PRODUCT DATA SHEET

XYLAR® 2/G4258 STANDARD SILVER

1. GENERAL INFORMATION
Product description
Specific end use(s)
Supplier/Manufacturer
Aqueous / acidic based aluminum "cermet" coating. Excellent chemical, corrosion
and abrasion resistance at extreme temperatures. Higher builds are possible.
Xylar coatings provide the aircraft, aerospace and marine industries with materials to
protect components from high temperature oxidation, salt laden atmospheres,
chemicals and abrasives.
Whitford Ltd., 11 Stuart Road, Manor Park,
Runcorn, Cheshire WA7 1TH England

2. PRODUCT SPECIFICATIONS
Solids, theoretical: 61.27 ± 3.0 % by weight 36.42 ± 2.0 % by volume
Relative density: 1.52 ± 0.03 g/cm³ 12.66 ± 0.25 lbs/US Gal
Coverage, theoretical: 9.61 m²/kg @ 25 microns 14.57 m²/lit @ 25 microns
103.44 ft²/kg @ 1 mil 593.64 ft²/US gal @ 1 mil
Viscosity: 15 - 16 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

3. 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 Whitford 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.

4. PREPARATION OF COATING MATERIAL

Mixing prior to use:
Recommended application
viscosity:
Viscosity adjustment:
Other information
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.
Optimum results are obtained when the material is at "room temperature" nominally
15 - 30°C.
This material is generally suitable for application as supplied. Addition of any solvent
will affect 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.
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.

Date of issue/Date of revision : 19 Nov 2020 Date of previous issue : 27 Jun 2016. Version : 1.02 1/3
XYLAR® 2/G4258 STANDARD SILVER

5. RECOMMENDED APPLICATION TECHNIQUE

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 gravity feed cup or pressure pot. Select a fluid nozzle and air cap that meet
application needs. Whitford UK 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 25 ± 5 microns
Thickness/coat: 1.0 ± 0.2 mil.
Number of coats Typically 2. Cure between coats if applying multiple coats. After curing each coat
recommended: 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.

6. 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: 10 mins. @ 400°C (750°F)
Minimum cure schedule: 30 mins. @ 345°C (650°F)
Maximum cure schedule: 15 mins. @ 400°C (750°F)

7. TYPICAL CURED FILM PROPERTIES

Evaluate the coating according to the following specifications:
Dry film thickness >50 microns in total.
(Whitford TM114A): >2.0 mil in total.
Appearance Shiny, aluminum-like finish when burnished.
(Whitford TM120A):
Pencil Hardness >3H
(Whitford TM131A):
Adhesion - Crosshatch & No adhesion loss.
Tape
(Whitford TM132C):

8. SHELF LIFE, STORAGE AND HANDLING

Shelf life: 6 months
Acidic corrosive material.
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.
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.
Prepared by lbentley@whitfordww.com

Date of issue/Date of revision : 19 Nov 2020 Date of previous issue : 27 Jun 2016. Version : 1.02 2/3
XYLAR® 2/G4258 STANDARD SILVER

8. SHELF LIFE, STORAGE AND HANDLING

NON-WARRANTY: Statements and methods described herein are based upon the best information and practices known to PPG Industries,
Inc. (“PPG”). Any statements or methods mentioned herein are general suggestions only and are not to be construed as representations or
warranties as to safety, performance, or results. Since the suitability and performance of the product is highly dependent on the product
user’s processes, operations, and numerous other user- determined conditions, the user is solely responsible for, and assumes all
responsibility, risk and liability arising from, the determination of whether the product is suitable for the user’s purposes, including without
limitation substrate, application process, pasteurization and/or processing, and end use. No testing, suggestions or data offered by PPG to
the user shall relieve the user of this responsibility. PPG does not warrant freedom from patent infringement in the use of any formula or
process set forth herein. Continuous improvements in coatings technology may cause future technical data to vary from what is in this
bulletin. Contact your PPG representative for the most up to date information.