YR 1003731 GE PO-4501126581 – Rev No.

1 – Dt: 25/08/2021

Prepared By:

Adnan Hussain
Adnan

(NACE CIP-2 Coating Inspector)

18th July 2021
adnan.hussain@hitechradiators.com
PROBLEM REPORTED 1

 Hitech reported the problem in the 2nd week of July for observation
of paint defects which included bubbling and Popping.
 The defects were observed in the primer coat, which is EMC 182 and
EMD 30, the Intermediate coat.
 And majorly the defects were observed after the radiator is baked in
the oven at 70°C for 1hr 10 mins.
 Below mentioned are the batch numbers of the CHING paints for
which the defects were observed.
o EMC 182 - 21174402 - Part A
21171068 - Part B

o EMD 30 - 21171679 - Part A

21173996 - Part B
 The coating protocol followed for the flow coating process:
o HDG - 80 mics
o EMC 182 – 1 coat – 60 mics
o EMD 30 - 3 coats – 210 mics
o ADD 43 – 1 coat – 60 mics
o Total DFT 410 microns
 Ambient Conditions:
o Dry Bulb Temperature: - 30.1 Degree C
o Wet Bulb Temperature: - 27.2 Degree C
o Relative Humidity: - 79.8 %
o Dew Point: - 26.2 Degree C
o Surface Temperature: - 31.8 Degree C
o Delta - 5.6 Degree C
o Time: - 1:30 PM IST
 Description: The radiator is kept to natural dry for 8 - 9 hrs. and then
forced dried in oven at 70 ⁰C for 70 minutes to ensure 100% hard dry
before next coat. Even after this we have observed issues like
Bubbling / Popping due to solvent entrapment and paint drops.
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 Pictures

 Number of effected radiators – 5

 Number of radiators processed prior to the phenomena – 23 + 5
 Viscosity:
 Base Coat – 20 - 25 secs*
 Intermediate – 22 - 28 secs*
 Topcoat – 22 - 28 secs*
*Viscosity measurement is done via B4 cup
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RADIATOR TRACABILITY

Following table shows the radiators coated with CHING paints (Paint batch no. mentioned
above) on 13th July 2021 in night shift. Of the 10 radiators, 05 were found with
popping/bubbling effect and hence the production was on hold.

Sr. No HTU No. of radiators processed prior to Hi-Tech’s Comment

the occurrence of popping & bubbling
1 21070104 Found Satisfactory
2 21070156 Popping & Bubbling Observed
3 21070111 Found Satisfactory
4 21070101 Popping & Bubbling Observed
5 21070120 Found Satisfactory
6 21070143 Popping & Bubbling Observed
7 21070139 Popping & Bubbling Observed
8 21070108 Found Satisfactory
9 21070105 Found Satisfactory
10 21070162 Popping & Bubbling Observed

Table 1

Following radiators were coated with the CHING paints with the same paint batch from 10th
July (Night Shift) to 13th July (Day Shift)
Sr. No HTU No. of radiators processed prior to Hi-Tech’s Comment
the occurrence of popping/bubbling
1 21070110 Found Satisfactory
2 21070115 Found Satisfactory
3 21070132 Found Satisfactory
4 21070146 Found Satisfactory
5 21070147 Found Satisfactory
6 21070149 Found Satisfactory
7 21070150 Found Satisfactory
8 21070151 Found Satisfactory
9 21070159 Found Satisfactory
10 21070158 Found Satisfactory
11 21070102 Found Satisfactory
12 21070107 Found Satisfactory
13 21070113 Found Satisfactory
14 21070125 Found Satisfactory
15 21070127 Found Satisfactory
16 21070129 Found Satisfactory
17 21070133 Found Satisfactory
18 21070135 Found Satisfactory
19 21070138 Found Satisfactory
20 21070145 Found Satisfactory
21 21070152 Found Satisfactory
22 21070155 Found Satisfactory
23 21070160 Found Satisfactory
Table 2
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Following radiators were coated with revised procedure as recommended by CHING paints.

