How is the Vehicle Painted

8/8/2019 How is the Vehicle Painted

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HOW IS THE VEHICLE PAINTED?

Everybody seems to have an opinion on how cars are painted at the factory.Some people think that all cars are painted manually. This is not true except forsome limited production and very expensive automobiles that are still beingpainted manually. The vast majority of vehicles are painted using an automatedprocess on the assembly line. Some people think that the vehicles are dipped in a

huge tank of paint to achieve their color and final finish. This is not true for thefinal steps, but it is true for the first primer process called the E-coat, or Electro-

primer.

STAGE 1

The E-coat is possibly the most important step in a paint process. This step givesthe vehicle its corrosion protection. These days the chances of large areas of thevehicle rusting out are now almost non-existent because of this step. The vehiclesare on the assembly line with the structural part of the bodies assembled and are

first cleaned of dirt, oil, and grease by way of a dip pretreatment whichpenetrates even the smallest cavities. Next is a rinsing and drying cycle and then

the bodies are electrocoated and dipped with this special rust-inhibitive primer.

ELECTROSTATICS

The electrostatic paint process; simply put, is achieved by negatively charging thepaint particles and grounding, or positively charging the workpiece (the vehicle)so that opposites attract. This is an environmentally responsible way to paint avehicle because it significantly increases quality and production, and equally

decreases paint costs and VOC emissions. This process produces a much highertransfer efficiency, which means more paint ends up on the vehicle, speeding up

the entire process and making it safer on the environment and more costeffective to the manufacturer.

In the case of the E-coat, the vehicle is electrocoated with levels that can becontrolled by sophisticated equipment. This will determine how much of thisprimer will stick to the vehicle surface after it is dipped and then goes throughanother rinsing and drying process. This is the last time the vehicle will be dippedin any kind of primer or paint. The rest of the painting process is done withautomated spray equipment.

ELECTROSTATIC SPRAY EQUIPMENT

In the remaining steps, the vehicle is painted with automated equipment. This isstill an electrostatic process, but the type of equipment may vary. Somemanufacturers use spray guns, but many are choosing a device called a rotaryatomizer or bell cup. This device does not look like a spray gun at all. It looks likea large bullet and at the nose, or cone, the paint is mixed, charged, and sprayed.The bell or nosepiece rotates at a very high rate of speed (up to 55,000 RPM) tofinely atomize the paint particles. In the pictures shown, the bell edge has very

fine serrations to further atomize the paint. A charging electrode is located at thetip and the atomized paint becomes negatively charged. Even further atomization

is achieved as the charged particles repel each other to form an even finer cloudof spray. There are other types of electrostatic spray equipment for assembly line

use as well as refinishing.

STAGE 2 SPRAY PRIMER


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After the vehicle goes through the E-coat dipping, rinsing and drying, it is thencaulked and sealed and sent into spray primer. This is a very important step for anumber of reasons. This primer will fill very minute scratches and imperfections inthe body, and also it gives the basecoat something to "stick" to. For years somecarmakers left out this step to save time and money, but it led to problems suchas chalking, powdering, and delamination. Also the primer can be made color

specific to better hide stone chips and scratches. BMW uses color specific primersnow on all their vehicles. For 1999 there are 16 different primers for 19 different

basecoat applications. This is obviously a much more expensive and time-consuming process, but it can make a big difference in customer satisfaction.

The next operation is the basecoat or color coat. This gives the vehicle its color.Basecoat will dry dull, like the old lacquer systems, and has no gloss. Thedifference is that the old lacquer paints needed to be sanded and buffed toachieve their gloss. Again, this was very time consuming and rather expensivebecause you had to apply enough coats with the anticipation that some of itwould be sanded and buffed off. With basecoats, all you want is coverage. A highfilm build is not needed, and there is no sanding or buffing of a basecoat.

CLEARCOAT

Basecoat/clearcoat systems have been around for quite a long time. ManyEuropean cars have been painted like this since the early 80's. However thetechnology has changed dramatically.

