The flat surface has no issues, but the corners are rusting. The film thickness at the edges drops to less than half of that on the flat surface. We will improve this by requesting a chamfer and adding measurement points.
The surface is clean, but only the edges and the rims of the holes rust first. It's not due to the corrosion resistance of the paint; it's that the film thickness is insufficient in those areas. The film thickness at the edges drops to 30-50 percent of that on the flat surfaces. ────────────── ■Cause of Occurrence The paint escapes from the corners due to surface tension and is pulled toward the flat surfaces. In powder coating, static electricity concentrates at the corners, leading to unstable adhesion. ■Truth The oversight is due to measuring the film thickness only on the flat surfaces. Even if it meets the standards, the corners fall below the corrosion resistance limit. ■Improvement Measures Request a chamfer of R0.5 or more during the design phase to reduce sharp edges. Paint the corners first, then coat the entire surface, and add corners as measurement points for film thickness. Please utilize the document summarizing the film thickness management standards by area.
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basic information
Corresponding materials: Iron / Stainless steel / Aluminum / Aluminum die casting / Zinc die casting / Film thickness measurement: Multiple point measurement of flat surfaces, corners, and hole edges / Recommended shape: Edge R0.5 or more / Monthly production of 300,000 units, 100 types, 30 colors / ISO 9001 certification obtained.
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Applications/Examples of results
Corrosion-resistant coatings for building materials, industrial machine frames, sheet metal processed products, construction machinery parts, outdoor installation equipment, etc. Proposals for chamfering specifications are also available.
Company information
We are not just a "subcontracted painting factory." Established in 1958, our company has a foundation of painting technology and also specializes in chemical treatment, stripping, and cleaning, functioning as the "external surface treatment department" in your organizational chart. Based on our philosophy of "preparation is eight-tenths of the work," we emphasize participation from the "upstream process" before the drawings are finalized. We conduct test painting on a wide range of metals and difficult materials, and we produce the entire process from assembly, packaging, to delivery, thereby reducing your management workload. Additionally, by being able to perform zinc phosphate treatment in-house, we achieve stable painting quality. Furthermore, our micro-heating stripping technology, which does not use chemicals, maintains the electrical state of the "jigs (hangers)" that influence painting quality. Our approach of "pre-treatment determines painting quality" ensures the stability of the paint film during mass production. Rather than simply "applying specified standards," we work backwards to achieve optimal painting specifications and prevent scratches during transportation, sparing no effort in thorough discussions from the outset. This diligent preparation is the shortest path to preventing rework and minimizing total costs. From the development stage, please utilize the expertise of our specialists as part of your production line.
