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    Troubleshooting Guide

    powder coating troubleshooting guide

    1.POWDER APPLICATION 2.CURED FILM DEFFECTS
    3.MECHANICAL &CHEMICAL PROPERTY
    1.1.Thin Film (Substrates show through and coating layer has grainy flow)
    Possible Causes Solutions
    High humidity powder Control environment
    Ensure all powders are kept sealed until required to use
    Poor charging Increase voltage
    Clean or replace electrodes,cables,etc if needed
    Decrease powder delivery rate
    Poor grounding Use clean hooks; Check and improve grounding
    Poor deposition rate Increase powder delivery air;Reduce line speed
    Faraday cage effect Adjust voltage and forward air flow
    1.2.Poor Fluidization (Poor fluidization causes slow and no transportation of powder from fluid container to guns)
    Possible Causes Solutions
    Fluidizing air too low or too high Change air pressure; Use large hose diameter
    Oil remnants in compressed air Check filter in front of coating booth
    Damp or compact powder Manually loosen powder in hopper
    1.3.Poor Penetration in Faraday areas
    Possible Causes Solutions
    Voltage not optimized Reduce voltage,so that surfaces closest to the gun do not repel powder
    Powder delivery rate
    not optimized
    Adjust delivery rate
    Poor part ground Check and improve grounding
    Incorrect powder spray pattern Try different spray nozzle
    Poor gun placement Adjust gun position
    Poor part presentation Improve part presentation
    Powder too fine Reduce ratio of reclaim to hopper
    1.4.Back Ionization (Surface looks uneven and broken before curing )
    Possible Causes Solutions
    Gun voltage too high Reduce voltage
    Gun too close to part Increase the distance between gun and part
    Poor part grounding Check and improve the grounding
    Excessive powder build-up Spray thinner film
    Moisture powder Ensure no moisture is entering the system
    1.5.Powder Surging or Spitting
    Possible Causes Solutions
    Not optimized powder
    delivery rate
    Optimize powder delivery rate
    Incorrect hose diameter Uses smaller diameter hose
    Improper air pressure Optimize air pressure
    Clogged worn parts,tubes or hoses Check and clean or replace worn parts as needed
    Moisture in compressed air Ensure clean dry air
    Much more fines powder Add virgin powder
    1.6.Much Thicker Film(layer shows uneven surface before curing,orange peel or pinholes will show after curing
    Possible Causes Solutions
    Excessive powder delivery Reduce powder feed to gun
    Increase distance between gun and component
    Curing time too long Shorten curing time
    Gun voltage too high Adjust voltage
    Too much pre-heat(if exists) Reduce pre-heat cycle
    2.CURED FILM DEFFECTS
    2.1.Pinholes In the Filem(Fine pores on the surface,also can leads to change in gloss )
    Possible Causes Solutions
    Inadequate cleaning of substrate Check cleaning and phosphating
    Silicone,oil Contaminatants Check source and eliminate,check degreasing plant
    Oil in compressed air supply Ensure clean ,dry air supply
    Moisture content in powder
    too high
    Testing through drying of powder
    Very porous workpiece Check for satisfactory workpieces,maybe no enough sandblasting
    2.2.Picture Framing(Higher film build-in on the edges of part due to wrap,uneven flow)
    Possible Cause Solutions
    Excessive film thickness Reduce film thickness
    Poor part grounding Check and improve grounding
    Voltage too high Adjust voltage to suit
    Feed air or powder flow too high Adjust powder flow
    2.3.Outgassing or blistering
    Possible Cause Solutions
    Excessive film thickness Check system parameter,reduce film thickness
    Cast or other porous substrate De-gas at or above cure temperature
    Water on workpiece Check dryer and hanging configuration
    Liquid paint under powder Remove pain,de-gas at or above cure temperature
    2.4.Orange Peel(Poor flow,short or long waviness of coating layer,shown after curing)
    Possible Causes Solutions
    Heat up cycle of part too slow Increse heat up rate
    Improper film thickness Check system parameter and adjust film thickness
    Incompatibility with other powder Clean booth,check compatibility
    Voltage too high Optimize voltage
    Substrate profile Increase film thickness or change substrate
    Powder Stored at or
    exposed to elevated temperature
    Replace powder
    Store powder at or below recommended temp.
    Unsuitable particle zise distribution Optimize particle size distribution
    2.5.Low Gloss
    Possible Causes Solutions
    Oven temperature too high Redue temperature,and check metal temperature,or increase line speed
    Time in oven too long Increase line speed;decrease oven temp.
    Contamination with a powder Clean all equipment including gun,booth,recovery system
    2.6.High Gloss
    Undercured coating flim Increase curing time or temperature
    Slow heat up cycle Increase cure temperature;preheat substrate
    2.7.Poor Adhesion
    Undercured film Increase oven temperature;decrease line speed
    Poor pre-treatment Check pre-treatment
    2.8.Contamination of colos
    Possible Causes Solutions
    Poor cleaning when
    color changing
    Clean plant,gun and recycling system
    Cross contamination
    at manufacturer
    Contact powder supplier
    Contamination from
    equipment cleaning
    Vacuuming is more effective
    Desposits from dust and
    particle in oven
    Donot cure other color at same time; reduce air speed
    2.9.Off-color or yellowing
    Possible Causes Solutions
    Overbaking Reduce curing time or temperature
    Increse line speed
    Check burner locations to eliminate hot spots
    Line stoppages Eliminate line stoppages or reduce oven temp.during stoppages
    Leave gaps to provide for scheduled line stoppages
    Inadequate oven exhaust Increase oven exhaust rate or reduce line loading
    1.POWDER APPLICATION 2.CURED FILM DEFFECTS

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