Automotive painting processes - today and tomorro · Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt Introduction - Topographical

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


Introduction

Automotive painting - where does it come from?

Automotive painting today

Building blocks for future processes

Summary

Content


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


Introduction - Coating components

Pigments Binders

Solvents

Additives

Paint


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


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


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


Source:

Main focus

Improvement or keeping of product quality and performance

Reduction of process cost

Automotive painting today - Cost of car painting


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


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


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


cesses - Overview


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


cesses - New development Oxsilan (CHEMETALL) (I)


Cleaning Purge Activation Phosphatization DI purge Passivation DI purge

Cleaning Purge Bonderite DI purge DI purge

NGC

Zinc phosphating

Bonderite NGC process


cesses - New development Bonderite NGC (HENKEL)



cesses - New development Zircobond (PPG)


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)


Currentless deposition of the coating

Equal film build inside and outside

Very good edge coating

Overpaintable

Autophoreseis is in use worldwide in the

general industry for steel

Use for multi metal substrates in process

(Aquence - HENKEL)

Cleaning Oven Purge Reactive

purge ACC Purge

Cleaning Purge Purge Phosph. Activation Purge CDP Purge Oven

Possible substitute for

pretreatment and

electrocoat, significant

process shortening

Process until now

Possible new process

Automotive painting today - Technology trends in

preprocesses - Autophoresis


Substitution of phosphating and electrocoat by fusion of both layers

Simultaneous electrochemical deposition of an inorganic and an organic layer as corrosion

protection primer

Process simplification by reduction of single process steps in the preprocess

Useable for multi metal substrates

UV stable coating, therefore useable in primer-less paint structures

Intense research with combinations of intermediate metals and new polymers, in parallel

development of an optimized cleaner system

Inorganic layer

Metal reaction

Adhesion to substrate

Corrosion protection by

influence on corrosion

mechanism

Substrate

C e n t e g r a

Organic layer

Barrier properties

against H2O diffusion

Levelling

Primer for top coat

Automotive painting today - Technology trends in

preprocesses - Centegra (PPG)


Source:

Basic requirements and competitive factors

Smoothness (good levelling)

Stone chip resistance

Surface hardness for sanding purposes

Adhesion to CED and topcoat

UV-protection of CED

UV-durability

Process reliability

Contaminant resistance

Automotive painting today - Primer surfacers


Main requirements and competitive factors for effect colours

Process reliability

Circulation pipe stability

Reproducible colour and effect

No mottling

High smoothness (good levelling)

High hiding power (low film build)

No colour fading (weather stability)

Repairability, inline and in field

Short flash off

Clearcoat compatibility

Automotive painting today - Waterborne basecoats

Source:


Cavity

prot. E-coat

+ oven

Pretreat-

ment

WBBC1/2

Slurry

+ oven

Seam

sealing

+ oven

Blower/

CR

A-, B-

class

Rastatt

process

(since 1996)

WBBC 1

Integrated

process 1

(IP 1)

Mini

Oxford,

BMW

Spartanb.

Integrated

process 2

(IP 2)

Interme-

diate

oven 1

A-, B-

class

WBBC 2

Interme-

diate

oven 2

WBBC 1

WBBC 2

Interme-

diate

oven

Automotive painting today - Integrated waterborne

basecoats (I)


Ideal

Integrated

process 2

(IP 2) Oxford

Integrated

process 1

(IP 1)

Integrated

process 2

ideal (IP 2)

WBBC 2

I

P

WBBC 2

O

E

WBBC 1

O

E Slurry

WBBC 2

I

P

WBBC 2

O

P

WBBC 1

O

E 2p-clearcoat

WBBC 2

I

E

WBBC 2

O

E

WBBC 1

I

E

WBBC 1

O

E 2p-clearcoat

WBBC 1

I, O

E, P

Material

Inside, Outside

Electrostatic, Pneumatic

A-, B-

class

today

Technically

implemented

Interme-

diate

oven

Interme-

diate

oven

Interme-

diate

oven 1

Interme-

diate

oven 2

Automotive painting today - Integrated waterborne

basecoats (II)


Automotive painting today - New colours and new

effects


Automotive painting today - Clearcoats

Source:


Source:

Issue Performance Cost Environment

Ultrathin pretreatment

Ecoat Pb- and Sn-free

Ecoat low bake

Ecoat with reduced weight loss

Basecoat application 100% ESTA

Integrated (shorter) processes

Clearcoat scratch resistant

Clearcoat UV curable

Building blocks for future processes - Technology trends


Coating

components

Coating

materials

(paint)

Coating

(process)

technology

Process chain for coating research and application

Basic research - Application oriented research - Analytics - Services

Coating

University of Stuttgart

Institutes of physics - Chemistry - Manufacturing engineering -

Materials sciences

Basics

Process

chain

Education

and training

Building blocks for future processes - FRAUNHOFER

institute for manufacturing engineering in Stuttgart -

Fields of activity in paint and coating technology


Novel approaches with organic and/or inorganic

(nanoscale) coatings and coating components

Novel corrosion protection coatings

UV curing clearcoats

Coatings with reduced curing temperature

Optimized multilayer coating systems

Bio-based coatings

New coating

properties

Coating curing

New material- und

coating systems


R&D activities - Drivers for new coating systems


Fraunhofer IPA (Stuttgart)

Self-cleaning coatings on the basis of

UV/IR-reflection (AiF project)

Self-healing coatings “to cure” mechanical

damages and improve corrosion

prevention (planned project)

Fraunhofer ISC (Würzburg)

Photocatalytic coatings for interiors or anti-fogging in headlamps

Printed coatings for instrument panels or displays

Thin corrosion protection coatings as Cr(VI) alternative

Acid resistant easy-to-clean coatings for metallic surfaces

Abrasion resistant and easy-to-clean coatings for leather

Controlled

release


R&D activities - Novel approaches with organic and/or

inorganic (nanoscale) coatings UV

FORSCHUNGSGESELLSCHAFT

FÜR PIGMENTE UND LACKE E.V.


