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Troubleshooting Equipment: Film Property Issues

Part Three of Our Troubleshooting Series: Common Issues  with Film and Their Solutions

Troubleshooting Made Easy

Achieving a perfect finish can sometimes be tricky, even with the best equipment. In this blog, we'll categorize common film property issues to help you quickly identify and resolve them.

Each issue is linked to a table of possible causes and solutions, making it easy to find the answers you need. Click on the specific issue to get back on track with top-quality results!

Poor Fluidization:

Too Much Orange Peel

Problem

Solution

Film thickness too low/high

· Increase/decrease film thickness by adjusting application equipment

Oven temperature too low

· Set oven to correct temperature

Heat up rate too slow

· Modify oven baffling heat rate at front of oven

Back Ionization

· See application blog - Back Ionization section

 

Gloss Is Too High/Low:

Too Low for High Gloss Powder

Problem

Solution

Incompatible powder contamination

· Clean application equipment before changing powders

 Micropinholing from gassing

 Check component for porosity

· Check component for moisture

· Check powder for moisture from reclaim or compressed air

· Check film thickness, coating too thick
Too High for Low Gloss Powder

Problem

Solution

Undercured

· Check burners, isolate oven

· Increase dwell time in oven

 

Contamination:

Powder Is Contaminated

Problem

Solution

Reclaim in-line sieve torn

· Repair sieve or replace if necessary

 Contamination from plant air circulated through spray booth

· Isolate and preferably enclose spray booth area

 

Film Thickness:

Inconsistent Film Thickness

Problem

Solution

Guns positioned incorrectly

· Check and reposition guns

Reciprocators not matched to line speed

· Adjust line speed

· Adjust reciprocator stroke

Air speed in booth disturbing spray pattern

· Consult your equipment supplier

Defective spray equipment

· Consult your equipment supplier

 

Color:

Off Shade

Problem

Solution

Stoving time too long

· Adjust line speed

Oven temperature too high

· Decrease oven temperature

Variation in film thickness

· See Film Thickness section above

Foul oven air

· Check has supply, burners and venting

 

Pin Holding:

Pin Holding and Gassing Through Coating Surface

Problem

Solution

Occur during curing as gasses that are trapped escape through the powder

 

 

Check cleanliness of the part Prebaking may help solve this Cleaning the lines and checking for oil

 

Film Aspect:

Texture Pattern Or Metallic Effect Incorrect

Problem

Solution

Poor powder charging

· See Application blog - Poor Charging Section

Poor earth

· See Application blog - Poor Charging Section

Guns too close or distant from component

· Adjust distance

Separation in hopper

· See Poor Fluidization section above

Powder delivery too high

· Adjust

Film thickness too high or low

· Adjust

 

Poor Mechanics:

Poor Impact Resistance / Flexibility

Problem

Solution

Under cured

· Increased oven temperature

· Increased dwell time in oven

Poor cleaning or pretreatment

· Check pretreatment equipment and chemicals

Film thickness too high

· Reduce film thickness by adjusting application equipment

Change in substrate thickness or type

· Check substrate with supplier

 

Adhesion:

Poor Adhesion

Problem

Solution

Poor cleaning or pretreatment

· Check pretreatment equipment and chemicals

Change in substrate thickness or type

· Check substrate with supplier

Under cured

· Increase oven temperature

· Increase dwell time in oven

 

Chemical Resistance:

Poor Chemical Resistance

Problem

Solution

Undercured

· Increase oven temperature

· Increase dwell time in oven

 

Surface Hardness:

Poor Pencil Hardness / Abrasion Resistance

Problem

Solution

Under cured

· Increase oven temperature

· Increase dwell time in oven

 Under cured

· Reduce oven temperature

 

In Conclusion:

By learning about these common problems and how to fix them, you can keep your equipment running smoothly and get great results. Remember, every situation is different, and sometimes you might face issues that need more specific solutions.

Don’t hesitate to reach out to us for expert guidance and support. We are committed to helping you overcome any hurdles and ensure your powder coating process runs smoothly.