It all starts with what the manufacturer wants. A car company may want theirvehicle to have the absolute best gloss you can possibly achieve. They also willwant the surface to be resistant to scratches and marring. They also will want the

paint surface to be very resistant to atmospheric pollution, such as acid rain,industrial fallout, tree sap, bird droppings, stone chipping, etc. In a nutshell they

want the surface to be bulletproof. Unfortunately, for the manufacturer they willalmost certainly have to give up something to achieve something else. Forexample, if they want a great gloss they will have to give up a little durability. Iftheir concern is durability, the gloss may not be quite as rich. This is a double-edged sword. Some paint manufacturers say that the technology is available toproduce an almost bulletproof clearcoat but paint costs have skyrocketed. Mostcar manufacturers in trying to keep costs down will opt to play a game of giveand take with the clearcoat surface.

CHEMISTRY LESSON

A major difference between a factory or OEM clearcoat and a refinish clear is how

they are activated and dried. In a refinish situation the clearcoat can be air-driedand harden on it's own. In an assembly line situation, this would be much tootime consuming. On the assembly line, the vehicles must be painted, dried andon to next assembly step in a relatively short period of time. Therefore the paintschemical makeup is totally different. There are basically 2 types of OEM clearcoatsystems. The first is 1K or melamine; the second is 2K or polyurethane.

1K MELAMINE

In any type of paint system there must be activation, or something that starts the

drying and curing process. With a melamine clear or 1 component, the activation

is started by a baking process. It is activated or cross-linked by temperature andtime frame. This type of system is baked at a very high temperature, typically265-285 degrees farenheight for about 20-30 minutes. In this system the


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components in the resins are very stable and have a very long pot life, so noactivation or cross-linking will take place until it reaches a certain temperature.

2K POLYURETHANE

In a polyurethane system, it is a 2 component clearcoat that is more of achemical reaction and is accelerated by heat. The activation starts when the 2components are mixed together at the sprayer, where they are precisely blended,

before the paint is atomized and sprayed on the vehicle. This system is baked atlower temps, typically 140-165 degrees for about 30-40 minutes

There is still another type of technology available called powder- coating, in whichthe resins stay in powder form and adhere to the surface electrostatically. Thenthey are baked at a very high temperature and fused into a smooth coating. Thisis a very fast growing finishing technology. While not many vehicles are paintedwith this system there are more and more parts and components painted like this(such as wheels.)

CROSS LINKING

I have mentioned the process where the clearcoat starts its curing process as

cross-linking. The chemists I spoke with referred to this as cross-link density. Asdetailers we would refer to this as how hard or soft the paint is. My intention fordoing this research was to determine why some cars buff differently than othersusing the same procedure. Why were some cars left with swirl marks and somecars looked fine? Why does one vehicle have such a great shine and anothervehicle just looks okay after doing the exact same thing? It is not our imagination

playing tricks on us. It all comes back to this cross-link density.

Simply put, this is how tight or dense the surface will get after is it fully cured.Think of this as drawing a tic-tac-toe board, or checker board on a piece of paper.The smaller the squares and closeness of the lines will dictate a tighter or densersurface. The chemists would not generalize what paint systems were harder orsofter, (1K or 2K) or what makes and models had more shine or durability, butlooked at the chemical makeup of the clearcoat resin itself, the amount ofactivation, and the heat and duration of the baking process, as determiningfactors in how hard or soft and amount of gloss the car would have. Another keyfactor in gloss and appearance is the line speed of the vehicles on the assembly

line. If a car is moving at a very high rate of speed it does not give the paint achance to "lay out" and flow as well as a vehicle that is moving slower. Again,

time is money. Other factors that effect gloss are the flow rate or orifice openingin the sprayer and how well the paint is being atomized. These are all things that

the engineers have to take into consideration before the spray system isdesigned.

Another thing that the chemists agreed on was that no system is bulletproof.They design the paint system and clearcoat for what the carmaker wants andthere is always a degree of give and take involved.

WHEN TO WAX?

A topic for consideration, about which many people are misinformed, is when youcan wax the vehicle or apply paint sealant. Looking back at the curing process,

both the 1K and 2K systems are 90-95% cured upon cool down, after the bakeprocess, in the factory spray booth. The additional 5-10% will cure within 3-7days. This means that by the time any vehicle reaches its destination at a dealer,


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the paint is fully cured. By not applying some sort of protection to the paintsurface upon delivery or shortly after, the customer is actually hurting the paintinstead of helping it. Salesmen that say don't wax a car for 6-12 months aremisinformed. This is a huge problem in our business because customers will tendto believe a salesman who knows nothing about paint, rather than a trainedprofessional. This is often why fairly new cars are in such bad shape even after a

short period of time.

