Xylar 1 Coated Fasteners

Stud Bolts, Nuts, Screws, Threaded Rod & Washers

Xylar 1 is aqueous / acidic based aluminum "cermet" coating. Excellent chemical, corrosion and abrasion resistance at extreme temperatures. Specific end uses of Xylar 1 coatings is to provide the aircraft, aerospace and marine industries with materials to protect components from high temperature oxidation, salt laden atmospheres, chemicals and abrasives.

Xylar 1 Product Specifications

Solids, theoretical 60.47 ± 3.0 % by weight 38.79 ± 2.0 % by volume
Relative density 1.56 ± 0.03 g/l 13.05 ± 0.25 lbs/US Gal
Coverage, theoretical 9.92 m²/kg @ 25 microns 15.52 m²/lit @ 25 microns
106.78 ft²/kg @ 1 mil 632.21 ft²/US gal @ 1 mil
Viscosity 20 - 24 seconds in a Zahn 2 viscosity cup at 23°C.
Operating temperature -40°C - +535°C Continuous
Flash point Closed cup: Not applicable.
VOC content 0 g/l

Xylar 1 Substrate Preparation

Final product quality and performance depends on careful substrate preparation. Contaminated substrates may cause poor adhesion or defects in the final dry film. Each item to be coated must be free of all contaminants e.g. oil, grease, detergent, rust and blast media. Substrate preparation should be based on the design requirements of the item. If you are unsure which process is best suited to your needs please contact a TorqBolt representative for advice. The following are the recommended substrates and substrate preparation used with this coating

Substrates Aluminium. Mild steel.
Substrate preparation Degrease. Light grit blast. An Ra (mean roughness) of 3 - 4 microns, measured using surface roughness measuring equipment is recommended. Typically use 80 - 100 mesh (150 - 200 micron) iron free, aluminum oxide grit. Since the Ra value achieved depends on the actual substrate, initial trials are recommended to establish the optimum grit size and air pressure for each substrate type.

Xylar 1 Preparation Of Coating Material

Mixing prior to use This material settles rapidly during storage. It is imperative that the material is adequately mixed before use. The material should be high speed / shear mixed before use to eliminate any settling. Check that there is no sediment on the bottom of the container.
Recommended application viscosity Optimum results are obtained when the material is at "room temperature" nominally 15 - 30°C.
Viscosity adjustment This material is generally suitable for application as supplied. Addition of any solvent will effect the specifications of the product. If absolutely necessary adjust viscosity with water. Add thinner in 2% increments, while mixing, until the desired application characteristics are obtained. Take care not to add too much thinner as low viscosity may produce rapid settling, runs and sags or low film thicknesses.
Other information This material is sieved before dispatch from our factory but as an added precaution we recommend that you filter it through a 40 mesh (400 micron) sieve prior to use.

Xylar 1 Recommended Application Technique

Application information/ technique This product is designed primarily for spray application. Consult with a TorqBolt representative if other types of application are being considered. Use a spray gun with a siphon cup or pressure pot. Select a fluid nozzle and air cap that meet application needs. TorqBolt uses a DeVilbiss GTi HD spray gun with a Pro 200-14 fluid nozzle and a GTi Pro T1 air cap.
The air supply line should be equipped with traps to remove water and oil. Drain and service these traps frequently.
The proper amount of coating should be achieved with two or three passes of the spray gun across the work piece. Apply the coating to a uniform, full wet appearance.
Recommended Dry Film Thickness/coat 20 ± 5 microns.
0.8 ± 0.2 mil.
Number of coats recommended Typically 2. Cure between coats if applying multiple coats. After curing each coat burnish ideally with glass beads otherwise aluminum oxide at a low air pressure 20 - 30 psi (1.4 - 2.1 kgf/cm2) to improve the appearance, abrasion and corrosion resistance. Determine if the burnishing is complete by using an ohmmeter. The burnished surface should have less than 1 ohm resistance at any two points on surface. If surface is not conductive continue burnishing until it is.
Clean-up solvent Water.

Xylar 1 Flash Off And Cure Schedule

Please note that oven temperatures can be very different to substrate temperatures and the following cure conditions apply to PEAK SUBSTRATE TEMPERATURE.

Flash-off conditions 5 mins. @ 65 - 95°C (150 - 200°F)
Optimum cure schedule 30 mins. @ 345°C (650°F)
Minimum cure schedule 30 mins. @ 345°C (650°F)
Maximum cure schedule 15 mins. @ 400°C (750°F)

Xylar 1 Typical Cured Film Properties

Dry film thickness: >40 microns in total.
>1.6 mil in total.
Appearance Shiny, aluminum-like finish when burnished.
Pencil Hardness >3H
Adhesion - Crosshatch & Tape) No adhesion loss.

Xylar 1 Shelf Life, Storage And Handling

Avoid breathing vapours, spray or mists. Wash hands before eating, drinking or smoking. Wear appropriate personal protective equipment. Avoid direct contact with the human body. See SDS for more information.

Shelf life 3 months
Acidic corrosive material.
This material settles rapidly during storage. This material settles rapidly during storage.Turn container(s) upside down or high speed / shear mix the material(s) every month to maintain quality and minimize settling. Containers that have been opened must be carefully resealed and kept upright to prevent leakage. This product may be irreversibly damaged if subjected to temperatures below 0°C (32°F). Store between the following temperatures: 5°C - 30°C.

NON-WARRANTY: The information presented in this publication is based upon the research and experience of TorqBolt. No representation or warranty is made, however, concerning the accuracy or completeness of the information presented in this publication. TorqBolt makes no warranty or representation of any kind, express or implied, including without limitation any warranty of merchantability or fitness for any particular purpose, and no warranty or representation shall be implied by law or otherwise. Any products sold by TorqBolt are not warranted as suitable for any particular purpose to the buyer. The suitability of any products for any purpose particular to the buyer is for the buyer to determine. TorqBolt assumes no responsibility for the selection of products suitable to the particular purposes of any particular buyer. TorqBolt shall in no event be liable for any special, incidental, or consequential damages.