1074 Stinson Drive, Reading PA 19605
800/338-2855  Fax 610/926-6125
www.bulkchemicals.us  info@bulkchemicals.us
GENERAL METALS INDUSTRY
TROUBLESHOOTING GUIDE
Cleaning System
PROBLEM CAUSE
Improper concentration
Poor Cleaning  Faulty chemical addition
 Increases in soil load
Improper temperature
 Faulty thermostat or heating element
 Scaled heating element
 Shortened exposure time
 Change in soils, drawing compounds, wax
lubricants
 Tank life exceeded
 Rinse stage contamination
 Improper etch (aluminum)
 Check for steam leaks if etch rate is low
when running aluminum
 Improper temperature
Foaming  Soap forming (saponification)
(Cleaning Stage)
 Excessive cleaning solution carry-over
Foaming
(Rinse Stage)
 Concentration too high
Excessive Chemical  Spray pattern out of adjustment causing
Use cross-spraying
 Leaky pumps, valves, tanks, etc
 Aluminum build-up in cleaner
 Carbonate build-up in cleaner
 Excessive carry-over from parts
SOLUTION
 Adjust concentration to proper level as determined
by titration
 Check build-up of carbonate or other reaction
product
 Repair or replace defective equipment
 Descale heating elements and/or desludge tank
 Increase chemical concentration and/or temperature
 Adjust exposure time
 Eliminate new soils or re-evaluate cleaning
compounds, concentrations, temperatures, etc.
 Dump and recharge
 Increase overflow rate
 Maintain active etch
 Repair or replace defective equipment
 Maintain temperature within specification
 Eliminate soils containing animal fats if possible
 Modify cleaning chemicals
(Ex. Adjust cleaner concentration,
add defoamer, overflow, etc.)
 Reposition nozzles and/or use proper nozzles
 Reposition parts to minimize carry-over
 Increase rinse overflow
 Check additions
 Adjust nozzles
 Repair leaks
 Decant or dump bath
 Check washer exhaust
 Check for carbon dioxide leaks
 Decant or dump bath
 Change positioning to eliminate excessive carry-over

Pretreatment System
PROBLEM CAUSE
 Low concentration or temperature
Uneven coating or low of cleaning solution
coatings.  Low concentration or temperature
of zirconium bath
 Low bath concentration
 Shortened exposure time
 Plugged spray nozzles
 Spray pattern out of adjustment
 Improper pH in zirconium bath
 Steel source may have changed or is
passivated.
 High bath concentration
High Coating Weight
 High bath temperature
• Exposure time too long
 Improper pH of zirconium bath
 Line stoppage
Powdery zirconium  Excessive iron in bath
Coating  Spray volume inadequate
 Improper spray pattern
 Improper pH in zirconium bath
 Excessive soil load
Excessive Sludge  Fluctuating bath temperatures or
excessively high temperatures
 Concentration too high
 Carry-over of alkaline cleaner
 Improper pH of zirconium bath
 Water contamination or change in
quality
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SOLUTION
 Maintain cleaner per Product Data
Bulletin or SOP
 Maintain cleaner per Product Data
Bulletin or SOP
 Maintain bath concentration per Product
Data Bulletin or SOP
 Increase chemical concentration and/or
temperature
 Increase exposure time as needed
 Clean or replace nozzles
 Realign nozzles
 Adjust pH
 Check steel source. Check for
passivation.
 Maintain bath concentration per
Product Data Bulletin or SOP
If temperature of bath is too high:
 Lower bath concentration OR
 Shorten exposure time
 Decrease chemical concentration and/or
temperature
 Decrease exposure time
 Adjust pH
 Check for line stoppage
 Decant or dump bath
 Adjust spray volume
 Adjust nozzles to correct spray pattern
 Adjust pH
 Decant or dump bath
 Check heating equipment, if any.
 Decant a portion of the bath
 Decant or dump bath
 Adjust pH
 Check water quality
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Performance Failures

PROBLEM CAUSE SOLUTION

 Low concentration of zirconium bath  Maintain bath concentration per
Rusting Product Data Bulletin or SOP

 Improper pH of zirconium bath  Adjust pH

 Excessive temperature of zirconium  Maintain temperature per Product Data

bath Bulletin or SOP
 Improper rinsing  Check spray nozzles
 Increase overflow
 Check rinses for contamination

 Improper concentration of final seal (if  Maintain bath concentration per

available) Product Data Bulletin or SOP

 Plugged spray nozzles  Clean and/or replace nozzles

 Improper spray pattern  Realign nozzles

 Improper racking  Change positioning of parts

 Parts drying between stages  Keep parts wet between stages

Ex. Install misting nozzles

 Line stoppages  Minimize line stoppages

 Improper concentration or temperature  Maintain bath concentration per
Poor Accelerated Corrosion in cleaner bath Product Data Bulletin or SOP
Test Results
(Salt Spray – Humidity)  Improper concentration or temperature  Maintain bath concentration per
in zirconium bath Product Data Bulletin or SOP

 Improper pH in zirconium bath  Adjust pH

 Baths overloaded with oils or other  Decant or dump bath

contaminants
 Uneven zirconium coating  See Pretreatment Troubleshooting Guide

 Contaminated rinses  Increase overflow

 Check rinses for contamination

 Improper concentration of final seal(if  Maintain bath concentration per

available) Product Data Bulletin or SOP

 Contamination of final seal (if  Decant or dump bath

available)