Sr. No HTU No. of radiators processed with Hi-Tech’s Comment

revised procedure
1 21070103 Found Satisfactory
2 21070106 Found Satisfactory
3 21070109 Found Satisfactory
4 21070112 Found Satisfactory
5 21070114 Found Satisfactory
6 21070116 Found Satisfactory
7 21070117 Found Satisfactory
8 21070118 Found Satisfactory
9 21070119 Found Satisfactory
10 21070121 Found Satisfactory
11 21070122 Found Satisfactory
12 21070123 Found Satisfactory
13 21070124 Found Satisfactory
14 21070126 Found Satisfactory
15 21070128 Found Satisfactory
16 21070130 Found Satisfactory
17 21070131 Found Satisfactory
18 21070134 Found Satisfactory
19 21070136 Found Satisfactory
20 21070137 Found Satisfactory
21 21070140 Found Satisfactory
22 21070141 Found Satisfactory
23 21070142 Found Satisfactory
24 21070144 Found Satisfactory
25 21070148 Found Satisfactory
26 21070153 Found Satisfactory
27 21070154 Found Satisfactory
28 21070157 Found Satisfactory
29 21070161 Found Satisfactory
30 21070163 Found Satisfactory
31 21070164 Found Satisfactory
Table 3
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ROOT CAUSE

During blasting (even when all blasting parameters are compiled with) there is a probability that the radiator
surface which has peaks and valleys there may be a remote possibility of moist air or solvent entrapment
under the layer of primer due to the nature of primer used. This entrapped solvent or moist air is released on
heating the surface resulting in bubbles. Henceforth CHING advised us to put the radiators in oven before
coating with the primer.
There can be some variables in the paint, In order to overcome them we have standardize pre-heating of the
radiators before the application of EMC 182.

REWORK PROCEDURE

The below procedure was followed to rework the 5 affected radiators with the popping/ bubbling.

1. Identified the affected radiators in which popping/ bubbling was observed.

2. Two radiators (HTU No. 21070156 & 21070162) were found with intense popping / bubbling, however three
radiators (HTU No. 21070101, 21070143, 21070139) were observed with moderate popping / bubbling.
3. Hi-Tech has followed two different rework procedures for two different level of intensities of
popping/bubbling.

For High Popping/ Bubbling:

 Complete blasting over the radiator surface to remove all primer coat of EMC 182.
 After blasting radiators were kept in the oven at 70⁰ C for 70 minutes.
 This was then followed by Hi-Tech’s standard paint flow coating process.

For Low popping/ Bubbling

 Identified the areas where popping/ bubbling observed, performed sanding operation over the
affected areas and applied the coat of primer EMC 182.
 After sanding and primer application radiators were kept in oven at 70⁰ C for 70 minutes.
 This was then followed by Hi-Tech’s standard paint flow coating process.
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COMMENTS FROM CHING PAINTS

Mr. Friedl reported that there may be a chemical reaction between the
fresh galvanizing and the alkaline hardener. During the reaction hydrogen is
formed which outgases from the galvanized surface. These reactions are
rare but can occur from time to time.

Problem solution

 Temper the galvanized radiators at maximum oven temperature

(ideally 110°c) before priming.
 It is important to open the radiator caps during annealing to allow
residual solvents from the RD 124 internal coating to escape.
Tempering has no negative effect on the quality of the RD 124.
 Before applying the primer cool the radiators to room temperature.
 The normal coating process can then be started.

HI-TECH’S REPLY TO CHING PAINTS

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TRIAL PROCESS AT HI-TECH

 As suggested above by the technical team from CHING, we

changed the process as follows:
o STEP 1: The radiators were fabricated and were sent for
Galvanizing process.
o STEP 2: Galvanized radiators were sweep blasted to SA 2.5
with Aluminum Oxide grit.
o STEP 3: Clean Blasted radiators were then sent for Oven
process to pre-heat them for 1 hr at 70°C
o STEP 4: The radiators are then cooled down to room
temperature.
o STEP 5: The radiators are then flow coated with EMC 182 and
is left to naturally dry for 5-6 hrs
o STEP 6: Once the radiators are naturally dried, it is then sent
for oven process for 70 mins at 70°C
 After the oven process was completed, no paint defects were
observed.
 Ambient Conditions:
o Dry Bulb Temperature: - 32.9 Degree C
o Wet Bulb Temperature: - 27.2 Degree C
o Relative Humidity: - 79.8 %
o Dew Point: - 26.2 Degree C
o Surface Temperature: - 31.8 Degree C
o Delta - 5.6 Degree C
o Time: - 1:30 PM IST
 46.7°C was recorded as surface temp of the radiators 15mins after
the radiator was sent out of the oven.
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 Pictures:

CONCLUSION & LESSONS LEARNED

1. There is a remote possibility of moist air or solvent entrapment due to the

nature of paint.
2. In future, Hi-Tech will follow the painting procedure recommended by CHING
with an additional heating cycle before application similar paint system.

Approved By:

SS Digitally signed
by S S Shinde

Shinde
Date: 2021.07.22
11:09:19 +05'30'

Saudagar Shinde
(G.M Quality)
HiTech Radiators Pvt. Ltd