Troubleshooting Guide for Powder Coating

[Link]

WHY POWDER COATING?

INTRODUCTION

Thermo setting powder coatings are now generally recognized as having a significant role in the metal finishing industries world-wide. Powder coatings have been a commercial reality now for close to thirty years Powder coatings are used for the same key reasons as any surface finishing process: To protect the substrate they have been applied to To enhance the appearance of the item they have been applied to. The key benefits of powder coatings are often summarized by the five E's of powder coating. Ease of application Environmentally friendly Economical Excellence of finish Excellence of performance

Other benefits include: The elimination to a large extent of solid waste disposal problems. Solvent emissions are virtually eliminated, resulting in much easier compliance with EPA regulations. Energy costs are greatly reduced and Volatile Organic Component easily controlled. No solvents are required in mixing, cleaning or maintenance. Up to 99% of powder overspray can be recovered and reused. The 1% residual can easily be disposed off as a solid.

For these reasons there has been a rapid growth in the coating industry. Powder coatings are often used as alternatives to liquid paint finishing. In comparisons with traditional liquid finishing, powder coatings offer two significant application benefits: they are single coat finishes, with no primer required. High film thickness can be achieved with a single coat.

The powder coating application process is also readily automated, enabling high volume industrial application plants to operate economically with a minimum of rejects. These benefits have enabled powder coatings to take a significant share of the industrial finishing market.

APPLICATIONS
HOME APPLIANCES

In the home appliance industry, powder coatings are well recognized as being a high quality finish for both major and minor applications. In the appliance finishing industry, the advantages of high corrosion resistance with single coat application has resulted in powder coatings being used on a wide variety of electrical appliances, including; air conditioners, clothes dryers, cookers, dishwashers, fans, freezers, microwave ovens, rice cookers, refrigerators, stereo components, television components, video components, washing machines, water coolers. In addition to the major appliances noted powder coatings are also widely used for smaller appliances such as toasters, irons, can openers, juice extractors, food processors, vacuum cleaners and floor polishers.
AUTOMOTIVE COMPONENTS

Although powder coatings are not yet widely used on auto bodies, they are finding growing applications on components for both interior and exterior applications. In most automotive applications, powder coatings are used for auto performance characteristics as most auto producers still prefer the use of liquid coatings for those areas requiring optimum appearance. Current applications in the automotive industry include: air filter housing, alloy road wheels, br ake calipers & components, bright trim molding, bumper bars, door handles engine blocks-iron & alloy, mirror housings, motorcycle frames, oil filter housings, rocker covers, seat frames, steel wheels assemblies, stereo system, components suspension systems, underbody primer, windscreen wipers.
FURNITURE

The furniture industry is a major market for powder coatings. Powder coatings are used extensively on both commercial and domestic furniture for both their performance and for their appearance. The performance characteristics of powder coatings which make them so suited to the furniture industry include : toughness hardness corrosion resistance

ARCHITECTURAL

Powder coatings have developed a strong position in the architectural industry as a coating for aluminum profile, cladding and other building components.
ELECTRICAL AND ELECTRONIC INDUSTRY

Computer casings, computer components, encapsulation, telecommunications equipments.

METAL PRE-TREATMENT

Metal Pre-treatment prior to powder coating is essential step to ensure proper coating performance. Metal Pre -treatment prior to powder coating is of two types.

a) Mechanical surface Preparation. b) Chemical surface Preparation. For powder coating most commonly used surface preparation method is chemical pre-treatment. It is essential for an applicator to know the following: [Link] for Pre-treatment [Link] Preparation [Link]-rusting Processors [Link] [Link] coatings for a) Mild steel b) Galvanised steel c) Aluminum d) Mazak [Link] Shooting [Link] for Pre-treatment: The performance of powder coating on a metallic surface mainly depends on Proper Pretreatment of the substrate. Proper pre-treatment is an essential factor because of the following advantages ([Link]-treatment process provides a clear, uniform, oil-grease free surface. ([Link] good adhesion of film ([Link] forms an inert layer which inhibit the corrosion of the paint film General Pre-treatment Process sequence: a)De-greasing Process b)Water-Rinse c)De-rusting d)Water rinse e)Activation f)Conversion Coating g)Water rinse De-greasing Process: Chemical de-greasing methods used in any particular application is closely related to the nature of the surface being cleaned and the amount and type of contamination.

