Powder Coating Defects and What Needs to Be Done

15 June 2022

Powder coating is a dry finishing process that is conducted in a wide array of components and parts. It is often maximised since it can yield a finish resistant to elements like impact, chemicals, moisture, ultraviolet light, and other extreme outdoor conditions. Components and parts that have undergone powder coating can also withstand scratches, abrasions, corrosion, fading, and chipping.

Aside from durability, powder coating can also enhance the appeal of the said products since it can offer many colour and texture options. This appeal can then retain for a long time, minimising the upkeep requirements of components and parts.

The properties associated with powder coating are expected to last for a long time. However, this dry finishing process can still fail. Here are some of the most common reasons behind powder coating defects and some things that can be done to avoid or resolve them.

Choosing the Wrong Powder

One of the most common reasons behind powder coating defects is the selection of the wrong powder. Before this finishing process must be done, manufacturers should know first the type of environment or surroundings to which the part or component will be exposed. Once the elements of this environment have been enumerated, they must choose the material that can withstand their effects. Powder finish may not last forever but ensuring that it can last for multiple years can already provide great value to users. 

Improper Substrate Preparation

Another reason behind powder coating defects is improper substrate preparation. One may have picked the right type of powder for the workpiece. However, if the workpiece or substrate itself has some issues, it may still get damaged despite coating it. Failure to prepare the substrate can lead to poor corrosion resistance or unacceptable creep in a specific area. To avoid this defect, the manufacturer should conduct accelerated corrosion tests on the substrate first before preparing it.

Overlooking Substrate Parts

Changes in the composition of the substrate over time can significantly affect the quality of powder coating. Failure to consider its elements or composition can lead to defects that can be costly to resolve. Maximising a different metal source can affect the coating layer, causing negative effects on the adhesion and corrosion resistance of the latter. All layers necessary for the workpiece must be accounted for – from the powder, pre-treatment, down to the substrate.

Powder Coating Application

The number of powders utilised on the surfaces of the workpiece can affect the powder coating quality. Applying them too thickly or too thinly can easily hurt the performance of the coating. Thick layers of powder, for instance, can generate a poor appearance to the workpiece. They can also diminish flexibility and impact resistance. Thin powder layers, alternatively, can generate problems with the overall appeal of the workpieces. They can likewise cause corrosion issues.

Undercured Powder Coating

One more reason why powder coating may fail is due to undercuring. When applying powder coating to an object, a specific amount of time should be allocated for the coating to be fully set. By overlooking the recommended curing time, the powder coating will only be undercured, making the finish look smooth, glossy, and more susceptible to external damages.

For optimal powder coating for your workpieces, you can call us at Epac Productions.

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