4.

Application Methods I

Contents Non Atomized

▼

Application Methods I
Dip …………………………………………………………………….

▼ ▼ ▼ ▼▼
4-2
Electrodeposition ………………………………………………….. 4-2
Flow Coat ………………………………………………………….... 4-3
Roller Coat …………………………………………………….……. 4-4
Curtain Coat ….…………………………………………………….. 4-5
Atomized
Air Atomize Spray ………………………………………………….
▼▼ ▼ ▼▼

4-6
High Volume Low Pressure (HVLP) Spray …………………….. 4-10
Spray Techniques …………………………………………………. 4-12
Steps To A Good Paint Job …………………………………….... 4-18
Surface Conditions of Spray Patterns ……………………….... 4-19

General ATOMIZED NON ATOMIZED

Application
Methods Conventional Air Spray Dip

HVLP Electrodeposition

Airless Flow Coat

Air Assisted Airless Roller Coat

Electrostatic Spray (Various) Curtain Coat

Electrostatic High Speed Rotary

Powder

General Transfer Efficiency Percentages vs. Application Methods

Method % Solid Range % Transfer

Siphon Gun 15-35 20-30
Conventional Air 20-60 25-35
HVLP 20-40 35-55
Airless 30-60 40-55
Air-Assist Airless 30-60 50-65
Electrostatic 20-60 55-75
High Speed Rotary 40-60 75-95
Powder 100 95 +
Dip 10-30 90 +

4-1
 Application Methods I

The The act of dipping an article in a container of paint and then removing it to dry,
Application Controls

is probably one of the oldest finishing methods in existence. It is still the best finishing
Application method for a number of industrial applications, and in some cases it is the only
Processes method that will work.

Dip coating is often the best and most economical method where protection is of
Dip Coating primary importance and appearance is secondary (such as farm and garden imple-
ments, tractor parts, welded structural sub-assemblies and roof trusses). At first glance
this appears to be an ideal painting system, however, we must also look at the limita-
tions
of dip coating.
1. Most dipping operations require a large volume of paint in the dip tank compared to
the amount necessary to coat the part. This represents a substantial material cost.
2. Dip tanks when filled with solvent based paints pose a definite fire hazard.
Underground storage facilities connected to the tank through quick dump valves are
often required by regulation. Fire extinguishing equipment must also be installed. This
problem is minimized when using water borne dipping materials which are rapidly
Dip moving into this application market. There can be an appreciable variation in the film
thickness from the top to the bottom of a dipped part. The thinner areas usually appear
at the top and also around openings or cut outs in the part.
3. If fat edges or beads occur at the bottom of the product, electrostatic detearing
may be necessary.
4. Close attention must be given to the condition of the paint in the tank, to minimize
contamination from dirty parts, and build-up of heat from cleaning operations.

Electro- In anodic electrocoating,

deposition the part to be painted is the anode,
with a positive electrical charge that
attracts the negatively charged paint
molecules. The reaction at the anode
also converts a small amount of metal
to ferrous ions.

In cathodic electrocoating, the product

is given a negative charge, attracting
the positively charged paint particles.
With this type of electrochemistry,
migration of metal ions into the paint
film is minimal

4-2
 Application Methods I

The fundamental physical principle of electrocoating is that materials with opposite

Electro-

Application Methods I
electrical charges attract each other. An e-coat system applies a DC charge to a metal
deposition part immersed in a bath of oppositely charged paint particles. The particles are drawn to
the metal and form an even, continuous film over every surface, in every crevice and
Cont. corner, until the coating reaches the desired thickness. At that thickness, the film
insulates the part, so attraction stops and electrocoating is complete. Depending on
the polarity of the charge, electrocoating is classified as either anodic or cathodic. The
diagrams here illustrate the principle in the coating bath itself; the drawing below depicts
a typical system in its entirety.

To bake —
— From pretreatment

Conveyor

Paint
Power supply supply Rinse Tank Rinse Tank
Process control center

Ultrafiltration
Heat exchange

Anodic coatings, the original e-coat finishes, were first used as automotive primers, and
since the early 1960's have found thousands of applications. Anodic systems continue
to provide the color control, film hardness, and overall durability users require for certain
applications. Anodic acrylics serve as one-coat finishing systems for applications from
office furniture to building components and switchgear.

