How to deal with the burnt edge of electrostatic spraying
How to deal with the burnt edge of electrostatic spraying
Burnt edges during **electrostatic spraying** are typically caused by **excessive voltage**, **incorrect gun distance**, or **poor coating technique** that leads to overheating or overexposure of the coating on edges. These “burnt” edges can manifest as areas with **too much paint**, **uneven coating**, or even **discoloration**. Here’s how you can address and prevent burnt edges:
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### **1. Adjust the Electrostatic Voltage**
– **Lower the Voltage:** High electrostatic voltage can cause **excessive paint accumulation** on edges. Reducing the voltage (e.g., **from 90kV to 60-70kV**) can help ensure a more even distribution of paint.
– **Gradually fine-tune the voltage** based on the coating material, part shape, and desired finish. Too high a voltage will concentrate paint on edges and corners.
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### **2. Increase the Gun-to-Workpiece Distance**
– **Increase the Distance:** The closer the spray gun is to the surface, the more the paint will be concentrated on the edges, especially due to electrostatic attraction.
– Ideally, keep the spray gun **at least 8–12 inches** from the surface to reduce the buildup on edges. Experiment with adjusting the distance for the best results.
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### **3. Modify the Spray Angle and Pattern**
– **Avoid Direct Angle on Edges:** When spraying, **angle the gun slightly** to avoid spraying directly onto edges. Spraying slightly off to the side will help ensure an even distribution across the surface, preventing excessive buildup on edges.
– **Use a Crosshatch or Circular Motion:** Using a cross-coating or circular motion can prevent the edges from getting hit too hard in one pass, which can lead to burning.
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### **4. Fine-Tune Airflow and Atomization**
– **Adjust Air Pressure and Atomization:** If the airflow or atomization is too low, the paint particles will be larger and more prone to uneven deposition, especially on edges. Increase the **air atomization pressure** to achieve a finer mist and reduce the chance of large paint droplets building up on the edges.
– Use **appropriate paint viscosity** and ensure that it is properly mixed. Thicker paint might need more atomization to distribute properly.
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### **5. Use Pre-Coating or Edge Masking**
– **Edge Masking:** Use **masking tape** or **shields** to cover the edges of your part before spraying. This helps to prevent overspray buildup at the edges and creates cleaner transitions between areas.
– **Pre-Coat Edges:** If you are spraying a large part, try applying a **light coat** to the edges first, allowing them to dry before applying the main layer. This can help avoid excessive accumulation on the edges during the main spraying phase.
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### **6. Control Booth Conditions**
– **Temperature and Humidity:** Ensure the spray booth is kept at the proper **temperature (around 65–75°F)** and **humidity (40–60%)** to prevent paint from curing too quickly or too slowly, which can exacerbate the problem.
– Ensure that **ventilation is adequate** to prevent hot spots and ensure that the air is consistently circulating.
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### **7. Sanding or Light Buffing (Post-Application)**
If the burnt edges are already present, here are ways to fix them:
– **Light Sanding:** Once the coating is completely dry and cured, use a **fine-grit sandpaper (600–1000 grit)** to gently sand down the burnt edges. This smoothens out excess buildup and blends the edges with the rest of the surface.
– **Buffing:** After sanding, you can use a **polishing compound** or **buffing wheel** to smooth out any imperfections, especially on gloss finishes.
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### **8. Experiment with Electrostatic Spray Settings**
– **Try Different Spray Guns:** Different electrostatic guns have different spraying patterns, so experimenting with a **gun that offers more control** over the spray pattern can be helpful in minimizing burnt edges.
– **Test Spray Parameters:** Test various parameters such as **voltage, distance, air pressure**, and **fluid flow** on sample parts to find the optimal settings for your specific coating material and part geometry.
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By carefully adjusting the **voltage**, **spray distance**, **air pressure**, and **spray technique**, you can reduce the likelihood of burnt edges and achieve a more uniform and professional finish. If you’re still facing issues, you might also consider **upgrading to a more advanced electrostatic system** that offers better control over spray patterns and charge distribution. Would you like help with settings for a specific type of material or spray system?
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