troubleshooting guide tiger

7/28/2019 Troubleshooting Guide TIGER

1/41

Coatings

TROUBLESHOOTING GUIDE


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TIPS & TRICKS FOR TIGER DRYLAC COATING

Dear Customer:

Powder Coating Technology, rom the application o powder to the coating itsel, has expanded at light-

ning speed in recent years. Experience and knowledge are essential or keeping pace and excelling in this

arena, and will exceed the traditional actors o work and capital in value in the uture.

Developing this knowledge involves learning curves and oten requires years o development. Against a

backdrop o intensive regional and global competition in the nishing industry, association with expertsin the eld o powder coating equipment and/or powder coating materials is a determining advantage.

With Tips & Tricks or Powder Coating with Tiger Drylac, we have attempted to categorize and com-

prehensively interpret several decades o knowledge or your use. Many troubleshooting solutions are

provided in this handbook, as well as detailed answers to a host o questions.

We hope to provide you with assistance in your production and planning agenda with this handbook, and

look orward to continued co-operation and partnering.

Your Tiger Team.


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Table of Contents

1 Pretreatment as an Error Source (Overview)1.1 Chromating o aluminum, zinc, magnesium1. Phosphating o steel and zinc plated steel

Powder Application.1 Poor fuidization. Sintering in the powder hoses.3 Powder drizzles o the work piece.4 Poor wrap.5 Clumping in the powder box.6 Poor penetration into recesses.7 Film thickness too high

.8 Film thickness too low.9 Film thickness varies

3 Surace Deects3.1 Powder pus on the work piece3. Craters3.3 Pin holes3.4 Picture raming eect3.5 Elevations, enclosures (other colors), contaminations3.6 Blisters3.7 Dripping

3.8 Orange peel eect3.9 Insucient drying o the substrate

4 Surace Variations in the Powder Film4.1 Color deviations4. Clouding4.3 Poor coverage4.4 Gloss level deviations, yellowing, discolorations

5 Deciencies o the Technical Properties (Mechanical and Chemical)5.1 Poor mechanical properties and chemical resistance

5. Oily surace5.3 Liting o the powder lm5.4 Poor rub resistance

6 Special characteristics o application involving reclaim6.1 Contamination o powder surace (additional to section 3.5)6. Poor processing properties (additional to section .1 and .6)6.3 Continuous discolorations

7 Special characteristics o application o metallic powder coatings7.1 Color deviation rom color chart o product sample7. Graying o the surace7.3 Color deviations during coating7.4 Clouding

8 Terminology index


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1. PRETREATmENT AS AN ERROR SOURCE (OvERvIEw)

Tiger is not a supplier o pretreatment chemicals, thereore the ollowing illustrations o the pretreatment o metals should

only provide a short overview o sources o errors. Certainly this subject deserves more thorough exploration. The principalstands: The best and most expensive powder coating cannot replace good pretreatment.

1.1 Chromating o aluminum, zinc, magnesium

Rinse beads o, insufcient wetting

Possible causes Corrections, testing, procedures

Degreasing power not sucient (example: hard to removeabricating oils, release agents which liquey at high tempe-

ratures, pressed in extrusion greases)

Increase temperature in degreasing unit, Increase chemicalconcentration, Increase duration, Increase agitation

Conversion layer (chromating) uneven or spotty


Degreasing not sucient, unit parameters incorrectly ad-justed , spray perspective not in order

Increase temperature in degreasing unit, Increase chemicalconcentration, Increase duration, Increase agitation

Inorganic layers (oxides) not suciently removed, including

un-removed chromate or anodizing layers (ater coatingremoval)

Check adjustments, check nozzles, Increase temperature or

concentration o acidic solution, Increase duration

Partial drying Increase liting times in dipping unit. Check side nozzles inspray units

Conversion layer (chromating) not bonded or wipeable


Bath ormulation not appropriate Correction (concentration, ph level, excellerator)Treatment duration too long Observe recommended duration, avoid inactive zones

Rinse tanks overburdened Increase dripping time over active baths, Increase rinsewater amounts

Rinse results not sucient (carried into the acidic solution) Increase mechanical action (nozzle pressure, ormation,movement in dipping units), Increase rinse cycle


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Surace becomes black ater degreasing / acidic solution, Discoloration is particulary wipeable


Insoluble egestions o alloy components caused by corro-ding the soluble ground metal in the degreasing and / oracidic solution

Decrease treatment time o the degreasing / acidic solution,Reduce concentration, use milder products

Img. 1.1.1. Spotty chromating Img. 1.1.. Poor (no) chromating Img. 1.1.3. Inappropriate basket-pretreatment

Img. 1.1.4. Procrastination o the pretreatment-media Img. 1.1.5. Residues on aluminum ater pretreatment Img. 1.1.6. Comprised pretreatment-crystals (salts, chlorides)


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1.2 Phosphating o steel and zinc plated steel

Rinse beads o, insufcient wetting


Degreasing action not sucient (example: hard to removeabricating oils, pressed in extrusion greases)

Increase temperature o chemical concentration in the de-greasing unit, increasing dipping duration, increase agitati-on, use appropriate molding additive.

Conversion layer (phosphating) not closed, rust


Bath ormulation not appropriate Correction (concentration, ph level, excellerator)

System parameters incorrectly adjusted Adjust, Renew chemicals

Rinse tanks overburdened (carried into the acidic solution,ph levels too low)

Increase dripping time over active baths, Increase rinsewater amounts

Rinse results not sucient (carried into the acidic solution) Increase mechanical action (nozzle pressure, ormation,movement in dipping units), Increase rinse cycle

Lapses in movement prior to layer ormation Ensure even movement

Conversion layer (phosphating) too thick, dusty layers

Possible causes Corrections, testing, proceduresTreatment duration too long Observe recommended duration, avoid inactive zones

Excellerator levels too high Observe recommended levels

Conversion layer (phosphating) too uneven o spotty


Degreasing not sucient Increase temperature or chemicals in degreasing unit Incre-ase dipping duration, increase agitationUse suitable molding additive.

Inorganic layers (scale, rust, oxide, hydroxide) insucientlyremoved

Increase temperature and chemical concentrationIncrease treatment timeAdjust nozzle systems

Drying Decrease liting time in dipping unitsUse side nozzles with spray units

Spray distribution insucient Adjust nozzles

Pre-phosphating Test rinse waterCheck procedure

Activation not sucient (with zinc phosphating) Check correct tank adjustments

Renew chemicals


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Img. 1..1 Fat-arrears ater pretreatment Img. 1... Primitive alternative o an oil separator Img. 1..3. Corrosion caused by Fe-phosphating on radiated pieces

Img. 1..4. Crater in powder coating lm caused by corrosion Img. 1..5. Corrosion o sandblasted work pieces ater pretreatment Img. 1..6. Poor purging, aterwards stored wet

Img. 1..7. Poor purging, radiated, KTL-grounded Img. 1..8. Poor purging, radiated, KTL-grounded and coated Img. 1..9. Poor purging, radiated, KTL-grounded and powder coated- comparison

Img. 1..10. Pretreatment-resistant deep-drawing greases Img . 1.. 11. Oilcoal caus ed by welding work Img . 1. .1. Procrastination o th e pre treatment med ia


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2. POwDER APPLICATION

2.1 Poor Fluidization Scenario: Powder is supposed to fow like water in the fuid container (boil). Poor fuidization is recognizable in a slow andnon-continuous transportation o the powder coating rom the fuid container to the guns. No homogenous powder cloud is

achieved.

