How to easily solve powder coating problems

 

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It is worth reading these tips if you have errors when troubleshooting powder coating problems on your computer. One of the main causes of punctures is surface contamination. Solvents, grease, release agents and engine oil can evaporate through the powder coated surface during the curing process. Residues or improper cleaning can expose your part to various surface defects, including punctures.

troubleshooting powder coating problems

 

Does powder coat go bad?

Shelf life of conventional powders is always indicated between 6 and 12 months during production under certain storage conditions. Highly reactive powder = powder at a low curing temperature, possibly only 3 months, some powders can only be stored for 10 days, even if you put them in a freezer (this is not for sale).

 

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Powder coatings have become the preferred finish in various sectors, from heavy equipment, electronics and outdoor products to equipment. The main advantages of powder coatings over liquid coatings include a solvent-free workplace, reduced overall line costs and ease of cleaning. Powder coatings can also help processors in their efforts to ensure sustainability, as they have a very low level of volatile organic compounds and offer the possibility of processing spray and waste products that can usually be disposed of in normal landfills (the applicable rules should be checked for appropriate disposal methods) .

Proper maintenance and spraying techniques are essential to ensure the efficiency and effectiveness of any powder coating process. Getting into bad habits easily and often goes unnoticed, but can lead to loss of effectiveness and quality problems. Although benchmarking of supervisors is a proven way to ensure uninterrupted If the line is operated on the day of its first installation, problems may arise even with the most productive powder coating lines.

When it comes to getting the most out of powder coating, the problems listed below are not the only ones that need to be addressed, but certainly the 10 most common. Identifying potential problems before they occur can save you time and money.

1. A well-grounded recommendation

Most electrostatic powder coatings are negatively charged with a powder gun when the workpiece is grounded. , This grounding provides the opposite charge and partially attracts the powder, but for this the workpiece itself must be properly grounded. A poor surface affects transmission efficiency and leads to the formation of a defective film. This can be avoided by good service practice.

For example, poor film accumulation can be caused by “dirty” hooks - those that were isolated over time from the hookPowder burning. Hooks must be kept clean or replaced if they can no longer be cleaned. The number of passes that a hook can make after cleaning varies. Regular floor checks help determine the correct cleaning schedule.

In addition, good contacts should be maintained throughout the system. The delivery line on which the parts are suspended must be grounded separately to ensure proper grounding of the part. Non-conductive contacts can develop due to poor maintenance practices, reducing or eliminating floors, and preventing powder from sticking to the workpiece. To confirm the correct resistance, a 500 volt megger should be used, and the resistance value should be <1 megohm.

2. More - less

The key to a high-quality powder coating is spraying the right amount of powder with minimal air. Excessive supply air pressure and powder volume do not cause coated parts to be faster or better, and as a rule, this can affect the finish, guns and camera.

If so much powder is blown because the other end of the spray chamber is not visible, perhaps too much powder is pumped out through the gun. A typical powder gun uses an electrode at the end of the gun tip to release negative ions into the air. The powder coating is then sprayed through the formed ion cloud, creating a negative charge. If too much powder is sprayed into the ion cloud or sprayed at too high a speed, the powder will not absorb charge with such efficiency, and uncharged powder will enter the cabin (see Figure 1). A powder gun works more efficiently with a smooth, smooth jet of powder exiting the nozzle of the gun. This allows the powder to restore the correct charge and adhere to the part.

Although the pumps and the spray gun are slightly worn out, blowing air at high speed, as a rule, should cause premature wear and possibly a melting blow (molten powder grains coming out of the gun in the form of an already hardened mass) and no longer can be melted). Components and FeaturesIf systems should be checked regularly for wear and replaced if necessary to maintain surface efficiency and quality. The powder supply lines to the guns should be wrinkled-free and have minimal bends. Weapons should be cleaned at least as often as indicated by the manufacturer, and possibly more often if used under harsh conditions. The cost of proper equipment maintenance is much less than the potential loss that often occurs if maintenance is ignored. The desire to speed up the line and increase productivity must be consistent with the reality of the capabilities of the devices. Optimum pressure can be established by regularly consulting with linear applicators and maintenance staff of powder coating and instrument manufacturers.

3rd Clean Air - Act!

The importance of air quality for powder coating should not be underestimated. Many of the problems associated with a powder coating spray installation are directly related to the poor quality of compressed air.

Humidity of air, oil and particles, such as dirt or dust, have the greatest impact on air quality during the coating process. Contamination can lead to poor surface quality, premature failure of the cartridge filter, destruction of the internal components of the system, poorly fluidized powder due to partially clogged fluidizing membranes, and possibly ripple in many of these problems, which ultimately leads to handling problems with powder throughout the system.

Compressed air can be naturally moist and contain oil. Depending on the conditions, particles may also be present. Air quality will be as follows:


To remove these objects in the air supply system, a desiccant and a dry air filter must be used before they reach the powder system. Regular inspections of these air supply components ensure that they can be replaced or replenished if necessary before the quality of the finish is compromised.

4. Problems of size (particles)

One of the mainThe benefits of powder coating are the ability to recover and reuse an aerosol that does not adhere to the parts. Trying to cover only with reconstituted material is inefficient and expensive.

Each powder coating is produced in a specific size range. The same range must be maintained in order to guarantee the correct layer thickness, surface quality and transfer efficiency, whether pure or reconstituted powder. Particles become smaller as they are continuously collected and reused, which prevents their proper fluidization and maintenance of the correct charge. This can reduce transmission efficiency by up to 50% or less. On the other hand, larger recovered particles can accumulate from parts to be coated, fall at the cab level and cause transmission efficiency of 30% or less. The best way to maintain an optimal particle size distribution is to constantly add new materials to the system, while reduction is used to achieve optimal efficiency.transfer efficiency. Powder suppliers can help determine the correct relationship between new products and the recovery of used powder.

5. Do not confuse

Incorrect color changes can lead to cross-contamination, which in turn can lead to defective parts.
Changing the color makes it possible not only to clean the entire system, but also to ensure the correct installation and operation of sprayers and components. Some types of powdered products present a higher risk of contamination than others, as they may not be compatible with other powdered products. Two different powder coatings may be incompatible due to different differences in composition, such as resins, textures, additives or other starting materials contained in the composition. For this reason, it may be advisable to have special pipes for certain colors and / or textures in order to avoid pollution problems.

General purity is often the main cause of color contamination. Postponing maintenance until the entire stand and component Systems will not be coated with excess powder on the floor, usually resulting in incompatible surface quality and / or color. Too much powder often causes the powder to move throughout the processing area, increasing the risk of color contamination if cleaning becomes more difficult. It can also lead to powder getting into the air conditioning system of the building, which can lead to depletion of these systems, creating uncomfortable working conditions and poor appearance when visiting the plant.

6. Treat them right!

The quality of the coating is as good as the quality of the surface on which it is fixed. Poor pretreatment practices can lead to adhesion, corrosion resistance, and impact resistance of coated parts.
Pavers have different pre-treatment technologies, each of which meets specific requirements. For example, before

 

 

How do you test powder coat adhesion?

Adhesion Tests
A hatch test is used to test the adhesion of a powder coating to a metal substrate. For this, a shaded mesh is cut from the coating onto the surface.

 

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