Introduction of Automotive Paint

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SUMMER TRANING PROJECT REPORT

ON

“AUTOMOBILE PAINTS MANUFACTURING”

AT

KANSAI NEROLAC PAINTS LTD.

AT

BAWAL

Submitted to: Submitted by:

Mr. Ashok Singh Yatin Khandelwal

B.Tech 7th sem.

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Acknowledgement

It is my pleasure to be indebted to various people, who directly or indirectly contributed in development of this work and who influenced my thinking, behavior and acts during the course of study.

I express my sincere gratitude to Mr. Ganesh Harbola worthy Principal to providing me an opportunity to under go summer training at Kansai Nerolac Paints Ltd. at Bawal.

I am thankful to Mr. Ashok Kr. Gupta for his support, cooperation, and motivation provided to me during the training for constant inspiration, presence and blessings.

I also extend my sincere appreciation to Mr. Narendra Kr. Garg who provided his valuable suggestion and precious time in accomplishing my project report.

Lastly I would like to thank the almighty and my parents for their moral support and my friends with whom I shared my day-to-day experience and receive lot of suggestions that improve my quality of work.

Yatin Khandelwal

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Declaration

I, Yatin Khandelwal student of B.Tech ,6th Semester, Chemical Branch, studying at Jaipur National University, Jaipur, Rajasthan, hereby declare that the summer training report on “Automobile Paints Manufacturing” submitted to Jaipur Nation University, Jaipur, Rajasthan in partial fulfillment of Degree of Bachelor of Technology in Chemical Branch is the original work conducted by me.

The information and data given in the report is authentic to the best of my knowledge.

This summer training report is not being submitted to any other University for award of any Degree and Fellowship.

Yatin Khandelwal

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Content

Topic Names Page No.

1. About Kansai Nerolac Paints 5

2. Introduction of Automobile Paints 5

3. Products in Automotive Coating 6

3. Strategic Partnership 9

4. Key Customers 9

5. Colour Research & Development 9

6. Introduction of Paints 10

7. Main Ingredients of Paints 10

8. Types of Resins 11

9. Paints Processing Flow Diagram 13

10. Process Description 14

11. Quality Control 16

12. Defects of Paints 17-22

13. Conclusion 23

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About Kansai Nerolac Paints:

Kansai Nerolac has been a cherished name in millions of households across the length and breadth of India. The company manufactures a diversified range of products for every surface. It is the second largest coating company in India and the market leader in automotive and powder coating. Nerolac paints as it is known popularly is an established brand in decorative paints.

Introduction of Automotive Paints:

Kansai Nerolac is the Market Leader in the automotive coating segment in India with a dominant market share with global technology acquired from Kansai Paint Co. Ltd, Japan. Kansai Nerolac offers the latest technology in automotive painting systems to the Indian automotive industry. In Automotive Coatings, Kansai Paints is one of the top five manufacturers in the world and is having a dominant market share in Asia Pacific in Automotive Coatings. In Japan, it is the largest Automotive Paint Company.

AUTOMOTIVE PAINTS segment has undergone a metamorphosis in past 3 decades in India. The paint technology for automobiles has undergone a complete transformation. Kansai Nerolac is proud to be associated with this path breaking change when it forged a technical collaboration with Kansai Paint Co. Japan by introducing contemporary paint technology for Maruti. Kansai Nerolac been in forefront to introduce new technologies in automotive sector in India from time to time be it Cathodic Electrocoats, TSA/Polyester based top coats, Mar Resistant Clear Coats, 3 Wet Coatings technology, Acrylic CED etc.

Through its various strategic collaborations, Kansai Nerolac offers a total painting system to auto makers in India with a range of products, starting from Pretreatment Chemicals, Electro Deposition Primers, Intermediate Coats/primer Surfacers, Solid & Metallic Top Coats, Clear Coats & Touch-up Paints. The products are approved by most Global Auto Majors.

Kansai Nerolac has a strong customer focus, one of the key factors behind our success. Working closely with our Customers, we jointly develop Products & Processes with focus on cost improvement, better productivity and energy savings.

Kansai Nerolac has strong reputation for innovation, Superior Technology, Value Engineering, Quality and Service. More than 85 Technical Service Team members are located at customer sites to support application processes, controlling the process parameters and jointly participate in improvement and optimization plans with customers.

