CED PAINTING

By
Murugadas P.
Tractors and Farm Equipment Limited (TAFE),
Doddaballapur Operations.
PAINT – INDUSTRIAL REVOLUTION & ELECTROCOAT DEVELOPMENT:
 Auto Mfrs. recognized problems with corrosion in the interior and recessed areas of car bodies.

 Ford electro coated the first wheels in 1961, with anodic E-coat.

 Anodic Electro deposition Since 1961 (FORD-Patent) Heyday: 1965 till approx. 1978.

 Cathodic Electro deposition ;Starting in 1975 State-of-the-art technology till today.

 Initially used for decorative purposes and slowly moved to protective coatings, ships & air
crafts painting.
CUSTOMER EXPECTATION

Better
Corrosion Require
Resistance CED coating
Eco-
High-Gloss
Friendly
& DOI
Coating

Customer
Expectation
Aesthetic
Durability
Look

Scratch
Low Cost
Resistance
AUTOMOTIVE OEM LAYERS – MAIN RESPONSIBILITIES

Chemical, Scratch & Weather 40-50 µ

resistance, Appearance, gloss

Color , Covering power

UV - Protection
15-25 µ

Smoothing ,
Stone chip Guard ; 30-40 µ
UV - Protection

Corrosion Corrosion protection 18-25 µ

resistance (together with pretreatment layer)
WHAT IS ELECTROCOAT ?
 Electro coat is an organic coating system that uses electrical current to deposit paint onto
a part or assembled product

 Due to its ability to coat complex parts and assembled products with specific performance
requirements, PPG electro coat is used worldwide throughout industry to coat various
products:

 Agricultural equipment
 Appliances
 Marine components
 Automobiles and auto parts

Proper pretreatment is so vital for successful Electro coating

ELECTRODEPOSITED PARTS
COMPONENTS OF AN ELECTROCOAT BATH
1. Resins - Holds the paint film together
Typical 20 % Solids of E-Coat
2. Pigments – Gives paint its appearance
1–2%
3. Solvents & Additives – Flow controls &
appearance
78 – 79 %
4. Water - Keeps paint liquid

WATER 16 %

• Must be free of dissolved salts and ions.

4%
• Conductivity below 10 µS required.
• DI are primary methods used to produce
quality water.
 TYPES OF ELECTRO DEPOSITION

Anodic Electro Deposition Cathodic Electro Deposition

Sl no Characteristics AED CED
1 Pencil hardness min.H-2H min.2H-3H
2 Impact resistance min . 30cm. min . 50cm.
3 Corrosion resistance ( Zinc phosphate dip ) 600 hours 1100 + hours
4 Acid resistance ( 0.2N H2SO4) 5 days 8-9 days
5 Distinctness of image 7-8 8-9
Other advantages of the cathodic electro - deposition are :

1. Increased throwing power with better paint capability to reach recessed areas, which difficult with anodic system.

2. Smoother film deposit during baking, and so lesser necessity of rectification work that ensure a smoother final finish.

3. With its better corrosion resistance, the DFT can be reduced (up to 50% in comparison with the DFT of anodic paint.)

4. Less problem in maintenance of the quality of paint as the cathodic paint has a greater resistance to bacteria.
CLASSIFICATION
 Anodic electro deposition “Substrate acts as anode”
ANODIC ELECTRODEPOSITION (AED)
 Substrate acts as anode
 Resin made water soluble by introducing carboxylic group
 Neutralized with ammonia or other base Anodic
(-) (+)
DC
REACTIONS AT ANODE
Acid
(H+)

Decomposition of water
2H2O - 2e- 2OH- +2H+ Paint(-) Fe++
2OH- H2O + [O]
2[O] O2
Anode Cathode

Neutralization of charged anion by hydrogen ion Moderate Corrosion

Resistance

RCOO- + H+ RCOOH
CLASSIFICATION
 Cathodic electro deposition “Substrate acts as cathode”
 CATHODIC ELECTRODEPOSITION (CED)
 Substrate acts as cathode

 Amine modified resin reacted with acid

Cathodic
(+) (-)
REACTION AT CATHODE DC

Basic
(OH-)
Decomposition of water producing hydroxyl and hydrogen ion

2H2O 2OH- +2H+ Paint(+) Fe++

2H++2e- 2[H] H2 Anode Cathode

Neutralization of charged ion by hydroxyl ion - Excellent Corrosion

- Best ability to coat inner surfaces
- Resistance (All applications)