Commercialized by PPG, cathodic electrocoatings offer the widest selection of color

and gloss combined with higher film builds and superior corrosion protection. Cathodic
technology covers bimetallic joints well, eliminates ferrous discoloration and shortens
cure time and temperature. Cathodic epoxy films stand up attractively even under pro-
longed exposure to extremely corrosive environments; cathodic acrylics resist fading
and retain gloss.

The process of flow coating can best be describe as an adaptation of dip coating. The
Flow Coating parts are carried by a horizontal conveyor through a flow coating chamber. Here they
are flooded with paint which is directed toward the parts from all angles through a large
number of nozzles. A much smaller volume of paint is needed as compared to dip
coating since the work does not need to be submerged. Instead a smaller reservoir is
used and the paint is pumped from it to the application nozzles. The run off returns by
gravity to the reservoir.

As with dipping, the flow coating process is dependent upon liquid coatings that will
flow off smoothly without runs and sags. The surplus coating drips off the edges of the
part leaving no strings and few, if any, congealled drops.
As the parts leave the flow coating booth they are carried into a flow out tunnel.
In this tunnel the concentration of solvent in the air is kept as high as fire hazard
regulations permit. This slows down the drying process and allows the surface liquid
to drain, producing a coating of relatively uniform thickness.

4-3
 Application Methods I

With water borne paints, this procedure must be altered to compensate for the slower
Flow Coating
Application Controls

evaporation rate of water compared with the evaporation rate of solvents. Sometimes
Cont. the parts are pre-heated before they are dipped so that the rate of evaporation of water
is increased after the coating has been applied. This can accelerate drying and make it
comparable to that of solvent based paints.

This process produces excellent coverage of the part. It must be stated

though that variations in film thickness from top to bottom of long parts will
be experienced.
It is essential to control the coating with respect to viscosity and solvent
evaporation to control film thickness as closely as possible and minimize “draw-back”
from sharp edges.

Roller Coating The coating may be rolled on to flat surfaces by resilient rollers coated with paint.
One could draw a parallel to the printing industry. When these rollers travel in the
same direction and at the same speed as the surface to be coated the process is
called “direct roller coating”. When they rotate in a direction counter to the
movement of the surface the process is “reverse roller coating”.
Applies almost any liquid coating to one or both sides of flat panels, continuous webs of
paper, film, fabrics, plastic or metals. Precision coating thickness down to 0.1 mil saves
up to 100% material over other methods. High speed application increases production.
Coatings: Water-based or solvent types including hot melts, cross-links, UV
(ultraviolet) and EB (electron beam) curables: paints, metal lubricants, drawing
compounds, sealers, resins, stains, inks, sizings, emulsions, waxes, polyesters, glues.

Schematic of direct roll coating Schematic of reverse roll coating

When direct or reverse roller coating is applied to a continuous strip of metal it is called
“coil coating”.

4-4
 Application Methods I

Curtain Curtain coating is a specialized type of flow coating in which the flat surface to be

Application Methods I
coated is passed through a continuous sheet or curtain of material. A typical curtain
Coating coater contains a coating system and a conveyor system. The coating system consists
of a coating head, reservoir tank, variable-speed pump, filter, and a catch basin or return
through (see Illustration below). The conveyor system consists of an infeed and an
outfeed conveyor with a variable-speed drive; speeds range from 0-600 fpm. A heating
system may also be incorporated in the curtain coater to maintain the coating material
at a specified temperature.

The curtain of material can be produced by a pressure/gravity type of coating head or

by a weir-type coating head. A pressure-type coating head is essentially a closed,
airtight,V-shaped reservoir that has an adjustable slot across the bottom to provide a
controlled, continuous curtain. Coating material is pumped from the reservoir tank and
through a filter into the coating head until the material reaches the overflow level. At this
point, the air bleeder valve is closed and the adjustable blades opened to the desired
width, causing the coating material to flow out under pressure (see illustration below).
If the bleeder valve is left open, the material flows out owing to gravity. In the weir-type
coating head, the coating material is pumped into the coating head at a controlled rate
through a distributor pipe.When the head is full, the material flows over the weir (knife
plate), forming a continuous curtain. The catch basin collects and returns any excess
coating material to the reservoir tank.

