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Cured Finish Physical Problems

What is the problem you are facing?

Poor surface flow - too much orange peel.

Possible Causes Possible Solutions
1. Film thickness to thin. 1. Increase film thickness by adjusting application equipment.
2. Heat-up rate too slow. 2a. Increase oven temperature.
2b. Modify oven baffling to increase heat rate.
3. Powder resin type or formula. 3. Check with powder manufacturer.

 

Gloss too low - for high gloss powder.

Possible Causes Possible Solutions
1. Incompatible powder contamination. 1. Clean application equipment before changing powders.
2. Micro-pinholding from gassing. 2a. Check substrate for porosity.
2b. Check substrate for moisture.
2c. Check powder for moisture from reclaim or compressed air.
2d. Check film thickness, coating too thick.
3. Over cured film. 3. Check oven temperature.
4. Powder resin type or formula. 4. Check with powder manufacturer.

 

Gloss too high - for a Matt type powder.

Possible Causes Possible Solutions
1. Under cured. 1a. Increase temperature of oven.
1b. Increase dwell time in oven.
2. Powder formula. 2. Check with powder manufacturer.

 

Contamination in powder.

Possible Causes Possible Solutions
1. See reclaim system : contamination No. 1 through No.4  
2. Virgin powder contaminated. 2. Check with powder manufacturer.

 

Inconsistent film thickness.

Possible Causes Possible Solutions
1. Guns positioned wrong. 1. Check and reposition guns so that spray patterns overlap slightly.
2. Reciprocators not matched to line speed. 2. Adjust line speed : Adjust reciprocator stroke.
3. Air flow in booth disturbing spray pattern. 3. Consult your equipment supplier.
4. Defective spray equipment. 4. Go through application section check list.

 

Off Color.

Possible Causes Possible Solutions
1. Improper oven exhaust. 1. Check exhaust vent fan(s).
2. Bake time too long. 2. Adjust line speed.
3. Oven temperature too high. 3. Lower oven temperature.
4. Variation in film thickness. 4. See coating appearance, point 5 inconsistent film thickness causes point 1 to 4.
5. Powder formula. 5. Check with powder manufacturer.

 

Pinholing and gassing through coating surface.

Possible Causes Possible Solutions
1. See coating appearance section, low gloss, No.2 and No.3.  

 

Pull-way or tearing coating film shrinks leaving bear substrate.

Possible Causes Possible Solutions
1. Uncharged powder. 1. See application section, poor charging, causes 1 to 7.
2. Poor cleaning, metal preparation or dry off. 2. Check pre-treatment process, dry off oven and part drainage.