R–N–R + OH- R–NR2 + H2O

H
 COMPARISON OF LIQUID SPRAY / POWDER / CED
Water based Solvent
Factor Powder Electrocoat
paint based
Coating
Uniformity Fair Fair Good Excellent
Operating Efficiency Fair Fair Excellent Excellent
Recess area coverage Fair Fair Poor Excellent
Resistance to runs Fair Fair Excellent Excellent
Color change Good Good Moderate Poor
Environmental
Water pollution Low Moderate Noble Slight
Air pollution Low Moderate Low Low
Cost
Capital Low Low Moderate High
Applied cost Moderate Moderate Moderate Low
CED – CATHODIC ELECTRO DEPOSITION

ELECTRO CHEMICAL REACTIONS :

- Electrolysis

- Electrophoresis

- Electrodeposition

- Electro endosmosis
ELECTROLYSIS :
Electrolysis of water is the decomposition of water into oxygen and hydrogen gas due to an
electric current being passed through the water. The reaction has a standard potential of
−1.23 V, meaning it ideally requires a potential difference of 1.23 volts to split water.
During the process, oxidation and reduction reactions will takes place simultaneously.

Oxidation is the process of losing one or more electrons – Loss of electrons / Electrons will
get released.

2H 2 O O 2 (G as) + 4 H + + 4 e-

Reduction is the process of gaining one or more electrons.

2H2O + 2 e- H2 (Gas) + 2 OH-

ELECTROPHORESIS
Electrophoresis is a separations technique that is based on the mobility of ions in an
electric field. ... Ions have different migration rates depending on their total charge, size,
and shape, and can therefore be separated.
ELECTRO DEPOSITION

1. Positively charged particles contacts alkaline surface.

2. Alkaline conditions causes precipitation of E - Coat paint particles.

3. Caustic & other highly alikaline materials are extremely detrimental to E - Coat paint.
TYPICAL INDUSTRIAL E-COAT BATH AND POST-RINSE SYSTEM
EPOXY LINED FLOOR & WALLS
EDUCATOR NOZZLE CED PAINT CIRCULATION

ED MAIN TANK EDUCATOR NOZZLE

ELECTRIFICATION :
ELECTRO ENDOSMOSIS
Electro endosmosis is the movement of liquid in a porous material due to an applied electric
field. The phenomenon of electro-osmosis is very useful in chemical separation techniques and
buffered solutions. Electro endosmosis or electro-osmosis can be used for organics removal. It
reduces the need for specialized electrodes. Electro endosmosis is also known as electro-osmosis
or electro osmotic flow (EOF).

ELECTRO ENDOSMOSIS THROWPOWER

Electrical charge draws paint tightly to Ability to coat recessed or hidden areas.
part.
Deposition process continues until paint
Film dehydrated by this process. film has uniform high electrical resistance.

Film resistant to physical distortion. Easily accessible areas coat first followed by
the more hidden areas.
FILM FORMING DURING THE ELECTRODEPOSITION :

• The amount of deposited material decreases with the time of deposition, as

the film forms a layer with strongly reduced conductivity.

• Depending on the softness of the E- coat (Tg of the resin), normal film
thickness (15 – 25 μm) up to high film build (25 – 50 μm) can be generated

• Throwing power: the ability of the E- coat to penetrate into holes

• The film is almost dry after deposition (<2% water) after rinsing
TURNOVER :

Is the time for full consumption of the material in the tank,

• Depends on coated surface/time

• Typical turnover is 2-5 weeks, but can go up to 1 year (stability challenge!)

• Tank size and turnover define the consumption of the

material; tank size can go up to 500 m³ (bigger cars, buses)
ANOLYTE & ULTRAFILTRATION :

• ANOLYTE = liquid phase in the anode, which absorbs the acid which is
generated by the deposition.

• ULTRAFILTRATION = additional removal of waterborne components from

the coatings system.
ANOLYTE SYSTEM:
Purpose The anolyte / catholyte is needed to control solubilizer levels of the paint bath.

Potential Problems

• Inability to maintain pH of the paint bath.

