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7/26/2019 05 Spray Applications and Defects TC 2012 [Compatibility Mod
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Training CenterAkzoNobel Aerospace Coatings
Spray EquipmentSpray Equipment
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2012 AkzoNobel NV. All rights reserved. Aerospace Coati ngs | Spray app li cati ons and defects 2
Types of spray guns / equipment
Conventional
HR/RP
HVLP
Airless
Air-mix
Electrostatic
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How did everything start?
The dentist Dr. Allen DeVilbissinvented in 1888 in Toledo, Ohio,a sprayer for liquids, to clean andrinse the patients mouth andthroat.
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Conventional spray equipment
Gravity feedSuction feed
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Conventional spray equipment
Used by nearly all airlines and manufacturers
Air pressure (inlet spray gun): 3.0 - 4.5 bar
Nozzle diameter: 1.2 - 1.8 mm
Distance gun - substrate: 15 - 25 cm
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Conventional spray equipment
Advantages
Controlled atomizing air pressure and paint flow
Easy to clean
Less expensive
Texture look possible (cabin coatings)
Disadvantages
Low paint efficiency (30- 70 % loss of paint)
Creates a lot of over spray
Less suitable for large aircraft painting/ time consuming
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HR/RP/ HVLP spray guns
HR = High Return
RP = Reduced Pressure
HVLP = High Volume Low Pressure
Gravity feed
Suction feed
Air pressure (inlet spray gun): 2.0 - 3.0 bar
Nozzle diameter: 1.0 - 1.8 mm
Distance gun - substrate: 15 - 25 cm
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HR/RP/ HVLP spray guns
Advantages
Meets (European) legislation
Controlled air pressure (similar like conventional)
Less over spray
Texture-look possible
High paint efficiency
Disadvantages
Less suitable for large aircraft painting/ timeconsuming
Consult user manual
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Airless spray equipment
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Manufacturers made an efficient improvement byintroducing airless application
Paint pressure: 150 -180 bar
Nozzle diameter: 6.11 - 6.13 (60o, 0.011 inch)
Distance gun - substrate: 35 - 45 cm
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Airless spray equipment
6.
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Airless spray equipment
Advantages
Can operate within wide range of viscosities
High output (up to 5 liters/ min)/ higher working speed
Less over spray and bounce back compared to air spray
Reduced pressure loss (long hoses/ working on heights)
Disadvantages
Tip must be changed to alter fan width
Paint output cannot be easily controlled Higher risk blocking of the nozzle/ tip
Cannot be used with the application of mica
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Air-mix spray equipment
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Air-mix spray equipment
Air-mix is combination of:
Airless
Air-assist
Developed to reduce the inconveniencesof Airless and air-assist
Air-mix is a brand name of Kremlin
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Air-mix spray equipment
Air pressure: 2.0 4.0 bar
Paint pressure: 60 - 120 bar
Nozzle diameter: 09.134 - 09.154
Distance gun - substrate: 30 - 35 cm
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Air-mix spray equipment
Advantages in comparison to conventional
Higher working speed
Improved working conditions
Advantages in comparison to airless
Lower purchasing price
Lower working pressure
User friendly
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Electrostatic spray equipment
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Electrostatic spray equipment
Electronic charging
Combines the features / advantages of existing spray equipment, air spray,
airless and air assisted airless with an electronic charge
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Electrostatic spray equipment
Electronically charging the paint creates a 'field' where the paint material is
attracted to the substrate resulting in less over spray
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Xs3 Air spray
Electrostatic spray equipment
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Electrostatic spray equipment
Graco PRO Xs3 (Xs3 = 60 kV/ Xs4 = 85kV)air-assisted electrostatic spray gun
Air pressure: 5.0 - 5.5 bar
Paint pressure: 1.0 - 2.5 bar
(paint flow rate 240 - 340 ml / min.)