IS THERE A CHART?

I have been asked if there is a chart, or list, that can be made of vehicles withcharacteristics such as hardness and degree of shine and what the buffingprocedure should be. Unfortunately, it is not that simple. Even vehicles of thesame make can have different paint systems and it will vary from model to modeland place of origin. There also may be areas on the vehicle that have beenrefinished. That paint may react differently to buffing that the factory paint.

As a detailer you will see many different cars in all types of condition. There is noset in stone way to buff any car. Many detailers make the mistake of getting into

a comfort zone and in do the exact same thing on every vehicle regardless ofage, condition, make and model, or color. Even though you are buffing only the

clearcoat the background color or basecoat is the backdrop on how theimperfections will show up.

Hopefully by understanding the entire paint process and knowing that all factorypaints are far from the same, you may better understand what steps andprocedures are needed to produce a near flawless vehicle every time.


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2K (two component) fluorinated urethane aerosol paints

DISADVANTAGE of 1K AEROSOL PAINTS

1K aerosol paints are prevail in market. They are lacquers. Lacquer isproduced by dissolve thermoplastics into solvents. Properties ofthermoplastics depend on molecular weights. For better properties highermolecular weight of thermoplastics are required. High molecular weightthermoplastics are difficult to be dissolved in solvents. It becomes a balanceto increase solubility and reduce molecular weight, and therefore, sacrificesproperties. For accepted properties of thermoplastics 1K aerosol containstypically 3-5% of solids. Low solids mean low coverage. For same amount ofcoverage it creates higher VOC pollution.

Because there is no chemical bonding between thermoplastics andsubstrates. The lack of bonding means low adherent, it makes 1K aerosolpaints unacceptable for industrial coating standards. Since thermoplasticsused are dissoluble in many solvents. The coatings formed by 1K aerosolsare re-dissoluble by many solvents. Other properties, such as chemicalresistance, weathering resistance, mechanical strength, etc., are very poor.

ADVANTAGE of 2K AEROSOL PAINTS

2K aerosol are based on two parts of components. The polymer componentand crosslinker component. After mixing the two components react to form

cross-linked macromolecules under the action of catalysts. The cross-linkedmacromolecules have superior properties comparing to thermoplasticlacquers in 1K aerosols. The reactive components in the 2K system providestrong chemical bonding between macromolecules and substrates. Theproperties of 2K enamels do not depend on molecular weights of originalpolymer or molecular weight of cross-linker. Therefore, both componentscan be low molecular weights. High solids 2K aerosol paints are possible for2K aerosol paints. For example 40-60% solids of 2K aerosol paints can beprepared. One bottle of 2K aerosol paints is equal to 10-20 bottles of 1Kaerosol paints.

ADVANTAGE of FLUORO-URETHANE

The 2K fluoro-urethane has the best weathering, chemicals, solvents,microbial, and mildew resistance.

High percentage of fluorine contents of fluoro-urethane with higheststrength of fluorine-carbon bonds provides weathering, UV, and chemicalresistance.

Low surface energy, chemical resistance, water and oil repellence providesexcellent stain resistance and self-cleaning properties.


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2K fluoro-urethane uses polyisocyanate as cross-linker with very lowconcentration of free isocyanate. Polyisocyanate is isocyanate free polymermaterial. Common urethane formulations use a polyisocyanate with lowconcentration isocyanate, or isocyanate for higher rate of cross-linking.Free isocyanate put applicators in a hazardous environment, which is

dangerous due to toxic isocyanate presence. 2K aerosol fluoro-urethaneeliminate low concentration of free isocyanate during activation and mixingprocesses when all chemicals are still in the 2k aerosol can. During sprayprocess ther is no free isocyanate.

Cross-linked fluoro-urethane bond network provides chemical resistance,and mechanical strength.

Water repellence and oxygen barrier properties provides excellent corrosionprotection for coated metals.

Excellent electric properties on volume resistances, dielectric strength, andlow dissipation are beneficial for electronic coatings.

