WHEN TO REPLACE YOUR WORN SPRAY TIPS
Although paint spray tips are made out of the highest grade of tungsten carbide inserts – the most abrasive-resistant material available – all spray tips will wear with normal use and should be replaced promptly. All coatings contain solids that are abrasive -- some more than others. Using a worn tip can cost you hundreds of dollars in wasted paint and labor; because when a tip wears the size of the tip orifice increases and the fan width decreases. This forces more passes to cover the surface, more labor, increased overspray, and a substantial waste of paint.
The left image above displays a new spray tip and the optimal pattern to acheive. The longer the tip is being used, the farther to the right the paint spray tip will become. It is imperative that the moment tips become worn, they are replaced. Although no one likes having to pay for a new spray tip, a worn tip will cost you much more in wasted paint and labor per hour.