The various chemical degreasing processes applicable to Mild steel, Galvanised Steel & aluminum substrates, are as follows: Solvent Cleaning: a) Solvent Wipe: Solvent cleaning is the cheapest and best method to remove heavy or sticky oil/grease like substances form nay surface. Since all solvents are almost neutral they do not attack to the base metal. In this process, the parts to be cleaned are wiped with rag of cotton soaked in a suitable solvent such as Kerosene, Benzene, Naptha etc. The following are the advantages and disadvantages of solvent wipe method. Advantages a)Cheapest cleaning method available in the industry to remove heavy oils, greases or sticky press compounds. b)Skilled labours and costly plant installation is not required. c)Suitable for smallest job coater as well as for OEM industry. Disadvantages a)The process is labour intensive. b)Since all the solvents are flammable, a great fire risk is associated with the solvent cleaaning. c)Frequent change of cloth and solvent is essential or otherwise it can affect the quality of cleaning. d)Solvent going into the drainage can cause effluent disposal problem. Vapour De-greasing: Vapour de-greasing is quite a sophisticated method of cleaning. In this method, special type of solvent is used which has following advantages. Mineral & veg. Oils removal is faster. Has lower boiling point than water Non-toxic to human being.

This process requires a closed system in which the item to be cleaned is exposed to the condensing vapours of solvent. This method effectively removes light oils, greases but cannot remove heavy oils, greases, and sticky press compounds. Advantages a)Very good method for cleaning light oils, greases. b)Less risk of fire hazard, minimum pollution as it is a closed system. c)Since the solvent used is a not-toxic there is no danger for the operating worker.

Disadvantages a)Require costly plant installation and skilled labour. b)Frequent removal of oil & grease is required or otherwise they increase the boiling point of solvent. c)Thin sheets having heavy oil grease or sticky press compounds can not be removed by the process as there is no mechanical action on the parts. d)Costly process. Emulsion Cleaning: Emulsion cleaners are popular as they are based on mild Alkalis and hence suitable to all substrates (Iron, Galvanised steel Mazak etc.) and operate at room temperature. Emulsion cleaners are generally based on either kerosene-emulsifier or turpentine-emulsifier. These cleaners are generally milky in appearance. Emulsion cleaners have a limited cleaning tendency and they leave a very thin film of solvent/emulsifier over the substrate even after water rinsing. Hence, Emulsion Cleaning is always followed by Alkali cleaning. In case of spray process the parts to be cleaned are suspended in a funner wherein they are constantly exposed to the spray solution for 2 to 5 minutes at a pressure of 2-3 kgs/cm for better results. In dip process, the parts to be cleaned are simply immersed in a bath of the cleaning solution. This process has following advantages and disadvantages Advantages a)Operates at a lower temperature (45-50c) hence consume less energy. b)Suitable for all the substrates such as Mild steel, Mazak, Aluminium, Galvanised etc. Disadvantages a)Limited cleaning ability as it can not remove heavy grease, oil etc. b)Not suitable for higher temp. As the emulsions are based on solvents which gets separated above 70c from the emulsion phase. Alkali Cleaning: Alkali cleaners enjoy superior position in the Pre-treatment industry due to following advantages. They operate at room temp. Bath stability is higher compared to all other degreasing processes, low foaming tendency. Simple bath control. Costly plant installation is not always required. High capacity to absorb oil.

These cleaners are based on strong alkalies such as Sodium hydroxide, Sodium silicates, other filters and builders such as soda ash etc, surfactants and additives. The parts to be cleaned are immersed in this bath at a recommended temperature and time. Strong alkaline cleaners are avoided in case of Manganese phosphate process as they can cause inferior quality coating.

Strong alkaline cleaners are also not suitable for non-ferrous substrate such as Zinc, aluminum, Brass, Copper, Glass, Galvanised Steel, because all these metals readily get attacked by strong alkalies.

De-rusting: Corrosion is common phenomenon for metals. Iron or steel when exposed to humid atmosphere the corrosion process is initiated resulting in rust formation. Rust is the oxide of iron which is loosely adhered to the substrate and hence it is very dangerous if overcoated by any surface coating. Rust is readily soluble in acids such as Hydrochloric acid, Sulphuric acid, Phosphoric acid and hence it can be removed by acid cleaning. De-Rusting Process Advantages a)Cheaper process than blast cleaning or flame cleaning. b)Can be done anywhere, no big plant or sophisticated equipments are required. c)Remove rust, Mills scale. d)Makes the surface reactive for the next phosphating stage. Disadvantages a)If Hydrochloric acid or hot Sulphuric acid is used for derusting it can create a corrosive atmosphere in the plant. b)Not suitable in case of spray application. c)Carry over can create problem in next stage (i.e.) in phosphating bath. De-rusting can be done with the following acids/acid combinations : ([Link] acid Pickling : Hydrochloric acid is fuming acid and mostly used for Pickling, as it readily dissolves the mill scales formed during the hot rolling operations. Hydrochloric acid pickling is the cheapest de-rusting process. The use of Hydrochloric acid is very limited in the industry due to the corrosive nature of the Hydrochloric acid fumes which can create problem in the coating plant and secondly the carry over of Hydrochloric acid to the next pre-treatment stage (i.e.) either activation or phosphating can damage the bath permanently. In case of Pure Hydrochloric acid de-rusting the tank should be of Stainless Steel. ([Link] Acid: Sulphuric Acid is a strongest acid and it is most suitable for the heavily rusted components. Sulphuric Acid at an elevated temp.(50-60c)gives outstanding results in a short time. The use of hot process is limited in the industry due to the corrosive nature of Sulphuric acid fumes. The use of inhibitor is must in hot process to avoid the excess arrack of acid on the base metal. Carry over of Sulphuric Acid bath in phosphating bath can permanently damage the phosphating bath. For Sulphuric Acid based de-rusting the tank should be of either stainless steel or Mild steel with lead lining. ([Link] Acid: Phosphoric acid based de-rusting process is more popular in the finishing indusry due to its following advantages.