Nozzle diameter: 1.2 - 1.5 mm
Distance gun - substrate: 35 - 45 cm
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Xs4 AA Air-assisted
Electrostatic spray equipment
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Electrostatic spray equipment
The Graco PRO AA Xs4 (85 kV) air-assisted airless electrostaticspray gun
Pressure: 150 - 180 bar
Nozzle diameter: 6.11- 6.13 (60o, 0.011 inch)
Distance gun - substrate: 30 - 45 cm
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Electrostatic spray equipment
Advantages
High transfer efficiency
Less over spray
Preferred in regular maintenance hangars
Disadvantages
Expensive equipment
Less suitable painting smaller parts
Cleaning must be done extremely well
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General safety instructions
Read and understand safety instructions
Equipment and A/C thoroughly grounding
All persons wear: shoes with conductive soles
Special gloves
Never flush the lines while ES is on
Habit of turning ES off immediately after spraying
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Comparison transfer efficiency
Conventional air spray: 30 %
Airless spray: 50 %
Electrostatic spray: 70 %
Airmix: 65 %
HVLP: 70%
HR/RP: 70 %
Roller coat: 95 %
Note: above figures are based on correctly adjusted spray equipment
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05 Spray Equipment
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Training CenterAkzoNobel Aerospace Coatings
Spray DefectsSpray Defects
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Spray defectsSpray defects
Overspray
Sags and runs
Foaming/ pinholing
Hazing/ poor gloss
Orange peel Cratering and fish eyeing
Poor opacity
Poor adhesion
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Overspray
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Spray gun too far from the job
Air pressure too high (over atomization)
Waving with the gun
Not triggering at the end of each lap
Incorrect routing resulting in poor melt in Incorrect viscosity (too much thinner)
No air movement
Overspray
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Sags and runs in paint coat
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Addition of too much thinner
High film build on overlaps
Spray-gun too close to the surface being painted
Incorrect fluid tip, needle or air-cap (poor atomization)
Slow application resulting in high film build Spraying too thick layer in one coat
Spraying irregular thickness
Insufficient flash-off between coats
Sags and runs in paint coat
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Sags and runs in paint coat
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Foaming/ pinholing
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Foaming/ pinholing
Too high absolute humidity (combination relative humidity andtemperature)
Solvent entrapment caused by air flow exceeding
0,5 m/. which can result in premature skinning
Too high viscosity of the paint
Too high film thickness
Insufficient flash-off between coats
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Foaming/ pinholing
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Foaming/ pinholing
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Hazing/ poor gloss
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Moistures substrate Cold substrate
Too quick evaporation solvent
Differences in temperature of paint versus surface to bepainted
Unstable circumstances during paint process and drying ofthe paint system
Too quick covering of not fully cured painted surfaces withplastic
Hazing/ poor gloss
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Application over incompatible substrate
Not adhering to recommended flash-off times
Incorrect use of accelerators or reducers
Using shelf life expired products
Hazing/ poor gloss
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Orange peel
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Incorrect viscosity (insufficient solvent)
Air pressure too low
Incorrect gun set-up (poor atomisation)
Paint dust in primer coat
Insufficient flow of primer system
Orange peel
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Cratering and fish eyeing
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Not properly stirring or shaking of the paint Solvent, evaporation leaving contamination on the surface
Use of contaminated air
Air born contamination
Poor cleaning/ degreasing (wipe-on-wipe-off method)
Contamination from skin contact after cleaning
Not degreasing before sanding
Cratering and fish eyeing
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Poor opacity
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Addition too much thinner Not stirring or shaking the material sufficiently to achieve total
dispersement
Low film thickness
Incorrect gun set-up (over atomization)
Too short flash-off time between coats, flash-off / drying timedepends on temperature and humidity
See the technical data sheet for the correct flash-off time
Poor opacity
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Poor adhesion
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Poor preparation (cleaning) Surface contamination
Not tacking off
Exceeding stated re-coat times
Incorrect system selection
Dry application of primer systems
Poor adhesion
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Standard paint shop equipment
Paint shaker
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Temperature & relative humidity meter
Standard paint shop equipment
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Tack-rags
Standard paint shop equipment
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Rulers
Standard paint shop equipment
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Flow cups ie. ISO cup,Zahn cup etc.
Standard paint shop equipment
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Stopwatch
Standard paint shop equipment
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Layer th ickness meter
Standard paint shop equipment
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Gloss meter
Standard paint shop equipment
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Technical data sheets
Standard paint shop equipment
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Depends on: Skill
Dedication
Experience
Proper tools and equipment Good housekeeping
Teamwork
Painting an aircraft successful ly
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A good paint job will be achieved with:
Good HousekeepingPersonal cleanliness Preciseness
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Teamwork is essential for a good paint job!
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05 Spray Applications and Defects
Thank you for your attention