Kansai Nerolac is the largest supplier of CED Coatings in India- catering over 75% of requirements in India.

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Products in Automotive Coating:

Kansai Nerolac offers a very comprehensive product range, technical support & service to cater to the specific needs of Auto OEMs & Components Suppliers keeping in mind the latest global trends.

SOC (Substances Of Concern) FREE AUTOMOTIVE PRODUCTS

Kansai Nerolac has pioneered the activity in India to remove SOCs from its automotive coatings to meet stringent environmental standards of global automotive customers.

A list of products is as under, though it is not exhaustive as we keep on developing newer products to meet customer requirements.

Pretreatment (PT) chemicals:

All automotive metallic surfaces need to be cleaned before the painting process.

Kansai Nerolac along with its collaborator Nihon Parkerizing Co., Japan offers Pretreatment Chemicals for cleaning various substrates and prepares these surfaces for improved Paint bonding & corrosion resistance. Pre treatment chemicals play a significant role in corrosion management along with E-coat and subsequent Primers. Zinc Phosphate Conversion Coating is widely used process in Automotive Industry.

Product Range

The product range consists of High & Low Temperature Degreasing Chemicals, De-rusting Chemicals, Di-cationic and Tri- cationic Phosphate Chemicals, Activation & Passivation Chemicals, Surface Conditioners & Pre Treatment Chemicals for Plastics.

Through its JV – Nipa Chemicals Ltd., Kansai Nerolac services all Pre- treatment requirements of Automotive Industry, Powder Coating Plants, Auto Ancillaries & General Industries segments with excellent line service & analytical support.

Electrodeposition (ED) Technology:

In E-Coat the metal substrate is immersed in an aqueous bath solution & coated with a charged organic primer under the influence of electric field.

The distinct Advantages of E-Coat are- Uniform coverage without pinholes or other surface defect leading to less paint consumption; Better edge protection resulting in Corrosion Resistance ; Coating / access to recessed areas like Box-sections etc. It is a single coat Environment friendly Water-based coating system. The E-Coat process is a fully automated process leading to less manpower requirement and cost effective process with possibility of a high paint recovery ratio (up to 99.5% with Ultra Filtrate & Reverse Osmosis system).

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Product Range

In CED, our product range consists of lead free Polybutadine Based Anodic Electro-deposition Primer (AED); Epoxy Resin Based Cathodic Electro-deposition Primer (CED) & Acrylic Resin Based Cathodic Electro-deposition Primer (ACED). The product ACED won an Innovation award for being first in the world for usage of a single coat application system for coating of Motorcycle frames.

Our CED is heavy metals free and meets the stringent environmental norms of Automotive Industry.

Intermediate Coats / Primer Surfacers:

The Primer Surfacer is the second functional layer and it acts as an intermediate coat between E-coat and the topcoats. It also provides excellent stone chip protection and protection against UV rays to the E-coat film. The Intermediate Coats are available in White, Light Grey, Dark Grey, Red, Blue and other specific colours as required by OE manufacturers. Water borne Dipping Primers are also developed with an eye on safer environment.

Kansai Nerolac also manufactures special Intermediate coats such as Anti Chip Primers and Non Sanding Primers and Wet on Wet Primers etc.

Top Coats:

Top Coats provide Colour, aesthetics and weather protection to the coating system in Automotives. Kansai Nerolac manufactures a large variety of Top Coats based on various resin backbones designed as per specific technical specifications of customers. Containing an extensive range of colored pigments and effect pigments, it plays a significant role in establishing the visual image. A general distinction can be drawn between a solid-color and a metallic paint finish in this segment. Various types of Metallic & Mica finishes are available.

New technologies in Top coats such as 3 Wet Coating Systems are available which are being adopted by various automotive customers to improve productivity, reduction in costs and meeting the environmental norms.

Clear Coats:

The Clear coat is the top layer in a Paint System which provides resistance to sunlight and weather and also to Chemicals and biological materials such as bird droppings. It helps provide a scratch resistant final coat to the coating system. Kansai Nerolac offers Clear Coats of various functionalities such as scratch resistance, acid & alkali resistance, UV resistance, mar resistance etc.

