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Automotive Painting Processes - Today and Tomorrow - Dr. Michael Hilt, Fraunhofer Institute, Germany PDF
Automotive Painting Processes - Today and Tomorrow - Dr. Michael Hilt, Fraunhofer Institute, Germany PDF
tomorrow
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Content
Introduction
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
Binders Adhesion
Recipies Substrate
Pigments Corrosion
Dispersion pretreatment
Additives protection
Rheology Application
Thinners, Durability
Colouration Drying, curing
solvents Functionality
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Solvents
Paint
Additives
Pigments Binders
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
Film/Air Interface
Bulk film properties
Film
Opacity
Flexibility
Interface
Film/substrate Diffusion
Substrate
Chemical resistance
interface properties
Water uptake
Weather resistance
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
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive Painting - where does it come from? - Ex-
ternal influences on a coated car surface
Physical influences Chemical influences
Coating surface
FORSCHUNGSGESELLSCHAFT Dr. Michael Hilt, Automotive OEM Coatings, Process and Materials 2011-05-16.ppt
FÜR PIGMENTE UND LACKE E.V. 7
Film build
in µm
Material type Usage in kg on car in kg Relative cost in %
110
100
Clearcoat 2.1 1.0 25
2K-Klarlack
80 Basecoat waterborne 4.0 0.5 25
60 WBL „2“
Primer surfacer 2.5 0.8 15
WBL „1“
WBL
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Cost of car painting
Main focus
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Primer
Seam Baking Baking San-
surfa-
sealing oven oven ding
cer
San-
Base- Drying Clear- Baking ding,
coat oven coat oven poli-
shing
As-
Spot Body
Wax sem-
repair repair
bly
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Alternatives for prepro-
cesses - Reasons
Development of alternative products for zinc phosphating
Goals
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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 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 Silane Purge
DI purge DI purge
Silan treatment
(Brownfield)
Cleaning Purge Silane Purge Empty
DI purge DI purge
Zink phosphating
as at today
Cleaning Purge Phosphatization Purge
DI purge Passivation
DI purge
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Zinc phosphating
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
Corrosion protection
Process reliability
Contaminant resistance
No entry markings
Low consumption in kg
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Technology trends in
preprocesses - Autophoresis
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Intense research with combinations of intermediate metals and new polymers, in parallel
development of an optimized cleaner system
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Primer surfacers
Basic requirements and competitive factors
UV-protection of CED
UV-durability
Process reliability
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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:
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Integrated waterborne
basecoats (I)
Integrated
Mini
Interme-
process 2 WBBC 1 WBBC 2 diate
Oxford,
(IP 2) oven BMW
Spartanb.
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
WBBC 1 Material
I, O Inside, Outside
E, P Electrostatic, Pneumatic
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - New colours and new
effects
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source:
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Building blocks for future processes - Technology trends
Issue Performance Cost Environment
Ultrathin pretreatment
Clearcoat UV curable
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Coating Coating
Process Coating
materials (process) Coating
chain components
(paint) technology
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 - Drivers for new coating systems
UV curing clearcoats
Coating curing
Coatings with reduced curing temperature
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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 - Novel corrosion protection coatings
Fraunhofer IPA (Stuttgart)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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 - Optimized multi layer coating systems
Fraunhofer IPA (Stuttgart)
BC Delamination
EC Corrosion
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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 - 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
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Spray coating
Dryer concepts
Modularisation
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 - Innovation alliance “Green car body
technologies” - “Paint loss free coating methods”
Fraunhofer IPA (Stuttgart)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Subproject partners
Source: Eisenmann
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 - Innovation alliance “Green car body
technologies” - “Modular concept for product and
coating”
Fraunhofer IPA (Stuttgart)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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)
.
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Energy collection
Internal labelling
…
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Summary
New ideas will continuously change the appearance and optimize the
functionality of the coated products
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt