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POOR ADHESION

CAUSE

Inadequate cleaning or pretreatment
Under cure
Film thickness too high

REMEDY

Check pretreatment equipment and chemicals
Increase oven temp and/or time in oven
Reduce thickness by lowering voltage or shorten spray time

Metal Pre-Treatment

CHIPPING

CAUSE

Powder not fully cured
Coating thickness too high

REMEDY

Check pretreatment equipment and chemicals
Reduce thickness by lowering voltage or shorten spray time

Iron Phosphating

CORROSION RESISTANCE (Poor)

CAUSE

Inadequate cleaning or pretreatment
Under cure

REMEDY

Check pretreatment equipment and chemicals
Increase oven temp and/or time in oven

CRATERING

CAUSE

Contamination with other powder
Inadequate pretreatment of substrate
Contamination with incompatible materials from spray area (i.e. silicone)

REMEDY

Clean the system and start with virgin powder
Check the pretreatment
Check for presence of incompatible materials

FLOW (Poor)

CAUSE

Curing temp too high
Preheat oven too high
Coating thickness too low

REMEDY

Reduce oven temp and/or time in oven
Reduce pretreat oven temperature and/or time in oven
Increase coating thickness by using a higher voltage, longer spray time or more dense powder cloud

Zinc Phosphating

OUT-GASSING

CAUSE

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

REMEDY

Preheat oven above curing temperature and coat hot

Chromate Process

GLOSS DIFFERENCE

CAUSE

Curing temperature too low or too high
Contamination caused by other powders with different flow or gel characteristics

REMEDY

Increase/decrease oven temperature and/or time in oven
Clean guns, hoses, and hoppers, use virgin material

IMPACT RESISTANCE / FLEXIBILITY (Poor)

CAUSE

Under cured
Poor cleaning or pretreatment
Film thickness too high
Change in substrate thickness or type

REMEDY

Increase oven temperature or increase dwell time in oven
Check pretreatment equipment and chemicals
Reduce film thickness by adjusting application equipment
Check substrate with supplier

OFF COLOUR

CAUSE

Improper oven exhaust
Bake time too long or too short
Oven temperature too high or too low

REMEDY

Check exhaust fans
Adjust line speed and/or temperature
Adjust oven temperature

OPACITY (Poor)

CAUSE

Coating thickness too low

REMEDY

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

ORANGE PEEL

CAUSE

Warming up of the coated material is too slow or too fast
Heat damage of the powder
Film thickness too low

REMEDY

Check curing cycle and curing oven, if necessary, contact your powder supplier
Replace the powder
Increase the thickness by raising the voltage or lengthen the spray time

PENCIL HARDNESS / ABRASION RESISTANCE (Poor)

CAUSE

Under cured

REMEDY

Increase dwell time or temp in oven

PENETRATION (Poor)

CAUSE

Powder delivery
Poor ground
Improper spray pattern
Voltage too high or too low
Poor gun replacement

REMEDY

Adjust powder delivery
Check ground
Select proper deflector or use suitable barrel and cover (consult equipment supplier)
Adjust voltage settings so powder builds on edges and leading surfaces, do not repel powder from corner
Adjust gun position so powder cloud has a direct path to recess area

PINHOLING

CAUSE

Coating thickness too low

REMEDY

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

SAGS

CAUSE

Coating thickness too high
Curing temperature too low

REMEDY

Reduce coating thickness by using a lower voltage, shorter spray time, or less dense powder cloud
Increase oven temperature

SOFT SURFACE

CAUSE

Curing temperature too low
Contamination with an incompatible powder, especially a thermoplastic

REMEDY

Increase oven temperature and/or time in oven
Clean guns, hose, and hoppers, use virgin materials