• Thin Paint
• Rupture
• No Paints

Preventive Actions

 Check for proper liquid level

 Check for proper functioning of the conductivity set point indicator probe
 Check for water supply availability
 Check the supply and return flows
ELECTRIFICATION :
 DIFFERENT TYPES OF ANODES

Anodes
Plate Tubular "C" Cell
Anolye solution
Outlet Shrink Wraped
Lead Connection Stainless Steel Bold
Anti-siphon Stainless Steel Nut
Hole

Plastic
Reinforcement

Semi-permeable
Membrane
Gasket
316L SS
Anode Housing
CED – ANOLYTE SYSTEM : REMOVES EXCESS ACID

1. In electrocoat system , an electric field is applied

between the object (-ve electrode ) & the counter
electrode by means of a DC power supply.

2. The paint solids are thereby attracted towards the

object (Cathode) releasing the solubilizer counter ions
(acid) into the E-Coat bath.

3. It is very important to remove the acidic solubilizer

counter ions released during the process to ensure
stability of CED bath.

4. This work of removing acid from the paint is done by

another circuit in the E-coat system called as Anolyte
system.
WORKING ANOLYTE SYSTEM IN CED :
1.The system only works when the current in ON !

2. The acidic Solubilizer ions gets attracter towards anode

thru membrane.

3. This acid Solubilizer ion forms acid bonding with H+

ions.

4. This mixture of acidic solubilizer with water is called as

anolyte.

5. The Circulation of Anolyte thru membrane even helps in

cooling the anodes.

6. The anolyte also contains low level metals ( iron ,

Chromium , nickel ) formed due to dissolution of anode.
ANOLYTE CONDUCTIVITY IN CED :
HIGH Conductivity LOW Conductivity

1. Can increase anode dissolution. Excess DI water usage

2. Due to more acidic can increase wear & tear

Will reduce throw power.
of anolyte equipments.

3. Can cause anode membrane fouling. Low film build-up.

4. Over flow in paint can cause dirt in paint or

Increase waste & cost.
more contaminantsin paint
ULTRA FILTRATION SYSTEM (UF) :
Purpose:

•To provide water for final rinse stage to accomplish

“closed loop” rinsing.

•To provide a means to purge paint of water soluble

contaminants.

Understand the Process:

•Ultrafiltration is a form of filtration that uses membranes to preferentially separate

different fluids or ions

•Ultrafiltration is a low-pressure membrane process used to separate low molecular weight

compounds from a feed stream
ULTRA FILTRATION SYSTEM (VS) MECHANICAL FILTRATION :
ULTRA FILTRATION IN CED :

1. Only Water, Solvent & low molecular

Weight resin are allowed to pass through
the membrane.

2. Polyvinylidene (PVDF) Ultrafiltration

Membranes used for Electrocoat paint
bath applications.

3. The system should be designed to

provide a minimum of 2 Liters / Minute /
Sq. Meter of coatable surface area.
WHY WE USE ULTRAFILTRATION UNIT IN ELECTRO COAT SYSTEM ??
Since E - coat is a Dip process . The
components which comes out are also
coated with loosely adhered paint (drag
out paint ).
This paint surface if not removed will show
rough appearance over the component
which is not visually appealing.
Hence the components had to be pre -
cleaned before curing into oven….
The most recommended cleaners are ;
1. D.I Water
2. Paint filtrate derived from ultra
filtration.
The limitations of using DI Water over Ultra Filtrate is ;
DI Water Ultra Filtrate ( Permeate )
Continous requirement of Since made from paint itself .It
D.Iwater . Since it should be can be sent to E-Coat tank .
drained when paint solids Hence , no loss of permeate
increase into it.
High solid loss as the loose No solid loss as the mixture of
paint removed from paint & permeate is returned
component cannot be re- back to the E-Coat tank.
used.
High amount of waste sent to No waste water is produced
ETP plant for treatment.
Difficult to control the solvent Less loss of solvent . Hence can
level of the bath. Due to high be controlled easily.
solvent loss.
Required to purge paint to Ionic contamination in paint
reduceany ionic can be reduced by purging
contamination. permeate.
SIGNIFICANT CHARACTERISTICS – UF FLUX RATE :
•UF system cleaning procedure
•Ionic contamination / phosphate drag-in
•Bacteria in the paint (as it affects paint pH)
•Paint – pH, temperature, % solids, % solvent, pigment/binder
•Paint velocity – through UF piping & membranes
•Adequate fresh paint feed rate
•Pump capacity – both paint and cleaning
•Inlet / outlet pressures
•Pre-filtration
•Temperature of UF unit
BAG FILTRATION :
1.Filtration system is used before Ultrafiltration module to avoid dirt let
-in into the membrances which may cause plugging of the membrane
pores.

