A PRESENTATION

ON
CAUSES OF
BODY
COVER(BDC)
SCRATCHES
IN PAINT

By: SONU VATS

NECESSITY OF PAINTING

Color and appearance

Covering of gaps between
the
weld joints
Corrosion resistance
Smoothening of sharp
corners

PAINT SHOP :
FLOWCHART

WELD BODY

COOLING

PRETREATME
NT

ELECTRODEPOSITION

UNDERCOA
T OVEN

UNDER COAT

INTERMEDIAT
DRY
SANDIN
G
FOR
ASSEMBLY

I/C OVEN

ED
OVEN
SOLSEALING

COOLING

E COAT (I/C)
TOUCH UP
AND
INSPECTIO
N

T/C
OVE
N

TOP COAT
(T/C)

DRY
SANDIN
G

PRETREATMENT
PROCESS

PRETREATMENT
PROCESS :
FLOWCHAR
T

HOT
WATER
RINSE

SURFACE
CONDITIONIN
G

PHOSPHATIN
G

SPRAY

DEGREASIN
G

IW
RINSE

IW
RINSE
FOR ED

DIP
DEGREASIN
G

IW
RINSE

IW
RINSE
FRESH DI
WATER
RINSE

IW
RINSE

DIP IW
RINSE

DIP IW
RINSE

IW
RINSE

PRETREATMENT STAGES
HOT WATER RINSE

Spray process.
Steam injection for
heating.
Automatic magnetic
separator for iron
particle removal.

OIL REMOVAL BY HOT WATER

RINSE

STEE
L
SHEE
T

OIL
FIL
M

HOT
WATE
R
SPRAY

PHYSICAL
PRESSURE BY
SPRAYING ACT TO
LOWER OIL
VISCOSITY

80-90% OF
OIL CAN BE
REMOVED

PRETREATMENT STAGES
DEGREASING (I)

Spray process
Heated degreasing chemical
solution
Oil separator tank for oil separation.
De-oiled liquid is recovered to the
second degreasing.

DEGREASING(II)
Full

dipping process using

heated degreasing chemical

OIL REMOVAL BY
STIRRING POWER TOGETHER WITH
DEGREASINGANCHORING
EFFECT FAVORS TO COLLECT
HYDROPHILI
C
RADICAL
OILPHILI
C
RADICAL

SURFACTAN
T

OIL
STIRRING

OILPHILIC RADICAL IN
THE SURFACTANT
DISSOLVES OIL AND
LOWERS ITS VISCOSITY
OIL SEPARATES
FROM THE
SURFACE

PRETREATMENT STAGES
SURFACE CONDITIONING
Full dipping process using Titanium based
surface conditioning chemical.
Titanium salts form fine colloids which get
adsorbed on the metal dipped in surface
conditioning bath.
Function : Adsorbed titanium colloids
provide fne active nuclei for phosphating
reaction.

PRETREATMENT STAGES
PHOSPHATIN
G
Full dipping
process using
heated zinc
phosphate
solution.

FUNCTIONS OF
PHOSPHATING
Cleans and provides oil & grease free
surface
Fine and crystalline corrosion inhibiting
base for ED.
Non conducting bond between the
substrate
and the paint.
Chemically inert surface to prevent the
reaction between the substrate & the
paint ingredients.

PHOSPHATING REACTION
[O
]

H2
Fe(H2PO4)2+2
O
H+
FePO4 + H3PO4 +
H2O

Fe +
Phosphati
Shee
2H3PO
4
t
meta
l

ng
solution

3Zn(H2PO4)
2

Phosphati
ng solution

Fe +
2Zn(HPhosphatin
2PO4)2
Shee
t
meta
l

g
solution

P ratio
=

SLUDGE

H2
O

Zn3(PO4)2.4H2O +
4H3PO4
H2

Coating - hopeite

Zn2Fe(PO4)2.4H2O +2H3PO4
+H2O

[O

Coating - phosphophyllite

phosphophyllite
]
(p)
phosphophyllite (p) + hopeite
(H)