Possible causes Beseitigung / Versuche / Manahmen

Fluidizing air too low or too high Change pressureUse larger hose diameter

Fluidizing plate deective Exchange plate

Fluidizing plate clogged Clean plate

Oil remnants in compressed air Check lter in ront o coating boothPowder too ne (reclaim), high overspray ratio Add virgin powder, change powder

Powder moist Dry powder and store at room temperature(max. 5 C, 77 F )

Powder in carton very hard or lumpy StrainDo not set fuidizing plate to continuous operation

Excessive temperatures in the coating system Correct condition / Provide circulation / Cool, Reconstruct

2.2 Clogging o the powder eed hoses

Scenario: Deposits (agglomerates) orm in the powder eed hoses, which sporadically are reed by delivery air and appear aspowder pus on the work pieces. Ater curing these powder pus appear as aulty surace elevations.


Feed air pressure too high/too low Reduce/increase pressure

Delivery air moist or oil in pressurized air Check in-line lters and moisture traps

Inappropriate hose mounting Establish appropriate hose mounting, no kinks

Particle size distribution o powder coating too ne Note appropriate particle sizeOptimize virgin powder plus reclaim ratio

Venturi nozzle worn Exchange nozzle

Feed hose diameter wrong Adjust hose diameter to appropriate powder fow

Feed hose too long Minimize eed hose length

Inappropriate hose material Exchange hose type, use appropriate type (silicone, polyure-thane, Tefon)

Img. .1.1. Fluidization - the powder has to fow like water Img. .1.. Poor fuidization Img. .1.. Poor fuidization - too much powder


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2.3 Powder does not adhere to substrate

Scenario: The powder coating, which should electrostatically adhere to the substrate, alls o no relevant coating thicknesscan be achieved.


Insucient grounding Test contacts and transport mechanism (especially booth)and hooks (< 1 MW). Insulation rom lubricants and residuesin transport

Voltage too low or no voltage Gun, test high voltage, cable and cable lead

Not enough charging Increase voltage, reduce powder fow

Wrong particle size distribution I reclaim is involved add virgin powder, Contact powdermanuacturer

Wrong grading (too coarse) Contact poweder manuacturer

Chain does not run smooth, vibration too strong Check conveyor systemFilm build too high Check geometry o part

Reduce powder fow

Insucient wetting Check pretreatment

Airspeed blow o air too high Optimize controls

Too much powder output Reduce air fow and/or powder fow

Gun distance to part too close, blast o eect Adjust distance

Unsuitable geometry o the part I possible change geometry or hanging position

Img. .3.1. Check earthing Img . .3.. No earthing at multi coated hooks Img. .3.3. Create an additional earthing


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2.4 Poor Wrapping

Scenario: With one sided gun positioning only minimal lm thickness can be achieved on opposite side.


Powder fow too low or too high Optimize system parameters, adjust air fow

Insucient grounding Use clean hooks, test transer resistance (< 1 MW), checkdiameter o hooks

Temperature o the part too high ater dry-o oven or pre-heating

Allow adequate time or cooling (less than 40 C / 104 F]

Supplemental air fow is too high or too low Adjust air speed and powder cloud

Unsuitable particle size distribution Consult powder manuacturer

Gun voltage too high Adjust voltage to suit part geometry

Insucient charging o the powder Adjust high voltagePoor or wrong positioning o the parts Adjust hanging conguration

Gun deective Consult equipment and powder manuacturer

2.5 Powder lumping in the box

Scenario: Lumping in the powder coating in powder box


Inappropriate storage (temperature too low/too high, inexcess o shel lie)

Strain beore use, use resh powder

Box eeding Avoid continuous vibratory operation

Transport too slow or too warm Strain powder beore use, consult powder manuacturer

Img. .4.1. Poor wrap-around Img. .5.1. Powder lumping in the box


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2.6 Poor penetration into recesses

Scenario: Despite the physical conditions (araday cage), it is possible to achieve a minimum coating thickness in the corners.With poor penetration procedures penetration depth is very limited. Extreme lm thickness variations are noticeable.


Feed supplemental or tribo air too high Change o lower pressure

Air speed too high Adjust equipment controls

Powder fow too high Adjust equipment controls to suit part

Not enough powder fow Adjust/optimize equipment parameters

Inappropriate application, unsuitable nozzle Utilize fat spray nozzle or defector; Adjust nozzle

Insucient charging o powder, deective gun Adjust voltage (increase, test)Contact equipment manuacturer

Voltage too high Adjust/reduce voltage

Faraday cage eect due to electric eld Use tribo equipment and powder; Reduce voltage

Insucient grounding Use clean hooks, test transer resistance

Powder spray too wide Use dierent gun nozzle o defector

Unsuitable particle size distribution Optimize through testing; Contact powder manuacturer

Distance rom gun to part is too big or too small Increase or decrease distance

Img. .6.1. Additional earthing or hollows Img. .6.. Rip up caused by poor metal-production


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2.7 Film Thickness too high

Scenario: Powder coat layer shows uneven surace prior to curing, ater curing shows orange peel, wavy fow, or pinholes.


Parts are too hot coming rom dry-o oven Allow longer cooling time (less than 40 [C] / 104 [F]) or parts

Preheat temperature too high Lower preheat temperature or allow or cooling (less than40 [C] / 104 [F])

Powder fow too high Lower powder eed

Coating time too long Lower coating time

Unavorable geometry o parts Change hanging or gun conguration

Gun-to-part distance too close Increase gun-to-part distance

2.8 Film thickness too low Scenario: Substrate shows through and powder coat has grainy fow.


Insucient charging o powder Test and adjust voltage

Inappropriate particle size distribution/percentage o over-spray too high

Continuous and even introduction o virgin powder toreclaim powder; Patio adjusted to actual consumptionOptimize particle size distribution through testing

Powder fow too low Increase powder fow

Powder delivery hose too long Shorten hose; Change hose diameter; Change injector

Fluid characteristics o powder not optimal Check fuidization (see .1 poor fuidization)

Residence time o parts in ront o gun too short Slow down line speed o conveyor; Increase number opasses o gun in ront o part; Add more guns

Suction o reclaim system too high Lower suction capacity

Booth drat too strong to allow powder cloud to deposit onits own

Change system conguration; Consult with booth supplierSlow down line speed

Changed powder supply due to powder deposits in thetransport system, injectors, hose and nozzle

Cleaning o the transport system components, coordinateeed and atomized air, check fuidization

Plugged transport system due to oreign materials(e.g. bers, cleaning residues)

Commit to cleaning cycles and regular maintenance

Inappropriate hanging o parts Check and adjust hanging congurationInsucient grounding Use clean hooks; Avoid thin hooks (note voltage loss)

Check transer resistance i system

Processing o non Tribo powders in Tribo systems Use Tribo powder

Img. .7.. Too thick powder cloudImg. .7.1. Film thickness too high (ornateness)


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Low level o powder in fuid hopper Replenish powder; Check minimum indicator

Particle size too ne due to circulation in system Increase virgin to reclaim ratio

Too much overspray in booth due to cleaning cycles Regular transport o overspray rom booth to reclaim systemIntermittent back pulse o lter too long, sudden shit opowder particle size (too ne)

Keep back pulse o compressed air short (e.g. 0 seconds)

Insulation o base coat too strong Reduce voltage or second coat and lower powder fowUse tribo powder coatings

Gun-to-part distance too high Reduce distance

Powder hose causes riction charge o opposite polarity tocharge generated in gun

Change hose material or ground hose

2.9 Film build varies

Scenario: Substrate shows through and powder coat has grainy fow. Or powder coat shows uneven surace prior to curing

orange peel ater curing, wavy fow, pinholes. These appearances vary on the surace o the work piece.


