Transfer efficiency for airless painting systems

Spray transfer efficiency (TE) is defined as the mass fraction of sprayed paint which is deposited on the intended target, the remainder of the sprayed paint becomes undesirable overspray. The relationship between TE and gun supply pressure (or paint mass flow rate), gun-to-target distance, gun traverse speed, the angle of the spray gun relative to the target (gun-to-target angle), plus spray cone angle is reported herein for a typical fan spray system. Experimental results indicate that spray momentum rate (SMR) and droplet size dictate the TE for the various combinations of parameters considered here. The key finding is that TE correlates with SMR and spray mean drop size (Sauter mean diameter, or D₃₂) via an expression of the form TE=a+b SMR − c (SMR)²+d D₃₂, where a, b, c, and d are coefficients, determined by fitting the experimental data, and SMR is estimated via SMR=m²/ρA, where the paint mass flow rate m, the paint density is ρ, and the gun exit orifice effective tip cross sectional area is A. This expression accounts for physical phenomena that govern sprayed droplet deposition characteristics, such as entrainment, bounce-back, and drop size. Experimental results also show that, for the range of parameters studied, gun traverse speed has no effect on TE, but increasing the angle of the spray gun relative to the target (gun-to-target angle), increasing the spray cone angle, or increasing the gun-to-target distance will decrease TE.