涂装异常分析及改善对策

1、涂装异常分析及改善对策漆膜缺陷原因分类:涂料问题(Product problems应用不良(Application problems设备因素(Equipment problems环境因素(Environment Cause颜色问题(Colour problems漆膜硬度不够(weak:描述(DESCRIPTION-表现为漆膜软, 很容易被划伤;相应的耐溶剂性能表现差。原因(cause:通常是漆膜树酯交链不够好,而交链不够的主要因素有:1树酯分子选择不合适;2未完全干燥;3高温漆或双组份漆烘烤温度不够;4双组份漆固化剂配比不对。起泡(blowing:起泡的原因(cause:通常是基底有锈迹(擴大

2、、污垢、小凹孔、磷化渣质、水汽等被封在漆膜底下,漆膜在烤干或受热(受熱膨脹时,这些物质彭涨将漆膜顶起造成。溶剂泡(Solvent Popping 描述(DESCRIPTION新喷漆膜表面有直径小于1MM的小气泡。Open topped blisters up to 1mm in diameter on the surface of the most recently applied paint film.起因(CAUSEAir or solvent vapour trapped by fast drying paint forming a skin. This may be due to:a

3、天那水太差或太快干。poor quality or too fast thinner.b 喷得太厚或两层漆之间干燥时间不够。excessive film thickness, or insufficient drying time between coats.c 压缩空气压力太低。compressed air pressure too low.d 加热太快。drying temperature too high, heat source too close to the film, too hot, or applied too soon.预防(PREVENTIONa 确保工件表面清洁Ensu

4、re that the surface is scrupulously clean.b 使用合适的天那水。Use only recommended thinner.c 每层漆膜厚度合适,并适当闪干Apply paint in thin, wet films. Allow sufficient drying time between coats.d 使用正确的喷漆压力Use correct compressed air pressure.e 烘烤前适当流平,避免加热过快,热源过近。Allow sufficient flash off time before force drying, ensur

5、e that the correct drying temperature is not exceeded. Do not allow the heat source to be placed too close to the surface.针孔(Pinholing描述(DESCRIPTION小凹穴,通常直径小于1MM。Small cavities, generally less than 1 mm in diameter,预防(PREVENTION a一次不要喷得太厚。Do not spray too thick one time,b烘烤之前适当流平。Flashing the film b

6、efore baking.c 使用涂料厂商推荐的附料。Use only recommended materials.d 正确调配油漆,使用较慢干稀释剂。Mix the paint correctly, use slow dry thinner.E保持底材干净。Keep materials clean.鱼眼/ Fish Eyes (cissing产生鱼眼的原因(cause:放大之后中间有核,通常是*素材被含硅silicon类的物质污染。*素材未很好清洁。*裸手接触工件。*油漆一次喷涂太湿。*油漆体质敏感。预防(PREVENTION鱼眼的产生Keep the part away from sili

7、cone pollutionThoroughly clean the surface with wax and grease remover. Do not allow cleaning solvents to dry on the surface but remove with a clean dry cloth,Always use the recommended materials.Ensure that the spraying area is properly ventilated.与鱼眼相似的其它缺陷1.水泡(blister工件表面被溅上水珠。你见过水性漆出现此缺陷吗?与鱼眼相似的

8、其它缺陷2.油污(oil pollution工件表面被轻质油污染.起云/斑纹,(Clouding / Mottling 起云/斑纹,(Clouding / Mottling 起因:常见于银粉漆,主要是银粉排列不一致。主要原因有:1十字交叉喷涂;2使用太差的稀释剂;或稀释剂加入太少。3枪未调好;4喷涂手法不正确。5素材厚薄不一(这种情况常叫应力纹。脏点/纤维/异色点(Dirt / threads / Bits此类缺陷目前占有相当大的比例,您知道其主要原因是什么吗?颗粒(particles产生原因素材本身灰尘未被去除;油漆未过滤,或滤网太粗或太脏;喷房、流平间、烤房等环境被污染;调漆间脏污,油漆未