Wrong positioning o guns in an automated system Empirical determination o proper gun positioning.Optimize interval curve o automatic guns. Check conveyor/lit speed

Inappropriate insulation o base coat Adjustment o hanging or gun confguration Additional grounding

No continuous, even introduction o virgin powder to rec-laim powder based on actual consumption Assure proper unctioning o recovery system Adjust virginto reclaim ratio

Sliding o powder lm (in an improperly used condition)due to conveyor vibration

Inspect conveyor and chain, Test grounding/charging

Flapping/swinging o the work pieces Adjust hanging conguration, Test astening method

Uneven powder transport Test powder transporting devices or clogging due to oreignparticles or plugs, Test or air pressure variations

Unavorable geometry o parts (Faraday Cage) Change hanging conguration or gun positioning Use fatspray nozzles

Geometry o parts varies greatly Optimize device and gun adjustments to suit work piece

Excessive manual touch-up Adjust automatic guns or possible pre-coat

Uneven manual touch-up I possible pre-coat, Train personnel

Img. .9.1. Unsteady lm thickness because o wrong mounting (to narrow distances)


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3 SURFACE DEFECTS

3.1 Powder pus on the work piece

Scenario: Powder pus are powder clusters that in an improperly used condition are visible as powder hills in the powderlm. Ater curing these powder pus appear as disturbing elevations on the surace.


Poor fuidization See section .1 (poor fuidization)

Powder hose too long or diameter too large Change hose diameter, Shorten hose, Change conguration

Powder too ne (reclaim) Add virgin powder

Uneven transport Test air pressure, Check or pressure variations

Clogging o the eed hoses Note hose path, see section .. (clogging o the powdereed hoses)

Powder alls o booth ceiling Adjust/increase requency o booth cleaning intervals

Powder alls o hanging devices Remove/ reduce powder coat layer, check grounding

Powder build-up on defector plate Check atomized air

Powder alls o work piece Test grounding, Check diameter o hoses

Catch nozzle worn Change nozzle

Air pressure variations in powder supply system Adjust air pressure

Level in powder supply container varies greatly Reduce distance between minimum and minimum level

Gun nozzle deective Check nozzle, replace

Powder moist Use dry powder; Check or condensation (temperature di-erence rom powder storage area to coating area), Check airlter and moisture traps in compressed air system

Img. 3.1.1. Filter residues cause powder spitters Img. 3... Powder spitters on the cured powder surace


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3.2 Craters

Scenario: deect blank area in the powder coat, which extends all the way to the substrate (diameter up to mm).


Insucient pretreatment (e.g. oil and grease residues) Test pretreatment i necessary, contact pretreatment supplier

Chemical residue, aulty pretreatment Test pretreatment, i necessary contact pretreatment supplier

Rust, white rust on parts Assure clean surace, apply recommended pretreatment,possibly bu or sandblast (sweep) surace

Oil in eed and/or atomizing air Check in-line lters and moisture traps in air system

Silicones rom chain lubricants or welding sprays Use product without silicon content, educate line operators

Incompatibility with powder coatings rom other manuac-turers

Cleaning o coating and application equipment, contactpowder coating supplier

Outgassing rom substrate Pre-heat work pieces, use OGF additive

Surrounding air contaminated Balance air fows in plant, avoid cross drats

Spin-o-products at the cross-linkage o the powder coatingin the curing oven

Adjust the powder coating, Consult powder manuacturer,Provide enough air circulation

Work piece moist/wet Increase drying time/temperatureNote material thickness especially with anodized parts

Liquid and powder paint in same plant Denitely avoid - recongure plant

Body ller or other compounds not compatible Forced drying, test suitability

Base coat was cleaned with solvents Preheat work piece or avoid solvents

Blasting media decontaminates surace Do not reclaim blasting media

Back ionization eect Adjust application, use tribo i possible

Instead o rough texture eect only penetration-to-metaland craters visible

Insucient coating thickness

Img. 3..1. Crater caused by oil in the compressed air Img. 3... Crater caused by oil residue


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3.3 Pin Holes

Scenario: surace deects development o ne pores on the surace,also leads to change in gloss level


Moisture content o powder too high Testing through drying o powder/test storage conditionsIn cold climates, watch or condensation in powder (coldstorage area to warm coating area)

Pre-reaction o powder coat Check storage parameters, storage time exceededConsult powder manuacturer

Trapped air Check heat up curvePossible slow heat up curveModiy powder coating

Film build too high Note recommendations o powder manuacturerMinimize lm thickness

Incompatible with other powder coatings Clean equipment/boothConsult powder manuacturer (i necessary change)

With rough textures, instead o eect development onlypinholes develop

Film thickness too low (see .8 lm thickness too low)

Very porous work pieces Check or satisactory work pieces, possible surace is toorough rom sand blasting

Out-gassing rom porous work pieces (cast parts, zinc galva-nized material, magnesium castings, anodized materials)

Preheat partsModiy powder coatingCast anodized materials not scaled and dried

Img. 3.3.1. Pinholes caused by too coarse steel resources


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3.4 Picture raming eect

Scenario: Higher lm build o coating on the edges o the part due to wrap, thereore uneven fow.


Powder particles too rough/unsuitable or particular appli-cation

Strain powder to optimize particle distributionConsult powder coating manuacturer

Voltage too high Adjust voltage to suit part

Distance rom gun to work piece too low Adjust/increase distance

Uneven lm thickness, especially in ne textures or metalliccoatings

Adjust parameters or work piece suspension

Feed air/powder fow too high Adjust powder fow

3.5 Elevations, Enclosures (other colors), Contaminations

Erscheinungsbild: im Pulverlacklm eingelagerte Fremd- oder Pulverlackpartikel (andersarbig)


Contamination through conveyor chain or chain lubricationetc.