PHOSPHATE
COATING :
QUALITY

Parameters
COATING
APPEARANC
E

COATING WEIGHT
P- RATIO
CRYSTAL SIZE
CRYSTAL SHAPE

Dip PT

Spray PT

UNIFORM
GREY
COMPACT
FINE COATING
2.0-3.5 gm/m2

UNIFORM
GREY
COMPACT
FINE COATING
1.5-2.5 gm/m2

> 90%

> 80%

< 10 m

< 10 m

COLUMNA
R
CRYSTAL
S

COLUMNA
R
CRYSTAL
S

PRETREATMENT
STAGES :
PROCESS
PROCESS PROCESS
CONDITIONS
STAGE
TIME
TEMP
SPRAY HOT WATER RINSE
SPRAY DEGREASING
DIP DEGREASING
SPRAY WATER RINSE (1)
SPRAY WATER RINSE (2)
DIP WATER RINSE (3)
SPRAY WATER RINSE (4)
SPRAY WATER RINSE (5)
SURFACE CONDITIONING
(DIP)
PHOSPHATING
(DIP) WATER RINSE (6)
SPRAY
SPRAY WATER RINSE (7)
DIP WATER RINSE (8)
FRESH DI WATER RINSE

20 sec
50 sec
120 sec
1 riser
15 sec
in/out
15 sec
1 riser
in/out
120 sec
1 riser
15 sec
in/out
1 riser

50-60 C
50-60 C
50-60 C
RT
RT
RT
RT
RT
RT
45 C
RT
RT
RT
RT

PROCESS
PRESSURE
0.7-1.1 kg/cm2
1.4-1.8 kg/cm2
1.2-1.6 kg/cm2
0.7-1.1 kg/cm2
0.7-1.1 kg/cm2
1.2-1.8 kg/cm2
0.7-1.1 kg/cm2
0.7-1.1 kg/cm2
0.4-0.8 kg/cm2
1.0-1.4 kg/cm2
0.8-1.2 kg/cm2
0.9-1.3 kg/cm2
0.9-1.3 kg/cm2
0.8-1.2 kg/m2

INDUSTRIAL WATER
SPECS.
TDS
: 60 mg/L

CONDUCTIVITY
TOTAL
HARDNESS
SULPHATES
CHLORIDES
NITRATES
DISS. IRON as
Fe
CHROMIUM
COD
pH value

: 100
S/cm
: 30.0
mg/L
: 5.0 mg/L
: 20.0
mg/L
: 10.0
mg/L
: 0.3 mg/L
: 0.05

DEIONISED WATER SPECS.

pH
: 6.5 - 7.5
ELECTRICAL
: 10
CONDUCTIVITY
DRIP WATER CONDUCTIVITYS/cm
: 50
s/cm
TOTAL
: NIL
HARDNESS
: NIL
CHLORIDES AS
: < 0.4
Cl
ppm
SILICA AS SiO2

ELECTRODEPOSITION

ELECTRODEPOSITIO
PROCESS :
N
FLOWCHART
E-COAT MAIN
TANK

D.I. WATER
RINSE

FRESH D.I.
WATER
RINSE

NO.1
RECOVERED
WATER
RINSE
NO.4
RECOVERED
WATER RINSE
FOR
SOLSEALING

NO.2
RECOVERED
WATER RINSE

NO.3
RECOVERED
WATER RINSE

ELECTRODEPOSITIO
PROCESS : FLOW
N
DIAGRAM
Dip Zone
Spray Zone Dip

Spray
Zone

Zone
Cu-rod
for
earthing

ED Main
Tank

2
Ultra
Filtrate

DI
Wate
r
Rinse

ELECTRODEPOSITION
PROCESS
ED
paint dispersed in water is electrically

deposited on surface of substrate (body) to

form a uniform and water insoluble flm.
Deposition of flm takes place by increase in
pH.
Paint gets deposited continuously through
concurrence of four different phenomenon:

ELECTROPHORESIS
ELECTRODEPOSITION
ELECTROLYSIS
ELECTROSMOSIS

ED PHENOMENON
ELECTROPHORESIS:

Electrically charged substances (dispersed

particles, soluble resins) move to the
electrodes.
Positively charged paint moves to the
substrate.

ELECTRODEPOSITION:

Insolubilization of resin takes place.

Positively charged resin gets deposited on
the substrate

ED PHENOMENON
ELECTROLYSIS:

Electrolysis of water takes place.

Cathode generates H2.

ELECTRO OSMOSIS:

Water contained in the flm moves

against the current of phoresis of resin
due to electric potential difference.

MECHANISM OF ED
C

A
OH
-

H + O2

RH-NH+

Neutralizer : organic
acid

Cathode
(substrate)
:
2 H2 O +
2eR
NH - +
OHWATER

2 OH- +
H2
R
N +
H2 O

WATER INSOLUBLE

Anode
(electrode) :

2
H2 O

4 H+ + 4 e- +
O2

E COAT
STAGES
E-COAT MAIN TANK
E-coat paint is deposited onto the
substrate.

