Methods for estimating the transfer efficiency of a compressed air spray gun

The transfer efficiency of a compressed air spray gun is an important performance index with regard to worker health, environmental, and economic considerations. It is defined as the fraction of paint sprayed that coats the surface. Worker exposure has been identified as a function of the transfer efficiency based on total mass of paint sprayed, which can be predicted by a mathematical model developed with nonvolatile oil. This study extends the existing model to include volatile effects by employing a mathematical approach based on a mass balance. This method allows the current model to predict transfer efficiency bounds at two extreme situations: all volatile compounds evaporate either before or after droplet impaction. Model predictions show that tight transfer efficiency bounds are obtained, especially for high values of transfer efficiency. Thus, the average of the upper and lower bounds should be a reasonable estimate of transfer efficiency. It is also found that the current model prediction, which is based on total mass of paint sprayed, for nonvolatile material can be converted to a transfer efficiency based on the mass of solids. The laboratory study shows that the predicted transfer efficiency based on the mass of solids is within the 95 percent C.I. of the measured value. This work relates the transfer efficiency used in industry, which is calculated on the basis of paint solids, with a model that predicts worker exposure during spray painting operations.