Cleaning o the equipment/check sieve or contamination ortears

Contamination o powder surace due to airborne dirt rom

outside o booth (e.g. surrounding air, foor, polishing area,blasting area

Isolate booth area, clean surroundings with vacuum

Avoid cross dratsBalance air fows in plantAvoid polishing in booth and oven area

Fibers rom broom and cleaning cloths Use suitable cleaning apparatus and materials

Insucient polished welding areas, metal shavings, weldingdrops, milling faws

Control nishing process- repeat i necessary Improve poli-shing stage and pretreatment

Contamination rom equipment cleaning Vacuuming is more eective than compressed air (powder isnot airborne)

Deposits rom dust and powder particles in the oven (toomuch convection inside, powder that doesnt adhere, isblown onto work pieces o dierent colors)

Reduce air speedInstall pre-gelling curing stageDo not cure other colors at the same time in oven

Deposits o dust and powder on cured work pieces Dust ree cooling zoneAvoid drats

Img. 3.4.1. Boil up o the coating caused by a too high lm thickness Img. 3.4.. Bacon edge at the same flm thickness on materials with 0,7 resp. 3 mm


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Dirt and color particle transer between adjoining booths I possible recongure areaEnclose booths

Contamination rom warehousing Assure orderly warehousing, Close powder bags and boxes,Separate by powder type

Insucient cleaned guns and hoses Careul cleanining o guns and hoses

Img. 3.5.1. Bead o sweat on a work piece Img. 3.5.. S urace deec t caused by a oreign body Img. 3.5.3. Fi bers in the powder co at ing sura ce

Img. 3.5.4. Clothing ber in the powder coating lm (cured) Img. 3.5.5. Bitter pits caused by metal sliver in the underground Img. 3.5.6. Uneven surace caused by poor zinc coating


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3.6 Blistering

Scenario: Elevations o diering size in the powder coat, no adhesion due to enclosures at the part surace.


Water on work piece Check dryer and hanging conguration

Water in scooping type o work pieces Note geometry, drying time and temperature or changehanging conguration; Air blast work pieces

Corrosion, oil and grease residues Optimize pretreatment

Over coating Assure fawless rst coat

Over coating o liquid paint Check suitability o base coat

Over coating o ller areas Dry or cure ller; Check suitability

Salt residues or chemical remnants on the work piece sur-ace, insucient wetting

Check pretreatment, nal rinse stage, and drying o media/chemicals during transport inaction

Film thickness too high, powder accumulations, powderdrizzles o work piece on edges and corners

Check system parameters; Reduce lm thickness

Break in zinc layer, double zinc layer, corrosion under the zinclayer

Avoid double zinc layers; Ensure fawless zinc layer

Img. 3.6.1. Corrosion as bubble causale Img. 3.6.. Bubbles caused by corrosion ater pretreatment Img. 3.6.3. Bubbles caused by outgassingat the die-cast aluminium

Img. 3.6.4. Bubbles caused by corrosion ater pretreatment Img. 3.6.5. Bubbles caused by tassels in the galvagnized plate


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3.7 Drip Developments

Scenario: Running or dripping o the gelling powder coat o the work piece


Film thickness too high (with wire or sheet metal parts) Reduce lm thickness

Powder slides to the edge Increase voltage; Check grounding

Substrate temperature is too high (rom preheating ordryer), thereore lm build too high

Increase cooling time (max. 40 [C] / 104 [F]) between dry-o oven and booth; Optimize lm thickness

Heat up rate too high or inappropriate Reduce heat up speed; Control oven temperature

Powder accumulation on inside corners rom drizzled opowder coating

Optimize system parameters and blast o eect

3.8 Orange peel

Scenario: Poor fow (orange peel look), short or long waviness o powder coat layer, noticeable only ater curing.


Heat up cycle o parts too slow Determine heat up curve and increase (especially with partso high wall thickness)

Substrate temperature exceeds the melt temperature o thepowder, causing excessive lm build

Check substrate temperature (max. 40 [C] / 104 [F])Increase cool down phase

Powder coating material too reactive Consult powder manuacturer

Shit in particle size distribution, portion o reclaimed

powder too high

Optimize deposit results o powder guns

Increase lit intervalsUnsuitable particle size distribution Optimize particle size distribution; Consult powder

manuacturer

Film thickness too high or too low Check system parameters

Incompatibility with other powder coatings Clean booth, check compatibilityConsult powder manuacturer

Powder stored too long/pre-reacted Check storage.I powder is too old, exchange

Voltage too high Optimize voltage; Change to low ionizing application ortribo guns

Uneven wall thickness (thick to thin) Optimize oven temperature

Back ionization eect Reduce voltage; Increase distance rom work piece to gunTextured work piece surace Optimize texture, check work piece surace

Air speed too high at oven entrance Reduce air speed (max. 0.5 [m/sec] / 1 1/ [t./sec]), changeair fow guides

Img. 3.7.1. Drop ormation caused by a too high lm thickness Img. 3.7.. Drop ormation


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3.9 Insufcient wet out o the substrate

Scenario: Poor or no adhesion o powder coat to the parts surace, large area liting o cured powder coat


Gummed oils, greases or separating compounds, insolubleextrusion oils

Check pretreatment or change, use dierent extrusion oilsor separating compounds

Pretreatment residues Final rinse de-ionized water

Encumbrance rom sweaty hands or soiled gloves Do not handle pretreated parts with bare hands or soiled gloves

Displaced oils or greases in pretreatment Pretreatment; Check oil separator

Conveyor halt during pretreatment, dried on chemicals Avoid conveyor halts, possibly mist

Img. 3.8.1. Smashing through o the scarred surace Img. 3.8.. Orange peel eect

Img. 3.9.1. Insucient wet out caused by corrision Img. 3.9.. Insucient wet out caused by oilcoal Img. 3.9.3. Insucient wet out o the substrate


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4. SURFACE vARIATIONS IN THE POwDER COAT

4.1 Color Deviations

Scenario: Continuous or suddenly appearing changes in color or eect compared to original sample part or compared to rstparts coated.


Film thickness varies greatly Assure constant lm thickness

Diering substrates and substrate colors (steel, aluminum,brass, glass)

Use substrates o same type or comparisons

Diering suraces and refections (polished, blasted, chro-mated)

For comparison use suraces o same type

Film thickness too thin (not covering) Apply higher lm thickness (same as samples)

Not sucient or wrong pigmentation in the ormulation Consult powder coating manuacturer

Color deviations due to curing technique or oven atmos-phere (example: direct red gas oven, IR oven), use o roomair or burner!

Use suitable powder coatingsControl ovenUse outside air supply or burner

Over curing o powder coating (especially with organicpigments)

Observe curing parameters o powder manuacturer

Diering curing parameters with same parts Observe powder manuacturers curing parameters

Diering curing parameters with greatly varying parts (di-erent wall thickness)

Observe curing parameters o powder manuacturers andadjust to wall thickness

Several powder manuacturers/suppliers Use powder coatings rom the same manuacturer or checkthe compatibility

Varying lm thickness with over coating Assure even lm thickness

Bleeding o rst coat with over coating Check suitability o rst coat when over coating

During over coating extensive color deviations rom rst coat Avoid over coating o strongly deviating colors

Uneven pretreatment o parts Assure more even pretreatment o parts

Metamerism, color deviations with diering light sources Judge work pieces in daylight (not direct sunlight)Use day light cabinet

Rough texture too pronounced Use suitable powder coat

Powder transport directly rom the powder box Use fuid container

Img. 4.1.1. Color shit between RAL-cards HR and GL Img. 4... Color shit caused by a communication mistake


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4.2 Cloud Formation

Scenario: Uneven light to dark or matte to glossy eect o the coating on the work pieces


Gun distance rom part too great or small Test distance

Reciprocator operation parameters inappropriate or linespeed and part conguration

