Training on Priming process

V.Venkatesan
14.08.14
 Special process

A process is called as a special process, wherein the

effect of process variables/ parameters on end
product quality is known only by destructive
method analysis.

a. Priming,

b. Painting,

c. Heat treatment,

d. welding
 What is priming?

A primer is a preparatory coating put on

materials before painting. Priming ensures
better adhesion of paint to the surface,
increases paint durability, and provides
additional protection for the material being
painted.
 Steps in priming process

Fabricated component

Pretreatment

Primer application

Baking of primed parts Air drying of parts

Testing of product parameters

 Pretreatment

1. Better adhesion of coating

2. prevent the spread of
Pretreatment
corrosion
3. eliminates reactions between
metals and between coatings
and metals

Cleaning Conversion Coating

The Process for removal of unwanted
matter , material is called as Cleaning.
E.g …
Contaminants- Dirt, oil, grease , metal chips etc
 Oxidised metal layer – Rust , sludge, superficial
layers etc
chemically applied treatment that is used
over a clean metal surface to enhance
adhesion and corrosion resistance
E.g….
Iron and zinc phosphate coatings are
the most commonly applied conversion
coatings
 Cleaning

Cleaning

Mechanical Thermal chemical

 Mechanical clearing method

• Abrasive
Blasting , Grinding, Sanding

• Non Abrasive
Spray Pressure , Ultrasound
 Thermal clearing method

• Direct flame Heating

Material get exposed directly
to Flame at defined temperature
• Indirect Heating
Heated Gases , Liquid, – e.g Hot degreasing

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 Chemical clearing method

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 Water is most Important Solvent For Cleaning

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11
12
13
 What Does A Surfactant Look Like

Hydrophobic (Water Hating) - Tail

“Charg
e”

Hydrophilic ( Water Loving )- Head

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 Deciding Factors for Cleaning
In selecting cleaning process, many factors must be considered , like
• · The substrate to be cleaned (i.e., ferrous, nonferrous, plastic etc.)
• . The nature of the contaminants to be removed
• · Condition of the surface to the end use of the part
• · The degree of cleanliness required
• · The total surface area to be cleaned
• · Effects of previous processes
• . Subsequent process
• · Rust inhibition requirements
• · Materials handling factors

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 Degree of cleanliness

• Water Break Test

• Millipore Value
• Visual
• Paper Test
• Tape Test

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 Conversion Coating

A conversion coating converts the surface

of a metal substrate to a uniform, inert
surface, which increases paint bonding,
minimizes the spread of corrosion under
the film if the coating is cut, and improves
the overall corrosion resistance of the final
product.

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 Cleaning & Conversion
Coating
 Stage two—clean/coat, rinse
 Stage three—clean/coat, rinse, rinse/seal
 Stage four—clean/coat, rinse, rinse/seal, deionized (DI)
water rinse
 Stage five—clean, rinse, phosphate, rinse, rinse/seal
 Stage six—clean, rinse, phosphate, rinse, rinse/seal, DI
rinse
 Stage seven--clean, clean, rinse, phosphate, rinse,
rinse/seal, DI rinse
 21Stage eight—clean, rinse, clean, rinse, phosphate, rinse,
 3in1 PT
method
1.Degreasing- Removal of oil and grease from the surface
2.Derusting- Removal of rust and light scale from the surface.
3.coating-- phosphate coating

Advantage: process time effective.

Disadvantage: corrosion resistance and bonding properties are not as
good as that of 7 tank process.

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 7 Tank process

Seven (or eight) stage treatment for zinc/iron phosphate include following
stages:
1. Degreasing 2. Water rinse 3. Derusting 4. Water rinse
5. Activation : This gives more compact and uniform coating of zinc
phosphate. This step can be omitted for iron phosphate process.
6. Phosphating : This forms coating of zinc phosphate (4 to 6 microns)
OR iron phosphate (1 to 1.5 microns) on the clean surface of M.S.
7. Water rinse
8. Passivation : This will seal the pores of phosphating.
9. Drying.
.

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 SOP for 3 in 1 Chemical application

Before 3 in 1 ensure part should be free from Rust/Scale/ Oxidation. For Removal of Rust
Scale/rust - suitable Wire brush sanding tool may be used.
1. Prepare 3 in 1 chemical solution with water - 30-33 % by volume. ( For 1 Ltr 330 ml in
770 ml of water)
2. Use small container to use prepared solution.