Curtain coating is most readily applied to flat surfaces and is widely used in the coating
of sheets such as plywood and chipboard surfaces, floor tiles, cabinet doors, corrugated
boxes, and mirror backings. Curtain coaters are capable of coating sheets in widths
from 12 to 144" (300 to 3650 mm). Some curtain coaters have been designed to coat
rolls (webs) of materials; the coatings produced are smooth and uniform in thickness.
Edges are not easily coated by this method if they are at right angles to the main surface.

Coating thickness from 0.5 to 100 mils (0.013 to 2.5 mm) can be applied by curtain
coating, depending on the characteristics and flow rate of the coating material, conveyor
speed, and the type of parts being coated. The coating thickness is directly proportional
to the flow rate and inversely proportional to the conveyor speed.

Coating materials used in curtain coating must be specifically formulated because not all
materials form a continuous, breakfree curtain. In addition, the viscosity and temperature
of the coating material should be constantly monitored because curtain behavior is
related to these factors. The coating material must also be carefully filtered because the
head slot can be easily blocked, causing a split in the curtain and streaks on the surface.

Pressure head-type curtain coater designed Cross section of pressure-type

for coating sheet products. coating head.

4-5
 Application Methods I

Air Spray Atomization

Application Controls

Basics Definition of Air Spray - Uses compressed air to break up fluid into small
atomized droplets.
Advantages of Air spray
• Versatile Fluid Feed Systems
• Low capital Investment
• Fine Finish
• Excellent for Metallics

System Adjustments - There are two types of air spray systems

Adjustments
Pressure Feed System
• There are two areas of adjustment in the pressure feed system: air and fluid.
• The air pressure is controlled by an air regulator in the main air line to the gun.
• Fluid flow is controlled either by a fluid regulator, or the regulator on the
pressure pot.
Siphon Feed System
• Only the air is adjusted in the siphon feed system.

Adjustments To Make Colors Containing Metallics

VARIABLES
For Metallic Lighter Darker
Finishes A. Shop Conditions
1. Temperature Increase Decrease
2. Humidity Decrease Increase
3. Ventilation Increase Decrease

B. Spray Equipment and

Adjustments
1. Fluid nozzle Smaller Larger
2. Air nozzle More air Less air
3. Fluid flow Decrease Increase
4. Fan pattern width Increase Decrease
5. Atomization pressure Increase Decrease

C. Thinner
1. Type of thinner Faster Slower
2. Reduction of color Increase Decrease
3. Use of retarder Do not use Add retarder

D. Spraying Techniques
1. Gun distance Increase Decrease
2. Gun speed Increase Decrease
3. Flash time Increase Decrease
4. Mist coat Will not lighten Wetter mist coat

4-6
 Application Methods I

Fluid at Gun Fluid adjusting Valve

Application Methods I
• The fluid adjusting valve controls the volume of fluid by restricting fluid flow. It does
Adjustment not effect the pressure of the fluid.
• When fluid regulation is possible (pressure feed systems ) it is best to regulate
pressure rather than restricting material flow with needle.

Pattern Adjusting Valve

• The pattern adjusting valve regulates air to the “horns” of the gun air cap. Horn air
controls the shape of the spray pattern.

FLUID TIP PATTERN ADJUST

VALVE
FLUID
NEEDLE
FLUID ADJUST
VALVE
AIR CAP

LOCK RING
AIR CONTROL
PACKING NUT VALVE

FLUID
INLET

BODY

AIR
INLET

4-7
 Application Methods I

BLEEDER GUNS
Air Spray
Application Controls

• No air valve is present, thus air passes through the gun at all times.
Gun Types • The gun trigger controls only the flow of fluid
• Generally used in the home consumer markets with small air compressor units having
no pressure controlling device.
NON-BLEEDER GUNS:
• In contrast to the bleeder type, this gun is equipped with an air valve which shuts off
the air when the trigger is released.
• Used with compressors having pressure controlling regulators.
• Most all spray guns fit into this non-bleeder category.
INTERNAL MIX VS EXTERNAL MIX
• Industrial air spray guns are commonly referred to as either Internal or External mix.
Both types may be used in manual or automatic operations.
• Internal Mix Guns combine air and material inside the air cap. The material is
atomized prior to leaving the gun. Internal mix guns must be supplied with materials
under pressure.
• External Mix Guns combine air and material just beyond (or outside) the fluid tip.
Air atomizes the material while leaving the gun. External mix guns may be supplied by
either pressure feed or siphon feed sources.

