Automotive painting processes - today and tomorro · Dr. Michael Hilt, +49 711 970 3820, Automotive...
Transcript of Automotive painting processes - today and tomorro · Dr. Michael Hilt, +49 711 970 3820, Automotive...
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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
Introduction
Automotive painting - where does it come from?
Automotive painting today
Building blocks for future processes
Summary
Content
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Introduction - Closed chain in painting technology due
to integration of FPL (research institute) into
FRAUNHOFER IPA
Binders
Pigments
Additives
Thinners,
solvents
Raw
materials
Paint Painting material
Painting technology Coating Finished surface
Recipies
Dispersion
Rheology
Colouration
Substrate
pretreatment
Application
Drying, curing
Adhesion
Corrosion
protection
Durability
Functionality
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Introduction - Coating components
Pigments Binders
Solvents
Additives
Paint
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Introduction - Topographical classification of coating
properties Top surface properties
Light reflection
Hardness
Scratch resistance
Surface slip
Repellent properties
Erosion resistance
Substrate
Interface
Film
Film/Air Interface
Bulk film properties
Opacity
Flexibility
Diffusion
Chemical resistance
Water uptake
Weather resistance
Film/substrate
interface properties
Adhesion
Durability
Anticorrosion
Source: S. K. GOSH, Functional Coatings
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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?
Dr. Michael Hilt, Automotive OEM Coatings, Process and Materials 2011-05-16.ppt FORSCHUNGSGESELLSCHAFT
FÜR PIGMENTE UND LACKE E.V. 7
Physical influences
Mechanics
Scratches
Stone chips
Car care materials
Abrasion
Radiation (sun light)
Temperature change
Chemical influences
Fuel, brake fluid, washer fluid …
Care care materials
Environmental chemicals
Tree sap
“Sour" residues
Bird excrements
Other materials (metal dust,
carbon, ...)
Coating surface
Automotive Painting - where does it come from? - Ex-
ternal influences on a coated car surface
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Film build
in µm
110
100
80
60
40
20
0
2K-Klarlack
Wasserfüller
WBL WBL „1“
WBL „2“
KTL
Material type 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 3
Sum 20.1 12.3 100
Automotive painting today - Consumption data
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source:
Main focus
Improvement or keeping of product quality and performance
Reduction of process cost
Automotive painting today - Cost of car painting
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Body
in
white
Body
washer
Pre-
treat-
ment
Elec-
tro-
coat
Baking
oven
San-
ding
Primer
surfa-
cer
Baking
oven
San-
ding
Base-
coat
Drying
oven
San-
ding,
poli-
shing
Seam
sealing
Baking
oven
Clear-
coat
Baking
oven
Spot
repair
Body
repair Wax
As-
sem-
bly
Online
plastic
parts
Inline
plastic
parts
Offline
plastic
parts
Automotive painting today - Classical painting process
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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 prepro-
cesses - Reasons
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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 prepro-
cesses - Overview
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Silane treatment
(Greenfield)
Silan treatment
(Brownfield)
Zink phosphating
as at today
Cleaning Purge Silane Purge
DI purge DI purge
Cleaning Purge Silane Purge Empty
DI purge DI purge
Cleaning Purge Phosphatization Purge
DI purge Passivation
DI purge
Spray or dip process
Solution in DI water
2 products
Room temperature
2 min process time
pH ca. 4
Tank control: pH, conductivity, material content
Automotive painting today - Alternatives for prepro-
cesses - New development Oxsilan (CHEMETALL) (I)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Cleaning Purge Activation Phosphatization DI purge Passivation DI purge
Cleaning Purge Bonderite DI purge DI purge
NGC
Zinc phosphating
Bonderite NGC process
Automotive painting today - Alternatives for prepro-
cesses - New development Bonderite NGC (HENKEL)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Alternatives for prepro-
cesses - New development Zircobond (PPG)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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 - Electrocoats (I)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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)
Cleaning Oven Purge Reactive
purge ACC Purge
Cleaning Purge Purge Phosph. Activation Purge CDP Purge Oven
Possible substitute for
pretreatment and
electrocoat, significant
process shortening
Process until now
Possible new process
Automotive painting today - Technology trends in
preprocesses - Autophoresis
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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
Metal reaction
Adhesion to substrate
Corrosion protection by
influence on corrosion
mechanism
Substrate
C e n t e g r a
Organic layer
Barrier properties
against H2O diffusion
Levelling
Primer for top coat
Automotive painting today - Technology trends in
preprocesses - Centegra (PPG)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source:
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
Automotive painting today - Primer surfacers
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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
Automotive painting today - Waterborne basecoats
Source:
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Cavity
prot. E-coat
+ oven
Pretreat-
ment
WBBC1/2
Slurry
+ oven
Seam
sealing
+ oven
Blower/
CR
A-, B-
class
Rastatt
process
(since 1996)
WBBC 1
Integrated
process 1
(IP 1)
Mini
Oxford,
BMW
Spartanb.
