Painter Training
1
Spray-Gun Operation
2
How to set the spray-gun
1. Needle adjuster
• Amount of material
2. Pressure regulator
• Higher – lower pressure
4
1
2
3. Spray pattern control 3
• Round till wide
4. Air cap & fluid tip set-up
3
Air pressure check
Air inlet 2 – 3 bar
30 – 40 PSI
4
Spray pattern check
Adjustment screws fully open
• Apply ± 15 cm from the paper
Correct air pressure
± 15 cm
5
Incorrect spray patterns
1 3
2 4
6
Pressure drop in bar
Hose length
Inner diameter Pressure
5 Meter 10 Meter 15 Meter
(mm) (bar)
3 0.7 1.2 1.8
4 1.0 1.6 2.2
6 5 1.3 1.9 2.5
6 1.5 2.2 2.8
3 0.2 0.4 0.6
4 0.3 0.6 0.8
9 5 0.4 0.6 0.9
6 0.6 0.8 1.1
7
Pressure drop in PSI
Hose length
Inner diameter Pressure
16.40 feet 32.80 feet 49.21 feet
(inch) (psi)
42.75 09.97 17.10 25.65
57.00 14.25 22.80 31.35
0.23 71.25 18.52 27.07 35.62
85.50 21.37 31.35 39.90
42.75 02.85 05.70 08.55
57.00 04.27 08.55 11.40
0.35 71.25 05.70 08.55 12.82
85.50 08.55 11.40 15.67
8
Air hose & connectors
Air hose and connector diameter
• Preferably Ø 8 mm or >
9
Maintenance
Use brand related maintenance tools
• Check with spray-gun supplier
10
Maintenance tools
11
Application Technique
1
Gun technique
The right distance from spray-gun to object
± 150mm
No Yes
2
Gun technique
Speed of movement
900 - 1200 mm/sec
3
Gun technique
Follow the shape of the surface, keeping the same distance
No Yes
4
Gun technique
Gun angle always 90º at the surface
No
5
Gun technique
Gun angle always 90º at the surface
Yes
6
Routing total re-spray
7
Cross-wise application
Application second coat on horizontal surfaces
• Crossed over the first coat
Better paint control
• Even flow on the panel
Less risk for
• Application pattern
• Runs at stand up surface
8
Application technique
Basecoat application
Overlap next coats
• 50%
Panel application
• Half way each panel
9
Application technique
Clearcoat application
Overlap next coats
• 50%
Panel application
• Half way each panel
10
Application pressure
Application pressure Mist / drop coat
• Spray gun distance • Lower pressure
• 5 – 15 cm • Larger distance
22
Equipment
1
Equipment
2
Spraybooth
1
Cleaning
Good housekeeping Poor housekeeping
• Clean and free of obstacles • Dirty, poor illumination
2
Cleaning
Keep the interior clean
Use protection coating
• Replace frequently
3
Open / closing doors
Keep the doors closed Fans on when doors are open
• Minimizing risk for dust • Keep dust particles out-side
4
Moving cars
In and out the spray booth
• Cool down after drying cycle
5
Temperature
Air temperature ± 60 Object temperature ± 50
6
Air & object temperature
70 °C
Air
60 °C
50 °C Object
40 °C
30 °C
20 °C
1 °C 0
0
0 5 10 15 20 25 30 40 50 60 Time in minutes
7
Pressure check
Maintain advised pressure
Pressure
indicator
Switch to adjust pressure
8
Over & under pressure
Over-pressure Under pressure
• Leaking door seals • Dust in the spraybooth
• Dirty filters • Dust in the paint jobs
• Spray mist inside the shop
Maintenance
Ceiling filter
Floor filter
Pre- and after filters
Filter replacement
Floor filter Ceiling filter Pre- and after filter
Filters Frequency
Pre-filter each 4-6months
Ceiling filter once or twice a year
Paint-stop / Floor filter each 2-3-4 weeks
After filter each 4-6 months
Compressed Air
36
Compressed air
37
Air conditioning
Filtering of contamination
• Oil & water
Polluted air result in defects in the paint film
Air in Air out
Dust particles Particle free
Water condense Water free
Compressor oil Oil free
38
Compressor
39
Compressed air system
ring
Refrigerant
dryer
2
receiver filters 4
dryer 3
Compressor
ring
compressor 1
Lakukan pengecekan minyak paling tidak seminggu sekali.