2. No bypass line should be provided as 100% material has to pass thru

filters.

3.Filter vessels are made of Stainless steel or coated with epoxy resin.
6.Pressure gauge to be provided for each filter vessel separately to
know the exact pressure difference of each vessel. (Pressure diff.
kg/cm2 is allowed )

4. Filters should be made of synthetic , non-water soluble material like

poly - propylene or acrylic fibers.

5. Required Bag/Cartridge filter of minimum 10-25 micron size to be

provided before paint enters the module.

6. Neoprene or Buna S rubber should not be used as gasket or O- ring.

RECTIFIER SYSTEM :
 Supply electrical power for the coating process from the rectifiers through
the anodes and to the paint.
CED BATH TEMPERATURE :
ADVANCED CED COATING TECHNOLOGY
COLOURS / PIGMENTS

• Epoxy CED for car / Tractor bodies: Grey

-TiO2, carbon black, (extenders)

• Epoxy CED for small parts: Black

-Carbon black, extenders

• Acrylic CED for Monocoat systems: Different colors

-Organic pigments
 POWERCRON®
FILM PROPERTIES – IMPROVED BLACK CED
Electrocoating

Property Test Method Performance

Color ---- Black
Film Thickness ---- 12 – 45 microns
Gloss - 600 ASTM D523 50 – 80
Pencil Hardness ASTM D3363 3H+
Crosshatch ASTM D3359 4B – 5B
Adhesion
Salt Spray ASTM B117 1000 Hours+
Humidity ASTM D1735 1000 Hours+
Water Immersion ASTM D870 1000 Hours+
Gravelometer GM 9508P 6+
Edge Corrosion GM 9632P < 5 Rust Spots
Throwpower GM 9535P 12 – 15 Inches

FrameCoat II
MAJOR TECHNOLOGY HIGHLIGHTS – 7 TH GENERATION CED

 High edge corrosion platform – Rust spots < 5

 Smooth surface profile – Ra < 0.3 microns
 Low cure – 160 deg.C / 20 min MT
 Excellent workability
 Long term performance - Exceeds current standards
 Environment friendly - Organic catalyst
 High film build - up to 60 microns. No finish defect
 High Throw – Better DFT optimization
Existing Coating process: With Epoxy Grey E-coat

Topcoat FES Green layer

Epoxy CED Grey
Pre-treatment Layer (Zn PO4)
Sheet Metal Substrate

Proposed Coating process: With Epoxy Green E-coat

Topcoat FES Red layer

Epoxy CED Green
Pre-treatment Layer (Zn PO4)
Sheet Metal Substrate

• Current Sheet Metal has Red Topcoat over Grey CED

• Proposed process will have Red Topcoat over Green CED
• CED Process will remain the same
• No changes are needed in the existing CED equipment
 ADVANTAGES / BENEFITS WITH GREEN CED
Advantages :

1. Eliminate / optimize Green topcoat on interior areas where there is no direct sunlight exposure
2. Improved workability – lower contrast between CED & topcoat layer
3. Lower wastage & sludge as topcoat is applied less
4. Working Capital saving – lower topcoat inventory
5. Less contrast between CED & topcoat will be beneficial in case of any mechanical damage to
topcoat layer.

Cautions:

1. Have to carefully identify the components & areas to avoid topcoat painting
2. Slight increase in CED cost – but will be greatly off set with topcoat savings.

Significant savings in
coating cost per Car !
 GREEN ELECTROCOAT KEY ATTRIBUTES
Superior Performance in:
 Corrosion protection
 Smooth film appearance
 Surface smoothness at 10 & 20 microns film build
 Throwing power
 Low cure
 E Coat features a different pigmentation system formulated to provide hiding @ 10 & 20 µm film build.

