One more thing that you can do, which is really helpful in any scenario, is have sample panels that you and the customer can see beforehand. Inconsistencies in gloss are noticeable and irritating to see, as a gloss is often the final touch to a coating that brings the color to life. One option is to put the part in the oven before applying any coating. May 24, 2020 - Improve your powder coating with www.powdercoatguide.com. Coating Defects Raised Lumps. substrates. Powder particles are typically 35 to 45 microns in size, but can be as large as 100 microns. These defects hurt appearance and may compromise the protective ability of the coating. Ward Barcafer, CEF aerospace - Wichita, Kansas . If you have the gun too close to the substrate causing back ionization or KV rejection, you will get, you guessed it, orange peel. Polyester Powder Coating involves a series of processes to create a coloured aluminium extrusion that is then used to manufacture a window or a door. See this article:  Phosphate-free Metal Pretreatment for more information on this. At AR Powder Coating, we have years of experience that allows us to foresee problems not only with outgassing, but the many other issues that can crop up during a powder coating job. Q. Hello, we are a company working on steel. PCI also advises that boxes of powder should never be stacked on top of one another; this can result in lumps that are not easily broken. Properly stored powder can prolong its shelf life, and possibly reduce contamination issues further down in the process. As a last tip for outgassing…if your job shop uses hot dip galvanized and the substrate forms white rust, then you need to mechanically or chemically remove it. Crank up the temperature, especially for thicker substrates, so that the metal heats up faster and the part and powder gets to a higher temperature quicker. Rejects are the bane of any job shop’s existence when applying powder coatings.Pulling apart out of the oven only to see whorls of orange peel powder, sections where the coating has sagged, or opacity issues bring a particular kind of dread alongside the question of what happened? Be mindful of your film thickness and follow the Technical Data Sheets instructions to the letter. Q. Refer to your TDS or call your supplier if you are ever unsure about a product or having issues with it.Jason explains a little more about dealing with sags in the 5 minute training video of the same name! Cool the part before applying the powder coating. Blooming looks like a foggy, hazy or smoky distortion in the resin, and if it does occur, shows up more noticeably on blacks, dark blues, dark greens, or, dark substrates. The top powder coating problems and how to fix them. Craters are circular interruptions in the coating that look like—you guessed it—lunar impressions. Lumps in cured film. Basically, they act as contaminants to one and other, and it shows. Change hose diameter, shorten hose. 2. Fading. A lot of the time, blooming occurs when there are issues with the resin. When they occur they must be sanded and repaired, which can lead to additional defects. Powder Coating Week 2021 – New Dates: April 27-30 – Register Today! “There needs to be a level of pretreatment underneath the coating to protect the metal from rusting or corroding.”, In such cases, the substrate will undergo a phosphatizing process-called a conversion coating-whereby an acid solution is used to attack, or etch, the surface of the base metal. The etching process followed by the powder coating and curing of the AA6060 aluminium powder coated profiles, the pick-up defects were not fully covered with the applied top coat of powder coating. In this guide, we have covered just some of the many ways a job can go wrong in terms of appearance. Following problems on mild steel panels powder coating are observed after the process is complete: 1) Powder peel off 2) Dust particles observed 3) Orange peel 4) Color shade difference one compared to other panels 5) Pin holes observed on the coated surface. “Let’s say there’s a crack in the coating,” he suggests. More powder also means wasted product, and can result in a significant increase in materials cost. Typically, the powder is applied via electrostatic spray deposition (ESD) to an electrically grounded metal substrate. This is the beginning of a series of articles that will help you solve issues with powder coating defects. Check out our short training video on fisheyes from our 5 minutes (or less!) However, heat it too much and the powder will melt and flow on contact – this can even go beyond sagging and 'icicle', a term applied when the coating will actually snap off like an icicle. Blooming is usually caused by either a poor resin – and if that's the case, the only thing to do is to talk to your powder supplier about using a better resin (which will likely also be more expensive!) The following articles will help you identify those defects and learn what you need to do to avoid seeing them again. The fabricator must remove all the welding slag before dispatch to the galvanizer. Process controls should be implemented upstream of the coating line to prevent a defective substrate from entering the line. Any advice? However, there are some basic things to check when addressing a particular … S Salt Spray Test - Corrosion test using salt (NaCl) solution sprayed as a mist in a heated humidity chamber to simulate seashore conditions, or to accelerate corrosion at a … There are no suspected pre-process problems, their likely causes, and it shows, the! Substrate, discoloring the finish or, chat to your powder coating, ” says Hale coatings! 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