Touch up Paints & Auto Refinishing Products:

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Kansai Nerolac manufactures various types of Touch Paints which are used to undertake small touch ups if the paint film is damaged. Kansai Nerolac offers a complete range of Auto Refinish product range to service requirements of Body Shops for repair coatings.

Heat Resistant Paints:

Kansai Nerolac manufactures specialty paints such as heat resistant paints, both for interior & exterior surfaces of motorcycle mufflers. These are made to withstand high temperature conditions up to 600 degree C.

Underbody Paints & PVC Sealants:

Kansai Nerolac manufactures Bitumen & PVC type Underbody Compounds for application on underbody surfaces of automotive bodies to impart anti chipping & sound deadening properties.

Rapgard Transit Protection Films:

Kansai Nerolac supplies Rapgard Transit Protection Films which are used for protection of automotive vehicles during transit from dust, chemicals, bird droppings and damages to the paint film. Films are available for protection of metal & plastics surfaces.

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Strategic Partnerships:

Kansai Nerolac has tie-up with the global players for product range offered to automotive and industrial customers. Kansai Nerolac has entered into collaboration with the following players for specific product range:

Company Product Category

Kansai Paint Co., Japan ED Primers, Automotive & Industrial Coatings,Auto –Refinishing System

Nihon Parkerizing Co., Japan

Pre-Treatment Chemicals ( JV- NIPA CHEMICALS LTD, Chennai)

Oshima Kogyo, Japan Heat Resisting Paints

Key Customers:

Kansai Nerolac is market Leader in Automotive Industry in India. Some of our main customers are:

Maruti Suzuki, Toyota Kirloskar, Honda Siel, General Motors, Tata Motors, Mahindra & Mahindra, Renault, Fiat, Hindustan Motors (Mitsubishi), Renault Nissan, Hero Honda, Yamaha, TVS Motors, Bajaj Auto, Honda Motorcycle & Scooters, Suzuki Motorcycle , Volvo India, Ashok Leyland, TAFE, Eicher Motors, TACO, Motherson Auto, Visteon, Wheels India etc. The list is long & growing. The Largest costumer of Nerolac is Maruti Suzuki is 80%.

Colour Research & Development:

Kansai Nerolac has a well equipped Colour R&D centre at Lower Parel, Mumbai which is backed by Kansai Paint Co., Japan to service ever expanding need of OEM industry for newer shades & finishes. The Colour Development Cell of Kansai Nerolac organizes Colour Presentations at customers’ locations to give wide choice of colour introductions and follows it through a rigorous activity from development to standardization.

There is a regular activity to liaise with automotive customers’ Styling & Marketing departments to continuously work for introduction of new shades for new models and refresh existing models as per need of the market.

Colour Development Cell also collects data on Indian and global Colour Trends.

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Introduction to Paints:

Paint is homogeneous mixer of Pigment, resin, solvent & additives.   .

 The functions of paint are “Protection” and “Beautification” of object.

Paint manufacturing process comprises of 4 categories.

1. Solid Paint

2. Metallic Paint

3. Lacquer

4. Thinners

Main Ingredients of Paints:

The main Ingrediants of paint are:

1. Pigment: These are insoluble solids that provide opacity and color. They can also provide improved surface adhesion, weather resistance, and corrosion resistance

2. Solvent or Volatile Material: This is a grouping of all other minor quantity but major role ingredients, such as dispersing agents , antioxidants, dryers, flow agents, anti-sagging agent, anti popping etc.

3. Resin or Binders: This is the polymerised viscous material that holds the pigments together, bonding them to the surface. Paints are often classified by the type of binder they contain, for example an Alkyd, Polyester, Acrylic & M.F.

4. Additives: This is a grouping of all other minor quantity but major role ingredients, such as antioxidants, dryers, flow agents, anti-sagging agent, anti popping etc.

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Types of Resins:

The resins that are used in fibre reinforced composites can also be referred to as 'polymers'. All polymers exhibit an important common property in that they are composed of long chain-like molecules consisting of many simple repeating units. Man-made polymers are generally called 'synthetic resins' or simply 'resins'. Polymers can be classified under two types, 'thermoplastic' and 'thermosetting', according to the effect of heat on their properties.