Fluoro-urethane provides water repellence and wet non-skid surfaces forbare foot contacts.

Broad optical transparency provides the brilliant color. By comparison,thermoplastic non-transparent fluoropolymer, such PVDF (Kynar 500), islack of gloss.

Non-combustible and heat resistance provides ideal surfaces for contactwith hot substances.

Low fraction coefficient and high mechanical strength provides abrasion,and wear resistance.

Graffiti, tar and 1 K paints on the surfaces can be cleaned with detergentwater or solvent wipe.

Mildew and mould can not grow on fluoro-urethane surfaces.

Dirt, bugs, fuel residue, pollutants, tree sap, and pollen will not able tostick to the coating.

Salts, acid, alkali, fuel, coolant, lubricating oil, break fluid, grease, wax willnot effect coated surfaces. Those pollutants can be removed with detergentwater.

APPLICATION of 2K FLUORO-URETHANE AEROSOL PAINTS

Luxecolor 2K aerosol paints combine the best paint material, 2K fluoro-urethane, with aerosol application convenience.


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2K fluoro-urethane can be applied on any solid surfaces: metals and alloys,such as iron, steel, aluminum, zinc, bronze, stainless steel, ceramics,porcelains, glass, thermoplastics, nylon, polycarbonate, epoxy, acrylics,polyesters, plastics, rubber, wood, paper, clothing, lather, wool, wires, PCBboards, and many other solid materials.

A primer is required only when a build-up surface is involved.

Versatile formulations are possible.

Followings are some professional and home applications:

Car finishes and repair Corrosion repair Repairing rusted surfaces Maintenance and repair of damage painted surfaces Aerospace, aircraft, jet, helicopter Marine, boat, ship, yacht, sport cruiser. Conformal coatings for PCB protection. Radar and antenna coatings. Repairing and touch up damage to metallic surfaces andobjects Vehicles, automobile, trucks, buses, trains, fleet, cycles,mopeds Pipe, railings, frame, gates and other metal structures Decorative, bathtub, wood, decals, signs, labels, graphics,

appliances, other minor applications

2 K aerosol provides a easy way to apply the complicated fluoro-urethane

paint without care about how to preparing the complex system. The 2 Kformulation contains two mutual reactive components, a catalyst, and otheringredients.

Proper cleaning of substrate is required. Surface must clean, without anyloss rust, silicone, grease, oil, wax and other contaminates.

If no oil, grease, or silicone contamination, even a rusted metal can bepainted directly by simple remove loss rust with sand paper.

For contaminated surfaces use medium concentrate detergent to removegrease, wax and other contaminants (silicone require polychlorinated


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solvent to clean it up) ; Use water and clean sponge to thoroughly washdetergent off ; Sanding with #200, #400, and #600 sand paper, Rinsing withclean water, Dry with lint-free and clean cloth; Allow surface drycompletely; Prime bare metal with 2 K primer; and Mask surrounding area.

HOW TO USE 2K AEROSOL

Activate and mixing 2 K components is a critical step: (1) Rotate aerosol canto familiarize the sound of a vial colliding with the aerosol can; (2) Firmlyhold aerosol can with stretch arm, risen to higher position and suddenlypulling down with fast movement to beak a vial, it may repeat severaltimes; (3) Rotate the aerosol can to check collision sound, if broken glasswith free rolling ball can be heard, go to next step, otherwise go back tostep 2; (4) Shake aerosol can for 5 minutes to mixing 2K component.

Application: Target the nozzle 4-8 inch distances with slow, even strokes.Spray "wet" coat, Allow 15-20 second spray second coat. Tack free time is 5-10 minutes, cure time is 6-8 hours. 2 K aerosol should used up in 8 hoursafter activation. After 8 hours, the aerosol formation becomes difficult.

Preparation: Checking color match carefully. Rub with xylene to test surfacebefore spray. If surface become soft or lifting with orange shape skin.thorough remove this area until see bare metal. Use 2 K primer to coverbare metal.

Luxecolor aerosol is equipped with a special nozzle to emit a fan-shaped

paint spray.

Luxecolor 2K aerosol contains approx. 340 grams of paint and with 40%solids which is enough for painting an area of 1 m2 or 10-12 square footarea.

