In the production of fluorocarbon spraying mesh plates, controlling the scrap rate requires a comprehensive approach, addressing aspects such as substrate treatment, spraying process, equipment selection, environmental control, personnel operation, process monitoring, and quality inspection. Systematic management reduces the probability of defects, ensuring products meet high standards.
Substrate treatment is fundamental to fluorocarbon spraying mesh plate production, directly impacting coating adhesion and durability. Dust, grease, oxide layers, or cracks on the substrate surface can lead to coating peeling and blistering. Therefore, a multi-step thorough cleaning process is necessary: first, alkaline washing removes grease; then, acid washing neutralizes residual alkaline substances; and finally, chromating forms a dense oxide film, enhancing the adhesion between the coating and the metal. If the substrate is a refurbished part, the chalky paint film must be sanded off to ensure a smooth and firm surface, preventing the old coating from affecting the quality of the new coating.
The choice of spraying process must be flexibly adjusted based on project requirements and substrate characteristics. Commonly used fluorocarbon spraying methods include air spraying, thermal spraying, high-pressure spraying, and two-day spraying. Air spraying offers flexibility but relies heavily on operator skill; thermal spraying requires preheating the paint and is more environmentally friendly; high-pressure spraying controls paint mist through pressure, reducing material waste; two-day spraying is suitable for large-area construction, retaining excess paint. For example, complex-shaped mesh panels require high-pressure spraying to ensure uniform coating, while large flat panels can benefit from two-day spraying for increased efficiency. Furthermore, the spray gun nozzle diameter must be selected based on the paint type and desired coating effect to avoid excessive coating thickness or sagging due to inappropriate nozzle diameter.
Equipment precision and maintenance are crucial for controlling scrap rates. Spraying equipment requires regular calibration to ensure stable paint flow, atomization, and spraying pressure. For example, spray gun blockage or poor atomization can result in a grainy coating, requiring timely cleaning or nozzle replacement; uneven curing oven temperature can lead to incomplete curing, necessitating real-time temperature monitoring with temperature sensors. Simultaneously, using automated equipment can reduce human error; for instance, using robotic arms for spraying can ensure consistent coating thickness and lower scrap rates.
Environmental conditions significantly impact the quality of fluorocarbon coatings. The ambient temperature during construction must be controlled between 5-40℃, and the humidity below 80%, otherwise blistering or sagging of the coating may occur. For example, high temperatures cause the paint to dry too quickly, leading to pinholes; high humidity can cause the coating to whiten or reduce adhesion. Therefore, construction must be carried out in a temperature- and humidity-controlled workshop, or environmental parameters must be adjusted using dehumidifiers and heating equipment. Furthermore, the construction area must be kept clean to prevent dust from adhering to the uncured coating and causing defects.
Personnel operating skills and awareness of standards directly affect the scrap rate. Operators must undergo professional training and be familiar with the spraying process and equipment operation, such as mastering the distance between the spray gun and the substrate, the moving speed, and the techniques for adjusting the paint flow rate. At the same time, strict adherence to process specifications is essential; for example, the thickness of each coating layer must be controlled within the specified range to avoid cracking due to excessive thickness or affecting protective performance due to insufficient thickness. For example, insufficient primer thickness will reduce impermeability, while excessive topcoat thickness will easily cause sagging; both must be avoided through standardized operation.
Process monitoring and real-time adjustments are effective means to reduce the scrap rate. During the spraying process, coating quality must be monitored through a combination of visual inspection and instrument testing. For example, a film thickness gauge is used to measure the coating thickness to ensure it meets design requirements; a gloss meter is used to check the gloss of the topcoat to avoid uneven gloss caused by insufficient or excessive curing. If coating defects are found, construction must be stopped immediately and the cause analyzed, such as adjusting spraying parameters, changing the paint batch, or reprocessing the substrate to prevent the defects from spreading.
Quality inspection is the last line of defense in controlling the scrap rate. For example, the cross-cut adhesion test is used to ensure there is no peeling; accelerated aging tests are conducted to simulate long-term outdoor environments and verify coating durability. Only products that pass all inspection items can leave the factory; substandard products must be reworked or scrapped to prevent them from entering the market and damaging the brand reputation.
