Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt Automotive painting processes - today and tomorrow Dr. Michael Hilt Research Society for Pigments and Coatings Department Coatings and Pigments Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt Introduction Automotive painting - where does it come from? Automotive painting today Building blocks for future processes Summary Content
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Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting processes - today and
tomorrow
Dr. Michael Hilt
Research Society for Pigments and Coatings
Department Coatings and Pigments
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Introduction
Automotive painting - where does it come from?
Automotive painting today
Building blocks for future processes
Summary
Content
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Introduction - Closed chain in painting technology due
to integration of FPL (research institute) into
FRAUNHOFER IPA
Binders
Pigments
Additives
Thinners,
solvents
Raw
materials
Paint Painting material
Painting technology Coating Finished surface
Recipies
Dispersion
Rheology
Colouration
Substrate
pretreatment
Application
Drying, curing
Adhesion
Corrosion
protection
Durability
Functionality
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Introduction - Coating components
Pigments Binders
Solvents
Additives
Paint
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Introduction - Topographical classification of coating
properties Top surface properties
Light reflection
Hardness
Scratch resistance
Surface slip
Repellent properties
Erosion resistance
Substrate
Interface
Film
Film/Air Interface
Bulk film properties
Opacity
Flexibility
Diffusion
Chemical resistance
Water uptake
Weather resistance
Film/substrate
interface properties
Adhesion
Durability
Anticorrosion
Source: S. K. GOSH, Functional Coatings
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Protection and decoration of wood and steel
Natural oil resins, alkyd resins
Protection and decoration of metals
Nitro cellulose resins
Nitro cellulose combination resins
Alkyd melamine resins
Acrylic melamine resins
Polymer dispersions
Epoxy resins
PU resins
Protection and decoration of plastics
See metals (last three)
Automotive Painting - where does it come from?
Dr. Michael Hilt, Automotive OEM Coatings, Process and Materials 2011-05-16.ppt FORSCHUNGSGESELLSCHAFT
FÜR PIGMENTE UND LACKE E.V. 7
Physical influences
Mechanics
Scratches
Stone chips
Car care materials
Abrasion
Radiation (sun light)
Temperature change
Chemical influences
Fuel, brake fluid, washer fluid …
Care care materials
Environmental chemicals
Tree sap
“Sour" residues
Bird excrements
Other materials (metal dust,
carbon, ...)
Coating surface
Automotive Painting - where does it come from? - Ex-
ternal influences on a coated car surface
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Film build
in µm
110
100
80
60
40
20
0
2K-Klarlack
Wasserfüller
WBL WBL „1“
WBL „2“
KTL
Material type Usage in kg on car in kg Relative cost in %
Clearcoat 2.1 1.0 25
Basecoat waterborne 4.0 0.5 25
Primer surfacer 2.5 0.8 15
Electrocoat 4.5 3.0 19
Seam sealing 6.0 6.0 13
Wax 1.0 1.0 3
Sum 20.1 12.3 100
Automotive painting today - Consumption data
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source:
Main focus
Improvement or keeping of product quality and performance
Reduction of process cost
Automotive painting today - Cost of car painting
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Body
in
white
Body
washer
Pre-
treat-
ment
Elec-
tro-
coat
Baking
oven
San-
ding
Primer
surfa-
cer
Baking
oven
San-
ding
Base-
coat
Drying
oven
San-
ding,
poli-
shing
Seam
sealing
Baking
oven
Clear-
coat
Baking
oven
Spot
repair
Body
repair Wax
As-
sem-
bly
Online
plastic
parts
Inline
plastic
parts
Offline
plastic
parts
Automotive painting today - Classical painting process
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Development of alternative products for zinc phosphating
Goals
Lower environmental impact concerning Nickel and phosphate sludge
Lower process costs
To be used as multi metal pretreatment
Constant quality
Classification of Nickel containing products was further enforced
Trication phosphating is classified as being carcinogenic
Change of water relevance for phosphate concentrates from WGK2 to WGK3, for
phosphate bathes from WGK1 to WGK2
Recommendations of IHO for classification of nickel containing products
R22 Health risk at swallowing
R36/38 Irritant for eyes and skin
R40 (Cat. 3) Irreversible damage possible (carcinogenic effect supposed)
R42/43 Sensitization due to respiration and skin contact possible
R50/53 Very poisonous for water organisms
Concerning the increase in WGK existing facilities do not needed not be changed. This
situation changes, if changes are made which must be approved by the authorities.
Automotive painting today - Alternatives for prepro-
cesses - Reasons
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
CHEMETALL: Oxsilan process
Thin layers of silanes with intermediate metals
HENKEL: Bonderite NGC (Tec Talis)
Thin layers of polymers and zirconium oxides
PPG: Zircobond process
Inorganic system with zircon oxide and additives
All processes can be used for multi metal treatment
Automotive painting today - Alternatives for prepro-
cesses - Overview
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Silane treatment
(Greenfield)
Silan treatment
(Brownfield)
Zink phosphating
as at today
Cleaning Purge Silane Purge
DI purge DI purge
Cleaning Purge Silane Purge Empty
DI purge DI purge
Cleaning Purge Phosphatization Purge
DI purge Passivation
DI purge
Spray or dip process
Solution in DI water
2 products
Room temperature
2 min process time
pH ca. 4
Tank control: pH, conductivity, material content
Automotive painting today - Alternatives for prepro-
cesses - New development Oxsilan (CHEMETALL) (I)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Cleaning Purge Activation Phosphatization DI purge Passivation DI purge
Cleaning Purge Bonderite DI purge DI purge
NGC
Zinc phosphating
Bonderite NGC process
Automotive painting today - Alternatives for prepro-
cesses - New development Bonderite NGC (HENKEL)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Alternatives for prepro-
cesses - New development Zircobond (PPG)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Basic requirements and competitive factors
Corrosion protection
Edge protection: Similar deposition on steel, galvanized steel,
Al etc
High throwing power for inner sections of the body and surface
smoothness at low film builds
Process reliability
Contaminant resistance
No entry markings
Low consumption in kg
High under bake tolerance Source:
Automotive painting today - Electrocoats (I)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt