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Powder Coating

Powder Coating Products

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Applications

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Quality Assurance

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Powder Coating Troubleshooting

PROBLEMS & SOLUTIONS

CLASSIFICATION OF PROBLEMS

Power Related

Lumps Formation

Application Related

Fluidization
Gun Spitting
Covering
Film Thinkness
Recycle Powder

Finish Related

Gloss
Finish
Color Change
Pin Holes
Orange Peel

Mechanical & Chemical Test

Impact Test
Band Test
Cross Hatch Test
SST Test
QUV Test

Lumps Formation

POSSIBLE CAUSE	SUGGESTED SOLUTION
The Powder Has Been Store for Too Longer Time or Temp Too High for Storage	Keep Powder Cool & Dry Area. Filter the Powder

Gun Spitting

POSSIBLE CAUSE	SUGGESTED SOLUTION
Poor Fluidization in Powder Hopper Pump & Blocked Hoses Not Adjusted Properly Pump & Blocked Hoses Not Adjusted Properly	Increase or Decrease the Fluidizing Air to Hopper Check Bottom of Hopper and Membrane Filter Increase Atomizing/ Diffuser Air Check All Air Tube Connections for Leak Reduce the Amount of Reclaim Powder

Poor Penetration (Covering)

POSSIBLE CAUSE	SUGGESTED SOLUTION
Insufficient Powder Poor Earth Incorrect Spray Pattern Voltage Too Fine Powder Too Fine	Increase the Pump Flow-rate Pressure Clean the Hook and Racks, Also Check and Improved Grounding Try Different Nozzles for Different Surface Reduce Gun Voltage (Kv) Reduce the Amount of Reclaim Powder

Coverage

POSSIBLE CAUSE	SUGGESTED SOLUTION
Powder Delivery Rate to High (Effect-thickness) Shape of Substrate Incorrect Spray Coating Method Recycle Powder Efficiency Poor Earth	Powder Delivery Rate Decreased (Control-thickness) Different Shape Change Area Check Gun Distance & Coating Method Check Recycle Powder % Clean Hocks , Hanger & Improved Grounding

Gun Parameters for Powder

FINISH	SMOOTH	STRUCTURE	TEXTURE	METALLIC
Charging (Kv) Air (Kg/cm3) Powder Current(????a) Fluidization(Kg/cm3)	70-90 1.5-4.0 As Per Required 20-40 As Per Required	70-100 1.0-2.5 As Per Required 20-40 As Per Required	70-80 1.5-4.0 As Per Required 20-40 As Per Required	50-60 0.5-1.5 As Per Required 20-30 As Per Required

Film Thickness Too Low or Too High

POSSIBLE CAUSE	SUGGESTED SOLUTION
Powder Delivery Too Low Insufficient Coating Time Faraday Cage Effect Poor Earthing Powder Output Too High	Increases Coating Time of Component Adjust the Gun Voltage & Other Parameters Clean Hooks & Racks Turn Down Pump Pressure & Move Gun Farther Away From the Parts Reduce Gun Voltage Reduce Time of Component Coating Time

Craters & Pin Holes

POSSIBLE CAUSE	SUGGESTED SOLUTION
Oil & Other Contamination on Parts Contaminated Compressed Air Contaminated Powder Moisture in Air Silicon Contamination Poor Sheet Quality	Check Cleaning and Pretreatment Ensure Compressed Air is Free From Oil Clean the Equipment and Recharge With Fresh Powder Drain Out the Water From Compressor Remove Located Source Point Choose Special Degassing Grade Powder Micro Pinhole in Gpsp Sheet

Gloss (Too High or Too Low)

POSSIBLE CAUSE	SUGGESTED SOLUTION
Cure Oven Temp Too Low Cure Oven Temp Too High Oven Cycle Time Low & Long Contamination With Incompatible Powderr	Increase the Oven Temp Decrease the Oven Temp Adjust Line Speed & Curing Time Remove All Contaminated Powder Thoroughly Clean All Equipment Then Use Fresh Powder

Poor Adhesion (Chip-off)

POSSIBLE CAUSE	SUGGESTED SOLUTION
Powder Under Cure Poor Pretreatment (Oil & Dirty Surface) High Coating Preheat After Pre-treatment Process	Increase the Temp Check the Pretreatment Process Adjust Coating as Per Product Std Check Condition & Suggested for Preheat

