What Is the Most Common Problem Encountered When Powder Coating?

Powder coating is a popular finishing process, contributing to an industry value of approximately $3.2 billion in the United States by 2026. Effective powder coating applications provide materials with a durable and aesthetic finish. However, some common powder coating mistakes prevent a seamless result.

Our guide will highlight the most frequent issues. We’ll also offer some preventive measures and best practices, enabling you to optimize the process and achieve better powder coating outcomes.

Overview of Common Powder Coating Problems

Understanding the various powder coating problems can help you alleviate them at the onset. Here are some common issues to look out for: 

• Abrasive embedment: Items with an existing powder coating must undergo abrasive blasting. Using inferior abrasives results in too many particles embedded in the material, ultimately interfering with the coating adhesion.
• Orange peel: Powder coating should provide a smooth finish, yet sometimes, the process delivers a bumpy texture comparable to orange peels. This issue is likely due to poor powder application (too thick or too thin) or an incorrect curing temperature, but there are other possible causes, too. 
• Pinholes: If you notice small craters roughly the size of a pinhole in the coating, you may need to improve your surface preparation techniques. Common causes are moisture content, oil contamination, curing problems, and there can be other causes, too. 
• Fish eyes: As the term suggests, fish eyes are small, round eye-like defects. There are many causes for fish eyes, including surface contamination such as oils, dirt, or moisture. 
• Powder not adhering: Occasionally, the powder does not adhere to the object, especially around corners. Poor adhesion has numerous reasons, but inadequate cleaning or surface preparation is a top cause.
• Under-curing: The curing process requires workers to heat the item at a precise temperature for a fixed period. Failing to meet these specifications leads to under-curing, which causes a brittle finish, reduced chemical resistance, inconsistent appearance, and a host of other issues.
• Over-curing: Exceeding the curing temperature or prolonging the curing process constitutes over-curing, which results in a weak finish that can crack easily, cause discoloration, and a number of other issues that will reduce the service life of the coating. 

Experiencing one or more of these issues will impact the overall quality and durability of the coating. It’s best to apply your chosen powder coating process to a small batch and assess the results before completing a mass order. In addition, periodically checking items post-application will help you detect and resolve any problems immediately.

The Most Common Problem: Poor Adhesion

While there are several powder coating problems to guard against, one stands out as the most common — poor adhesion. Characteristics of this issue include coating chipping and peeling, consequently leading to decreased durability. Learn about the causes of insufficient adhesion.

1. Inadequate Surface Preparation

Powder coating typically occurs in industrial facilities, which are synonymous with grease, oil, and dirt. When residues come into contact with metals, they prevent the powders from achieving a strong bond. In addition, older metals may show signs of rust or have existing finishes that hinder effective powder coating. 

Thorough surface preparation is necessary for better powder adhesion. While it’s possible to clean most metals with a blast of high-pressure water, abrasive blasting is more effective for removing paint, contaminants, and other finishes. It also produces a surface texture or profile that will enhance the strength of the bond between the part and the powder.

2. Incorrect Powder Type 

Powder coatings have several applications, ranging from industrial parts to household appliances. Utilizing different powders according to the material and intended application is key to ensuring the best result. For example, items exposed to the elements will require a more durable powder, usually with a UV modifier for the best durability, whereas epoxy options are often suitable for indoor components. 

Preventive Measures and Best Practices

Powder coating problems impact the appearance, durability, and, at times, even the functionality of an item. Here are some preventive measures you can apply to ensure better results:

• Regular equipment maintenance: Ensure your equipment performs as it should with frequent upkeep. At the end of each shift, clean spray guns and conduct a visual inspection. Follow the manufacturer’s guidelines on when to replace filters and how often to lubricate bearings.
• Training and education: As materials require different powders and curing times, you must provide staff with adequate training. Host demonstrations to showcase new techniques and encourage experienced workers to mentor junior employees.
• Apply quality control processes: Maintain quality by inspecting all metals before coating to ensure they are contaminant-free. Once the curing process is complete, inspect items for uneven coatings or small defects so you can address them straight away. 

Using the Right Sandblasting Material 

Prioritizing surface preparation in your operations is essential, and selecting the right abrasives can streamline the process. When choosing a product, consider the following: 

• Safety: Some abrasive media has a harmful effect on human health. Before purchasing a product, review its safety certifications to safeguard your employees’ well-being and maintain compliance. 
• Surface finish: Using a product that offers minimal embedment ensures a ready-to-coat surface. This will allow you to apply the powder to the item evenly, achieving a more professional end result. 
• Environmental sustainability: Companies can reduce their carbon footprint by choosing a sustainably manufactured abrasive media. Using an abrasive like superoxalloy, which is tempered and resists fracturing during blasting, will also minimize waste disposal costs.
• Reusability: While some abrasive media only allow for single-use applications, eco-friendly options often enable you to use them multiple times, helping reduce overall costs.
• Operations efficiency: Abrasive media has varying degrees of efficiency, impacting the amount of material you require and the time it takes to complete the application. Abrasives that are more efficient, like EpiX, are a more cost-effective solution.

Efficient Surface Preparation With 10X Engineered Materials

Powder coating provides items with a durable and smooth finish. However, preparing the surface effectively is crucial for optimal results. Selecting a high-performing abrasive media can fast-track the process. 

10X Engineered Materials offers a range of highly efficient media for abrasive blasting. With certifications from the California Air Resources Board (CARB) and other regulatory bodies, we also ensure optimal safety for workers and the environment. Explore our products today, or get in touch with our professional team for a personalized abrasive recommendation for your project!