3. Sand parts using sand paper ( Grit 120 - 320) to remove contamination.
4. Apply 3 in 1 chemical uniformly using cloth ( Swabing ). Ensure removal of oil,rust, loose
scale, dust etc. Ensure cloth should be changed frequently for better results.
5. allow chemical to dry for 5-7 min.
6. Clean the component with thinner wiping ( General purpose ) .after wiping clean
component with dry cloth.
7. uniform grey film will form. Ensure removal of all loose powder,dust,dirt.
8. component is ready for priming

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 7-Tank PT method
CHECK POINTS FOR 7 TANK PRETREAMENT Frequency
Before Phosphating ensure part should be free from Rust/Scale/ Oxidation. For
Daily
Removal of Rust Scale/rust - suitable Wire brush sanding tool may be used.
1.Ensure Pretreatment process is validated by M&M Lab. ( Every six month) Daily
2. Ensure level of all tank is maintained as per requirement. Daily
3.Ensure all stage chemical pointages are as per specification. Check
Daily
Temperature for Degreasing and phosphating stage
4. Ensure proper recommended timing at each stage. Continuous
5. Ensure component must get cleaned rust free and oil free before
Continuous
phosphating stage
6. Ensure Sludge removal frequency from Phosphate tank. There should not be
Continuous
any powder residue on component.
7. Avoid the chemical carryover from bath to water rinse tank. Continuous
8.Do not sand, buff phosphated parts , if any rework done on phosphated part
Continuous
must be follwed by Rephosphating process.

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 PT method

PT method

Wiping Dipping spray

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 Basic Knowledge on Paint/Primer

Gives the paint its color and filling properties

PIGMENT Un-dissolved by water or solvent.

Binds and wets the pigment giving paint its

RESIN Adhesion, gloss, hardness and durability.

Binds and wets the pigment giving paint its

Paint/Primer SOLVENT
Adhesion, gloss, hardness and durability.

ADDITIVE Improves paint & paint film properties.

THINNER Improves and assists paint application.

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 COMPOSITION OF PAINT
SR.NO INGREDIENTS FUNCTION TYPE

A) ALKYD.
B) ALKYD-AMINO
C) POLYESTER-AMINO
1 RESIN FILM FORMATION D) THERMOSETTING ACRYLICS
E) POLYURATHANES

A) COLOUR A) EFFECT PIGMENT LIKE MICA /

B) OPACITY ALUMINIUM
2 PIGMENT C) ANTI CORROSION B) COLOURED PIGMENTS
PROPERTIES C) EXTENDERS

SPECIAL FUNCTIONS A) WETTING AGENTS

OR ELIMINATION OF B) SURFACE CONTROL AGENTS
3 ADDITIVES C) RHEOLOGICAL CONTROL
DEFECTS
AGENTS
D) ANTI SETTLING AGENTS.
A) HYDROCARBONS
FLOW PROPERTIES B) ALCOHOLS
4 SOLVENTS OF PAINT C) KETONES
D) ESTERS

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 Baking of primer

How we set the baking temperature and

time?
Baking
window
 Paint Testing

1. Liquid paint
characteristics
2. Paint film characteristics
Short term testing
Long term testing

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 PAINT PROPERTIES

WET PAINT PROPERTIES DRY FILM PROPERTIES

• FINENESS OF GRINDING • COLOR/SHADE

• VISCOSITY • HIDING POWER
• SPECIFIC GRAVITY • GLOSS, HARDNESS, ADHESION
• % SOLID CONTENT • STONE CHIP RESISTANCE
• % VOLUME SOLIDS • ACID/ALKALI RESISTANCE
• SETTLING • WATER RESISTANCE
• THINNER INTAKE • SALT SPRAY RESISTANCE
• FLASH POINT • HUMIDITY RESISTANCE
• STORAGE STABILITY • RECOATABILITY
• ACCELERATED WEATHERING
• NATURAL WEATHERING
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 Liquid Paint Characteristics

Sr no Characteristic Instrument
1 Viscosity Ford Cup, Stormer viscometer
2 Particle Size Hegman Guage
3 Solids Oven
4 Specific Gravity, Wt/10 ltrs Wt/10 ltr cup
5 Settling Glass cylinder
6 Electrical Resistivity ER Meter
7 Hiding Power Black & White chart

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 Viscosity measurement
Temp vs vis Pink Primer

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35 35.1
34 33.8
33
32 32
31
30
30.4
29.6
viscosity in sec

