Technology of The Automotive Industry

10/1/2020 4.
BaseCoat / ClearCoat | Technology of the Automotive Industry
Technology of
the
Automotive
Industry
Technology of the Automotive
Industry
https://automotiveindustry.ru/en/paint_shop-bc-cc/ 1/23
10/1/2020 4. BaseCoat / ClearCoat | Technology of the Automotive Industry
CONTACT US 
HOME PRIVACY POLICY
INFORMATION 
COMPANY АВТОЗАВОДЫ РОССИИ
STAGES OF CAR PRODUCTION
BODY SHOP 
BODY SHOP – 1.WELDING OF BODY PARTS
BODY SHOP – 2-4.STAGES
BODY SHOP – 5-7.STAGES

PAINT SHOP 
PAINT SHOP – 1.CATAPHORESIS 
1.1.CATAPHORESIS-
ANAPHORESIS
1.2.CATAPHORESIS
– ANOLYTE
PROCESS
PAINT SHOP – 2.SEALER
PAINT SHOP – 3.PRIMER
PAINT SHOP – 4.BASECOAT/CLEARCOAT
PAINT SHOP – 5. ANTICORROSIVE PROTECTION
PAINT SHOP – 6. PAINT MIХROOM

ASSEMBLY SHOP 
ASSEMBLY SHOP – 1.PROCESSES AND
TECHNOLOGIES
PRODUCTION OF PARTS 
1.PRODUCTION OF PARTS – ABS
2.PAINTING PARTS – PLASTIC
3.PAINTING PARTS – POWDER COATING
ENGLISH РУССКИЙ
Paint Shop
4. BaseCoat / ClearCoat
Automotiveindustry.ru  01.01.2018
Копирование текста разрешено при условии ссылки Search … Search

на данный контент.4
Автоновости
4.1 BC/CC
The application takes place in 2 layers rst put the base В России ожидается
layer of enamel, next a layer of clearcoat. The body enters падение автомобильного
(enters) into the painting booth of the base layer. рынка
«РГ»: в России во время

пандемии выросли
продажи люксовых
автомобилей
Mercedes-Benz представил
длиннобазную версию
седана E-Class 2021
«Яндекс» сравнил расходы

на каршеринг, такси и
личный автомобиль
Volkswagen показал новый

The Spray booth consists of 12 operations: кроссовер Taos
1.
1. The body is blown with compressed air automatically in

the form of a frame, as well as manually with the help of
personnel.
2. Manual degreasing of the body surface using lint-free

wipes moistened in technical alcohol or impregnated by
the supplier in the form of disposable wipes.
3. Inspection of the bodywork by the painter on the subject

of polished areas, if necessary, painting 2K with universal
epoxy primer.
4. Manual painting of the internal space of the body, door

openings, engine compartment, trunk.
5. Robotic coloring of the front surface of the body with the

rst layer.
6. Exposure 2 minutes.
7. Robot painting of the front surface of the body with the

second layer.
8. Spare manual post in case of breakage of robots and

painting the front surface.
9. Flash off 12-15 minutes, i.e. the body travels further

along the booth; at this moment the house painters paint
the interior of the body, door openings, engine
compartment, and trunk with clearcoat.
10. Robotic painting of the front surface of the body 1K

clearcoat.
11. Spare manual post in case of breakage of robots and

painting the front surface.
12. Flash off zone 15 minutes before oven the complex.
In European manufactories, when painting the internal and

front surfaces of the body, automatic application of a
basecoat and cleatcoat is used. Manual application not
used in spray booth.
1. The body is blown with compressed air automatically in

the form of a frame, as well as manually with the help of
personnel.
2. Manual degreasing of the body surface using lint-free

wipes moistened in technical alcohol or impregnated by
the supplier in the form of disposable wipes.
3. Additionally and nally, the body is treated with special

rollers on which Emu feathers are installed. Feathers
remove static and nap that remained on the body.
4. The body “arrived” at the waiting point, then special

robots open the doors and x them, others paint the
interior, at the end of the painting the robots close the
doors and the same robots paint the front surface with a
delay between layers for 2-3 minutes. At the end of this
process of painting the body moves into the lacquer
chamber, where it is painted according to a similar process.
A signi cant advantage of this technology (process) is the

permanent sealing of the painting booth, the painters do
not enter and leave the painting booth. A complete
automated process allows you to save on materials and
reproduce quality to the level better, because There is no
human factor when painting. Accordingly, the dimensions
of the spray booth are signi cantly smaller than those of a
booth with manual posts. START / STOP technology is
used, the performance of automated booth in the range of
20-30 bodies per hour.
Basecoat AEO and AEM
Enamel (paint) or basecoat is designed for painting bodies

