Automotive Painting Processes

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
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)

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
FR PIGMENTE UND LACKE E.V.
Dr. Michael Hilt, Automotive OEM Coatings, Process and Materials 2011-05-16.ppt
Automotive painting today - Consumption data
Film build
in m
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
Sum
20.1
12.3
100
WBL
40
Wasserfller
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
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

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

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
Fraunhofer ISC (Wrzburg)
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

R&D activities - Novel corrosion protection coatings
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
Project supporting board
Nanoparticles fill the cavities of the

substrate surface

R&D activities - Optimization of UV-clearcoats
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
Consortium besides public funding

R&D activities - Optimized multi layer coating systems
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
CC
BC
PS
EC
Project supporting board
CC
BC
EC
Delamination
Corrosion

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

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

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

technologies - Paint loss free coating methods
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: Drr Systems
Subproject partners

technologies - New dryer concepts for energy
efficient operation
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

technologies - Modular concept for product and
coating
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

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


R&D activities - SiLat (simulation of the unsteady
drying of coatings at three dimensional objects)
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

Automotive Painting Processes

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Automotive painting processes - today and

Dr. Michael Hilt

Automotive painting - where does it come from?

Automotive painting today

Building blocks for future processes

Introduction - Closed chain in painting technology due

Introduction - Coating components

Introduction - Topographical classification of coating

Bulk film properties

Source: S. K. GOSH, Functional Coatings

Automotive Painting - where does it come from?

Natural oil resins, alkyd resins

Nitro cellulose resins

Protection and decoration of plastics

See metals (last three)

Fuel, brake fluid, washer fluid

Radiation (sun light)

Automotive painting today - Consumption data

Automotive painting today - Cost of car painting

Improvement or keeping of product quality and performance

Automotive painting today - Classical painting process

Automotive painting today - Alternatives for preprocesses - Reasons

Development of alternative products for zinc phosphating

Lower environmental impact concerning Nickel and phosphate sludge

Classification of Nickel containing products was further enforced

Automotive painting today - Alternatives for preprocesses - Overview

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

2 min process time

Tank control: pH, conductivity, material content

Bonderite NGC process

Automotive painting today - Electrocoats (I)

Automotive painting today - Technology trends in

Currentless deposition of the coating

Possible substitute for

Process until now

Possible new process

Automotive painting today - Technology trends in

development of an optimized cleaner system

against H2O diffusion

Automotive painting today - Primer surfacers

Smoothness (good levelling)

Surface hardness for sanding purposes

Automotive painting today - Waterborne basecoats

Main requirements and competitive factors for effect colours

Automotive painting today - Integrated waterborne

Automotive painting today - Integrated waterborne

Automotive painting today - New colours and new

Automotive painting today - Clearcoats

Building blocks for future processes - Technology trends

Ecoat Pb- and Sn-free

Ecoat with reduced weight loss

Basecoat application 100% ESTA

Integrated (shorter) processes

Clearcoat scratch resistant

Building blocks for future processes - FRAUNHOFER

Process chain for coating research and application

Building blocks for future processes - FRAUNHOFER

Novel approaches with organic and/or inorganic

(nanoscale) coatings and coating components