Environmentally friendly Economical

 Resin rich system with low ash content
 Low solvent content in bath
 Low usage (applied material, g/m2)
 Optimized film build distribution
 Reduced dry film density
 Low bath solvent.
 Low current consumption
 Higher bath temperature 32 – 34 °C
CHARACTERSITICS & TROUBLE SHOOTING
SIGNIFICANT CONTROL CHARACTERISTICS :

 Film build

 Throw Power

 Paint appearance
E- COAT CHARACTERISTICS (CED) :

• Solids content 15 – 20 %
• pH 4 - 6
• Conductivity 800 – 1500 μSi
• MEQ-value 25 – 40 (milli equivalent acid/100 g solid resin)
• Pigment binder ratio 0,15 : 1 (black)
• < 0,1 : 1 (organic)
• < 0,5 : 1 (grey)
E- COAT GENERAL PARAMETERS (CED) :

1. Voltage 30 – 420 Volt DC

2. Current (Ampere) depending on film resistance
3. Deposition time (sec)
4. Bath temperature (°C)
5. Electric charge (As, Cb)
6. Deposition equivalent (Cb/g deposited ecoat)
CHALLENGES :
• Cratering (external contaminations)

• Levelling

• Pinholes (MCT – behaviour)

• Coagulation in the tank (too low neutralisation, bacteria ?)

• Redissolution (too low pH in CED)

• New metal pretreatments (e.g. Zirconium- based)

CED TROUBLE SHOOTING PROCESS STEPS :
It is important to understand the process of troubleshooting in order to develop workable
solutions to problems.

There are five steps to troubleshooting, they are:

 Define the problem

 Measure the process

 Analyze and Identify the root cause

 Improve and establish corrective & preventive actions

 Control & Follow up

PREVENTIVE ACTION METHODS :
Troubleshooting should be more than a reaction to problems. Preventive maintenance is
often overlooked as a tool to guard against problems and defects.

–Tank agitation
–Oven
–Rectifier
–Electrodes
–Anolyte system
–Racking
–Rinsing
–Filtration
–Substrate cleaning process
–Pre treatment process
–DI water
–Substrate
TANK AGITATION :
Purpose : Agitation of a paint tank is necessary for paint suspension, filtration, and the removal of
excess heat generated from pumping and coating. Proper agitation is dependent on the
header/eductor system and the circulation pump.

Potential Problems

 Broken or misaligned eductors can cause appearance defects on production and dead zones in the
paint tank.
 A malfunctioning pump can cause poor bath circulation, foam, and appearance defects.
 Excessive tank agitation can cause swirls as well as parts to fall.

Preventive Actions

 Semi-annual tank cleanings should be performed to check for broken plumbing, missing eductors,
damaged tank liners and to remove fallen parts and any build up of settled paint.
 Keeping pump screens and bag filters clean will help prevent agitation problems.
OVEN :
Purpose : This is where the crosslinking occurs to provide a single uniform surface that is hard and
resistant to solvent attack.

Potential Problems

 Excessive glossiness
 Poor exhaust can cause ware color to become dark and yellowish
 Poor performance in corrosion testing

Preventive Actions

 It is recommended that the oven be monitored and cleaned of dirt when necessary.
 Oven temperature recorders should be run to ensure correct metal temperatures are reached for
sufficient time to cure the coating.
RECTIFIER :
Purpose : Converts AC to DC to provide a constant charge to the electrodes in the tank.

Potential Problems

• Rupture
• Pinholes
• Non-uniform film thickness
• No-Coats

Preventive Actions

 The rectifier should be checked yearly for voltage ripple; it should not exceed 5% under
anticipated load conditions.
 The amperage and voltage displays should also be checked to ensure calibration accuracy.
 There should be no stray voltage to the paint tank during non-production hours.
ELECTRODES :
Purpose Transmit the electrical charge from the rectifier to the paint bath.

Potential Problems

• Thin paint
• No-Coats
• Rupture

Preventive Actions

 Anodes should be checked quarterly for degradation (electrode weight and amperage draw),
proper operation of supply and return flows, and to ensure electrical leads are connected.

 Periodic checks of each electrode’s amperage draw can be used to monitor anode performance.

 Maintain a 4:1 or lower ratio of coated surface to electrode area based on a two-minute
immersion time, the standard for system design.
RACKING :
Purpose Racking includes design, part loading, and cleaning.

Potential Problems

• Lack of electrical grounding

• Appearance problems
• Liquid pooling
• Air pockets
• Floating and contact with other parts

Preventive Actions

 Maintaining clean racks and contact points will help prevent rack build up and no coats.
 The grounding system should be checked yearly for wear and good contact.
 Ensuring proper hanging of parts
SPRAY RINSING :
Purpose In order to remove drag out from electrodeposited surfaces a properly operating rinse
system is necessary.