a)It gives a uniform & fine de-rusitng pattern which ultimately gives less coarser coating in phosphating. b) It has less pitting tendency than Hydrochloric acid & sulphuric acid based de-rusting. c) It does not emit any corrosive hazardous fumes. d) Carry over of bath solution does not create much problem. Phosphoric acid based de-rusting is costly as compared with Hydrochloric acid or Sulphuric acid. For Phosphoric acid based de-rusting, the bath should be of Stainless steel. Activation Process: This process provides fine active crystal centres on the surface of the metal which ultimately results into tine phosphate coating layer in phosphating stage. This process helps to attain a uniform phosphate coating. There are two types of activation processes: a)Acidic Activation b)Basic Activation a) Acidic Activation: This is a cheaper process. Here bath testing and control is not required. Bath can be prepared in hard water. The process results into coarser bigger crystalline coating. Not suitable for non ferrous substrates such as Aluminium. b) Basic Activation: This process is based on titanium based compounds which are most suitable for Ferrous & non Ferrous substrate. It gives more compact, uniform fine crystalline coating having better corrosion resistance. Disadvantages are 1) The bath is unstable (Titanium forms colloids in aqueous solutions) 2) Bath cannot be prepared in hard water. Conversion Coatings: Phosphating is universal method of metal Pre-treatment. Phosphating consist of the deposition on the metal surface of insoluble metal phosphates which are actually chemically bonded to the substrate. Since this is a chemical reaction, it gives good adhesion for paint film. Phosphating can be either crystalline or amorphous. This process provides the following: a)A clean, grease/oil free surface. b)A corrosion inhibitive base for powder coating. c)A non-conductive bond between base metal and powder coating. d)A chemically inert surface which prevent the reaction between the base metal and powder/paint ingredients. Phosphating process is divided into 2 types, a)Zinc Phosphating (sub-divided into Mono, Di, Tri Cationic Process). b)Iron Phosphating a)Zinc Phosphating: Zinc phosphating process is widely in the automobile, hardware, home appliance industry. Zinc Phosphating bath solution contain a saturated solution of phosphoric acid along with Zinc phosphate. On immersion of an article in such a bath the iron gets attacked by the acid component of the bath, by lowering its concentration at

the metal surface. After certain time (within 2min. Maximum) the phosphate crystalises on the metal surface. Since this is a chemical reaction between the metal and the phosphating solution, it stops after the formation of crystalline phosphate layer. It is not advisable to keep the parts/components in the phosphating bath for more than 10 minutes because the bath pH is acidic (between 4.8 to 5.5, depending on the bath concentration) and at this pH th coating formed gets dissolved slowly thereby leaving the bare metal, which is again attacked by the phosphating solution forming fresh crystalline layer of phosphating. This process may go on till the end of the metal and it unnecessarily increases the chemical consumption. Zinc phosphating is sub-divided into 3 types: Mono-cationic : Cations are positively charges ions. Zinc is the basic cation in all crystalline phosphating processes. Mono-cationic processes are comparatively cheaper than di & tri cationic processes. The bath solution contains only zinc as a cation. These processes find a very limited use in the industry as they have a limited corrosion resistance. Di-cationic Process: In this type the bath solution consist of zinc and Nickel as cations. Zinc imparts adhesion and Nickel contributes to the corrosion resistance. Hence coating formed in this type is more durable and withstand drastic corrosive atmosphere than Mono-cationic. Tri-cationic Process: In this type, the bath solution consists of zinc, nickel and manganese as cations. Manganese improves wear resistance of the phosphate coating. Hence coatings formed in this type are more superior w.r.t adhesion, corrosion resistance and wear resistance. Today tri-cationic process is more popular in the metal pre-treatment industry because ([Link] gives superior quality coating along with better corrosion and wear resistance. ([Link] lesser amount of Soft Sludge as compared with mono or Di Processes. This process is mostly acceptable by automobile industry (most used prior to Electro-deposition process) Home &consumer appliance industry etc. Suitable for Mazak and Aluminium. b) Iron Phosphating: Iron phosphating is of limited use in the pre-treatment industry although this has got its own segment. Iron phosphating do not contain any zinc like cation. They are based on sodium or dihydrogen phosphate as amajor ingredient along with accelerators such as molybdate. The coating formed is non-crystalline (amorphous) and having dark bluish colour. The major advantage of Iron phospating is (due to its non-crystalline nature) iron phosphated parts can be welded prior to powder coating. Iron phosphated parts when powder coated give outstanding mechanical properties. Conversion coating for Aluminium: Aluminium can be pre-treated by the following ways. ([Link] ( Tri-catonic Zinc) ([Link] ( Green, Yellow or colourless) Phosphating : Aluminium parts can be phosphated like mild steel. For Alumnium mild degreasing chemicals should be used. Heavy, strong degreasing chemicals can cause excessive etching to the base metal. De-rusting process should be avoided in phosphating sequence, which should be re-placed by desmuting process (parts to be dipped in 10% Caustic Solution for 1 to 2 minutes ). Phosphating process is not popular in Aluminium pre-treatment because Aluminium ions beyond a limit can cause poisoning to the phosphating bath.

CHROMATISING:
a) Green Chromium Phosphate: This is general process for the pre-treatment of Aluminium. This bath contian Mixtures of phosphoric acids, chromic acids and additives. This process is more popular in the food industry as it is non toxic. This process forms excellent substrate for powder coatings. The coating formed is dark green in colour weighing 0.5 -1.5 gm/m. It gives limited corrosion resistance. b) Yellow chromium chromate : This process is more popular in the powder coating industry. The bath contain mixture of chromic acid along with accelerators. This process gives dark yellow coloured (process applicable to OEMs) coating which is having high corrosion resistance. Since this process is based on hexavalent croium, it suffers from the disadvantages such as effluent problems etc. c) Colourless coating : This process is a modified process originated from process b) and used for certain application ( lacquer coat/- clear coat applications) where it is desired to retain the original metallic Aluminium appreance. The coating formed is having limited protected value. This process is not popular in the industry.

A trouble shooting guide to iron phosphating PROBLEM Poor Coating formation in phosphating stage. Poor Cleaning in De-greasing stage CAUSE pH not in range See Poor Cleaning De-greasing bath Temperature too low. De-greasing bath Concentration too low. Poor exposure to cleaner solution Contamination rinses. Poor Cleaning Contamination rinses. Poor exposure Rusting Coating weight too low Dry-off too slow. Drying between stages. REMEDY Adjust pH (down with acid, up with Caustic) Increase the bath temperature Increase concentration of bath. Check racking . Check nozzles Check pressure. Increase the pressure if necessary. Check rinse tanks See Poor Cleaning Check rinse tanks. Check racking. Check nozzles. Increase the bath temperatures Lengthen time in phospating stage. Increase concentration of bath. Increase temperature in final rinse. Run at lower temperatures. Better placement of nozzles. Use fog nozzles. Increase the bath temperature. Check for plugged nozzles. Check pump packing. Check water level. Lower temperature. Lower concentration. See Poor Cleaning Look for source of silicone near washer. Check raw material for excessive oil.

Spotty Coating / Streaking

Solutions foaming in degreasing

De-grease bath temperature too low Pressure too high. Pump picking up air.

Poor Paint Adhesion

Phosphate Coating too heavy Poor cleaning in de-greasing stage. Contamination. Bad Steel.

A trouble shooting guide for Zinc phosphating

PROBLEM Coating weight too low

CAUSE Phosphate or Accelerator concentration too. Low. Phosphate bath temperature too low. Process time too low. Phosphate or Accelerator concentration too high. Process time too long. Poor rinses. Excessive sludge. Accelerator concentration too high. Higher bath temperature. Poor cleaning. Low concentration of Phosphatizer or Accelerator. Poor solution coverage Resistant Metal. Coating weight too low. Final dry-off too slow. Dry-off between stages. Higher free acid pointage in phosphating bath

REMEDY Increase Concentration. Increase phosphate bath temperature. Lengthen time phosphating stage. Decrease concentration Shorten time. Keep rinse overflowing. D-sldge tank. Allow concentration to drop. Lower the temperature of the bath. Check cleaning tank. Increase concentration. Check racking and nozzles. Add Jernstedt salts to rinse or clean tank. See Trouble-Coating Weight too Low Increase temperature in the final rinse use air blow-off. Better placement of nozzles Use fog nozzles Run at lower temperatures. Reduce the free acid pointage. Check cleaning stage. Keep over-flowing. Better arrangement of nozzles. Use fog nozzel. Run at lower temperatures.

