Xylar 101 Coated Fasteners

Stud Bolts, Nuts, Screws, Threaded Rod & Washers

Xylar 101 is a sealer/topcoat that enhances the corrosion resistance of Xylar 2. It is a dense, clear film that fills any surface pores on Xylar 2, and together they represent a breakthrough in coating technology a thin film barrier with extreme corrosion resistance. Xylar 101 is a sealer/topcoat that closes any surface pores of Xylar 2. The 1 to 1.5 mil (0.0254 to 0.0381 mm) combination provides an incredible 4,000+ hours of protection in ASTM B117 salt fog tests. Xylar 101 are used to separate dissimilar metals in engine/generator applications, suspension mounts, air cylinders, electrical controls, industrial brakes and clutches, air pumps, reels, materials-handling equipment, industrial ovens, tubing systems, gear reducers, ball screws, governor systems, motor housing, and literally hundreds of other applications at ambient or extreme temperatures.


% Theoretical solids (by weight) 37.35 ± 1.9
% Theoretical solids (by volume) 20.88 ± 1
Specific gravity (g/cc) 1.29 ± 0.02
Density (lbs/US gallon) 10.77 ± 0.17
Viscosity 16 - 18 seconds in a Zahn 2 viscosity cup at 23°C.
16 - 23 mPa.s using a Brookfield Viscometer, Spindle 1
Speed 60


Theoretical coverage (sq.m/kg @ 25 microns) 6.47
Theoretical coverage (sq.m/lit @ 25 microns) 8.35
Theoretical coverage (sq.ft/US gal @ 1 mil) 340.22
Flash point Does not flash.
Operating temperature 870°C - Continuous


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, deteregent, 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 Whitford representative for advice. The following are the recommended substrates and substrate preparation used with this coating.

Substrates Aluminium. Mild steel.
Substrate preparation Degrease. Grit blast. An Ra (mean roughness) of 4 ± 1 microns, measured using surface roughness measuring equipment is recommended. Typically use 40 - 80 mesh (200 - 350 micron) iron free, aluminium 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.
Optional primer None required but Xylar 1 / Xylar 2 may be used to improve overall performance.


Mixing prior to use 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.
Recommended application viscosity 16 - 18 seconds in a viscosity cup. 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. If absolutely necessary adjust viscosity with distilled water. Add in 2% increments until the desired application characteristics are obtained. Take care not to add too much water 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 150 mesh (100 micron) sieve prior to use.


Application information/technique This product is designed primarily for spray application. Consult with a Whitford 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. Whitford uses a Binks Bullows 630 spray gun with a 071 (1.8 mm) fluid nozzle and a 66SD1 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 acheived 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 10 ± 2 microns.
Number of coats recommended Typically 1.
Clean-up solvent Water.


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

Flash-off conditions 5 mins. at 80 - 100°C (175 - 212°F).
Optimum cure schedule 30 mins. at 343°C (650°F)
Minimum cure schedule 30 mins. at 343°C (650°F).
Maximum cure schedule 15 mins. at 400°C (750°F).


Evaluate the coating according to the following specifications

Dry film thickness (Whitford TM114A) 10 ± 2 microns.
Mudcracking (Whitford TM120K) None under x30 magnification.
Gloss - 60° meter (Whitford TM121A) 25 - 30°  Semi-gloss /  satin finish.
Pencil Hardness (Whitford TM131A) 8H
Adhesion - Knife (Whitford TM132A) No adhesion loss.
Adhesion - Crosshatch Tape (Whitford TM132C) No adhesion loss.


Handling :- Avoid contact with skin, eyes and clothing. Do not breathe vapors or spray mist. Dry residue is explosive. Change out of working clothes and wash hands before breaks and at the end of the working day.
Storage :- Keep containers tightly closed in a cool, well-ventilated place. Do not freeze. Keep at temperatures between 5°C and 30°C. Freezing will affect the physical condition but will not damage the material. Thaw and mix before using.
Shelf life :- 3 month(s). Turn container(s) upside down or high speed / shear mix the material(s) every month to maintain quality and minimise settling.
Further information :- Ensure you have a Material Safety Data Sheet before using this product. Data sheets more than 24 months old may not be reliable: Obtain an up-to-date version to be sure information is current.