Potential Problems
• Plugged or misdirected nozzles
• Spray not contained within the stage
• Recirculated rinse flow that is not balanced from stage to stage
• Build up of paint solids
• Fallen parts in the rinse stage

Preventive Actions

 The headers should be cleaned periodically to remove any settled or dried material from the
piping and to maintain pressure between 5 - 10 psi.
FILTRATION :
Purpose Filtration to remove various contaminants includes both bag filters and ultra filters.

Potential Problems
• Horizontal settle (bag)
• Dirt in paint (bag)
• Craters (bag with oil absorbent sheets)
• Rupture (UF)
• Poor performance in salt spray (UF)
• Goose bumps and drip marks (UF)

Preventive Actions
 Bag filters should be changed when the pressure differential inlet to outlet is 5-10 psi.
 Oil absorbent media may need to be changed as often as once per shift.
 The ultra filter flux rate should be checked daily using the sight gauges and cleaned per the manufacturer’s
recommendations.
 Most manufacturers recommend cleaning at 70% of the stabilized flux rate, caution - membranes can be
irreversibly fouled, shortening life span and making them more difficult to clean.
 The ultra filter pump should be monitored by pressure gauges and flow meters when appropriate.
 Train employees to hand parts appropriately to ensure proper handling.
SUBSTRATE CLEANING PROCESS :
Purpose A clean substrate is necessary for proper pretreating and coating. Proper cleaning
allows for the removal of substrate contaminants such as stamping oils, surface dirt, fibers,
and most organic lubricants.

Potential Problems
• Dirty substrate surfaces will cause final appearance and/or performance problems
leading to rejected parts and rework.

Preventive Actions
 Whether an acidic or alkaline cleaner is used, auxiliary cleaning steps such as shot
blasting and pickling can be used to insure that parts are clean and ready for phosphate
coating.
PHOSPHATING PROCESS :
Purpose Prepares the metal parts for improved paint adhesion and performance.

Potential Problems
• A non-uniform phosphate or conversion coating
• Poor electro coat appearance or performance
• Contamination of the electro coat bath

Preventive Actions
 Closely monitor, per the vendors’ recommendations, whether using iron or zinc phosphate,
immersion or spray, with or without a sealer.
 Monitor time, temperature, pressure(flow), and concentration, the primary control parameters of
good pretreatment operation.
 Routinely test for proper coating weights and crystal morphology which are good predictors of
product performance.
DI WATER :
Purpose High quality water is essential for operation of an electro coat system.

Potential Problems
• Contaminants in the water going to an electro coat bath will cause the conductivity to
increase, which will influence throw power, film rupture and performance
characteristics.

Preventive Actions
 Monitor water quality, which is characterized by low conductivity (less than 10µS/cm)
and free of bacteria.
SUBSTRATE :
Purpose Substrate quality is the first consideration in achieving a quality finish. There are
many types of metals used in electro coating ranging from aluminum to cold rolled steel
and which can be galvanized or heat-treated.

Potential Problems
• Roughness in appearance
• Gassing

Preventive Actions
 Using the “first in, first out” inventory management will help keep the substrates clean,
as the age of the metal and lubricants can affect treatment.
 Utilize protective storage conditions to aid in the prevention of flash rusting and other
surface defects.
ED PARAMETER CONTROL & RESULTS : Very critical factor

Bath parameter
Film
Appeara Anti- Anti-
thick- TP
nce crater GAS PIN
ness
NV P:B MEQ pH COND

PIGMENT
↗ ↗ ↗ ↘ ↗ ↘
PASTE

EMULSION ↗ ↘ ↗ ↗ ↗ ↘ ↗

Solvents feed ↗ ↗ ↗

Acid feed ↗ ↘ ↗ ↘ ↘ ↘

UF to DRAIN ↘
ED PARAMETER CONTROL & RESULTS : Very critical factor

Bath parameter
Anti - Anti -
Film appear
CRATE GAS TP
thick ance
NV P:B MEQ pH COND R PIN