Adjust lit speed to chain speed

Uneven powder transport Introduce sucient virgin powderTest or deviations in air pressure

Manual touch-up I possible pre-coat

Uneven charging Test application

Uneven grounding o parts Test grounding

Strongly varying lm thickness (especially with matte nishes) Optimize lm thickness

Separation o matte nish powders in reclaim system, une-ven parts o virgin and reclaim powder

Assure consistent powder qualityAdhere to the recommended percentage o virgin and rec-laim powder

4.3 Insufcient Coverage

Scenario: Smashing through o the underground through the scarred powder coating lm (especially on steel)


Film thickness to low Assure appropriate lm thickness, especially with criticalcolors (example: red, orange, yellow)

Film thickness varies greatly rom part to part Optimize system parameters

Reciprocator operation parameters inappropriate or linespeed and part conguration

Adjust lit speed to chain speed

Diering materials and material colors (steel, aluminum,brass, glass)

Use same materials or comparison

Diering suraces and refections (polished, blasted, chro-mated)

Use same suraces or comparison

Mechanical treatment shows through (example: polishing) Use ner grain materials or polishing

Img. 4.3.1. Dierent opacity on steel and aluminum


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4.4 Gloss Level Variations, Yellowing, Discolorations

Scenario: Dierence between suggested gloss level and color and the gloss level and color o the original sample or partscoated at the beginning o the job.


Cure parameters o manuacturer were not observed Optimize curing parametersAdhere to powder manuacturers suggestions

Oil, soluble materials in oven Do not use oil or soluble materials in oven area

Incompatibility with other powders, poor fow Clean system, Distribute incompatible powders to other booths

Film thickness to high or too low Optimize job parameters

Powder coating is not temperature stable Use temperature stable powder coatingsConsult powder manuacturer

Over curing in oven Adjust oven temperature and speed to parts being coatedLower temperature during conveyor halts

Incompatibility o powder coating in the oven Do not use powder coatings rom dierent manuacturersat the same time in one oven

Direct red ovens and IR ovens Adjust powder coating to oven parametersAdjust oven temperature to powder coating

Powder coating pre-cured or too old Check warehouse parameters, use resh powder coatings

Unsuitable cleaning agents or example prior to silk screening Check suitability o cleaning agents or powder coat, pre-testing necessary

Separation o component matte powders Check reclaim system or uneven suctioning o over spray

Uneven gloss level due to dierent wall thickness o work

piece

Lower oven temperature, Increase duration time,

Re-construct systemComponents o the powder ormula migrate to the suracecausing haze and lower gloss

Discuss possible changes with powder supplier and consi-der trade-o between perormance parameters and betterstability, Optimize oven parameters

Binder in powder coating poorly dispersed Consult powder manuacturer

Diused liquid paints, elt pens, stamping inks, markers Remove the residues beore coating with suitable solvents

Img. 4.4.1. Stamping ink (untreated) Img. 4.4.. Blood supply o elt pen or stamping ink Img. 4.4.3. Yellowing in the interior caused by UV-light

Img. 4.4.4. Color hue change caused by insucient adhesion


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5. LACK OF TECHNICAL PROPERTIES (mECHANICAL AND CHEmICAL)

5.1 Poor mechanical properties and chemical resistance

Scenario: Insucient compliance with the necessary technical properties o the powder coating (mechanical and chemical).


Too high/too low heat up temperature or time Observed curing parameters o powder coating manuac-turer

Oil, grease, extrusion oils, dust on the surace Optimize pretreatment

Insucient pretreatment Optimize pretreatment

Incompatible pretreatment and powder coating Adjust pretreatment method

Consult chemical and powder supplierInappropriate powder coating Use appropriate powder coatingConsult powder manuacturer

With transparent top coats slow deterioration o thepowder coating (chalking)

Over coating o interior grade powder coatings with exteriorgrade transparent powder coatings does not result in a UVresistant coating system, thereore adhesion problems o thetop coat

Img. 5.1.1. Chalking caused by aulty powder coating selection Img. 5.1.. Inltration caused by chemical exposure Img. 5.1.3. Metal particles oxidate at the cleaning

Img. 5.1.4. Mortar residues on the powder coat layer Img. 5.1.5. Mortar residues on the powder coat layer (microscopeview)


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5.2 Greasy Surace

Scenario: Haze like lm on the surace, which can be wiped o.


Blooming eect (white lm on the powder coating surace,which can be wiped o)

Change powder coating ormulaIncrease curing temperature

Insucient air circulation in the oven Increase air circulation

Contamination on the surace because o incompatiblepowder coatings rom dierent manuacturers

Use only powder coatings rom one manuacturer at thesame time in an ovenConsult powder manuacturer

Wrong powder coating choice Use suitable powder coatingsConsult powder manuacturer

Powder coating not suciently cured Observe curing parameters

Blooming-eect (accrual o a white, wipeable lm on thepowder coating surace) Increase the curing temperature

5.3 Liting o the powder coat layer

Scenario:Cured powder coat backs out o the workpiece under mechanical encumbrance, no adhesion to the surace o thework piece


Under or over curing o the powder coating lm (or exam-ple in IR oven)

Observe curing parameters

Insucient/inappropriate pretreatment Adjust pretreatment to job at hand

Basic material too thick or unevenly thick Observe curing parameters, use slower or aster curingpowder coatings

Scale, surace rust on the work pieces Use resh work pieces or store in dry environment; mecha-nical pretreatment

Oxide layer on the work pieces, white rust on zinc plating Store work pieces in dry environment or use resh workpieces; Use suitable pretreatment materialsUse mechanical pretreatment (sweeping) i necessary

No adhesion on laser cut edges Treat edges mechanically (brush, polish, sweep)

Purpose and powder coating properties are not suited oreach other

Use suitable powder coatings

Film thickness too high Reduce lm thickness or use more fexible powder coatings

No adhesion to base coat I possible lightly polish base coat or partially edge withsuitable solvent

Img. 5..1. Blooming-eect Img. 5... Blooming-eect


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No adhesion to liquid base coat, electro coat or coil coating Test suitability, lightly abrade base coat

Break in zinc, conversion or primer layer Adjust pretreatment to work piece and powder coating

Double zinc layers, corrosion under zinc layer Consult with H.D.G. supplierTransport residues on work pieces (salt, dust etc), whichhave not been removed by pretreatment

Assure fawless suraces and protected transportation, sui-table pretreatment

5.4 Abrasion resistance too low

Scenario: Insucient resistance o the powder coating against abrasive media.