Orifice Size At 8 P.S.I. At 12 P.S.I. At 18 P.S.I.

Delivery in (mm) (.6 bar) (.8 bar) (1.2 bar)
Ounces (cc) .040 (1.0) 12.5 (370) 15.0 (444) 19.0 (562)
Per Minute .046 (1.2) 17.0 (503) 21.0 (621) 27.0 (798)
Chart .052 (1.3) 20.5 (606) 25.5 (754) 33.0 (976)
.059 (1.5) 24.0 (710) 30.0 (887) 40.0 (1183)
.070 (1.8) 28.0 (828) 36.0 (1065) 48.0 (1420)

A rule of thumb that can be followed with standard

materials when setting pressures is that with the air 3 ft. (1 meter)
supply cut off, the paint will flow in a solid stream.
This fluid stream should begin to bend down about
three feet from the spray gun. Anything in excess of
three feet means too high a fluid velocity. (See figure
to the right).

4-8
 Application Methods I

The Fluid Tip The function of the fluid tip is to meter and direct the material into the air stream. As

Application Methods I
previously stated, the fluid tip is also the seat for the fluid needle. This fluid seat and
needle shuts off or restricts the flow of material.

The fluid tip and needle are a matched set and must be purchased as such. The user
selects an appropriate sized (orifice opening) fluid tip based on the material viscosity.
High viscosity materials flow slowly and require a large orifice and high fluid pressure to
obtain the necessary flow rates. On the other hand, lower viscosity fluids will require
smaller openings and less pressure for optimum performance.

Pressure feed and siphon feed guns use fluid tips of slightly different designs:

Pressure Feed Siphon Feed

Pressure feed guns require a tip which is tapered to guide the fluid needle into place
and allow it to fit snugly for positive shut-off.
Siphon feed guns require a fluid tip in which the inside walls are constructed at a wider,
more open angle. This extra opening allows the easy passage of material necessary in a
siphon gun. Since the fluid needle does not create a positive shut-off in siphon guns,
the needle need only seat itself tightly enough to prevent dripping from the tip.

The selection of the diameter of the fluid tip and needle will vary with the material
being sprayed. The following table designates tip sizes for materials of commonly
used viscosities.

Fluid Tip Fluid tip orifice size

Size Chart inches (mm) Viscosity Range Viscosity Example

.020 - .030 (.5 - .8) very thin solvents (acetone)

.040 - .050 (1.0 - 1.3) thin water
.055 - .070 (1.4 - 1.8) medium S.A.E. 10
.085 - .110 (2.2 - 2.8) heavy S.A.E 50
.125 - .300 (3.2 - 7.6) very heavy adhesives

The two materials most commonly used in the manufacture of fluid tips are: hardened
steel for solvent based fluids, and stainless steel for water based paints and chemicals.

4-9
 Application Methods I

HVLP High Volume Low Pressure

Application Controls

What is HVLP?
HVLP spray uses a high volume of air, delivered at low pressure, to atomize paint into a
pattern of low-speed particles.
The high pressure of conventional sprays tends to “blast” the material into small
particles. HVLP will work with any medium solids material that can be atomized
by the gun.

Why is HVLP growing in popularity?

Advantages: Disadvantages
• Less overspray • Slower production rates
• High transfer efficiency • Not all materials break up well (ie. high solids)
• Booth maintenance
• Material costs
• Waste disposal

What makes one HVLP system different from another?

• Atomization quality
Two basic air supply designs:
• One generates air flow from a turbine generator
• The other converts 80 to 100 psi (5.5 to 6.9 bar) shop air to a lower
2 to 10 psi (.1 to .7 bar).