and plastic products in order to provide a decorative look.
The main components included in the basecoat:П
Pigments.
Fillers.
Different metallic materials (mica, titanium, aluminum,

etc.).
Saturated polyester resins.
Melamine resins or melamine alkyd resins.
Solvents, heavy, medium, light.
Aliphatic solvents.
Aromatic solvents.
Cellulose acetobutyrates.
Additives from litter, from coagulability and to

stabilize the paint.
AEO – not metallic under a clearcoat, thickness from

30 to 50 microns.
AEM – metallic, thickness from 10 to 25 microns

depending on color.
The thickness of the base and clearcoat should always

correspond to the speci cation, material passport or
technical speci cation.
The base of BC1 and BC2 is painted in the ratio of 60/40 or

70/30 between the robots of the rst and second layers,
this is necessary so that later the painted body has
maintainability in the case of point repair.
Base enamel must pass the entrance control before

painting and must comply with the following indicators:
1. Viscosity at delivery (initial viscosity) by viscometer VZ-

4 (VZ-246).
2. Mass fraction of non-volatile substances in%.
3. The degree of dilution to working viscosity in% (the

more, the better and more economical for the production
process).
4. Sedimentation or exfoliation.
5. Speci c volume electrical resistance.
6. The drying time of basecoat before applying claercoat.
7. Hiding power.
8. Color.
9. The appearance of the painted plate in the laboratory

(there should be no inclusions).
10. Coating strength at impact and tension.
11. Conditional light resistance.
12. Flash point in closed crucible.
13. Adhesion of the basecoat to the secondary primer.
1K Transparent clearcoat, or 1K a Clearcoat 130C.
1K Clear coat necessarily passes the input control before

painting and must comply with the following indicators:
1. Viscosity at delivery (initial viscosity) by viscometer

VZ-4 (VZ-246).
2. Mass fraction of non-volatile substances in%.
3. The degree of dilution to working viscosity in% (the

more, the better it is more economical for the
production process).
4. Speci c volume electrical resistance.
5. Color (should be transparent after the furnace).
6. The appearance of the painted plate in the laboratory

(there should be no inclusions).
7. Coating strength at impact and tension.
8. Conditional light resistance.
9. Flash point in closed crucible.
10. Adhesion to the base enamel.
11. Gloss coverage of at least 95%.
12. Resistance varnish to gasoline and water.
13. Resistance of varnish to bird droppings (European

methods and requirements).
Salt fog test is 1500 hours, the width of the X-shaped

incision does not exceed 1 mm.
Complies with quality standards.
Spraybooth BC / CC and Primer have a similar structure,

including the principle of operation. The only exception is in
size, it is longer due to the application of two layers in one
booth. The robots of metallized basecoat can also differ,
the principle of application can be pneumatic or the base /
clearcoat booth, also consists of 3 main parts:
The base (foundation) is a hydraulic lter. Due to the

circulation of water, the paint is washed off under the
grate oor of the main spraybooth, then the water is
ltered through the cleaning system and returned to
the spraybooth, and the paint is stored in containers,
i.e. This is a complete paint recycling system from the
spraybooth. The new approach is offered by German
companies, the EISENMANN E-Cube system is the
best in this segment. The principle is based on the air
ow of the inlet fans, with the help of the latest paint
waste is collected in cardboard boxes and right at the

time of the camera operation, the full boxes can be
replaced with empty boxes.
The spraybooth itself is of the type through passage;

oor chain conveyors or roller conveyors are used as
transport equipment. In order to save material, static
paint is used in almost all plants. In comparison with
the pneumatic principle, the economy of material is up
to 70%. An integral part of the working cycle is the
correct balance in the booth (horizontal and vertical
air ows), in the case of a weak stream, dust will
occur in front of or behind the running bodies, with a
strong stream of non-paint and blowing paint into the
hydraulic lter. The temperature range in the chamber
ranges from 19 ° C to 24 ° C and a relative humidity of
65-75%, regulated by industrial air conditioners.
At the top of spraybooth system is used with lters

duct called “plenum”, the problem of this design is to
create a working air balance in the booth and air
supply.
The connecting link between the application chamber and

the drying chamber is the “spreading zone”, this is a dust
tunnel with a length of about 15 meters and serves to
evenly spread paint on the body.
4.2 Oven Base/Clearcoat
The principle of operation of the drying booth (“Drying”),

namely the equipment, is completely identical to
cataphoresis and secondary primer. The difference lies in
the set temperatures for the zones and the heating rate of
the metal. The temperature window of the metal should be