Insucient curing Observe curing parametersPackaging causes abrasion to powder coat surace Use suitable packaging/oils to wrap work pieces (tissue

paper, bubble wrap, oam, feece)

Powder coating scratches too easily/too sot Select suitable powder coating or purposeConsult powder manuacturer

Abrasion during urther mechanical treatments (proles) Careully handle work piece in urther manuacturing steps

Unsuitable transport containers Avoid slidingTransport bundled and restrained on pallets or in boxes

Img. 5.3.1. Poor adhesion caused by direct heated gas oven Img. 5.3.. No adhesion o the top coat caused by directed heatedgas oven

Img. 5.3.3. Blistering caused by cross-linkage

Img. 5.3.4. Blistering caused by an inappropriatepretreatment Img. 5.3.5. Inltration caused by an insucient pretreatment


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6. SPECIAL CHARACTERISTICS OF APPLICATION wITH RECLAIm

6.1 Contamination o the Powder Coating (additional to section 3.5)

Scenario: Foreign or powder particles o a dierent color are enclosed in powder lm


Powder remnants or dirt in coating booth, cyclone or lter Clean systemConstantly clean screen

Powder remnants in application, powder accumulation rominjector, hose or gun

Clean applicationCheck screen

Contamination o reclaim No sieve or insucient screen; Use proper screen size (meshsize approx. 00 [m] / 8 [mils]); Check screen or tears or dirt

Final lter deect, powder is blown into coating area Check and repair nal lter

Chang o carpet material in carpet systems Use suitable carpet or replace carpet

6.2 Poor Processing Characteristics (additional to section .1 to .6)

Scenario: Continuously or suddenly deteriorating application while processing parameters are unchanged.


A change in particle size distribution due to reclaim, powdertoo ne

Optimize cyclone parameters; Continuously add virginpowder and ensure proper ratio o virgin to reclaim powder

( max. 1:1); Reduce over spray; Change rack congurationIntroduce reclaimed powder continuously

Img. 6.1.1. CO

Beads o sweat in the lter residue Img. 6.1.. Contamination rom poor equipment cleaning Img . 6.1.3. Fibers at the reclaim

Img. 6.1.4. Dust in the lter residue Img. 6.1.5. Dust in the reclaim powder (enlarged)


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6.3 Continuous Shade Variations

Scenario: Continuous or sudden changes in color/shade or eect compared to sample or originally coated parts


Separation or particle size distribution changes throughreclaim

Add virgin powder

Powder remnants in reclaim system Clean reclaim system

Detraction due to several booths being located next to eachother

Reconstruct coating area layout; Cover booth during down-time, since powder or dirt may transer and contaminate area

Powder transer due to uneven air fow or perormance obooths

Reconstruct/recongure area

With powder extraction rom box eeder no even ratio oreclaim and virgin powder is achieved

Use fuid containerEnsure even ratio o virgin to reclaim powder

Addition o reclaim powder is inconsistent, virgin powderratio is too high or too low Add sucient virgin powderEnsure consistent ratio

Img. 6.3.1. Continuously test o the reclaim Img. 6.3.. Color hue change during the production


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7. SPECIAL CHARACTERISTICS OF APPLICATION OF mETALLIC POwDERS

7.1 Color shit rom color chart or original sample

Scenario: Result o the coating process not equivalent tothe original color sample/tamplet


Inconsistent batches Coat each job with powder rom a single batchConsult powder manuacturer

Varying application (Corona, Tribo, Corona modied with ioncatch)

Use only one type o application equipmentConsult with powder manuacturer

Deective application, gun short circuits Check applicationUse proper application

Object related coating jobs With several applicators or one coating job, colors andsystems have to be checked against each other. Use originalsamples, and warn customers o risks involved

Diering work pieces For comparison always use a single work piece with itsparticular substrate color (aluminum, steel, zinc plated steel,glass, wood)

Poor grounding Check ground and contacts

Wrong RAL chart used or eect dierence between RALchart and powder coating

Use proper RAL chart (GL or HR), inorm customer

For the processing o metallic powder coatings also observe identifcation sheet 36 - processing guidelines or powder coatings

with metallic-eect o the Austrian coating institution (see addendum).

Img. 7.1.. Eect dierence at dierent applications Img. 7.1.3. Color compare with the original color sample during theproduction

Img. 7.1.1 Color shit at coatings odierent manuacturers


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7.2 Greying o the Surace

Scenario: Disappearance o the metallic or non-metallic eect components (drowning)


Powder coating is tribo suitable, or metallic eect appearsdierent

Use Corona gun, always conduct pretests

Varying application methods (Corona, Corona modied withion catcher or Tribo) and inappropriate gun settings

Adjust KV setting and gun-to-part distance: the higher theKV setting, the lesser the metallic appearance; the lower theKV setting, the more metallic eect will appear

Varying deposition o eect pigments gives rise to color/e-ect changes

Use one suitable application method

Dierent powder coating equipment I possible ll all orders in only one coating system

7.3 Color Variations during Coating

Scenario: Continuous or sudden change o color or eect rom original sample or begin o coating job.


Powder extraction rom box eeder Use fuid container

Powder separation Check reclaim; Spray to wasteRead metallic application guidelines datasheet

Separation o powder in cyclone or in reclaim system Check Cyclone; Check reclaim

Batch change during coating job Use only one batch or each coating job

Color change between manual and automatic application Touch-up dicult to spray areas beore automatic application

Img. 7..1. Greying caused by cleaning compounds

Img. 7.3.1. False position caused by incompatibility o the fux Img. 7.3.. Color variations caused by reclaim Img. 7.3.3. Color variations caused by dierent application manu-acturers


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Img. 7.3.4. Eect-deviations caused by reclaim I mg. 7.3.5. Col or-devi at io n at dorma nt ca used by two dierentshades in the oven

7.4 Cloud Formation

Scenario: Uneven light to dark eect o the coating on the work piece


Gun distance to work piece to big or too small Check distance

Reciprocator operation parameters inappropriate Check lit and chain speed

Uneven powder transport Add sucient virgin powderCheck compressed air or variation

Manual touch-up Position manual touch-up beore automatic booth

Uneven charging (deective gun) Check application

Uneven grounding o work pieces Check grounding

Extremely varying lm thickness (especially with mattecoatings)

Optimize lm thickness

Powder extraction rom box eeder Use fuidizing hopper

Img. 7.4.1. Cloud ormation at metallic Img. 7. 4.. Cloud ormation caused by dierent lm thickness Img. 7.4.3. Sweat-c inder not removed


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8. TERmINOLOGY

The ollowing is a brie overview o the most commonly used terminology in the powder coating industry. It should be notedthat the explanations were not intended to be scientically and linguistically correct terminology, but rather a collection ocommonly used terms or the purpose o creating a general understanding.

AA

AdditiveMaterials added in powder produc-tion to optimize powder lm or certainapplications

AdhesionSticking o the powder coating to thework piece; Mechanical anchoringand/or chemical connection betweenpowder coating and substrate surace.Prerequisite is proper pretreatment

Adhesive RemnantsRemnants that are not removableby pretreatment cause these suracedeects and adhesion problems

AgglomerationPowder which does not adhere to thework piece or does not get recycled, butrather piles in the booth

AnodizingSurace treatment or aluminum, esta-blishment o a (colored) aluminum oxidelayer and its subsequent solidication

Application EquipmentEquipment necessary or powder appli-cation, I.e. guns, charging equipment,

nozzles, hoses etc.

AdditiveEquipment necessary or powder appli-cation, I.e. guns, charging equipment,nozzles, hoses etc.