Coating weight too high

Powder on Coating

Spotty Coating

Rusting

Streaking

Poor cleaning Poor rising Dry-off between stages.

A trouble shooting guide for chromate process PROBLEM Bath pickles Metal and creates Dusty Coating. Low Coating Weight CAUSE Accelerator level too high REMEDY Reduce accelerator level by processing the aluminium or autodraining* and adjusting the bath. Autodrain* and adjust. Add accelerator. Add make-up chemical Autodrain* bath and adjust. Add accelerator

Aluminium concentration too high in bath. Accelerator too low. Concentration too low. Total acid too high in relation to chromium concentration. Total absence of accelerator in bath

No coating Sludge Plugging in Nozzles

Aluminium concentration in bath too Autodrain* bath and adjust high. Alkaline salts dragged into bath Increase overflow rate of rinse following cleaner.

Trouble Shooting Guide for Powder Coating

INTRODUCTION There are a wide variety of powder coating materials available; each with its own characteristics. Fluidised bed or electrostatic application can be used. Application reclaim and auxiliary equipment vary from supplier to supplier. However, there are operation problems common to all. This chapter will provide a systematic check list to follow when a problem arises. Many of these problems can be avoided with good procedure and supervision. Close attention to a few critical areas will eliminate potential operation problems with a powder finishing system. Careful attention should be given to having a clean, dry, compressed air supply, clean sieved reclaim powder, good ground to parts and equipment, humidity controlled spray booth air, and regular inspection and replacement of wear parts. The powder coating equipment should be installed and operated as recommended by the equipment supplier's manual. Follow the recommendations on your powder coating material data sheets. Have a good regular preventive maintenenace program and good housekeeping practices. Following are some trouble shooting procedures that may be of value in correcting difficulties that may arise with powder coating operations.

POWDER SUPPLY PROBLEMS:

1) Fluidized Bed Operation Trouble 1. Dusting-powder blowing Out of hopper

Possible Causes 1. Air pressure to high 2. Powder too fine

[Link] air pressure 2. No air-precolaitng through powder surface [Link] Membrane [Link] membrane Stratification-powder separating

4. Compacted powder [Link] level too low [Link] or moist powder.

into layers of fine and coarse particles. [Link] holing-air blowing large jet holes through power surface

[Link] membrane

4. Plugged or broken membrane

[Link] level too high 2. Powder too fine.

Possible Solutions [Link] air regulator to lower pressure to fluid bed. 2a. Too much reclaim added to virgin powder 2b. Virgin powder pulverised too fine by manufacturer. 1a. Check air supply, Increase air regulator pressure [Link] air line size to equipment. 2. Check membrane for plugged pores dirty air supply. [Link] bottom of bed for plastic, cardboard or other large obstructions. [Link] loosen powder and fluidize well with clean, dry air. [Link] powder until hopper is 2/3 f ull when fluidized . 2a. Manually loosen powder and fluidize well with clean,dry air 2b. Check compressed air and booth air for high humidity. [Link] bottom of bed for plastics, cardboard or other large obstructions. [Link] membrane for plugged pores from dirty air supply, cracks or holes. [Link] powder until 2/3 full when fluidized 2a. Too much reclaim added to virgin

powder. 2b. Virgin powder pulverized too fine by manufacturer POWDER SUPPLY PROBLEMS : 2) Hoses and pumps : Venturi operation Trouble [Link] from impact fusion hard build-up

2. Insufficient powder feed.

Possible Causes 1. Normal build-up [Link] pressure too high

Possible solutions

POWDER APPLICATION PROBLEMS : 3) Electrostatic coating operation

1. Clean or replace parts Trouble [Link] down air settings on pumps and guns [Link] charging inadequate powder [Link] in air supply 3. Check air supply for clean, dry air build or wrap on part. [Link] of powder feed hoses [Link] hoses. [Link] venturies and wear parts [Link] worn parts [Link] too fine [Link] much reclaim added to virgin powder 6 b. Virgin powder type pulverized too fine by manufacturer 7. Powder type of formula [Link] resin types tend to have more impact fusion. Check with your powder supplier 1. Powder not fulidizing [Link] from contamination powder supply [Link] fluidized bed section. 2.a. Clean out venturies and hoses 2b. Check powder supply for contamination 2c. Sieve all reclaim before using 3. Kinked or flatened hoses. 3a. Replace if permanently deformed. 3b. Avoid sharp bends. Use hose saddles for reciprocators. 3c. Run hoses in covered trenches across traffic aisles. 4. Worn pump venturies 5. Low air pressure 4. Replace worn parts. [Link] air supply. Adjust all setting to pumps and guns.

