| Problem |
Cause |
Remedy |
| Chipping |
1.
Powder not fully cured |
1.
Increase oven temperature, time, or both. |
| |
2.
Coating thickness too high |
1.
Reduce thickness by lowering voltage or reducing
spray 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.
Contaminations with incompatible materials from the
spray area |
3.
Check for presence of incompatible materials. |
| |
4.
Oil or moisture in air lines |
4.
Check air lines; install filters if necessary. |
| Off
Color |
1.
Improper oven exhaust |
1.
Check exhaust vent fans. |
| |
2.
Bake time too long or too short |
2.
Adjust the conveyor speed, oven temperature, or
both. |
| |
3.
Oven temperature too high or too low |
3.
Adjust oven temperature. |
| Orange
peel |
1.
Warm-up of the coated material too slow or too fast |
1.
Check curing cycle and curing oven; if necessary,
contact your powder supplier. |
| |
2.
Heat damage to powder |
2.
Replace the powder. |
| |
3.
Film thickness too low |
3.
Increase the thickness by raising voltage or
increasing spray time. |
| Poor
adhesion |
1.
Inadequate cleaning or pretreatment |
1.
Check pretreatment equipment and chemicals. |
| |
2.
Undercured powder |
2.
Increase oven temperature, or increase dwell time in
oven. |
| |
3.
Film thickness too high |
3.
Reduce thickness by lowering voltage or reducing
spray time. |
| Poor
Corrosion Resistance |
1.
Inadequate cleaning or pretreatment |
1.
Check pretreatment equipment and chemicals. |
| |
2.
Undercured powder |
2.
Increase oven temperature, or increase dwell time in
oven. |
| Poor
impact resistance or poor flexibility |
1.
Undercured powder |
1.
Increase oven temperature, or increase dwell time in
oven. |
| |
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 with supplier. |
| Poor
pencil hardness or poor abrasion resistance |
1.
Undercured powder |
1.
Increase dwell time in oven. |
| Poor
penetration (Powder won't coat Faraday cage areas,
such as holes, grooves, channels, inside corners,
and recesses) |
1.
Poor 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). |
| |
4.
Voltage too high or too low |
4.
Adjust voltage settings so that powder builds on
part edges and leading surfaces don't repel powder
from corner. |
| |
5.
Poor gun placement |
5.
Adjust gun position so that the powder cloud has a
direct path to the recess area. |
| |
6.
Powder too fine or too coarse |
6.
Consult your powder supplier. |