Nanoparticles fill the cavities of the

substrate surface


R&D activities - Novel corrosion protection coatings


Idea: Exploration of potential of nanoscale

corrosion protection pigments for use e.g.

in primer layers with improved corrosion

protection (AiF project)

Evaluation of self-healing properties and

adhesion of model coatings



Project supporting board



R&D activities - Optimization of UV-clearcoats


Idea: Concept development for UV-curing

clearcoats with optimized adhesion, high

weather resistance and optimized scratch

and chemical resistance

Improved understanding of UV-curing

process concerning kinetics

Consortium besides public funding



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R&D activities - Optimized multi layer coating systems


Idea: Economic and energy efficient

coating systems for automotive and

industrial coatings with reduced number of

layers

Improved understanding of opportunities

and limits of those systems

Project supporting board



EC

PS

BC

CC

EC

BC

CC

Corrosion

Delamination


Joint research project „Energy efficient coating

of car bodies“ (innovation alliance green car

body technologies)

Coating of complex plastic parts (project

ENSIKOM)

Numeric simulation of the paint drying process

(project SiLat)

Automated pretreatment with CO2 snow

blasting

Spray coating,

dryer concepts,

modularisation

UV technology

Drying process with

circulating air

Cleaning of parts


R&D activities - Developments in coating process

technology


Semi-finished part: Sheet metal

Tool shop

Press shop

Body shop

Paint shop

Joint research project

„Energy efficient coating of

car bodies“


R&D activities - Innovation alliance “Green car body

technologies”

Idea: Reducing energy consumption in

car body manufacturing

Initiative of German automotive

manufacturers and suppliers as well as

of FRAUNHOFER institutes




technologies” - “Energy efficient coating of car bodies”

Involved FRAUNHOFER institutes

IWU Chemnitz (total coordination)

IPT Aachen

IPA Stuttgart (coordination of joint research project “Energy efficient coating

of car bodies” with three subprojects

Spray coating

Dryer concepts

Modularisation


Source: Dürr Systems



technologies” - “Paint loss free coating methods”


Idea: Development of overspray free

coating methods

Drastically reduce energy intensive

disposal activities in paint shops

Minimization of demand for conditioned

air supply in spray booths

Eventually use of modified coating

materials

Elimination of overspray is the most

effective prerequisite for reducing energy

and material consumption at spray coating

Subproject partners


Source: Eisenmann



technologies” - “New dryer concepts for energy

efficient operation”


Idea: Plant specific and controllable “energy

on demand” and “energy regeneration”

measures for the optimization of curing areas

Energy savings up to 30%

Subproject partners


Source: Daimler AG



technologies” - “Modular concept for product and

coating”


Idea: Component optimized concept for

product and painting process

Multi material substrates

Reduction of material and energy

consumption in paint shops

Assembly of finished parts at OEM

Subproject partners



R&D activities - ENSIKOM Fraunhofer IPA (Stuttgart) and IFAM (Bremen)

Idea: Implementation of UV technology for eco-

friendly and economic coating of automotive plastic

parts

“100%” material transfer efficiency due to

overspray recycling

Low energy consumption due to UV curing of the

coating

Assistance by numeric simulation

UV curing of coating on three dimensional objects

Monitoring of molecular curing mechanism

Consortium partners (in total 13)

Daimler, other end-users, paint and facility manufacturers, institutes



R&D activities - SiLat (simulation of the unsteady

drying of coatings at three dimensional objects)


Idea: Creating a software to

simulate to forecast the drying of

coatings in continuous dryers

Prognosis of drying (curing)

kinetics

Elimination of coating defects by

product specific setting of oven

parameters

Consortium partners

.

Paint and facility manufacturers, software houses, universities

Heating of the car body during the first 5 minutes


Building blocks for future processes - New ideas

Self cleaning surface

Colour change of car body on demand

New functionalities in coatings

Energy collection

Internal labelling

Super durability of coatings

Fully automated processes (no touch, no repair)

…


Summary

Automotive painting materials and processes are continuously

changing

Actually dramatic change due to simultaneous change in

preprocesses and in primer/basecoats

New ideas will continuously change the appearance and optimize the

functionality of the coated products

Intelligent coating systems will offer new perspectives for coated

surfaces by implementation of smart functionalities

Coating processes will have to follow the needs according to the

megatrends and the changing substrates: Improvements in economy,

in ecology and sustainability and implementation of new functionalities

for improved customer satisfaction

Documents

Automotive painting processes - today and tomorro · Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt Introduction - Topographical