Possible Causes

Possible Solutions

POWDER APPLICATION PROBLEMS :

1. High -voltage source not providing 1a. Check high voltage source is on. Trouble enough KV at charging electrode or Systematically check electrical grid. continuity from voltage source to [Link] penetration powder will not electrode ( grid)including cable, coat Faraday Cage areas ( holes, resistors and fuses. grooves, channels inside corners and recesses.) 1b. Replace missing or broken electrode (grid) insulated by powder build or impact fusion. 1c. Clean electrode (grid) insulated by powder build or impact fusion. 2. Poor ground. [Link] ground from conveyor rail ( or rub bar when used ) through hanger to part. All contact areas must be free from heavy grease and other insulating material

3. Powder delivery (feed) is too high [Link] down powder feed until all material passing through charging carona ( field) is adequately charged. [Link] moisture in powder booth air. 5. Powder too fine. [Link] in humid air will tend to dissipate humidity in the powder spray area. 5a. Too much reclaim added to virgin powder. 5b. Virgin powder pulverized too fine by manufacturer. [Link] resin type charge better than others and some formulas are designed for thin firm applications. Check with your powder supplier. [Link] down air setting or move gun position further away from part.

[Link] charging powder layers are repelled from part in spots.

6. Powder type or formula

[Link] delivery air too high. Powder blowing by part.

[Link] picks up charge through powder hoses. Reverse charging usally through reclaim system.

Possible Causes 1. Powder delivery too high

[Link] delivery and/or reclaim equipment ground.

2. Poor ground.

3. Powder spray pattern too wide

4. Voltage too high.

5. Powder delivery velocity too high

6. Poor gun placement

7. Powder too fine

1. Voltage too high. 2. Gun positioned too close to part. 3. Poor ground

4. Powder too fine.

[Link] booth air too dry

[Link] ground for all equipment. Possible Solutions 1a. Turn up powder delivery air setting. 1b. Use barrel extension. [Link] ground. See page 16 2. Poor ground. - solution. [Link] smaller deflector or use suitable slotted barrel and cover. ( consult your equipmnet supplier). [Link] voltage setting down so powder builds on part edges and leading surfaces do not repel powder from corner. [Link] air setting down so powder/ air stream does not blow powder out of corners. [Link] gun position so powder cloud has direct path to recess area. 7a. Too much reclaim added to virgin powder. 7b. Virgin powder pulverised too fine by manufacturer. 1. Turn down voltage setting. [Link] gun placement away from part. [Link] ground See page 16 2. Poor ground - solution. 4.a. Too much reclaim added to virgin powder. 4b. Virgin powder pulverized too fine by manufacturer. [Link] powder spray area humidity. [Link] spray pattern not a symmetical powder cloud ( not applicable when using special deflectors for desired effect.) Continued Trouble [Link] feed spurting or slugging interrupted powder feed. Possible Causes 1. Insufficient air pressure volume

[Link] kinked, flattened or too long. [Link], pump venturies or guns clogged with powder.

[Link] E/S gun parts. [Link] fusion build. [Link] ( feed) air too low. [Link], venturies or gun blocked with powder

Possible Solutions

1 Check air supply. Air supply piping to equipment is large enough. Enough air volume must Trouble be provided so that when other equipment such as reverse air [Link] in reclaim powder. cleaning in reclaim housing pulses, air pressure to powder feed does not drop. 2. Check powder feed hoses. 3a. Clean hoses, venturies and guns. 3b. Check air supply for moisture that causes powder compaction. 3c. Check spray booth air humidity. 3d. Check powder supply for contamination. Check reclaim sieve. [Link] worn feed tubes, orfices deflectors and covers. [Link] gun parts as needed. [Link] air supply, Increase air for powder feed. [Link] hoses, venturies and guns.

POWDER SUPPLY PROBLEMS : 4) Collection and reclamation operation

Possible Causes [Link] in-line sieve torn, missing or inoperable. [Link] or dirt falling in spray booth from conveyor or hangers.

[Link] from parts entering spray booth [Link] from plant air circulated through spray booth.