Color Variation

POSSIBLE CAUSE	SUGGESTED SOLUTION
Film Thickness Variation Differing Substrates & Substrate Color Over Curing of Powder Coating	Assure Constant Film Thickness Use Substrate of Same Type for Comparisons Observe Curing Parameters of Powder Manufacturer

Color Fading

POSSIBLE CAUSE	SUGGESTED SOLUTION
Cleaning Method Very Poor Poor Paint Film Adhesion Small Pin Hole & Degassing on Finish Sun Uv Rays, Many Pollutant Section Are Faster Fade Some Place Choose Wrong Chemistry Powder COLOR HAS A LIMITED LIFE EXPECTANCY	Check Pre-treatment Process Check Temperature Check Pinhole Source Discuss Conditions With Manufacture Choose Outdoor Durability Architectural Grade Powder Contact Manufacture

Structure Pattern

POSSIBLE CAUSE	SUGGESTED SOLUTION
Flat Pattern Small Pattern (Pin Hole)	Adjust the Air Pressure & Lower Thickness Increase Thickness. Long Curing Time

Dusting (Foreign Particle in Film)

POSSIBLE CAUSE	SUGGESTED SOLUTION
Substrate Surface is Dirty Booth Area is Not Clean Powder is Too Coarse or Not Sieved	Check the Pretreatment Process Clean the Substrate by Air Cleaning Clean the Booth Area. Sieve All Reclaim Powder

Orange Peel (Poor Flow)

POSSIBLE CAUSE	SUGGESTED SOLUTION
Film Thickness is Too High or Too Low Voltage Too High Heat Cycle of the Too Slow Air Pressure is Too High	Check System Parameters Optimize Voltage Determine the Heat Up Curve and Increase Reduce the Air Pressure

Cloud Problem (Carbon Layer) in Finish

POSSIBLE CAUSE	SUGGESTED SOLUTION
Corrosive Urban Atmosphere Uniform Exposure to Air & Its Pollutants Coating Defects or Coating Damage Uncured Substrate Chloride Contamination on Phosphate Film Damp Moisture Films Over Metal Surface Wet Films of Dew & Rainwater	Use Corrosion Resistant Metal or Alloy Reduce Atmospheric Pollutants Do Regular Surface Cleaning Check Curing Temperature Regularly Avoid Coating Defects Use Suitable Corrosion Inhibitors Coated Substrate Packing Area Should Be Dry/li>

Corrosion (Rust)

POSSIBLE CAUSE	SUGGESTED SOLUTION
Corrosive Urban Atmosphere Uniform Exposure to Air & Its Pollutants Coating Defects or Coating Damage Uncured Substrate Chloride Contamination on Phosphate Film Damp Moisture Films Over Metal Surface Wet Films of Dew & Rainwater	Use Corrosion Resistant Metal or Alloy Reduce Atmospheric Pollutants Do Regular Surface Cleaning Check Curing Temperature Regularly Avoid Coating Defects Use Suitable Corrosion Inhibitors Coated Substrate Packing Area Should Be Dry/li>

Use of Recycle Powder

Maintain Use of Recycle Powder Percentage With Maximum (70:30) Ratio. If We Use With Higher Ratio That Cause Problem in Finish. Use Recycle Powder Only After Sieving. If We Use Without Sieving That Cause Dusting. Collect the Recycle Powder Separate Box & Cover Properly Otherwise Face in Pinhole Problem.

Color Variation (in Metallic)

POSSIBLE CAUSE	SUGGESTED SOLUTION
High Charging High Air Pressure Gun Distance Too High or Too Low Color Variation in Recycling	Reduce the Charging to Below 60 Kv Optimize the Air Pressure Adjust the Gun Distance Maintain 90/10 Ratio Use of Recycle Powder

Contact us

Address

Plot No. 631, Sec-69, IMT,
Ballabgarh, Faridabad, Haryana, India
121004

Phone

+91-9999052262, +91-9891990223

+91-1294000946, +91-1292981223

Email

info@durolacpaints.com
sales.durolacpaints@gmail.com

Ral Chart