9、盖好;调漆罐、供漆管路、喷枪清洗不够。压缩空气未过滤,或滤网太脏。纤维或毛丝:主要来自衣服纤维,人员走动太多,未穿防尘衣。也有来自劣质空气过滤网。当这类缺陷很多时,怎么办?建议当这类缺陷很多时,建议将缺陷样品抽取30-50片进行详细分类(有必要的话,使用放大镜观察缺陷形状、颜色等,然后分析原因改善检察改善效果制定SOP 贯彻执行SOP。干喷/异常光泽低(Dry spray/loss of gloss描述(DESCRIPTION虽然漆膜表面光滑,但漆膜表面光泽异常偏低. Although apparently smooth and evenly applied, the surface lack

10、s shine.起因(CAUSEMicroscopic roughness of the surface which may result from:a底漆太差或底漆未干就喷面漆. poor hold out of primer, or the application of topcoat over primer which is not thoroughly dry.b稀释剂太差或加了不合适的添加剂. poor quality or incorrect thinner, or the use of additives in the paint.c 素材前处理不当或喷漆手法不对. incorr

11、ectly prepared or poorly applied paint.d 素材质量太差application over a poor substrate.e 高湿低温时漆膜干燥太慢. excessively slow drying due to high humidity or low temperature.f 溶剂蒸气在漆膜表面冷凝. solvent fumes or exhaust gases attacking the surface.g 表面被污染. surface contamination by wax, grease, oil, soap or water.预防(PRE

12、VENTION a 选择正确种类和比例的稀释剂Use the correct proportion of recommended thinner.b 正确的喷漆手法: 枪距, 扇形, 气压Use correct spraying techniques, ensure that equipment is clean, set air pressure as low as possible, consistent with proper atomisation, spray from the correct distance.c 使用合适的喷房, 确保喷房有良好的空气流通. Use a spray

13、 booth, and ensure that air circulation and extraction is at the correct velocity.漆膜太薄Inadequate Colour Coverage描述(DESCRIPTION漆膜过薄可见底材, 通常出现在比较难喷涂的底侧面等地方. Underlying surfaces visible through the paint film, most frequently in hard to spray areas, on lower panels or on sharp edges and contours.预防(PRE

14、VENTIONa 使用合适的喷涂方法确保合适的漆膜厚度. Use the correct spraying technique, ensure even and adequate film thickness.b 使用合适的治具, 合适的灯光照明; 特别注意难喷涂表面. Work under good lighting conditions in a properly sized spray booth, pay special attention to inaccessible areas.c 确保漆料混合均匀. Ensure that the materials are thoroughl

15、y mixed.橘皮(Orange Peel 描述(DESCRIPTION 漆膜表面不平整如同桔子皮表面. Pebbled, uneven surface of the paint film, similar in appearance to orange skin.起因(CAUSEa喷漆手法太差, 枪距, 空气压力、出漆量调节不合适。b漆膜不要喷得太厚或太薄。cc 油漆品质太差、粘度调整不合适、混合不均匀。d两层漆之间干燥不够。Insufficient drying time between coats.e 工件表面温度不正常。Incorrect ambient or surface tem

16、perature, draughts.预防(PREVENTION a 使用正确的喷漆手法、正确调节喷枪。Use the correct spraying technique and ensure that equipment is correctly adjustedb均匀喷漆。c使用合适的天那水,并调节到合适的粘度。Ensure that the paint is correctly mixed, use only recommended thinner with the correct graded 两层漆之间充分干燥。Allow sufficient drying time betwee

17、n coatse 在合适的温度范围内和良好的空气流通条件下喷漆。Spray within the re-commended temperature range and ensure proper ventilation流挂(Runs / Sags 流挂(Runs / Sags 描述(DESCRIPTION 通常在垂直面等处,出现漆膜局部过厚造成大波纹、乳头现象。Well defined local thickening of the paint film in the form of a wavy line or shallow, rounded ridges, normally confin

18、ed to sharply sloping or vertical surfaces.起因(CAUSESlumping of the paint film due to:a 喷得过厚,空气压力太低,扇形太窄,枪距太近,运枪太慢。Excess thickness of application, air pressure too low, fan width too narrow, spray gun too close to the surface or moving too slowly.b 使用太差的天那水。Use of poor quality or incorrect thinner.c 粘度调整不正确。Incorrect viscosity of the paint.d 素材表面或气温太低。