Bath temp. UP ↗ ↗ ↗ ↘ ↗ ↘

Bath temp.
↘ ↘ ↘ ↗ ↘ ↗
DOWN

Voltage UP ↗ ↘ ↗

Voltage
↘ ↗ ↘
DOWN

Very critical factor

DAILY CHECK SHEET & CONTROLS
BATH CONDUCTIVITY : INDICATES THE IONIC CONCENTRATION OF A LIQUID
BATH SOLVENT : INDICATES THE LEVEL OF % SOLVENT IN THE BATH
BATH PH : SHOWS THE ACIDITY OR BASE OF THE CED BATH
BATH SOLIDS : THIS INCLUDES THE PIGMENTS & NVM OF PAINT
P/B RATIO : RATIO OF PIGMENT AND BINDER IN THE MIXED PAINT
 E-COAT DEFECTS : COUNTERMEASURE
Defects Problem Description Reason Countermeasure
Stain mark Marks caused by film Drying mark ,  Install spray nozzle for preventing drying
thickness differences of Degreasing mark in
ED, which is connected pretreatment process  Confirm kinds of oil or check if amounts of oil has
with pretreatment been changed or not
stained marks
 Keep right range of all the pretreatment
parameter
 As for ED paint , increase film resistance
( Pigments UP, Solvents DOWN)

Contaminatio Abnormal deposition of Rinse problems before  Strengthen deionized water rinse & treat uniform
n mark ED on contaminated ED treatments dry off
area on the substrate  Rinse hanger
Electrolyzed material  Prevent water dropped from hanger
contained in dropped  As for ED paint , get down conductivity increase
water is condensed film resistance
 E-COAT DEFECTS : COUNTERMEASURE
Defects Problem Description Reason Countermeasure
Gas pin Hydrogen gas is discharged Voltage is high and paint  Care need to be taken because EGI /GA
on substrate during ED film temperature is low /GI tend to produce this gas pin easily.
coated, then a part of ED  Ensure Good flow of rheology during
film is cured and pinhole baking by increasing amounts solvent
looked like pricked mark by contents, then simultaneously reduce
needle created and coating voltage.
remained by discharged Increase bath Paint temp.
energy
Increase P:B ratio gradually
 E-COAT DEFECTS : COUNTERMEASURE
Problem
Defects Reason Countermeasure
description
Water Water is dropped or  Dews fall on substrate from  Pre-Heat for hanger
dropping produced on hanger / oven wall especially in  Reduce water come in into oven
substrate before winter  For drop of dew, main contribute factor is excess
paint film is baked Water remained on horizontal of steam
/ prominence and depression  Improve air blow on horizontal to Prevent water
area from remaining on the area of prominence and
depression
Loss of Loss of gloss of ED Phosphate Sludge  Strengthen rinse after phosphate
gloss precipitation on horizontal  Increase agitation speed ( especially optimize
on horizontal area )
Pigments precipitation on  Reduce paste addition
horizontal  Improve filtration
★ Ra value, appearance of ED is mostly
Increased P : B ratio depended open kinds of steel and pretreatment
condition
 E-COAT DEFECTS : COUNTERMEASURE
Defects Problem Description Reason
Debris Defects attached on film Debris due to ferrous particles
( Seed ) thickness due to debris on horizontal area during
phosphating process
Debris & ferrous particles
during ED process
Coagulation debris is stocked
in UF rinse system
Stocked in DIP rinse after UF
rinse
Coming down from conveyer
Tar or debris from oven
Countermeasure
 Strengthen rinse before ED ( Remove
ferrous particle by rinse )
 Reduce amount of ferrous particle coming
into phosphating bath
 Optimize the liquid flow in ED bath
 Keep away from too severe spray
 Reduce PH in Dip
Prevent falling particles by periodic
cleaning
 Clean periodically tar on oven
 E-COAT DEFECTS : COUNTERMEASURE
Defects Problem Description Reason Countermeasure
CRATER The crater is the defects Degreasing defects on  Degreasing. Rinsing need to be strengthened
occurring randomly , substrate – oils remain ★ Especially Care need to be taken when crater
which has the less than after degreasing occurred in inside section
0.1 ㎜ of diameter for  Remove oil magnetic filter
small one or a few ㎜ of E D bath being
diameter for big one, on  Increase ash contents
Contaminated by oil  Foreign particles including oil such as conveyer
the paint film that must
be flat. comes in especially be careful of coming
Oil contents spouts continuously / unexpectedly sometimes cases of oil
from various equipments emits from Air Blow