 Paint improperly applied or poorly  Check paint supplier specifications

cured Ex. Cure temp, pencil hardness, rubs, etc

 Metal and/or paint changes
Performance Failures - continued
PROBLEM CAUSE
 Poor rinsing
Streaking
 Zirconium temperature too high
 Excess zirconium drying on parts
 Improper zirconium concentration
 Drag down of alkaline material or
cleaner from conveyor
 Drips from conveyor
Mottling  Improper pH of zirconium
(windows, hot spots)
 Improper spray pattern
 Metal source
 Welded areas
Smut/Inorganic Soot  Improper cleaning
 Improper pH in zirconium bath
 Contaminated dry-off combustion air
 Metal source
Poor Adhesion  Improper cleaning
 Improper pretreatment
 Improper spray pattern
 Improper pH of zirconium bath
 Paint cure
 Metal source
Poor Adhesion  Casting imperfections
(Non ferrous Casting)
 Improper cleaning
 Improper pretreatment
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 Check for changes
SOLUTION
 Increase overflow
 Check rinses for contamination
 Maintain temperature per Product Data
Bulletin or SOP
 Make sure parts are rinsed thoroughly
 Maintain bath concentration per
Product Data Bulletin or SOP
 Protect conveyor and check over-spray from
first stage
 Check over-spray and conveyor belt
 Adjust pH
 Realign nozzles
 Check for work hardened steel
 Discuss with BCI representative
 See Cleaning System Troubleshooting
 Adjust pH
 Repair
 Check specification of metal source
 See Cleaning System Troubleshooting
 See Pretreatment System Troubleshooting
 Realign nozzles
 Adjust pH
 Check paint supplier specifications
 Check metal source
 Check metal source
 See Cleaning System Troubleshooting
 See Pretreatment System Troubleshooting
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 Die release agent  Check for cleanability and quality of die

release agent (presence of silicone)
General Painting Problem Guide
Description Investigate

Adhesion Failure (peeling, flaking) Clean all contaminates like water, oil, soap and soils from substrate/primer – Over
or under cure of paint – Incompatible primers with topcoats

Bleeding Check for soluble pigment finish – Wash all equipment when changing colors –
Avoid overspray from adjacent application

Blistering (bubbling, pimpling) Oil and water supply – Insufficient flash times between coats – Too fast
evaporating/poor solvents – Dry spray of film

Blushing (milkiness, white area) Condensation of moisture on film from fast solvents – Fouled air supply in oven –
Reduce atomizing air spray to avoid cooling

Checking (crazing, alligatoring) Excessive paint films – Improper cure – Repaint over soft uncured paint –
Improper thinning techniques and selection

Dirt Straining of paint – Paint lines, conveyor cleaning – Filters, fans, air balance in
booths and ovens – Lint clothing, tacking

Fisheyes (poor wetting, cratering) Surface contamination – Clean surfaces thoroughly before coating

Mottling (blotching, dappling) Too slow evaporating solvent – High viscosity – Atomizing air pressure low – Gun
distance too close – Too wet a finish coat

Orange Peel Too fast solvent – High viscosity – Atomizing air pressure low – Gun distance too
far from unit – Rough unsanded primer

Off-Color (mismatch) Container settling, low film build, hiding, power, dry spray, pigment float – Use of
catalyst and type – Spray method on metallics

Overspray Cratering (pinhole) Contamination on undercoat before painting – Unbalanced spray booth –
Incompatible spray from another paint or pouring together

Sags or Runs Too much reducer – Heavy paint films – Air atomizing pressure low – Short flash
time – Gun distance too close – Fluid delivery high

Low Gloss Film thickness low – Overbake of paint – Lack of fresh air in oven – High oven
temperature – Incompatible paint applied over different one

Soft Paint Alkali residue on parts – Low oven temperature – Too much film build – Amount
of catalyst added – Too short total time in oven – Received paint from supplier

Seed Condition Moisture, oil, or other incompatible products mixed together – Storage stability of
paint – Excessive shear in pumps – Low film

Solvent Pop (solvent trap, rupture) Too heavy film – More flash time – Too much overlap in spray method – Use
slower reducing solvent – Lower temperature in first oven zone
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Wrinkling (crinkling, puckering) Avoid very thick films – Slow drying air dry paints or storing in hot sun while
drying – Fouled ovens – Use of lacquer thinner with enamel

Preventative Maintenance

PROBLEM AREAS SPECIFIC PROBLEMS SOLUTION

Spray Nozzles  Improper spray pattern  Inspect weekly

 Missing nozzles  Clear blockages – readjust, replace or
 Blocked spray nozzles repair nozzles
 Misdirected spray nozzles  Establish routine boil-out
maintenance

Temperatures  Faulty thermostat or heating element  Calibrate monthly

 Scaled heating element  Repair or replace defective
 Holes in fire tube, steam plate, etc. equipment as needed
 Faulty thermocouples

Pumps/Spray Pressures  Broken equipment  Repair of replace faulty/defective

 Blocked pump filter equipment
 Misadjusted pressure regulator
 Faulty air regulator
 Cracked pump head or faulty seal

Overflows  Improper level controls  Check for proper overflows and tank
Solution Levels solution levels
 Check feed equipment

Automatic Control  Not functioning properly  Recalibrate or repair equipment

Equipment