkable matting effects. Superior corrosion resistances can be observed for almost all the coated panels incorporated with Al(OH)<sub>3</sub> in contrast to those with BaSO<sub>4</sub>. Other aspects are slightly influenced by the difference between the two fillers, such as the angle of repose values (AORs) of powder paints, the impact resistance and flexibility of coating films.
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