Thermoplastics, like metals, soften with heating and eventually melt, hardening again with cooling. This process of crossing the softening or melting point on the temperature scale can be repeated as often as desired without any appreciable effect on the material properties in either state. Typical thermoplastics include nylon, polypropylene and ABS, and these can be reinforced, although usually only with short, chopped fibres such as glass.

Thermosetting materials, or 'thermosets', are formed from a chemical reaction in situ, where the resin and hardener or resin and catalyst are mixed and then undergo a non-reversible chemical reaction to form a hard, infusible product. In some thermosets, such as phenolic resins, volatile substances are produced as by-products (a 'condensation' reaction). Other thermosetting resins such as polyester and epoxy cure by mechanisms that do not produce any volatile by products and thus are much easier to process ('addition' reactions). Once cured, thermosets will not become liquid again if heated, although above a certain temperature their mechanical properties will change significantly. This temperature is known as the Glass Transition Temperature (Tg), and varies widely according to the particular resin system used, its degree of cure and whether it was mixed correctly. Above the Tg, the molecular structure of the thermoset changes from that of a rigid crystalline polymer to a more flexible, amorphous polymer. This change is reversible on cooling back below the Tg. Above the Tg properties such as resin modulus (stiffness) drop sharply, and as a result the compressive and shear strength of the composite does too. Other properties such as water resistance and colour stability also reduce markedly above the resin's Tg.

Although there are many different types of resin in use in the composite industry, the majority of structural parts are made with three main types, namely polyester, vinylester and epoxy.

There mainly four type of resin those are used in manufacturing of automotive paints:-1. Polyester Resin2. Alkyd Resin3. Acrylic Resin4. Melamine Formaldehyde Resin

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There are two process of polymerization is required for the manufacturing the resin:

1. Addition Polymerization (for the Acrylic Resin)

2. Condensation Polymerization (for Alkyd, M.F & Polyester Resin)

About Resin plant of Kansai Nerolac Paint Ltd.:

1. Number of Reactors : 7 Reactors2. Type of Heating : 2 Thermic fluid oil& Boiled water3. Number of Alkyd Reactors : 3 Reactors

Capacity 7tons & 2 tons : 2 & 1 Reactor 4. Number of Acrylic Reactors : 2 Reactors Capacity 2tons & 5tons : 1 & 1 Reactor 5. Number of M.F. Reactors : 2 Reactors Capacity 8tons & 4tons : 1 & 1 Reactor 6. Number of Polyester Resin : 2 Reactors Capacity 2tons & 8tons : 1 & 1 Reactor

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Paint Processing Flow Diagram:

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Process Description:

1. Premixing: Pigment manufacturers send bags of fine grain pigments to paint plants. There, the pigment is premixed with resin (a wetting agent that assists in moistening the pigment), one or more solvents, and additives to form a paste.

2. Grinding: The paste mixture for most industrial and some consumer paints is now routed into a sand mill, a large cylinder that agitates tiny particles of sand or silica to grind the pigment particles, making them smaller and dispersing them throughout the mixture. The mixture is then filtered to remove the sand particles. In sand mill zirconium beads are used for the grinding.

Ball Mill is also use for the grinding but premixing is not required here.

In case of metallic paints a high-speed dispersion tank is use for the dispersion of Al. or Mica paste. Here grinding is not require.

3. Thinning: Whether created by a sand mill or a dispersion tank, the paste must now be thinned to produce the final product. Transferred to large kettles, it is agitated with the proper amount of solvent for the type of paint desired. Its require for increase the flow property and desired parameters.

4. Tinting: It is the operation in which stainers is mix to get the desired shade.

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5. Filling & Packing: The finished paint product is then pumped into the canning room. For the standard 8 pint (3.78 liter) paint can available to consumers, empty cans are first rolled horizontally onto labels, then set upright so that the paint can be pumped into them. A machine places lids onto the filled cans, and a second machine presses on the lids to seal them. From wire that is fed into it from coils, a bailometer cuts and shapes the handles before hooking them into holes precut in the cans. A certain number of cans (usually four) are then boxed and stacked before being sent to the warehouse.