Atomized AirTo support spray cloud, also to help avo-id sintering at the corona needle anddefector

Atomizing AirSupplemental air to regulate amount opowder in the gun, higher supplemen-tal air less powder coating, smallerpowder cloud

AutomationPowder application in connection withautomatic guns (permanently mountedon reciprocator or robotics)

B

Base MaterialSubstrate

Bonding AgentsMain components o powder coatings,resins like epoxy, polyester, polyuretha-ne or acrylic

BoothsCabinet or coating ( steel, stainless,glass, plastics)

BubblesElevations in the powder lm caused bywater, salt and oil remnants etc

BubblingGassing o the powder itsel at highmil thickness (starting at 150 [m] / 6[mils]), especially with TIC-ree powdersand IR ovens)

Buchholz HardnessTest procedure to measure the resi-stance o powder coating suraces

against pointed pressure demands; DIN53 153/ISO 815

C

CarbonBurnt oil or grease on the work piece,burnt in through welding

ChalkingDecomposition o the resin and blea-ching o the pigments through UV light

or chemical infuence

ChargingElectrostatic charging o the powderthrough corona or tribo method

Chemical ResistanceResistance o the powder coat suraceagainst various chemicals

CleaningCleaning o powder application unitduring color change. A necessary evil opowder coating

Coating System MaintenanceNecessary regular servicing o the coa-ting system by the system manuacturer

ColorPerception transmitted by the eye, causedby light sources and light refexes

Color DeviationDierence in color rom original sampleto test part (color chart to work piece or

work piece I to work piece II)

Color StandardOcial color charts, which represent in-dustry standards (RAL, Pantone)

ContaminationDirt

Conveyor HaltMaterials added in powder productionto optimize powder lm or certain

applications

Corona ChargingSee e-static

CorrosionThe reaction o a metallic work piecewith its surrounding environment,which causes measurable changes a-ecting the unction

CraterSurace deects, which reach through

the powder lm to the surace

Cratering o Hammertone EectsThrough insucient grounding, deve-lopment o star shaped voltage cratersthat expose the underlying surace


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CrosslinkingThe setting up o chemical links bet-ween the molecular chains o a resin

to orm a three-dimensional networkpolymer system

CuringComplete using o the powder coat.Minimum time and temperature are re-quired

CycloneDevice to return and circulate over-sprayed powder. Always requires a nallter

D

De-ionized Water RinseFinal stage o pretreatment with saltree water (0 15 tds)

Development o StripesUneven lm thickness caused byuneven sinus curve

Dip PretreatmentPretreatment or parts, not suitable orscoop shaped parts

DirtMainly contributes to reduce quality ocoating (dust, bers, shavings etc)

Distance IDistance rom gun to work piece

Distance IIDistance between work pieces

Dry-o ovenOven (chamber) or drying parts aterliquid chemical pretreatment

Duration TimeTime a coated part remains in the cu-ring oven

E

Edge Deposits

Powder accumulation at the work pieceedge

Environmental ConditionsExisting climate and environmentalconditions in the coating area

E-StaticElectrostatic charging o the powderparticles in the area o corona dischar-

ge, whose voltage is produced by theelectrode inside the gun or co conveyedby cable

F

Faraday CageA physical phenomenon the area oa part where the electric eld does notpenetrate

Filiorm corrosion

Thread like development o metal hy-droxides (not AlO3)on aluminum sur-ace, shows as thin threads with sharpedges under the powder coating

Film (Float)Suracing o additives in the powdercoating, example OGF additive

Film (Haze)Undesirable haze on powder coat surace

Film ThicknessThickness o the powder coat

FilterUsed to separate the powder-air-mix-ture (overspray) in reclaim system (plate,pocket or cartridge lters)

Final Filter (Purication Filter)Final lter in the coating system ormicro particles, which are not elimina-ted by the reclaim system

Fish eyesSame as craters

FlowSmoothness o the powder coat lmFluidizingStirring o powder coating in the fu-id container or powder storage box viapressurized air

Fluidizing baseAir permeable sinter material in the

powder storage container. Powder is fui-dized through incoming air (0.3 0.5 bar).

Fresh Water RinseRinse stage in the pretreatment systemto rinse cleaning chemicals with reshwater

Friction ChargingSee Tribo Charging

G

Galvanized Zinc PlatingApplication o an approximately 5 15[m] / 0. 0.6 [mils] layer o corrosionprotection (zinc) via electrolytical sepa-ration o watery, acidy or alkaline zincelectrodes

Gas QualityGas used to heat the dry-o oven andpowder curing (natural gas, city gas, bu-

tane, propane). Heating value and blendare o essence

GassingIngredients in the substrate, whichthrough melting o the powder on thesurace escape (evaporation, air, gasesetc.) can cause irregularities in thepowder lm

Gel ParticlesUnopened resin particles in the powdercoating

Glass PointTransition phase o the powder gelling

GlossRefection capacity o a surace, withpowder coatings ranging rom glossy tofat mat.

GraininessIngredients in the substrate, which Sur-ace deects, elevations in powder lm

GroundingContact by work piece and coating sy-stem component with earth/ground

GunNecessary or charging and application opowder coat (Corona charging and Tribo)

H

Hanging Devices

For suspension o work pieces duringthe coating processG

Heat Up SpeedTime required to heat an object to re-quired temperature


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HeaterFor pretreatment and powder drying;gas and oil, direct/indirect, electric, IR

Hiding PowerAbility o the powder, given appropriatelm thickness, to suciently hide thecolor o the substrate

HoseComp. Transport hose

Hot Dip Galvanizing (H.D.G.)Corrosion protection- application o anapprox. 30 80 [m] / 1 3. [mils] thickzinc layer by dipping at high tempera-tures (approx. 400 [C] / 75 [F])

I

IncompatibilityCondition o the surace through un-controllable chemical reactions

InltrationDevelopment o corrosion throughmoisture and salts (osmosis) betweenpowder coating and part

InjectorVenturi pump or powder transportation

Insulation o work piecesInsucient grounding, caused by excessivelm thickness on parts and hanging devices

Intercoat AdhesionAdhesion between rst and secondpowder coat layer

IonizationComp. e-static

L

LitingCured powder coating lits rom substrateunder various types o mechanical stain(i.e. during deburring, cutting, milling)I

LubricantsOils and greases used to help in glidingduring orming o proles in the manu-acturing process

LumpsClustering o powder coating in the boxdue to transportation, moisture infu-ence, Corona charging or heat

m

Material Selection (Powder Coating)Suitable powder coating (exterior vs. in-terior coating, special eects etc) or anapplication

Material Selection (Substrate)Suitable, coatable materials (steel, alu-minum, glass) or the application

MattingReduction o the gloss level, powdercoating surace appears lower in glosslevel

Mechanical PropertiesNecessary properties o the powder coa-ting (test according to ASTM, example:Conical bending or impact test, Erichsencupping etc)

Metal ShavingsMachining residues on parts (cutting,polishing, drilling etc)

Metallic PigmentsConductive or non-conductive eect

producers in powder coatings

Metallic Powder CoatingsEect powder coatings with metallicappearing surace (pearl, glitter, Glim-mer etc)

MetamerismColor dierence at varying light conditions

MoistureAbsolute moisture content in a powdercoating

Movement o ReciprocatorSpray pattern with reciprocating guns,infuenced by conveyor speed and lit

N

NozzlesVarious end pieces on the gun (powderbells, nger nozzles, round and fat typenozzles)

O

OGF-Additive(OGF = Out-gassing Forgiving) Additiveto help reduce out-gassing o the sub-strate in the powder lm

Oil RemnantsRemnants o oil on parts, which werenot removed by pretreatment (Lanolin,extrusion oil etc.)

