Aluminium powder

The amount of aluminium powder determines the processing consistency. The following quantities refer to 100 parts by weight of the fully mixed resin/hardener system.

Mixing Ratios and Consistency

The stated consistencies are guideline values. The actual consistency depends primarily on the initial viscosity of the resin system.

Formulation Examples with Epoxy Resin L / Hardener L

Resin-to-hardener mixing ratio = 100:40 parts by weight. The following examples differ only in the amount of aluminium powder added.

These formulations are starting points for application trials. A suitable thixotropic agent can also be used to produce non-sagging filling and repair compounds.

Aluminium-Filled Tooling Gelcoat and Surface Coats

Clear EP Gelcoat combined with a suitable hardener can be used to produce spreadable, aluminium-filled epoxy surface coats with high surface hardness and scratch resistance.

Example: Thoroughly mix 100 g of prepared EP Gelcoat/hardener with 100 g of aluminium powder.

The traditional R&G formulation is based on clear EP Gelcoat with a suitable hardener, such as S, L or EPH 161, depending on the specific product version.

When using EP Gelcoat Clear NOVA with Hardener L, the mixing ratio is 100:40 parts by weight. The suitability of the aluminium-filled tooling formulation for the selected gelcoat system should be verified before use.

Processing: Gradually add the aluminium powder to the fully mixed resin/hardener system and stir until a homogeneous mixture is obtained. The specified resin-to-hardener ratio remains unchanged.

• Improves compressive strength and impact resistance of casting and moulding compounds
• Increases thermal conductivity and improves heat distribution
• Reduces curing shrinkage
• Enables dimensionally stable moulded parts and backing compounds
• Allows controlled adjustment of processing consistency
• Suitable for hard, scratch-resistant epoxy tooling surface coats

The achievable properties depend on the resin system, filler loading and curing conditions.

• Mould making and pattern making
• Aluminium-filled epoxy surface coats
• High-compressive-strength casting and moulding compounds
• Dimensionally stable backing compounds and tooling structures
• Technical castings and repair compounds
• Paste-like and kneadable resin mixtures

1. Thoroughly mix the resin and hardener at the specified mixing ratio.
2. Gradually add aluminium powder to the prepared resin/hardener mixture.
3. Mix carefully until the powder is fully wetted and evenly dispersed.
4. Increase the filler loading gradually until the desired consistency is achieved.
5. Apply or cast the mixture within the working time of the resin system.

Minimise air entrapment during mixing. For high filler loadings, carry out a preliminary test to assess processability and curing behaviour.

Store aluminium powder in tightly closed containers in a dry environment. Avoid generating dust, keep away from ignition sources and use appropriate personal protective equipment. Observe the safety data sheet.

The melting point of aluminium (660 °C) does not indicate the temperature resistance of the cured resin compound. The relevant limits are determined by the properties and curing conditions of the resin system used.