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Quality Control :

Paint manufacturers utilize an extensive array of quality control measures. The ingredients and the manufacturing process undergo stringent tests, and the finished product is checked to insure that it is of high quality. A finished paint is inspected for its density, fineness of grind, dispersion, and viscosity. Paint is then applied to a surface and studied for bleed resistance, rate of drying, and texture.

In terms of the paint's aesthetic components, color is checked by an experienced observer and by spectral analysis to see if it matches a standard desired color. Resistance of the color to fading caused by the elements is determined by exposing a portion of a painted surface to an arc light and comparing the amount of fading to a painted surface that was not so exposed. The paint's hiding power is measured by painting it over a black surface and a white surface. The ratio of coverage on the black surface to coverage on the white surface is then determined, with .98 being high-quality paint. Gloss is measured by determining the amount of reflected light given off a painted surface.

Tests to measure the paint's more functional qualities include one for mar resistance, which entails scratching or abrading a dried coat of paint. Adhesion is tested by making a crosshatch, calibrated to .07 inch (2 millimeters), on a dried paint surface. A piece of tape is applied to the crosshatch, then pulled off; good paint will remain on the surface. Scrubbability is tested by a machine that rubs a soapy brush over the paint's surface. A system also exists to rate settling. An excellent paint can sit for six months with no settling and rate a ten. Poor paint, however, will settle into an immiscible lump of pigment on the bottom of the can and rate a zero. Weathering is tested by exposing the paint to outdoor conditions. Artificial weathering exposes a painted surface to sun, water, extreme temperature, humidity, or sulfuric gases. Fire retardancy is checked by burning the paint and determining its weight loss. If the amount lost is more than 10 percent, the paint is not considered fire-resistant.

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Defects of paints:

Cissing: Cissing or tiny craters are caused by oily or greasy surface or due to water based paints being applied over gloosy or smooth enamel paints. The Remedy is to clean the surface thoroughly with soap solution and water. Roughen enamel paint with Sandpaper or use a barrier coat of matt primer.

Blistering: Blistering or Swelling of paint is caused due to trapping of air, moisture or solvent between the surface and the paint film. The remedy is to remove any unstable paint films. Allow the wall to dry thoroughly, and repaint with a recommended paint. Also, avoid painting under direct sunlight

Sagging: Sagging happens when the paint droops downward after being applied on the surface. It is caused by the pigment separating from the paint and settling at the bottom of the container and comes as a result of insufficient stirring or shaking during storage, storing for too long or under too much heat, or faulty thinning. The Remedy is to avoid storing in hot locations for long periods. Store in accordance with the manufacturer's recommendations and thin only with appropriate recommended thinners.

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Wrinkling: Wrinkling happens when the paint forms film-like undulating waves. Applying too much paint or drying during high temperatures or painting on a topcoat before the undercoat is dry can cause this defect to happen. The Solution- Avoid applying too much paint. Make sure no paint accumulates around bolts, rivets, etc. Wait until each coat dries before you re-coat.

Cracking: This is caused when the paint or varnish is applied over a base layer of different elasticity before it has been given enough time to cure (which can take up to a month). For example, two separate brands of varnish may react with each other and form cracks. The Remedy is to allow the surface to dry fully and then rub it down to make it ready for repainting. However, you could consider leaving the cracking visible. It is a very popular ageing technique.

Orange-Peel Effect: is an uneven surface formation, much like that on the skin of an orange .When viewed under a magnifying glass, the paint surface looks rough, bumpy, or textured.Orange peel is caused by poor fusion of atomized paint droplets. Paint droplets dry out before they can flow out and level smoothly together. Note that some degree of orange peel can be found in most finishes, both OEM and repainted. It is when theorange peel becomes obvious or offensive that it becomes a paint problem.

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Bleeding: “ Discoloration” A Red or Yellow discoloration in the topcoat color. Solvent in the new topcoat dissolves soluble dyes or pigments in the original finish, allowing them to seep into and discolor the new topcoat. Allow color to cure, isolate with two component undercoat(s) and refinish.Or, remove original paint film and refinish.

Isolate suspected bleeding finish by applying a two component surfacer and/or sealer. Allow to cure following product recommendations, then apply desired topcoat.