Oil ResiduesResidues not removed by pretreatment

Orange PeelShort or long ripple eect on the powdersurace

Oven TypesOven dierences through constructionand heating unit, i.e. chamber oven,conveyor oven, radiation oven, IR oven

(comparable to heating, gas quality)

Over CoatingA second layer o powder is applied

Over CuringTemperature in the curing unit is toohigh, or time in the oven is too long.

Oversize ParticlesPowder particles that are larger thanthe screen size and are separated duri-ng straining

OversprayPowder coat that does not adhere tothe surace during application

Oxide LayerCorrosion residues on the work piecesurace

P

Particle DistributionDistribution o powder coat particlesaccording to size and percentage

PenetrationAbility to coat in to the corners, recessesand hollow areas

PicklingCaustic, watery cleaning procedure,which removes oxide layers, rust, groundin dirt and oreign materials

Picture Framing EectHigher lm thickness o the powdercoating on the edges o the work piece,caused when current is too high at theedges, e.g. noticeable with ne texturesand metallics


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PigmentsColoring agents in the powder coating

Pimple

Elevation in the powder surace

Pin HolesSurace deect. Development o smallpores in powder coating

Polishing MarksMechanical surace treatment. Can bevisible through powder coats

PowderDry, dust like thermosetting coatings

Powder AdhesionSee adhesion

Powder CenterCompact device or powder transporta-tion, made o thread with integratedcleaning unit

Powder CirculationTransport o unapplied powder throughreclaim or re-use (comp. to over spray)

Powder ClustersI.e. powder pus

Powder DryerNecessary device or gelling and drying othe powder coating lm(see oven types)

Powder FilmDesired surace development o the gel-led powder coating

Powder Hose

Comp. To transport hose

Powder PusAgglomeration o powder coat on thecoated surace

Powder Transport DeviceFor transport o powder coating romstorage container to gun

Pressure PointsVisible notches in the powder coat

surace, caused by too much pressurestrain, especially at high lm build

PretreatmentCleaning and conversion layer developmentwith liquid chemicals (dipping, spraying)

R

ReclaimDevice to reclaim over spray

Release Agent 1Sprays used in the metal abrication in-dustry, to reduce the adhesion o wel-ding residues

Release Agent IILiquid used or castings, to reduce theadhesion between cast part and castingmold

Remnant Powder 1

Contaminated powder rom reclaim

Remnant Powder IIEconomically not usable powder coa-ting in carton or warehouse

Retracted AreasAreas unreachable with powder (i.e.araday cage), example: orm tubing,welded parts

Return Point

Up and down end points in automatic re-ciprocating powder coating equipment

RinseRemoval o pretreatment residues viaresh or de-ionized waterRunRunning o the powder coating lmrom the work piece (synonymous withliquid paint)

Rust

During corrosion o iron or steel

S

Salt ResiduesUnremoved residues ater pretreatment

Scratch ResistanceDurability o the powder coating surace(i.e. abrasion resistance)

Screen Tear

Deective screen used to qualiy powder,oversize particles may cause fowproblems

Screening AnalysisDetermination o particle size

Screening EquipmentIntegrated in reclaim system to strainpowder. External straining possible (min.mesh size approx. 00 [m] / 8 [mils])

Scu ResistancePowder lm resistance against abrasivemedia, i.e. sand, scouring liquid, card-board, wood, paper

Security StandardsSecurity standards published by equip-ment manuacturers and OSHA must beobserved

ShavingsFine manuacturing contaminations(metal, wood or plastic)

Short CircuitUncontrolled (electric) contact betweenhigh voltage and ground

SinteringDepositing o powder in the powdereed system, application equipment orreclaim system

Snowboard Eect

Powder does not adhere to work piece,slides o in sheets, drizzles o

SotenerAdditive used in plastics production

SoteningSotening o the powder coat lmthrough use o solvents

SpikesElevations

Spray Wash SystemPretreatment o work piece via spraywasher(approx. 1,5 bar) mechanical clea-ning power

SprayingApplication o powder coat to part withspray equipment

StabilityContinuous resistance depending on re-quirement, or example against chemi-

cals, weather or UV infuence

SubstrateWork piece, to be coated material (steel,aluminum, stainless steel, glass, plastics,MDF)


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Super FinesSpectrum o particle size distribution othe powder coating (< 10 [m])

Surace DeectsDamages to the surace properties othe powder coating

SweepingLight blasting o parts. Mechanical re-moval o corrosion layer, especially orhot dipped galvanized parts

T

Tears

Surace deects, tearing/breaking duri-ng insucient gelling, ater mechanicalstrain

Temperature CurveElevating and dropping o substratetemperature during the curing process

TexturesSurace developments

TGICTriglycidylisocyanurate - Popular harde-ning system or polyester

TGIC-FreeAlternative hardener

ThermoplasticsRe-ormable plastics that can be re-shaped with re-heating

Thermosetting CoatingsIrreversibly used lm, not changeableby re-heating

Transport HoseHose used to transport powder and airmixture rom powder container to gun

Transportation AirNecessary air to transport air to thepowder gun. Increasing o air = increa-sed powder consumption

Tribo ChargingThrough charging separation (PTFE rod)

powder particles are positively chargedand transported to the part

U

Use o AdhesivesLarge selection, check suitability beoreuse

v

VoltageNecessary electrical voltage orcharging

w

Wall Thickness

Material thickness o the work piece

Welding PointsSurace treatment. May be visiblethrough powder coat. Problems withcarbon

Work PieceSee substrate

WrappingAccumulation o powder on the back-side and/or edge o a work piece

Y

YellowingColor change caused by excessive tem-peratures or time in direct red gasovens

Z

Zinc Coating

Application o a corrosion protection la-yer (Zn) on steel (galvanizing)


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9. APPENDIx


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40/41page 40 05-007

Publisher and distributor:TIGERWERK Lack- u. Farbenabrik GmbH & Co.KG.

Negrellistrae 36 | 4600 Wels | AustriaT +43 / (0) 74 / 400-0

F +43 / (0) 74 / 650 08E [email protected]

www.tiger-coatings.com

007 byTIGERWERK Lack- u. Farbenabrik GmbH & Co.KG.

All rights reserved

Proper useThis manual is intended to provide the relevant reader and user with a tool to clariy the major sources o errors in the indivi-dual application stages and to allow these error sources to be rectied as comprehensively as possible. Under these circum-

stances it is acceptable to quote rom the relevant documents or your own requirements.

All rights reservedThis document and all texts included in this document are copyright-protected. They may not be used outside the restrictionsimposed by copyright law without the prior approval o the originator and any such use will be liable to prosecution. In specicterms, no part o this document, including relevant systems and nomenclature, may be copied, reproduced, duplicated, trans-lated, processed, amended or recorded by electronic, analogue or digital means, saved, recovered, transerred or distributed or

used in any other way.

Image rights

All rights shall remain with the originators or their representatives.

We can accept no liability or the accuracy o the inormation or any mistakes which may have occurred in drawing up thismanual despite the great care taken during this process.


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