30 minutes at 130 ° C.
Temperature by zones:
Gateway from 90 to 110 ° C
1 zone = 130 ° C
2 zone = 150 ° C
3 zone = 140 ° C
In Russia, gas is used as a fuel for heat generators of oven

booth; in Europe, infrared drying lamps with a certain
frequency and wavelength are used for drying booth. The
essence of the difference is only in the cost of energy.
After the oven booth, the body goes through a cooling zone
in order to lower the temperature and carry out the
following operations.
European industry uses more modern technologies of

applying a base and clear coat:
1. More and more technology and materials called 3WET

are gaining momentum, this is when 3 layers (Primer +
BaseCoat + ClearCoat) are applied wet on wet. Primer
+ Basecoat is water-based, which is cheaper when
recycling paint and making it. This technology requires

high quality on the paint line and ltration system,
because all defects will appear on the next layer.
2. Hi-Tech / Ceramic clearcoat / powder-based clearcoat.

All these clearcoat have an increased hardness of the
coating while not losing their elasticity. During
operation, less are chipped, scratched, the risks of
hand clearcoat. Used on premium cars. Powder lacquer
uses the company BMW, in fact, waste-free production,
because it is recycled (captured) and re-stained.
4.3 Polishing
The process is completely identical to the process of

grinding the body for the re nement and placement of
personnel, all the difference is only in materials.
Defects of the complex paintwork are detected visually and

tactile with the help of special gloves.
The grinding of the specks is eliminated with the help of

Dynadrady or 3M machines with 3M grinding discs A5 and
A7.
In extremely rare cases, manually using a keg.
Remains of grinding dust is removed, lint-free cloth 3M.
Put paste 3M – the most common and one-step is

considered to be 13,084. Polishing is carried out using
polishing machines f. Dynadrade or 3M – polishing time 1
point from 7 to 10 seconds.
Rubbing polishing paste residue.
4.4 Inspection, quality control of the coating
The inspector of the Quality Control Department on the

inspection line inspects the surface of the paintwork on the
painted body, then decides on its quality, if OK then sends

further to Movil (anti-corrosion coating), if not, for minor
repairs or repainting.
Selective quality control of the body.
Once a shift, the inspector or controller must check the

body of the same type and one color for compliance with
the requirements of the quality of painting, if the body
types are 5, then all 5 and all different colors are checked.
Quality indicators that are checked by an engineer or senior

quality inspectors:
Adhesion on non-face surfaces
Thickness of complex and layer coating
Thickness consists of:
cataphoretic coating from 20 to 25 microns (foreign

manufacturers from 30 to 35 microns)
secondary primer from 35 to 45 microns (foreign

manufacturers – the same indicators)
Base AEO or AEM, depending on the color and hiding

index from 10 to 30 or 40 microns
Clearcoat from 35 to 45 microns foreign

manufacturers – the same indicators)
The total average coverage is 22 + 40 + 20 + 40 = 122 μm,

with a repainting of the body, + 20 (Base) + 40 (clear) = 184
μm are added to 122 μm.
Practice has shown that a thickness of more than 200

microns leads to strong chips and a violation of the
elasticity of the lm, possibly with chips, detachment of the

full complex.
Gloss – measured by the instrument BYK-Gardner, gloss

varnish should not be below 95%.
Orange peel – is also checked using a BYK-Gardner Wave-

Scan.
Hardness – must be 0.7 (at the pendulum) or not lower than

HB.
The color is measured using the X-Rite device, BYK-Gardner

and visually, the panel is applied to the body and evaluated
for compliance, if necessary, corrected on the base robots.
Thickness – measured by the Elcometer device or more

expensive and modern thickness gauges, the cost in the
range of 150 thousand rubles. up to 1 million rubles
Reporting of paint and metal defects:
Quality control per unit of output, is recorded in all

defects for analysis and further response.
“Ideal production” of coloring, provided that products

are repaint per day by no more than 5%, in European
factories the indicator is in the range of 1–2%
(maximum).
4.5 Spot Repair and Heavy Repair
Small repair (Spot Repair) is used in the event that on the