Crater caused conveyer ★ Oil contents attached after ED coat cause

from oven Deposits come crater
down from conveyer
( Debris contained oil or  Review oil kinds
rust )
 Prevents Foreign particles from coming down by
periodical cleaning
 E-COAT DEFECTS : COUNTERMEASURE
Defects Problem Description Reason Countermeasure

CRATER The crater is the defects Contaminated oil used for ㅇ Strengthen oil not to come from paint
occurring randomly , surrounding equipment's shop process ( Even small oil mists can
which has the less than installed ( Especially lubricant oil cause crater )
0.1 ㎜ of diameter for sprayed )
small one or a few ㎜ of
diameter for big one, on Paint mist of surfacer or Top
the paint film that must ㅇ Strengthen paint spray dust not coming
coat is attached from
be flat.

Boiled crater This defect happen Oil remained on steel joint ㅇ Strengthen degreasing
when a water is boiled area → degreasing defects ㅇ Decreasing baking climb temperature
during baking, which is
caused oil to spout out
from seaming area ● As for paint , increase ash contents
TYPES OF CRATERS

Reason :
Heavy oil is used
 E-COAT DEFECTS : COUNTERMEASURE
Defects Problem Description Reason Countermeasure
Permeate It happens that the Paint liquid is remained in  Modify the section of substrate,
Oozing paint liquid remained in seaming area or inside of Improve hanging position
seaming area or inside substrate
of substrate come out  Improve Rinsing
during baking process

 When air blow done or preheating

installed before baking, sometimes it is
effective

As for paint , Bring Bath %age NV down,

The tilt Table before Oven Entry to drain

off max. water / liquid

In crease the solvent level

TESTING METHODS
PAINT TESTING TO ASSURE GLOBAL STANDARDS - DBR

SALT SPRAY TEST HUMIDITY CHAMBER ED LAB RECTIFIER

IMPACT TESTER CONICAL MANDREL HOT AIR OVEN

ADVANTAGES OF ELECTRO COAT - SUMMARY
 Application Advantage
 Outstanding film uniformity
 Total coverage of complex geometries
 Precise film build control
 Multi-metal applications
 No sags, beads.
 Economic Advantages
• 95-99% transfer efficiency
• Highly automated
• Total coverage
• High productivity
• Low maintenance
• Lower insurance rates
Limitations : Rather high investments for the coating line and Curing temperature >140°C
 Performance Advantages
• Corrosion protection
• Chemical resistance
• Mechanical properties
• Abrasion resistance
 Environmental Advantages
• VOC as low as 0.024 kgs / 1 kgs supply
• HAPs free products available
• Closed loop operation in some systems
• Less solid waste
• Reduced fire hazard with water based materials
CED APPLICATIONS :
DO’S:

1. Test all required parameters of CED bath and rinses every day before start of production.

2. Preferably complete entire addition well before start of production .

3. CED sample to be taken from sampling point.

4. Rinses sample to be taken from top of the tank if sampling is point not provided.

5. In case of addition sequence , add emulsion followed by paste. It is good practice to flush pump with DM
water after addition of individual components flush pump thoroughly after addition is complete. ( i. e. Dose
DM water through dosing line).
DONT’S:
1. Never enter CED tunnel while rectifier is ON

2. Do not add paint / additives directly to bath paint. It must be added through dosing pump with delivery at pump
suction.

3. Do not use any contaminated bucket for paint dosing .

4. Do not dip any wooden / mild steel stirrer either in bath or supply paint . Use either plastic or SS stirrer.

5. Do not run production with anolyte circulation OFF.

6. Do not turn off UF feed pump without proper blushing of UF modules.

7. Do not keep the UF modules on paint without circulation for more than 15 min.

8. Do not run turbid UF through pump mechanical seals.

9. Do not run production with CED tank exit spray OFF.

DONT’S:
10. Do not load components with rust.

11. Do not load components with heavy oil without proper wiping.

12. Do not allow any foaming in CED tank.

13. Do not add pigment paste without stirring the paint in barrel. Homo genenize paint barrel .

14. Do not add solvent additive / pH stabilizer immediately after paste or emulsion without flushing the line with DM.

15. Do not allow bath temperature to exceed 35 deg .c as it may create harm to UF modules.

16. D not run production if bath temperature is less than 25 deg.c

17. Do not run the production if oven temperature is not achieved as per set point as under cure gives poor film
properties.

18. Do not allow fallen parts to remain in rinses for long time.