Integrated
process 2
(IP 2)
Interme-
diate
oven 1
A-, B-
class
WBBC 2
Interme-
diate
oven 2
WBBC 1
WBBC 2
Interme-
diate
oven
Automotive painting today - Integrated waterborne
basecoats (I)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Ideal
Integrated
process 2
(IP 2) Oxford
Integrated
process 1
(IP 1)
Integrated
process 2
ideal (IP 2)
WBBC 2
I
P
WBBC 2
O
E
WBBC 1
O
E Slurry
WBBC 2
I
P
WBBC 2
O
P
WBBC 1
O
E 2p-clearcoat
WBBC 2
I
E
WBBC 2
O
E
WBBC 1
I
E
WBBC 1
O
E 2p-clearcoat
WBBC 1
I, O
E, P
Material
Inside, Outside
Electrostatic, Pneumatic
A-, B-
class
today
Technically
implemented
Interme-
diate
oven
Interme-
diate
oven
Interme-
diate
oven 1
Interme-
diate
oven 2
Automotive painting today - Integrated waterborne
basecoats (II)
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - New colours and new
effects
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Automotive painting today - Clearcoats
Source:
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source:
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
Building blocks for future processes - Technology trends
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Coating
components
Coating
materials
(paint)
Coating
(process)
technology
Process chain for coating research and application
Basic research - Application oriented research - Analytics - Services
Coating
University of Stuttgart
Institutes of physics - Chemistry - Manufacturing engineering -
Materials sciences
Basics
Process
chain
Education
and training
Building blocks for future processes - FRAUNHOFER
institute for manufacturing engineering in Stuttgart -
Fields of activity in paint and coating technology
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Novel approaches with organic and/or inorganic
(nanoscale) coatings and coating components
Novel corrosion protection coatings
UV curing clearcoats
Coatings with reduced curing temperature
Optimized multilayer coating systems
Bio-based coatings
New coating
properties
Coating curing
New material- und
coating systems
Building blocks for future processes - FRAUNHOFER
R&D activities - Drivers for new coating systems
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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)
Fraunhofer ISC (Würzburg)
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
Controlled
release
Building blocks for future processes - FRAUNHOFER
R&D activities - Novel approaches with organic and/or
inorganic (nanoscale) coatings UV
FORSCHUNGSGESELLSCHAFT
FÜR PIGMENTE UND LACKE E.V.
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Nanoparticles fill the cavities of the
substrate surface
Building blocks for future processes - FRAUNHOFER
R&D activities - Novel corrosion protection coatings
Fraunhofer IPA (Stuttgart)
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
FORSCHUNGSGESELLSCHAFT
FÜR PIGMENTE UND LACKE E.V.
Project supporting board
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Building blocks for future processes - FRAUNHOFER
R&D activities - Optimization of UV-clearcoats
Fraunhofer IPA (Stuttgart)
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
FORSCHUNGSGESELLSCHAFT
FÜR PIGMENTE UND LACKE E.V.
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Building blocks for future processes - FRAUNHOFER
R&D activities - Optimized multi layer coating systems
Fraunhofer IPA (Stuttgart)
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
Project supporting board
FORSCHUNGSGESELLSCHAFT
FÜR PIGMENTE UND LACKE E.V.
EC
PS
BC
CC
EC
BC
CC
Corrosion
Delamination
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Joint research project „Energy efficient coating
of car bodies“ (innovation alliance green car
body technologies)
Coating of complex plastic parts (project
ENSIKOM)
Numeric simulation of the paint drying process
(project SiLat)
Automated pretreatment with CO2 snow
blasting
Spray coating,
dryer concepts,
modularisation
UV technology
Drying process with
circulating air
Cleaning of parts
Building blocks for future processes - FRAUNHOFER
R&D activities - Developments in coating process
technology
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Semi-finished part: Sheet metal
Tool shop
Press shop
Body shop
Paint shop
Joint research project
„Energy efficient coating of
car bodies“
Building blocks for future processes - FRAUNHOFER
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
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Building blocks for future processes - FRAUNHOFER
R&D activities - Innovation alliance “Green car body
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
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source: Dürr Systems
Building blocks for future processes - FRAUNHOFER
R&D activities - Innovation alliance “Green car body
technologies” - “Paint loss free coating methods”
Fraunhofer IPA (Stuttgart)
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
Subproject partners
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source: Eisenmann
Building blocks for future processes - FRAUNHOFER
R&D activities - Innovation alliance “Green car body
technologies” - “New dryer concepts for energy
efficient operation”
Fraunhofer IPA (Stuttgart)
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
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Source: Daimler AG
Building blocks for future processes - FRAUNHOFER
R&D activities - Innovation alliance “Green car body
technologies” - “Modular concept for product and
coating”
Fraunhofer IPA (Stuttgart)
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
Subproject partners
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Building blocks for future processes - FRAUNHOFER
R&D activities - ENSIKOM Fraunhofer IPA (Stuttgart) and IFAM (Bremen)
Idea: Implementation of UV technology for eco-
friendly 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
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
Building blocks for future processes - FRAUNHOFER
R&D activities - SiLat (simulation of the unsteady
drying of coatings at three dimensional objects)
Fraunhofer IPA (Stuttgart)
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
.
Paint and facility manufacturers, software houses, universities
Heating of the car body during the first 5 minutes
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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)
…
Dr. Michael Hilt, +49 711 970 3820, Automotive painting processes – today and tomorrow 2011-08-22.ppt
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