1. Bag or cartridge filters blinding

[Link] booth dusting inadequate air flow through spray booth 2. Final filters clogged

[Link] large of open area in spray booth housing. [Link] delivery ( feed) too high

Possible Solutions [Link] sieve or repair as necessary [Link] conveyor regularly ( or continuously) before entering powder spray booth. Strip hangers as needed. [Link] cleaning pre-treatment equipment and ensure proper part drainage before spray booth.

CURED FINISH PROBLEMS 5) Coating finish-cured physical properties Trouble [Link] impact resistance/ poor flexibility.

Possible Causes [Link] cured. [Link] cleaning or pre-treatment. [Link] thickness too high [Link] in substrate thickness or type. [Link] resin type or formula. [Link] cleaning or pre-treatment [Link] in substrate [Link] cured. [Link] resin type or formula [Link] cleaning or pre-treatment

[Link] spray booth area. Preferably enclose in a room filtered, humidity controlled air. [Link] adhesion 1a. Clean or replace bags or cartridge filters 1b. Check spray booth air humidity. 1c. Check reverse air cleaning. [Link] filter bags or cartridges for powder leakage, repair or replace as needed. [Link] open area. Increased opening reduces booth air velocity. [Link] chemical resistance

[Link] corrosion resistance

[Link]-cured [Link] cured. [Link] resin type or formula

[Link] cured. [Link] the number of spraying or the amount of powder to each [Link] pencil hardness/poor abrasion [Link] resin type or formula. resistance.

Possible Solutions

CURED FINISH PHYSICAL PROBLEMS

Possible Causes

1a. Increase oven temperature [Link] thickness to thin 1b. Increase dwell time in oven. [Link] pre-treatment equipment Trouble [Link]-up rate too slow and chemicals [Link] film thickness by adjusting [Link] surface flow-too much orange application equipment. peel. [Link] resin type or formula. [Link] substrate with supplier. [Link] powder contamination [Link] with powder manufacturer. [Link]-pinholding from gassing. [Link] pre-treatment process [Link] substrate with supplier. 3.a. Increase oven temperature b. Increase dwell time in oven. [Link] with powder manufacturer [Link] pre-treatment equipment and chemicals. 2.a. Increase oven temperature b. Increase dwell time in oven. 1a. Increase oven temperature 1b. Increase dwell time in oven. [Link] too high for a Matt type 2. Check with powder manufacturer. powder 1a. Increase oven dwell time. [Link] with powder manufacturer. [Link] in powder. [Link] positioned wrong. [Link] not matched to line speed. [Link] film thickness [Link] flow in booth disturbing spray pattern. [Link] spray equipment [Link] too low-for high gloss powder

[Link] cured film. [Link] resin type or formula [Link] cured [Link] formula [Link] reclaim system : contamination No. 1 through No.4 [Link] powder contaminated

Possible Solutions

[Link] film thickness by adjusting application equipment. 2a. Increase oven temperature. Trouble 2b. Modify oven baffling to increase heat rate. 6. Off. Color. 3. Check with powder manufacturer. [Link] application equipment before changing powders. 2.a. Check substrate for porosity. b. Check substrate for moisture. c. Check powder for moisture from reclaim or compressed air. d. Check film thickness, coating too thick. [Link] oven temperature [Link] with powder manufacturer 1a. Increase temperature of oven. 1b. Increase dwell time in oven [Link] with powder manufacturer.

CURED FINISH PHYSICAL PROBLEMS Continued

Possible Causes [Link] oven [Link] time too long. [Link] temperature too high [Link] in film thickness

[Link] formula. [Link] coating appearance section, low gloss, No.2 and No.3. [Link] powder. [Link] and gassing through coating surface. [Link]-way or tearing coating film shrinks leaving bear substrate. [Link] cleaning, metal preparation or dry off..

2. Check with powder manufacturer [Link] and reposition guns so that spray patterns overlap slightly 2.a. Adjust line speed : Adjust reciprocator stroke. [Link] your equipment supplier. [Link] through application section check list.

Possible Solutions [Link] exhaust vent fan (s) [Link] line speed [Link] oven temperature. [Link] coating appearance page 21, point 5 inconsistent film thickness causes point 1 to 4 [Link] with powder manufacturer.

POWDER APPLICATION PROBLEMS 6) Output of powder insufficient to Possible Causes coat parts. [Link] of fluidzing air too low. Possible Reasons [Link] membrane is blocked [Link] fluidizing properties in the powder hopper. [Link] of compressed air too high [Link] of the powder too high

[Link]-flowing properties of the powder are bad. [Link] of the powder in the venturi [Link] application section, poor charging, Page 16, causes 1 to 7. [Link] pre-treatment process, dry off oven and part drainage. [Link] in venturies and hoses. [Link] of the powder in the hoses. [Link] of the powder in the hoses

[Link] free flowing properties of powder.

