Powder Coating Troubleshooting Tips
| Problem | Cause | Remedy |
| Adhesion Poor | ۱٫ Inadequate cleaning or pretreatment | ۱٫ check pretreatment equipment and chemicals |
| ۲٫ Under cure | ۲٫ Increase oven temp and/or time in oven | |
| ۳٫ Film thickness too high | ۳٫ Reduce thickness by lowering voltage or shorten spray time | |
| Chipping | ۱٫ Powder not fully cured | ۱٫ Check pretreatment equipment and chemicals |
| ۲٫ Coating thickness too high | ۲٫ Reduce thickness by lowering voltage or shorten spray time | |
| Corrosion Resistance (Poor) | ۱٫ Inadequate cleaning or pretreatment | ۱٫ Check pretreatment, equipment, and chemicals |
| ۲٫ Under cured | ۲٫ Increase oven temp or dwell time | |
| Cratering | ۱٫ Contamination with other powder | ۱٫ Clean the system and start with virgin powder |
| ۲٫ Inadequate pretreatment of substrate | ۲٫ Check the pretreatment | |
| ۳٫ Contamination with incompatible materials from spray area (i.e. silicone) | ۳٫ Check for presence of incompatible materials | |
| ۴٫ Oil or moisture in air lines | ۴٫ Check air lines. Install filters if necessary | |
| Flow (Poor) | ۱٫ Curing temp too high | ۱٫ Reduce oven temp and/or time in oven |
| ۲٫ Preheat oven too high | ۲٫ Reduce pretreat oven temp and/or time in oven | |
| ۳٫ Coating thickness too low | ۳٫ Increase coating thickness by using a higher voltage, longer spray time, or more dense powder cloud | |
| Out-Gassing | ۱٫ Air entrapped in substrate (i.e. castings, sandblasted parts) | ۱٫ Preheat above curing temp and coat hot |
| Gloss Difference | ۱٫ Curing temp too low or too high | ۱٫ Increase/decrease oven temp and/or time in oven |
| ۲٫ Contamination caused by other powders with different flow or gel characteristics | ۲٫ Clean guns, hoses, and hoppers, use virgin material | |
| Impact Resistance/Flexibility (Poor) | ۱٫ Under Cured | ۱٫ Increase oven temp or increase dwell time in oven |
| ۲٫ Poor cleaning or pretreatment | ۲٫ Check pretreatment equipment and chemicals | |
| ۳٫ Film thickness too high | ۳٫ Reduce film thickness by adjusting application equipment | |
| ۴٫ Change in substrate thickness or type | ۴٫ Check substrate with supplier | |
| Off Color | ۱٫ Improper oven exhaust | ۱٫ Check exhaust fans |
| ۲٫ Bake time too long or too short | ۲٫ Adjust line speed and/or temp | |
| ۳٫ Oven temp to high or too low | ۳٫ Adjust oven temp | |
| Opacity (Poor) | ۱٫ Coating thickness too low | ۱٫ Increase coating thickness by using higher voltage, longer spray time, or more dense powder cloud |
| Orange Peel | ۱٫ Warming up of the coated material is too slow or too fast | ۱٫ Check curing cycle and curing oven, if necessary, contact your powder supplier |
| ۲٫ Heat damage of the powder | ۲٫ Replace the powder | |
| ۳٫ Film thickness too low | ۳٫ Increase the thickness by raising voltage or lengthen spray time | |
| Pencil Hardness/Abrasion Resistance (Poor) | ۱٫ Under cured | ۱٫ Increase dwell time or temp in oven |
| Penetration )Poor) | ۱٫ Powder Delivery | ۱٫ Adjust powder delivery |
| ۲٫ Poor grount | ۲٫ Check ground | |
| ۳٫ Improper spray pattern | ۳٫ Select proper deflector or use suitable barrel and cover (consult your equipment supplier) | |
| ۴٫ Voltage too high or too low | ۴٫٫ Adjust voltage settings so powder builds on pans edges and leading surfaces do not repel powder from corner | |
| ۵٫ Poor gun placement | ۵٫ Adjust gun position so powder cloud has a direct path to recess area | |
| ۶٫ Powder to fine or too coarse | ۶٫ Consult powder supplier | |
| Pinholing | ۱٫ Coating thickness too low | ۱٫ Increase coating thickness by using a higher voltage. longer spray time, or move dense p9wder cloud |
| ۲٫ Curing temp too high | ۲٫ Decrease oven temp and/or time in oven | |
| Sags | ۱٫ Coating thickness too high | ۱٫ Reduce coating thickness by using a lower voltage, shorter spray tiem, or less dense powder cloud |
| ۲٫ Cure temp too low | ۲٫ Increase oven temp | |
| Soft Surface | ۱٫ Curing temp too low | ۱٫ Increase oven temp and/or time in oven |
| ۲٫ Contamination with an incompatible power, especially a thermo-plastic | ۲٫ Clean guns, hoses, and hoppers, use virgin materials |