Powder Coating Application Problems & Solutions

Poor Charge or Low Film Build

Due to poor charging, Low Film thickness is observed due to this you will see orange peel & substrate especially in white, Ivory & yellow colours.

Cause of Problem	Solutions
The most common cause of these issues is poor grounding. Because good ground is necessary for charging. Ground is not the only factor in this issue. Gun settings may actually be the problem. Too much powder flow and incorrect kV levels can affect an application also.	1. Make sure that you have a good earthen ground. 2. Ensure that connecting parts are clean. 3. Powder builds up on hooks needs to be cleaned regularly. 4. Check your kV levels and powder flow. Double check the Technical Data Sheet or call up your supplier for the correct kV and flow settings.

Cause of Problem

Solutions

The most common cause of these issues is poor grounding. Because good ground is necessary for charging. Ground is not the only factor in this issue. Gun settings may actually be the problem. Too much powder flow and incorrect kV levels can affect an application also.

1. Make sure that you have a good earthen ground.

2. Ensure that connecting parts are clean.

3. Powder builds up on hooks needs to be cleaned regularly.

4. Check your kV levels and powder flow. Double check the Technical Data Sheet or call up your supplier for the correct kV and flow settings.

Poor Penetration of Powder into Corner Areas

Due to the electrostatics traveling through the metal, the powder will not apply to corner areas easily. This is called a Faraday Cage. The powder pulls away from the corners towards the flat areas or edges. This results in areas of a surface that are left bare.

Cause of Problem	Solutions
Most of us face the Faraday Cage effect. It's difficult to deal with, but what causes this problem. Grounding and gun settings, not enough powder flow, gun to part distance, poor spray pattern, and too fine powder can produce a Faraday Cage effect.	There are some methods to prevent Faraday Cage effect. 1. Adjust your flow and increase the amount of powder leaving the gun. 2. Adjust gun to part distance. 3. Reclaimed powder is too fine, it will not carry a charge as well, meaning the risk of a Faraday Cage is increased. Check your mix of virgin to reclaim powder.

Cause of Problem

Solutions

Most of us face the Faraday Cage effect. It's difficult to deal with, but what causes this problem. Grounding and gun settings, not enough powder flow, gun to part distance, poor spray pattern, and too fine powder can produce a Faraday Cage effect.

There are some methods to prevent Faraday Cage effect.

1. Adjust your flow and increase the amount of powder leaving the gun.

2. Adjust gun to part distance.

3. Reclaimed powder is too fine, it will not carry a charge as well, meaning the risk of a Faraday Cage is increased. Check your mix of virgin to reclaim powder.

Back Ionization

Each part is only capable of taking so much charge. Go over that amount, and it will start to reject the charge. This results in the coating behaving differently, kind of like it is standing up or looks different in that area it’s called back ionization.

Cause of Problem	Solutions
Poor grounding and too fine powder can contribute to this application issue. forcing a part to accept more charge than it can handle, or continuing to apply powder once that limit has been overloaded. Faraday Cage issue can be a factor here as well.	1. Check for good ground 2. Reducing your micro amps and kV settings. 3. Decreasing your powder flow.

Cause of Problem

Solutions

Poor grounding and too fine powder can contribute to this application issue. forcing a part to accept more charge than it can handle, or continuing to apply powder once that limit has been overloaded. Faraday Cage issue can be a factor here as well.

1. Check for good ground

2. Reducing your micro amps and kV settings.

3. Decreasing your powder flow.

Gun Spitting

When the gun spits out powder and it's going on good coating. It results in uneven coatings with bad finish.

Cause of Problem	Solutions
Too much fluidization is a possibility of this problem. This means that the flow coming out of the gun is not a consistent mix of air and powder, there is too much air. Powder built upon the tip of the gun and on the electrode and longer hose can cause spitting. Humidity or moisture in the air is also the cause of this problem.	1. The best thing to do is to check with your equipment manufacturer what the ideal hose length should be for your system. 2. Check Air moisture.

Cause of Problem

Solutions

Too much fluidization is a possibility of this problem. This means that the flow coming out of the gun is not a consistent mix of air and powder, there is too much air. Powder built upon the tip of the gun and on the electrode and longer hose can cause spitting. Humidity or moisture in the air is also the cause of this problem.

1. The best thing to do is to check with your equipment manufacturer what the ideal hose length should be for your system.

2. Check Air moisture.

Application Process For Metallic Finish Powder

Metallic can be more difficult to spray than solid color powders. Especially when there is a large difference between the base color and the color of the metallic flake. For most metallic applications, you may find that you’ll have great success if you turn down your kVs and Voltage Settings. Range between 60 and 75, with the KV between 25 to 35 Is best for metallic powders. Do not Apply the powder too fast.