Buang air secara teratur.
Lakukan pengecekan air inlet fillter.
Lakukan pengecekan filter secara teratur
40
Air line
Main air line
• Slope ± 1%
Drop end connection on top
• Less risk for condensation
Air tap connection
• Half way drop end
41
Infra Red
42
Why Infra Red
Reduction of drying cycle time resulting in
• Better use of bodyshop capacity
• More even workload for the spraybooth
• Ideal for small spot repairs; ½ day or 1 day repair
43
Various heat transfer
44
Heat transfer - Conduction
Heat transfer by contact
• Heated metal
Physical contact
45
Heat transfer - Convection
Heat transfer
• Inside the Spraybooth
Circulated Heated air
46
Heat transfer - Radiation
47
Heat transfer efficiency
Amount of energy used
• 100% transfer
• % energy loss during transfer
• % energy which will be reflected
• % energy which will be absorbed
48
Heat transfer efficiency
Reflection – Lighter colors
• Lower surface temperature
• Longer drying time
Absorption – Darker colors
• Higher surface temperature
• Shorter drying time
49
Different radiations levels
Infra Red drying units – drying waves
Short Medium Long
50
Infra Red drying information
Product and object related
• Product flash off times
• Distance IR drying equipment and object
• Total drying time needed for IR curing
Infra Red drying unit settings
1. Low potential
2. High potential
51
Polishing
Why polishing?
Restoring color and gloss
• Old and weathered paint
Restoring gloss after application errors
• Dust – Runs – Orangepeel
Restoring gloss after blending
• Fade-out areas
Points of attention
Respect recommended Additional IR curing in case of
T.D.S. drying times • Application error
• Blending area
Points of attention
Clean surface prior to sanding
• Contamination causes additional scratches
Clean surface prior to polishing
• Remove sanding residues
Points of attention
Correct sanding steps prior to polishing
The finer the sanding
• The easier to polish, which reduces the total polishing time
Polishing tools
Electrical tools
• Constant rotation strength
Adjustable rotation speed
• Easy to handle
Polishing tools
Air driven tools
• No constant rotation speed
Too much pressure on the tool
• Reduces rotation speed
Polishing cloths
Use clean cloth
• Throughout polishing steps
• One cloth per separate polishing compound
Polishing check
Clean or degrease after polishing
• Dedicated cleaner or M600
Removing polishing compound
• Check if all sanding scratches are removed
General Polishing Advises
General polishing information
Dust – Runs – Orangepeel
• Process approach
Product selection
• Sanding materials
• Polishing materials
Polishing process steps
Masking Techniques
62
Masking technique
Masking interior side
• Mask on sealant edge
• Accurate masking required; use fine line tape
63
Masking technique
Pre-masking, final masking on edge with tape
• Easy to remove after spraying or drying
64
Masking technique
Pre-masking, final masking on edge with tape
• Easy to remove after spraying or drying
65
Fine line masking tape
Fine detail masking
• Taping curved lines
• Flexible, follows easily difficult contours
Vinyl backing
• For sharp paint line
66
Soft masking foam tape
Easily applicable in
• Door jambs, bonnet, tailgate, etc.
67
Masking technique
Folding the masking tape
• To gain minimum overspray on the panel edge
Edges on panel
Inside of panel, door
68
Masking technique
Trim masking tape and Rubber string
• For lifting sealed window or screen rubbers
69
Blending area
Covering blending area
70
Pre-masking
71
Pre-masking
72
Efficient masking
73
Efficient masking
74