Mottling: The existing paint film shrivels, wrinkles or swells during new finish application or drying.Solvents in a newly applied product attack the previous finish causing wrinkling, raising, or puckering of the paint film due to: Recoating enamels or urethanes that are not fully cured; Exceeding maximum flash or recoat times during application; Recoating a basecoat/clearcoat finish, where existing clearcoat has insufficient film build. Remove lifted areas and refinish.Check questionable finishes by rubbing a small inconspicuous area with a shop towel saturated with lacquer thinner. Finishes susceptible to lifting will soften, swell or shrivel as lacquer thinner is applied. If any of these reactions occur, the following recommendations should be considered. Do not exceed a product's maximum recoat time during or after application. Allow enamels or urethanes to thoroughly cure before recoating or attempting a repair. Avoid applying undercoats or topcoats excessively wet. Avoid the use of lacquer products over an air dried enamel finish. When insoluble material (enamel/urethane) has been applied over a soluble material (lacquer): avoid sanding through and exposing areas of the soluble material apply two component primer surfacer

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and/or sealer as a barrier between the new and the old finish. When applying two component undercoats over soluble finishes, the complete panel must be coated. Use water borne undercoats to repair extremely sensitive finishes.

Chalking: Oxidizing, Fading, Weathering

A chalky white appearance on the surface of the paint film

Pigment is no longer held and protected by resin, resulting in a powder-like surface and lack of gloss due to: Natural weathering of the paint film; Improper application of paint material; Using generic thinner/reducer and/or hardener in the paint material; Excessive use of mist/fog coats when applying single stage metallic finishes.Compound to remove oxidation and polish to restore gloss.

Or, sand to remove "weathered" paint film and refinish.Weekly washing and occasional polishing or waxing will remove oxidation from the finish.Thoroughly stir, shake or agitate all paint materials. Use the recommended thinner/reducer hardener, and measure accurately.When spraying single stage metallic finishes, apply mist/fog coats panel by panel while finish is still wet.

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Blushing: A milky gray cloud appears on the surface of the paint film immediately or shortly after application.

When spraying during humid conditions, air from the spray gun and solvent evaporation lowers the substrate temperature below the dew point, causing moisture in the air to condense in or on the paint film. The condition is aggravated when too fast drying or unbalanced thinner/reducer is used.

Should blushing occur during application: apply heat to the affected area, or add retarder and apply additional coats.If the finish has dried, minor blushing may be corrected by compounding or polishing, how ever, severe blushing will require sanding and refinishing.

Always use good quality solvent and thin/reduce material according to label directions. Select proper thinner/reducer for spray condition. AApply heat after application to evaporate moisture.

Cracking:Cracks or lines of various lengths and widths in the topcoat finish often resembling the cracking of dried mud.

Excessive film thickness of the undercoat and/or topcoat. Refinishing over a previously crazed/cracked surface. Insufficient flash time between coats and/or force drying undercoats using air from the spray gun. Mixing incorrectly or using too much hardener. Paint ingredients not thoroughly stirred or agitated. Breakdown of finish due to prolonged exposure to sunlight, moisture, and extreme temperature changes. Using generic reducers and/or hardeners.

Remove all cracked paint film and refinish. Apply all materials following label direction.

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Completely remove crazed/cracked finishes before refinishing. Do not force dry undercoats by fanning with spray gun air.Mix ingredients thoroughly using the recommended additives. Add each component in proper sequence following the recommended mixing ratio. Stir or agitate materials thoroughly before use to ensure all ingredients are in solution. Use premium two component undercoat and topcoat system to provide maximum gloss and durability. Use the recommended thinner/reducer and hardener, and then measure accurately.

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Conclusion:

The main focus in the development of automotive coatings is on the protection against corrosion, weathering, chemical and mechanical influences as well as appealing surfaces. Research continues unabated to further increase performance and appearance. Thus, this session focuses on topics such as scratch resistance by nanotechnology, generation of distinct rheological profiles, replacement of organic peroxide and improvement of flexibility.

If you look at the many types of automotive paints available for any vehicle, you will soon come to the conclusion that urethane auto paint presents the best value. Urethane paints combine the best in paint and plastics technology so that metals receive the best coverage possible.

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