Application Notice:

For high gloss surface using extra fine sending paper (400-600 grit) gentlyrub the surfaces and carefully remove the dust following by washing anddry.

Use tape, paper or insoluble plastic to protect any areas you do not want topaint.

Ensure adequate ventilation and use personal protective wear.

Paint 1 to 2 thin layers at a distance of 10-20 cm (4-8 inch) from the surfaceto be painted.

Let each layer dry for 15-20 seconds.


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Clean the aerosol nozzle after painting by turning the can upside down andpressing the nozzle until only gas comes out. Remove any fresh splashes ordefects.

The whole content in the aerosol can must be used during 8 hours after

activation.

Luxecolor 2k aerosol paints contains butyl acetate, xylene, and MEK (methylethyl ketone) as a solvent. Our next step of development is to replacingbutyl acetate, xylene, and MEK with non-hazardous solvents such asacetone, methyl propyl ketone (MPK), amyl methyl ketone, butyl propionatefor environmental friendly porpose.

Luxecolor 2k aerosol paints are propelled by DME (dimethyl ether) gas,which does not harm the ozone layer. The paint spray is highly flammableand should never be used near open flame or glowing objects, or in placeswhere static electricity could cause sparking or discharge. Smoking isprohibited where Luxecolor 2k aerosol paint is being applied.

Use Luxecolor products outdoors or only in adequately ventilated spaces.Always wear suitable protective face mask with organic vapor (activecarbon) air cartridge, clothing, gloves and eye protection. Store aerosolcans in cool, ventilated area. When transported, keep automobile cool. Donot puncture used containers or dispose of by burning, even when empty.

Our new development is PFOS and PFOA free, micronized PTFE powder

which is environmental friendly product.

On market all PTFE including Du Pont Tefron contain at least 200 ppm PFOAor PFOS.

PFOS, PFOA and other low molecular weight perfluoro surfactants aredangerous, bio-cumulative pollutants. Animal test showed they arecarcinogen, and cause liver tumors in animals. Human population statisticsshown that PFOS and PFOA increase breast cancers, birth defects, highcholesterol, and etc.. However, 95% of Americans, human including babies,of four continents, and animals all over the world have been contaminated

with PFOA and PFOS. PFOA and PFOS have been accumulated in protein,liver, and blood. For human, the main route is the anti-stain papers forfood package and dust particles from anti-stain carpets, non-stick cookingware, and food chains. All animal accumulate PFOA and PFOS from waterand food chains.

A new product, LuxeColor SS-1, is 2K aerosol stone sealer for granitesurfaces. It contains micronized PTFE, and is PFOS and PFOA free.

2K aerosol paints for industrial coatings have the 150 color shades as shownin our color cards.


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The color match to a color shade require 14 days ahead time and a minimum1 case (24 cans) order

Technical Data of Luxecolor 2K fluoro-urethane:

Properties A

white, highgloss Enamel

B

white, semi-gloss Enamel

C

TransparentHigh glossEnamel

Gloss 80 10 - 20 80

Adhesion Force Grade A Grade A Grade A

Hardness, Pencil 2H 2H 2H

Flexibility 1 mm 1 mm 1 mm

Scrub Resistance Tests, Circles >10,000 >10,000 >10,000

Solids, % w/w Solution > 50 > 50 > 50

Tack Free Time, minutes 5-10 5-10 5-10

Cure Time, hrs 8 8 8

Pot Life, hrs 8 8 8

Shelf Life, month 12 12 12

Recommend DFT, mils 0.5-1 0.5-1 0.5-1

Recommend Total Wet Coat,mils

1-2 1-2 1-2

Waterproof Tests, 288 hrs No Change No Change No Change

10 Days Immersion in 10%NaOH

No Change No Change No Change

10 Days Immersion in 10% HCl No Change No Change No Change

10 Days Immersion in 10%H2SO4

No Change No Change No Change

10 Days Immersion in 10% No Change No Change No Change


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Ammonia

Salt Spray Tests, 1,000 hrs No Peeling,No Foaming

No Peeling,No Foaming

No Peeling, NoFoaming

Accelerated Aging Tests, 5,000hrs

No Cracking,No Powdering



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