Automotive painting processes - today and tomorrow - European ...

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

Content  Introduction

 Automotive painting - where does it come from?

 Automotive painting today

 Building blocks for future processes

 Summary

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

Raw materials    

Binders Pigments Additives Thinners, solvents

Paint

Painting technology

Coating

Painting material

   

Recipies Dispersion Rheology Colouration

Finished surface

 Adhesion  Corrosion

 Substrate

pretreatment  Application  Drying, curing

protection  Durability  Functionality


Introduction - Coating components Solvents Paint

Additives

Pigments


Binders

Introduction - Topographical classification of coating Top surface properties properties      

Light reflection Hardness Scratch resistance Surface slip Repellent properties Erosion resistance

Film/Air Interface

Bulk film properties Film Interface Substrate

Film/substrate interface properties  Adhesion  Durability  Anticorrosion

     

Opacity Flexibility Diffusion Chemical resistance Water uptake Weather resistance

Source: S. K. GOSH, Functional Coatings


Automotive Painting - where does it come from?  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) Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt

Automotive Painting - where does it come from? - External influences on a coated car surface  Physical influences

 Chemical influences

 Mechanics  Scratches  Stone chips  Car care materials  Abrasion

 Fuel, brake fluid, washer fluid …  Care care materials  Environmental chemicals  Tree sap  “Sour" residues  Bird excrements  Other materials (metal dust, carbon, ...)

 Radiation (sun light)  Temperature change

Coating surface FORSCHUNGSGESELLSCHAFT FÜR PIGMENTE UND LACKE E.V.

Dr. Michael Hilt, Automotive OEM Coatings, Process and Materials 2011-05-16.ppt

7

Automotive painting today - Consumption data

Film build in µm

Material type

110 100

2K-Klarlack 80

60

WBL „2“ WBL „1“

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

WBL

40 Wasserfüller

20

KTL 0


Automotive painting today - Cost of car painting

 Main focus

 Improvement or keeping of product quality and performance  Reduction of process cost Source:


Automotive painting today - Classical painting process Online plastic parts Body in white

Inline plastic parts

Offline plastic parts

Body washer

Pretreatment

Electrocoat

Baking oven

Sanding

Seam sealing

Baking oven

Primer surfacer

Baking oven

Sanding

Basecoat

Drying oven

Clearcoat

Baking oven

Sanding, polishing

Spot repair

Body repair


Wax

Assembly

Automotive painting today - Alternatives for preprocesses - Reasons 

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 preprocesses - Overview  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 preprocesses - New development Oxsilan (CHEMETALL) (I)  Spray or dip process

 2 min process time

 Solution in DI water

 pH ca. 4

 2 products

 Tank control: pH, conductivity, material content

 Room temperature

Silane treatment (Greenfield) Cleaning

Purge DI purge

Silane

Purge DI purge

Cleaning

Purge DI purge

Cleaning

Purge Phosphatization DI purge

Silan treatment (Brownfield) Silane

Purge DI purge

Empty

Zink phosphating as at today Purge Passivation DI purge


Automotive painting today - Alternatives for preprocesses - New development Bonderite NGC (HENKEL) Zinc phosphating

Cleaning

Purge

Activation

Phosphatization

DI purge

Bonderite NGC process

Cleaning

Purge

Bonderite NGC

DI purge


DI purge

Passivation

DI purge

Automotive painting today - Alternatives for preprocesses - New development Zircobond (PPG)


Automotive painting today - Electrocoats (I)  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 Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt

Source:

Automotive painting today - Technology trends in preprocesses - Autophoresis     

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)

Possible substitute for pretreatment and electrocoat, significant process shortening

Process until now Cleaning

Purge

Activation Phosph.

Purge

Purge

Purge

Oven

CDP

Purge

Oven

Possible new process Cleaning

Purge

ACC

Reactive purge


Automotive painting today - Technology trends in preprocesses - Centegra (PPG)  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

Organic layer  Barrier properties

against H2O diffusion  Levelling  Primer for top coat

C entegra Substrate


 Metal reaction  Adhesion to substrate  Corrosion protection by

influence on corrosion mechanism

Automotive painting today - Primer surfacers  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

Source:


Automotive painting today - Waterborne basecoats

 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

Source:


Automotive painting today - Integrated waterborne basecoats (I)

Rastatt process (since 1996)

Pretreatment

E-coat + oven

Seam sealing + oven

Blower/ CR

Integrated process 1 (IP 1)

WBBC 1

Intermediate oven 1

WBBC 2

Integrated process 2 (IP 2)

WBBC 1

WBBC 2

Intermediate oven

WBBC1/2

Slurry + oven

A-, Bclass

Cavity prot.

Intermediate oven 2

A-, Bclass

Mini Oxford, BMW Spartanb.


