Coating Adhesion Problems
When paint doesn't stick, there's always a reason. Here's how to find and fix adhesion failures.
What You're Experiencing
Applied coatings are not adhering properly to the substrate, leading to peeling, flaking, or delamination.
Visual Signs:
- Paint peeling or lifting at edges
- Flaking or chipping
- Coating easily scratched off
- Delamination between coat layers
- Tape test failure
- Blistering under coating
- Coating sliding or wrinkling during cure
Sound Signs:
- Crackling sound when coating flexes
Safety Risks — Read Before Proceeding
Product failures in field
Action: Adhesion failures mean coating won't protect the substrate. Don't ship defective parts.
Customer complaints and warranty claims
Action: Address root cause before it affects more production.
Rework chemical exposure
Action: Stripping and recoating increases chemical exposure. Use proper PPE.
Immediate Steps to Take
- 1
Stop production and save samples of failed parts
- 2
Review surface prep procedure—was it followed?
- 3
Check for contamination sources (gloves, handling, air)
- 4
Verify coating is correct for substrate
- 5
Check cure parameters (temp, time)
- 6
Review booth conditions during application
- 7
Perform adhesion test on recent production
Common Causes
Here are the most likely reasons you're experiencing this problem, ranked by how often we see them.
Surface Contamination
commonOil, grease, silicone, wax, or other contaminants on the surface preventing coating bond.
Inadequate Surface Prep
commonSurface was not properly cleaned, abraded, or primed before coating application.
Wrong Product for Substrate
occasionalCoating system is not compatible with the substrate material (plastic, galvanized, etc.).
Insufficient Cure
occasionalPrevious coat or primer was not fully cured before topcoat, or final cure was inadequate.
Booth Conditions
occasionalTemperature too low, humidity too high, or contamination from booth affecting adhesion.
Intercoat Adhesion Failure
occasionalRecoat window exceeded or incompatible products used between coats.
Interactive Diagnostic Tool
Adhesion Problem Diagnostic
Step 1 of 5
Is adhesion failing at the substrate (bare metal showing)?
If unsafe at any point: If adhesion failure is widespread, stop production and call WERCS at (877) 489-3727 for process evaluation.
When to Call WERCS
While some issues can be resolved with basic troubleshooting, these situations require professional service:
- Cannot identify adhesion failure cause
- Multiple products or batches affected
- Need process improvement help
- Booth contamination suspected
- Customer complaints about adhesion
- Need adhesion testing equipment
Coating Adhesion Problems FAQ
Common questions about this issue
Have a question not answered here?
Call us at (877) 489-3727Related Parts & Components
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Can't Fix It? We Can.
WERCS expert technicians service paint booths and extraction systems nationwide. 24/7 emergency service available.