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28
28.4
27.5
27
26.5
26 25.8
25
25.4
24.8
24
24.4 24.1
23.7
23 23.2
22.8
22 22.1
21.4
21 21
20.5
20 20.1
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
temp °c
 Paint Testing

1. Dry film Thickness measurement

2. Paint adhesion test

3. Pencil hardness test

4. Gloss Value
 1. Dry film Thickness measurement

Ferrous parts Non-ferrous Parts Non-metallic parts

Magnetic Principle for Eddy Current Principle Ultrasonic Principle for

Steel for Aluminum Plastic
Mechanical gages When the instrument’s probe The probe of the
use a permanent is brought near a metal instrument contains an
magnet, a calibrated (conductive) surface, a coil ultrasonic transducer that
spring, and a within the probe generates sends a pulse through the
graduated scale. By an alternating magnetic field coating. The pulse reflects
measuring the force that sets up eddy currents back from the substrate to
required to pull the on the metal’s surface. the transducer and is
magnet off the These eddy currents create converted into a high
coated surface, a their own opposing frequency electrical signal
thickness electromagnetic field that that is analyzed to
measurement can be can be sensed by a second, determine coating
determined adjacent coil thickness
Unit of measurement: Micrometer/mile

Conversion: 1micron----210mil
 Effect of DFT

Thin Film---wrong color, or they may not provide the necessary level
of performance. Water can more easily penetrate to the substrate.

Thick film--more likely to crack in use or they may create problems when two
mating parts must be fitted together.
2.Paint adhesion test
 Testing procedure(ASTM)
Step-1
Place the cutting tool on the sample, press
down
gently and pull the tool towards you in one
steady movement to make a series of parallel
cuts approximately 20 mm long. Apply sufficient
pressure to ensure that you cut through the
coating to the substrate.

Step-2
Place the cutting tool on the sample at 90° to the
first cut and repeat step (1) to create a lattice
pattern on the coating.
Step-3
Brush lightly to remove detached flakes or
ribbons of coating.
Step-4
Inspect to ensure the cuts have penetrated
all the way through the coating.

Step-5
Remove and discard two complete turns of
adhesive tape. Remove an additional
length of tape at a steady rate and cut a
piece approximately 75 mm from this
length.
Step-6
Centre the cut piece of tape over the lattice
and smooth into place using a finger. Rub
the tape firmly using the eraser on the end
of a pencil to ensure good adhesion
between the tape and the coating.
Step7:
Within 90 seconds (± 30 seconds) of
applying the tape, remove the tape by
pulling in a single smooth action at an
angle of 180° to the coating surface.

Step-8
To maintain a permanent record of the test,
retain the tape by applying it to a
transparent film
3.Pencil hardness test

9H 8H 7H ……….. 2H H F HB B 2B …….. 7B 8B
Softest
Hardest

The degree of hardness of the pencil which damages the surface is taken
as a measurement for scratch hardness. Under ASTM, fourteen pencil
leads in the range from 6B to 6H are used. (7H, 8H, and 9H are sold
separately.) The pencil leads can be exchanged quickly and easily
Pencils of varying hardness, starting
with the hardest lead, are moved over
the surface under a fixed pressure of
7.5 Newtons (765g±2%) and at a fixed
angle of 45 degrees to the surface.
4.Glass value

Gloss is measured by shining a known amount of light at a

surface and quantifying the reflectance. The angle of the light
and the method by which the reflectance is measured are
determined by the surface.
Gloss Range with 60° Gloss
Measure With:
Meter
If Semi Gloss - 10 to 70 GU 60 °
If High Gloss > 70 GU 20 °
If Low Gloss < 10 GU 85 °
 5.Salt spray testing

The use of salt solution spray testing is an

attempt to accelerate the corrosion
process and cause early paint failure.

Test condition:
5% salt solution & Temp:33/35deg C

The panels are evaluated for two types of

corrosion:
1. Rust-through—the percentage of the
surface, which has rust visible through
the paint
2. “Creep”—the distance in 1/32 of an
inch (0.8 mm) from the center of the
scribe line that the paint film breaks down
and separates from the substrate
 M&M requirement
Sl.No Parameter Specification
1 After PT Free from Rust/Dust/oil/grease
2 DFT 25/40micron
3 Adhesion 100% ok
4 Salt spray test Should pass for 100hr
5 Visual defects Free from rundown, dust, uncover etc
6 Calibration of oven 9 point calibration for thermal uniformity

7 Adhesion tape M&M approved source

8 PT chemical & primer & M&M approved source
Thinner
 Thank you
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