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Efficient Powder Coating Transfer

Posted on: November 10th, 2014 by byersbushblog

Electrostatic charges are what make powder coating work. The gun creates a charge on the powder particles, so when the charge is higher, the transfer becomes more efficient. There are important factors that affect the strength of the electrostatic field. Those factors include the voltage of the applicator and the target distance between the applicator and the part that is being powder-coated.

Charging the Powder Particle

When the powder particle is charged, the time the particle is in the field will affect the the charge. The first pass transfer efficiency is affected by the time in the field and the strength of the field, too. You can easily adjust the speed of the gun, so you slow the velocity of the powder to improve the efficiency of the coating.

Improving Transfer Efficiency One Setting at a Time

There are other ways to improve the transfer efficiency of the first pass with a few techniques that can be used on manual and automatic applications.

Adjust the Voltage

Adjusting the voltage of your powder coating gun is the best way to improve the first pass transfer efficiency. The recommended voltage setting is the maximum setting. There are some rejection issues that can occur when working with thicker films, so you might have to lower the setting to make sure the powder releases from the gun efficiently.

Set the Gun for Fewer Faraday Cage Issues

The setting of the gun is important, but so is the part ground. This setting needs to be set at a resistance that is equal to or less than one megohm. With this setting, you will be following the NFPA guidelines and you will also have fewer problems with Faraday Cage issues as well as rejection at the electrostatic level. With this setting, the maximum voltage can also be set.

Create the Ideal Distance from Gun to Part

The distance of the gun from the part is another way to improve the transfer efficiency. Ideally, the gun should be 6 to 12 inches away from the part. If you move the gun less than 6 inches from the part, then you run the risk of disrupting the attraction between the forces. The aerodynamics shift when you move the gun too close to the part and it can cause unwanted effects.

Manipulate the Gun Setting for More Time in the Field

The speed of the powder particles can also affect the transfer efficiency of the first pass. When the particles travel quickly through the electrostatic field the first pass transfer efficiency drops. When you reduce the velocity of the powder output and use gentle patterns devices on your gun, you will reduce the speed of the powder particles. With a slow gun motion, the transfer efficiency improves because the powder particles spend more time in the electrostatic field.

Set the Part to Face the Gun

The position of the surfaces that are being coated is also important key to success. The surfaces need to be positioned facing the sprayers and guns so the results meet your expectations. With proper positioning, transfer efficiency is at its best and wasted effort is reduced. The positioning of the part helps improve the other suggested principles.

Improving Efficiency and Reducing Waste One Job at a Time

When you pay attention to the details of powder coating and gun use, you will improve the efficiency of the first pass. This removes the amount of overspray and less to reclaim. With the right settings, you create less waste and you will be able to save money in the long and short run.

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