Pressure Cup
Schematic

4-10
 Application Methods I

Pressurized Pressure Cup Hookup

Application Methods I
(Low) Fluid
Delivery
Systems

Pressure Tank Hookup

Pressure Circulating Hookup

4-11
 Application Methods I

1. Hold the spray gun with a firm but comfortable grip, let it be a natural extension of
Spray
Application Controls

the arm. Hold the air and fluid hoses in the other hand allowing enough slack.
Techniques
2. While facing the work piece, stand with your legs slightly wider than shoulder width.
Position the leg opposite the spray gun back slightly and pivot on the forward
foot during your spray strokes.

3. Avoid arcing the spray gun (moving the arm in a circular motion rather than staying
perpendicular to the work surface).

4. Keep the distance between the spray gun and the target an even 8” to 14”
(20.3 to 35.6 cm).

5. For best hiding and uniformity of film thickness, stroke overlap should be
approximately 50%.

6. Gun triggering (on-off) should occur before and after each pass of the object to
provide good edge coverage and to clean out the fluid tip at the end of each stroke.

7. Coat large objects in segments; blend each segment with adjacent segments.

8. Hold the gun at a 30 to 45 degree angle for tubular objects.

9. Move spray gun across the work at the same speed.

10. Put a full wet coat whenever possible.

11. Avoid “toeing” or “heeling” the spray gun.

12. Carryover of the off-spray and rebound should be directed toward the
unpainted surface.

Remember that good body balance and spray techniques before and during spray
processes are critical in achieving and maintaining consistent quality work!

Spray Technique:
• Do not arc your movements.
• Do use perpendicular movements to the work piece.

Incorrect

4-12
 Application Methods I

Spray

Application Methods I
Techniques
Cont.
6” - 8”
(15.2 - 20.3 cm)

Correct

4-13
 Application Methods I

Spray Spray Technique:

Application Controls

Techniques • Use 50% overlap for each spray stroke.

Cont.

6” - 8”
(15.2 - 20.3 cm)

6” - 8”
(15.2 - 20.3 cm)

Correct

4-14
 Application Methods I

Spray Spray Technique:

Application Methods I
• Band first, spray critical surfaces last.
Techniques
Cont.

Correct

Incorrect

4-15
 Application Methods I

Spray Spray Technique:

Application Controls

Techniques • Methods of overlap & cylindrical objects

Cont.
18” - 36”
(45.7 - 91.4 cm)
stroke

Incorrect Correct

4-16
 Application Methods I

Spray Technique:
Spray

Application Methods I
• Do not toe or heel.
Techniques • Ensure overspray is always directed towards uncoated portion of surface.
Cont.
Correct

Incorrect
6” - 8”
(15.2 - 20.3 cm)

Spray Technique:
• Various types of spray patterns

Incorrect Correct

2” Arc
(5.1 cm)

4” - 5” Spray
(10.2 - 12.7 cm)

4-17
 Application Methods I

Surface CLASS A: The most critical surfaces for appearance that require uniform coating
Application Controls

coverage, ZERO defects.

Quality Rat-
ings CLASS B: Surfaces that require uniform coating coverage but not as critical for
appearance.

CLASS C: Non critical surfaces that do not require uniform coating coverage.

The 1, 2, 3's STEPS TO A GOOD PAINT JOB

of a good 1. Control Paint
paint job A. Viscosity
B. Temperatures
C. Film Thickness

2. Control Equipment Parameters

A. Fluid Delivery
B. Air Pressure
C. Stroke Speed
D. Gun Distance
E. Gun Spacing
F. Fan Width
G. Gun Offset
H. Bell Speed
I. Booth Temperature

3. Proper Equipment, Filtration and Maintenance

4-18
 Application Methods I

Proper gun adjustment and maintenance will result in a normal spray pattern.
Surface

Application Methods I
Conditions
of Spray Condition Cause Correction

Patterns Heavy top or bottom 1. Material build-up on air 1. Soak cap or tip in suitable
pattern. cap, partially plugged horn solvent and wipe clean. To
holes, center hole or jets. clean orifices use a broom
Material build-up on fluid straw or toothpick. Never
tip or partially plugged use a wire or hard instru-
fluid tip. ment. This damages holes
and distorts spray pattern.