Automotive painting today - Integrated waterborne basecoats (II) Integrated process 1 (IP 1)

Integrated process 2 (IP 2) Oxford

Integrated process 2 ideal (IP 2)

WBBC 1

O E

Intermediate oven 1

WBBC 2

WBBC 2

I P

O E

WBBC 2

WBBC 1

WBBC 2

I P

O E

O P

WBBC 1

WBBC 1

WBBC 2

WBBC 2

I E

O E

I E

O E

Intermediate oven

Intermediate oven 2

A-, Bclass today

Slurry

Technically implemented

2p-clearcoat

Intermediate oven

2p-clearcoat

Ideal

WBBC 1

Material

I, O E, P

Inside, Outside Electrostatic, Pneumatic


Automotive painting today - New colours and new effects


Automotive painting today - Clearcoats

Source:


Building blocks for future processes - Technology trends 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



 Source:






Building blocks for future processes - FRAUNHOFER institute for manufacturing engineering in Stuttgart Fields of activity in paint and coating technology

Basics

Process chain

Education and training

Process chain for coating research and application Basic research - Application oriented research - Analytics - Services

Coating components

Coating materials (paint)

Coating (process) technology

Coating

University of Stuttgart Institutes of physics - Chemistry - Manufacturing engineering Materials sciences


Building blocks for future processes - FRAUNHOFER R&D activities - Drivers for new coating systems

New coating properties

 Novel approaches with organic and/or inorganic

(nanoscale) coatings and coating components  Novel corrosion protection coatings

Coating curing

 UV curing clearcoats  Coatings with reduced curing temperature

New material- und coating systems

 Optimized multilayer coating systems  Bio-based coatings


Building blocks for future processes - FRAUNHOFER R&D activities - Novel approaches with organic and/or inorganic (nanoscale) coatings UV  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)

Controlled release

FORSCHUNGSGESELLSCHAFT FÜR PIGMENTE UND LACKE E.V.

 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


Building blocks for future processes - FRAUNHOFER R&D activities - Novel corrosion protection coatings  Fraunhofer IPA (Stuttgart)  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 FORSCHUNGSGESELLSCHAFT FÜR PIGMENTE UND LACKE E.V.

 Project supporting board

Nanoparticles fill the cavities of the substrate surface


Building blocks for future processes - FRAUNHOFER R&D activities - Optimization of UV-clearcoats  Fraunhofer IPA (Stuttgart)

 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 FORSCHUNGSGESELLSCHAFT FÜR PIGMENTE UND LACKE E.V.

 Consortium besides public funding


Building blocks for future processes - FRAUNHOFER R&D activities - Optimized multi layer coating systems  Fraunhofer IPA (Stuttgart)

 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 FORSCHUNGSGESELLSCHAFT FÜR PIGMENTE UND LACKE E.V.

CC BC PS EC

 Project supporting board

CC BC EC

Delamination Corrosion


Building blocks for future processes - FRAUNHOFER R&D activities - Developments in coating process technology Spray coating, dryer concepts, modularisation

UV technology

 Joint research project „Energy efficient coating

of car bodies“ (innovation alliance green car body technologies)

 Coating of complex plastic parts (project

ENSIKOM)

Drying process with circulating air

 Numeric simulation of the paint drying process

Cleaning of parts

 Automated pretreatment with CO2 snow

(project SiLat)

blasting


Building blocks for future processes - FRAUNHOFER 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 Paint shop

Body shop

Press shop

Tool shop

Semi-finished part: Sheet metal

Joint research project „Energy efficient coating of car bodies“


Building blocks for future processes - FRAUNHOFER R&D activities - Innovation alliance “Green car body 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


Building blocks for future processes - FRAUNHOFER R&D activities - Innovation alliance “Green car body technologies” - “Paint loss free coating methods”  Fraunhofer IPA (Stuttgart)

 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

Source: Dürr Systems

 Subproject partners


Building blocks for future processes - FRAUNHOFER R&D activities - Innovation alliance “Green car body technologies” - “New dryer concepts for energy efficient operation”  Fraunhofer IPA (Stuttgart)

 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: Eisenmann


Building blocks for future processes - FRAUNHOFER R&D activities - Innovation alliance “Green car body technologies” - “Modular concept for product and coating”  Fraunhofer IPA (Stuttgart)

 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 Source: Daimler AG

 Subproject partners


Building blocks for future processes - FRAUNHOFER R&D activities - ENSIKOM  Fraunhofer IPA (Stuttgart) and IFAM (Bremen)

 Idea: Implementation of UV technology for ecofriendly 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 Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt

Building blocks for future processes - FRAUNHOFER R&D activities - SiLat (simulation of the unsteady drying of coatings at three dimensional objects)  Fraunhofer IPA (Stuttgart)

 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

Heating of the car body during the first 5 minutes

 .  Paint and facility manufacturers, software houses, universities


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
