Problem

Cause

Remedy

Adhesion

1. Inadequate cleaning or pretreatment.

1. Check pretreatment equipment and chemicals.

 

2. Under cured

2. Increase oven temp and/or time in oven.

 

3. Film thickness too high.

3. Reduce thickness by lowering voltage or shorten spray time.

 

4. Over cured.

4. Reduce oven temp for thin steel and bake time in oven.

 

 

 

Chipping

1. Powder not fully cured.

1. Check pretreatment equipment and chemicals.

 

2. Coating thickness too high.

2. Reduce thickness by lowering voltage or shorten spray time.

 

 

 

Corrosion Resistance (Poor)

1. Inadequate cleaning or pretreatment.

1. Check pretreatment equipment and chemicals.

 

2. Under cured.

2. Increase oven temp or dwell time.

 

 

 

Cratering

1. Contamination with other powder.

1. Clean the system and start with virgin powder.

 

2. Inadequate pretreatment of substrate.

2. Check the pretreatment.

 

3. Contamination with incompatible materials from spray area (i.e. silicone).

3. Check for presence of incompatible materials.

 

4. Oil or moisture in the air lines.

4. Check air lines. Install filters if necessary.

 

 

 

Poor Flow

1. Curing temp too high.

1. Reduce oven temp and/or time in oven.

 

2. Preheat oven too high.

2. Reduce pretreat oven temp and/or time in oven.

 

3. Coating thickness too low.

3. Increase coating thickness by using a higher voltage, longer spray time, or more dense powder cloud.

 

 

 

Out-Gassing

1. Air entrapped in substrate (i.e. castings, sandblasting parts)

1. Preheat oven above curing temp and coat hot.

 

 

 

Gloss Difference

1. Curing temp too low or too high.

1. Increase/decrease oven temp and/or time in oven.

 

2. Contamination caused by other powders with different flow or gel characteristics.

2. Clean guns, hoses, and hoppers, use virgin material.

 

 

 

Impact Resistance Flexibility (poor)

1. Under cured

1. Increase oven temp or dwell time

 

2. Poor cleaning or pretreatment.

2. Check pretreatment equipment and chemicals.

 

3. Film thickness too high.

3. Reduce film thickness by adjusting application equipment.

 

4. Change in substrate thickness or type.

4. Check substrate supplier.

 

 

 

Off Color

1. Improve oven exhaust.

1. Check exhaust fans.

 

2. Bake time too long or too short.

2. Adjust line speed and/or temp.

 

3. Oven temp too high or too low.

3. Adjust oven temp

 

 

 

Opacity (poor)

1. Coating thickness too low.

1. Increase coating thickness by using higher voltage, longer spray time, or more dense powder cloud.

 

 

 

Orange Peel

1. Warming up of the coated material is too slow or too fast.

1. Check curing cycle and curing oven. If necessary, contact your powder supplier.

 

2. Heat damage of the powder.

2. Replace powder.

 

3. Film thickness too low.

3. Increase the thickness by raising voltage or lengthen spray time.

 

 

 

Pencil Hardness/ Abrasion Resistance (poor)

1. Under cured.

1. Increase dwell time or temp.

 

 

 

Penetration (poor)

1. Powder delivery.

1. Adjust powder delivery.

 

2. Poor ground.

2. Check ground.

 

3. Improper spray pattern.

3. Select proper deflector or use suitable barrel and cover. (consult your equipment supplier).

 

 


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