E-COAT STAGES
RECOVERED WATER RINSE (I)
Spray process using UF permeate liquid.

RECOVERED WATER RINSE (II)

Spray process using UF permeate liquid.

RECOVERED WATER RINSE (III)

Full dipping process using UF permeate
liquid.

RECOVERED WATER RINSE(IV)

Spray process using permeate liquid

ULTRAFILTRATION
Membrane Separation Technology using
Pressure
difference method :

An appropriate pressure is applied to the

solution to be processed.
Water and low molecular weight substances
suspended in the water pass through the
innumerable micropores on the membrane surface.
High molecular weight substances and colloidal
matter contained in the solution are retained by
the membrane.

Advantages:

Efficient separation without the aid of heat

ADVANTAGES OF ED
COATING
Corrosion
resistance of car body increases.
Paints are deposited even on surfaces
inaccessible to conventional methods of
painting.
Uniform flm of desired thickness is
obtained easily by adjusting voltage.
Quantity of drag-out solids is small
since bath paint being diluted with
water is low in solid content.

STAGE

ED PROCESSES AND
SPECS.

E-COAT MAIN TANK

NO.1 RECOVERED WATER
RINSE
NO.2 RECOVERED WATER
RINSE
NO.3 RECOVERED WATER
RINSE
NO.4 RECOVERED WATER
RINSE
NO.1 D.I. WATER RINSE
FRESH D.I. WATER RINSE

DIP/SPRAY

PROCES
S TIME

PROCES
S
TEMP
26-32
26-30

DIP
SPRAY

180 SEC
30 SEC

SPRAY

30 SEC

26-30

DIP

IN/OUT

26-30

SPRAY

30 SEC

26-30

SPRAY
SPRAY

15 SEC
1 RISER

STANDARD
SPECIFICATIONS
ED MAIN TANK :
Solid content is 16 ~ 20 %
Specifc conductivity is 1200-1800
S/cm

pH is 6.1 + 0.3
Paint temperature is 29 + 2
C

ED application voltage is 150-350

V
ED oven temperature is 180 + 5
C

PAINT SUPPLY
EQUIPMENT
N.V.

F-1 (PIGMENT) : 56-60 WT

% F-2(RESIN) : 35-39 WT%

DENSITY

1
2

(PIGMENT) : 1.45 KG/L

(RESIN) : 1.05 KG/L

MIX RATIO 1:4 + 1

E.D. PARAMETERS
Anode to cathode ratio

1:5 ~ 1:7

Cathode

Body / Substrate

Main anodes

Tube type

Bottom anodes

Tube type

PAINT
TESTING

PAINT PROPERTIES
WET PAINT PROPERTIES
PROPERTIES
FINENESS OF GRINDING
VISCOSITY
SPECIFIC GRAVITY
% SOLID CONTENT
% BATH SOLIDS
SETTLING
FLASH POINT
STORAGE STABILITY

DRY FILM

COLOR/SHADE
DFT(Outer / Inner)
GLOSS
HARDNESS
ADHESION
Ra Value
SST
CCT
IMPACT RESISTANCE

S.
No.
1
2
3
4
5
6

PAINT
CHARACTERISTICS
Characteristic
Instrument
Viscosity
Particle Size
Percentage Solids
Specific Gravity, Wt/10
ltrs
Settling
Throwing Power

Viscosity meter
Hegman Gauge
Oven
Wt/10 ltr cup
Residue Check
Box Method/Pipe Method

PAINT FILM
(A)
Short term
CHARACTERISTICS:
characteristics
S.
No.
1
2
3
5
6
7

Characteristic

Instrument

Gloss
Glossometer
Hardness
Pencil
Adhesion
Cutter & Cross cut guide
DFT (Outer/Inner) DFT Meter
Impact
Impact tester
Resistance
Ra Value
Ra Meter

PAINT FILM
(B)
Long term
CHARCTERISTICS:
characteristics
Characteristic
Flexibility

Corrosion resistance
(Humidity Resistance, Salt
Spray Resistance, Cyclic
Corrosion)
CCT

Instrument
Flexibility
tester
Corrosio
n
Cabinet
CCT Cabinet

PAINT
TECHNOLOGY

PAINT INGREDIENTS
PIGMENT Gives the paint its color and
flling properties, undissolved
by water or solvent.
RESIN

Binds and wets the pigment giving

paint adhesion, gloss, hardness and
durability.

SOLVENT Binds and wets the pigment giving

paint adhesion, gloss, hardness and
durability.
ADDITIVE Improves paint and paint
flm properties.

THANK
YOU