Uneven film thickness Film thickness fluctuates significantly
Fault Profile Potential Causes
Not optimized spray gun
arrangement in automatic
booth or incorrect ratio of
conveyor and reciprocation
speed
Insulating effect from initial
coating
Uneven film thickness
distribution on Heavily fluctuating ratio of
workpiece fresh and reclaimed
powder in hopper
Uneven powder delivery
Complex shape of
workpieces (crevices
cavities, Faraday cage)
Geometry of workpieces
varies greatly
Elimination | Experiments | Measures Remarks
Determine the correct spray gun distances
and also the ratio of reciprocation and
conveyor speeds using calculation programs
(e.g. Gema, Wagner, Nordson)
 Reduction of current and voltage settings
 Increase distance between spray gun and
workpiece
 Use of ion conductor (Coronastar,
Supercorona), if necessary
 Continuous and/or regular addition of
virgin powder adjusted to the optimum
powder output needed
 Checking fluidization, injectors (or
powder pumps), as well as routing,
lengths and diameters of hoses
 (Insufficient ability to penetrate cavities)
 Optimize application
 Change position of workpiece
Optimize spray gun and plant settings for the
workpiece