What are the basic parameters of powder electrostatic spraying?
What are the basic parameters of powder electrostatic spraying?
The **basic parameters** of electrostatic powder spraying affect the quality, efficiency, and durability of the coating. Here are the key parameters to consider:
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### **1. Powder Characteristics**
– **Particle Size**: Typically **10-100 microns**, with **30-50 microns** being ideal for most applications.
– **Powder Composition**: Common types include **epoxy, polyester, polyurethane, and acrylic powders**, each with different properties.
– **Powder Flowability**: Affects even distribution and adhesion to the surface.
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### **2. Electrostatic Voltage**
– Applied voltage range: **30-100 kV** (kilovolts).
– **Low Voltage (30-50 kV)**:
– Used for **complex shapes** to reduce back ionization.
– Better for **recoating or second-layer applications**.
– **High Voltage (60-100 kV)**:
– Provides **stronger electrostatic attraction**.
– Ideal for **flat surfaces and high transfer efficiency**.
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### **3. Air Pressure & Powder Flow Rate**
– **Atomizing Air Pressure**: **0.5-2.5 bar (7-35 psi)** – controls powder dispersion.
– **Flow Rate**: Adjusted to **10-250 g/min** depending on the coating thickness required.
– **Too High Pressure**: Causes **overspray and wastage**.
– **Too Low Pressure**: Leads to **uneven coating**.
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### **4. Spray Distance (Gun-to-Object Distance)**
– **Ideal range: 10-25 cm (4-10 inches)**.
– **Too Close (<10 cm)**: Causes **overcharging and uneven coating**.
– **Too Far (>25 cm)**: Leads to **poor adhesion and excessive overspray**.
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### **5. Curing Temperature & Time**
– **Typical curing temperature**: **150-220°C (300-430°F)**.
– **Curing time**: **10-30 minutes**, depending on the powder type and metal thickness.
– **Under-curing**: Leads to a **soft, weak coating**.
– **Over-curing**: Causes **color fading and brittleness**.
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### **6. Substrate Grounding**
– The workpiece must be **properly grounded** to **improve powder attraction** and reduce overspray.
– Ideal **grounding resistance**: **Less than 1 megaohm (MΩ)**.
– Poor grounding results in **low transfer efficiency and uneven coating**.
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### **7. Spray Gun Type & Nozzle**
– **Corona Discharge Guns**: Most common, use **high voltage to charge powder**.
– **Triboelectric Guns**: Generate charge via **friction**, good for thin layers.
– **Nozzle Types**:
– **Flat Nozzle** – Better for **large, flat surfaces**.
– **Round Nozzle** – Ideal for **complex shapes and edges**.
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### **8. Environmental Conditions**
– **Humidity**: **40-60%** is optimal. **Too high (>70%)** causes powder clumping, and **too low (<30%)** increases static buildup.
– **Temperature**: **18-30°C (65-85°F)** for stable powder flow and adhesion.
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### **Final Thoughts**
Setting these parameters correctly ensures **high-quality, durable, and efficient** powder coating. Would you like help troubleshooting a specific issue?
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