Possible Solutions

POWDER APPLICATION PROBLEMS Continued Possible Causes [Link] in the gun or gun outlet.

[Link] (increase) pressure of Possible Reasons fluidizing air. [Link] or replace the fluidizing 3. Blockage in the gun. membrane : see instructions of equipment supplier [Link] an air dryer with a corresponding oil-micro filter or another suitable drying system. [Link] storage facilities. Powder shall be stocked at room temperature (30C) in closed packing (Maximum humidity 60%) [Link] your powder supplier. [Link] or replace the hoses ( see instruction of the equipment supplier) if necessary reduce pressure of powder of transport air. [Link] the hose by bending and breaking up the fused powder if necessary replace it. [Link] an air dryer with a corresponding oil micro filter or an air dryer with a corresponding oil micro filter or another. [Link] your powder supplier.

[Link] caused by contamination of the powder with dust of other coarse materials.

Solutions

POWDER APPLICATION PROBLEMS 7) Poor or insufficient coverage Possible Causes [Link] electrostatic charging of the powder.

[Link] the gun according to the Possible Reasons instructions of your equipment supplier. When blocking occurs [Link] wrap-around frequently check humidity of compressed air and the free-flowing properties of the powder. [Link] the gun according to the instructions of equipment supplier and determine the reason of this contamination.(check powder pumps for possible impact fusion. Impact fusion particles which break off in the pump could be transported to the spray gun and result in blockage)

[Link] ground contact.

[Link] of powder too low [Link] an unsuitable powder supplier. [Link] of powder too low. [Link] penetration into corners, flanges, slots, etc [Link] ground contact. [Link] cloud too wide

POWDER APPLICATION PROBLEMS Continued Solutions Possible Reasons Possible Causes

1a. Adjust level of electrostatic 3. Poor adherence of powder to part, [Link] electrostatic charging of the kilovoltage (Increase ).if not powder falls from part easily. powder. possible, check equipment and guns according to instructions of the equipment supplier. 1b. Check for broken electrodes on the spray gun. If found, replace electrodes. 1c. Check for possible frictional [Link] output too high or the transport through powder hose. pressure for the transport air too If evident, consult powder high, which blows the powder from supplier for hose material the object. recommendation. [Link] the ground contacts using a [Link] particle size distribution measuring device. Correct and of the powder or unsuitable insure sufficient earth to ground powder type for the objects. control. [Link] up powder delivery air setting. [Link] your powder type.

[Link] up powder delivery air setting. [Link] the ground contact and if necessary use a suitable measuring instrument. [Link] powder cloud. If necessary install a more suitable deflector or adjust air for cone adjustment.

Possible Solutions

1a. Adjust level of electrostatic kilo -voltage. (increase voltage if not possible, check equipment and guns according to instructions of Possible Reasons equipment supplier.) 1b. See Insufficient Wrap around [Link], precured or other coarse problem 1b, page 25. material. [Link] powder output and/or reduce pressure of the transport air. [Link] your powder supplier. [Link] or powder surface.

CURED FINISH APPEARANCE PROBLEMS 8) Coating finish-cured films appearances.

Possible Causes 1a. Dust or other coarse parts on the metal surface. 1b. Dust or other coarse parts in powder.

[Link] with other powder (based on other raw materials). [Link]-up of the coated material is too slow or too fast. [Link]-peel. [Link] type too fast or too coarse particle size distribution. [Link] contamination. [Link] with other powder (based on other raw materials.) [Link] [Link] pre-treatment. [Link] with incompatible materials from the spraying areas e.g. silicones

CURED FINISH APPEARANCE PROBLEMS Continued Possible Solutions 1a. Check pre-treatment. High sludge level in phosphate bath. Possible Reasons 1b. Check powder and locate the cause of this contamination;if [Link] necessary clean up the installation and use fresh or sieved powder. [Link] up the installation, if necessary contact your powder supplier. [Link] curing-cycle and curing oven; if necessary contact your powder supplier. [Link] your powder supplier. [Link] the powder. [Link] up the installation;if necessary contact your powder supplier. [Link] pre-treatment and if necessary contact pre-treatment supplier. [Link] the presence of incompatible materials : if necessary clean up the installation and contact your powder supplier. [Link] entrapment and escaping due to chemical reaction. Possible Causes [Link] of the powder too high

[Link] entrapment with casting.

Possible Solutions [Link] storage facilities. Powder shall be stocked at room temperature in closed packing (maximum humidity 75%) [Link] objects over 320 F (160c)and cool down before applications ( only galvanized), or contact your powder supplier, who can advise you a special developed powder. [Link] coating thickness below 100 microns; if necessary contact your powder supplier.