Heavy right or left side NOTE: To determine where material build-up is, invert cap
pattern. and test spray. If pattern shape stays in same position the
condition is caused by material build-up on fluid tip. If
pattern changes with cap movement, the condition is in the
air cap.

Heavy center pattern. 1. Too much material.
2. Material too thick.
1. Reduce fluid flow by turn-
ing screw clockwise on
suction guns. Reduce fluid
pressure or increase atom-
ization pressure.
2. Thin.

Split spray pattern. 1. Not enough material. 1. Reduce air pressure or

increase fluid flow by
turning fluid needle adjust-
ing screw counterclockwise
on suction feed, increase
fluid pressure on pressure
feed guns.

Jerky or fluttering spray. 1. Insufficient fluid in cup or 1. Fill cup or tank.

pressure tank.
2. Gun (with cup) tipped at 2. Do not tip excessively or
excessive angle. rotate fluid tube.
3. Obstructed fluid passage 3. Clean.
or hose.
4. Loose or cracked fluid 4. Tighten or replace.
tube in cup or tank.
5. Loose fluid tip or damaged 5. Tighten or repair.
tip seat.
6. Too heavy fluid for suction 6. Change to pressure feed.
feed.
7. Dry or worn packing or 7. Lubricate or replace.
loose packing nut. Tighten.

Improper spray pattern. 1. Gun improperly adjusted. 1. Readjust gun. Follow

instructions carefully.
2. Fluid tip obstructed. 2. Clean.

4-19
 Application Methods I
Surface Condition Cause
Application Controls
Conditions Unable to get round 1.Fan adjustment stem not
of Spray spray. seating properly.
Patterns
Will not spray. 1.No air pressure at gun.
Cont. 2.Internal mix air cap used
with suction feeder.
3.Fluid pressure too low
with internal mix cap and
pressure tank.
4.Screw not open enough.
5.Fluid too heavy for suction 5. Change to pressure feed.
feed.
Fluid leakage from 1.Packing nut loose.
packing nut.
2.Packing worn or dry.
Dripping from fluid tip. 1.Dry packing.
2. Sluggish needle
3. Tight packing nut.
4.Sprayhead misaligned, on 4. Tap all around sprayhead
type MBC guns causing
needle to bind.
Runs and sags. 1. Too much material for
spray pace.
2.Material too thin.
3.Gun tilted on angle.
Excessive overspray. 1. Too much atomization air
pressure.
2.Gun too far from surface.
3.Improper stroking, i.e.
arching moving too fast.
4-20
Correction
1. Clean or replace.
1. Check air lines.
2. Change to pressure feed.
3. Increase fluid pressure
at tank.
4. Open fluid adjusting screw.
1. Tighten, but not so tight as
to grip needle.
2. Replace packing or
lubricate. See
“Preventative Maintenance.”
1. Lubricate. See
“Preventative Maintenance.”
2. Lubricate. See
“Preventative Maintenance.”
3. Adjust. See
“Preventative Maintenance.”
with wood or rawhide
mallet and retighten
locking bolt.
1. Reduce pressure and
readjust.
2. Remix or spray light coats.
3. Hold gun at right angle to
work.
1. Reduce.
2. Check distance. See
spraying hints on page 4.
3. Move at moderate pace,
parallel to work surface.
See “Using the Spray
Gun” on page 4.
 Application Methods I

Condition Cause Correction

Application Methods I
Surface Excessive fog. 1. Too much or quick drying 1. Remix
Conditions thinner
of Spray 2. Too much atomization air
pressure
2. Reduce

Patterns
Cont.
Thin, sandy coarse 1. Gun too far from surface. 1. Check distance. See
finish drying before it “Using the Spray Gun” on
flows out. page 4.

2. Too much air pressure. 2. Reduce.

Thick dimpled finish 1. Gun too close to surface. 1. Check distance. See
“orange peel”. Too much “Using the Spray Gun” on
material coarsely page 4.
atomized.
2. Air pressure too low. 2. Increase air pressure or
reduce fluid pressure.

Other –

1. Improper thinner. 1. Follow paint manu-

2. Material not thoroughly
mixed.
3. Surface rough, oily, dirty.
facturer's instructions.
2. Mix thoroughly.
3. Properly clean and
prepare

4-21
 Notes

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