surface of the body it is necessary to eliminate the defect
after straightening, tearing the paintwork with paintwork
(for example, touched with a hose), large or medium litter
in one place .
The body is driven into the painting booth, then the painter
mates the surface of the plot, puts the base, then 2K
clearcoat, then “blurs” the border with transitional clearcoat
to eliminate the visibility of the transition boundaries
between the repair and conveyor surfaces.
Drying is carried out with the help of an IR lamp, heating the

surface to 130 ° C for 15 minutes, then the metal cools
naturally at ambient temperature, then the painter polishes
the painted surface and the body goes to the application
station (anticorrosive).
Repaint (Heavy Repair) or replacement of body elements is

divided into 2 stages:
1. In the case of a mass defect on the body, not paint,

clouds, pulsations, i.e. all those defects that do not
meet the quality standard must be eliminated or

repainted, then the body is prepared for re-painting
according to the process of identical grinding of
secondary primer, but the whole surface is necessarily
matted, otherwise there will be no adhesion and the
body will be written off into marriage. By all the rules
and regulations, only 1 repaint is allowed, then the
body is rejected and written off.
2. Replacing any elements of the body, i.e. Everything

that is removed on the body is sent to the OK (Quality
Department), the parts that have not passed the
Quality Control Department, are painted separately on
the defective body and are left for possible
replacement of another body. In this case, a
mandatory rule, all elements and parts are painted in
the same color to eliminate tonal differences. Such a
defect may serve as an argument for replacing the
vehicle or item.
Previous
5.Anticorrosive protection – Paint Shop
Next
3.Primer – Paint Shop
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10/1/2020 4.

BaseCoat / ClearCoat | Technology of the Automotive Industry

BODY SHOP – 2-4.STAGES

BODY SHOP – 5-7.STAGES

PAINT SHOP – 2.SEALER

PAINT SHOP – 3.PRIMER

PAINT SHOP – 4.BASECOAT/CLEARCOAT

PAINT SHOP – 5. ANTICORROSIVE PROTECTION

PAINT SHOP – 6. PAINT MIХROOM

2.PAINTING PARTS – PLASTIC

3.PAINTING PARTS – POWDER COATING

Копирование текста разрешено при условии ссылки Search … Search

«РГ»: в России во время

«Яндекс» сравнил расходы

Volkswagen показал новый

1. The body is blown with compressed air automatically in

2. Manual degreasing of the body surface using lint-free

3. Inspection of the bodywork by the painter on the subject

4. Manual painting of the internal space of the body, door

5. Robotic coloring of the front surface of the body with the

7. Robot painting of the front surface of the body with the

8. Spare manual post in case of breakage of robots and

9. Flash off 12-15 minutes, i.e. the body travels further

10. Robotic painting of the front surface of the body 1K

11. Spare manual post in case of breakage of robots and

12. Flash off zone 15 minutes before oven the complex.

In European manufactories, when painting the internal and

1. The body is blown with compressed air automatically in

2. Manual degreasing of the body surface using lint-free

3. Additionally and nally, the body is treated with special

4. The body “arrived” at the waiting point, then special

A signi cant advantage of this technology (process) is the

Basecoat AEO and AEM

Enamel (paint) or basecoat is designed for painting bodies

The main components included in the basecoat:П

Different metallic materials (mica, titanium, aluminum,

Saturated polyester resins.

Melamine resins or melamine alkyd resins.

Solvents, heavy, medium, light.

Additives from litter, from coagulability and to

AEO – not metallic under a clearcoat, thickness from

AEM – metallic, thickness from 10 to 25 microns

The thickness of the base and clearcoat should always

The base of BC1 and BC2 is painted in the ratio of 60/40 or

Base enamel must pass the entrance control before

1. Viscosity at delivery (initial viscosity) by viscometer VZ-

2. Mass fraction of non-volatile substances in%.

3. The degree of dilution to working viscosity in% (the

5. Speci c volume electrical resistance.

6. The drying time of basecoat before applying claercoat.

9. The appearance of the painted plate in the laboratory

10. Coating strength at impact and tension.

11. Conditional light resistance.

12. Flash point in closed crucible.

13. Adhesion of the basecoat to the secondary primer.

1K Transparent clearcoat, or 1K a Clearcoat 130C.

1K Clear coat necessarily passes the input control before

1. Viscosity at delivery (initial viscosity) by viscometer

2. Mass fraction of non-volatile substances in%.

3. The degree of dilution to working viscosity in% (the

4. Speci c volume electrical resistance.

5. Color (should be transparent after the furnace).

6. The appearance of the painted plate in the laboratory