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E-raamat: Automotive Paints and Coatings

Edited by (Markt & Management, Münster, Germany), Edited by (Dupont Performance Coatings, Wuppertal, Germany)
  • Formaat: PDF+DRM
  • Ilmumisaeg: 08-Sep-2008
  • Kirjastus: Blackwell Verlag GmbH
  • Keel: eng
  • ISBN-13: 9783527622382
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  • Formaat: PDF+DRM
  • Ilmumisaeg: 08-Sep-2008
  • Kirjastus: Blackwell Verlag GmbH
  • Keel: eng
  • ISBN-13: 9783527622382
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Now in its second edition and still the only book of its kind, this is an authoritative treatment of all stages of the coating process -- from body materials, paint shop design, and pre-treatment, through primer surfacers and top coats. New topics of interest covered are color control, specification and testing of coatings, as well as quality and supply concepts, while valuable information on capital and legislation aspects is given.
Invaluable for engineers in the automotive and paints and coatings industry as well as for students in the field.

Arvustused

"Intended for use by engineers in the motor vehicle and paint and coatings industries as well as for students." (World Surface Coatings Abstracts, February 2008) " Die Verfasser haben ein Werk geschaffen, dass erstmals systematisch den Automobillackierprozess in all seinen Facetten von "vorn nach hinten" beschreibt und ihn in Kontext zu Trends für die Zukunft setzt. Gemeinsam mit ihren Co-Autoren haben sie es verstanden, dieses komplexe Gebiet ausgewogen zwischen fachspezifischem Anspruch und allgemeiner Verständlichkeit darzustellen." Dr. Ulrich Meier-Westhues, Bayer MaterialScience AG, Leverkusen, März 2008

"Die Kapitel wurden allesamt von Experten in ihren Spezialfeldern geschrieben, daher die beeindruckende Tiefe der dargestellten Themen." Metalloberfläche April 2008

Preface xvii
Abbreviations xix
List of Contributors
xxiii
Introduction
1(12)
Hans-Joachim Streitberger
Historic Development
1(6)
Legislation
7(2)
Automotive and Automotive Paint Market
9(4)
Materials and Concepts in Body Construction
13(48)
Klaus Werner Thomer
Introduction
13(2)
Methods of Body Construction
15(5)
Monocoque Design
15(3)
Space Frame
18(1)
Hybrid Type of Construction
19(1)
Modular Way of Construction
19(1)
Principles of Design
20(6)
Conventional Design
20(2)
Design Under Consideration of Light-Weight Construction
22(1)
Bionics
23(3)
Materials
26(21)
Steel
26(1)
General Remarks
26(3)
Low-Carbon Deep Drawing Steels
29(1)
Higher-Strength Steels
29(2)
High-Strength Steels
31(1)
High-Grade (Stainless) Steels
32(1)
Manganese--Boron Steels
32(1)
Light-Construction Steel with Induced Plasticity (TWIP Steel)
33(1)
Aluminum
34(1)
General Remark
34(1)
Further Treatment
35(3)
Aluminum Alloys
38(1)
Aluminum as Light-Weight Construction Material
39(1)
Magnesium
40(2)
Titanium
42(1)
Nonmetallic Parts -- Fiber Composites
43(4)
Manufacturing Methods
47(5)
Tailored Products
47(1)
General Remarks
47(1)
Tailored Blanks
47(1)
Tailored Tubes
48(1)
Tailored Strips
48(1)
Patchwork Blanks
48(1)
Future
49(1)
Hydroforming
49(1)
Press Hardening
50(1)
Metal Foam
50(1)
Sandwich Structures
51(1)
Roll Forming to Shape
52(1)
Joining Methods
52(5)
Bonding
53(1)
Laser Welding
54(1)
Others
55(1)
Clinching
55(1)
Riveting
56(1)
Roller Hemming
56(1)
Outlook
57(2)
Surface Protection
59(2)
Precoating of Sheets
59(1)
Corrosion Prevention in the Design Phase
59(2)
Pretreatment of Multimetal Car Bodies
61(28)
Horst Gehmecker
Introduction
61(1)
Car Body Construction Materials
61(4)
Sheet Materials
61(2)
Surface Conditions/Contaminations
63(2)
Pretreatment Process
65(12)
Sequence of Treatment
65(1)
Degreasing
65(4)
Activation
69(1)
Zinc Phosphating
70(5)
Passivation
75(1)
Pretreatment of Aluminum -- Steel Structures
75(1)
Pretreatment of Magnesium
76(1)
Pretreatment of Plastic Parts
77(1)
Car Body Pretreatment Lines
77(8)
Spray Lines
80(1)
Continuous Horizontal Spray/Dip Line
80(1)
RoDip3 Line
80(1)
Vario Shuttle Line
81(1)
Other Types of Lines
82(1)
Construction Materials
82(1)
Details on Process Stages
82(1)
Precleaning Stage
82(1)
Spray degrease
83(1)
Dip Degrease
83(1)
Rinsing
84(1)
Activation
84(1)
Phosphating
84(1)
Rinsing
85(1)
Passivation
85(1)
Deionized water rinsing
85(1)
Entering the Electrocoat Line
85(1)
Properties and Specifications of Zinc Phosphate Conversion Layers
85(1)
Environmental Legislations
86(1)
Outlook
86(3)
Electrodeposition Coatings
89(40)
Hans-Joachim Streitberger
History and Introduction
89(1)
Physico-chemical Basics of the Deposition Process
90(5)
Data for Quality Control
95(3)
Voltage, Current Density, Bath Temperature, and Bath Conductivity
96(1)
Wet Film Conductivity
96(1)
Solid Content, Solvent Content, and pH
97(1)
Resins and Formulation Principles
98(3)
General Remarks
98(1)
Anodic Electrodeposition Paints
99(1)
Cathodic Electrodeposition Paints
99(2)
Film Performance of Cathodic Electrocoatings
101(5)
Physical Film Data
101(1)
Corrosion Protection
102(2)
Chip Resistance
104(1)
Surface Smoothness and Appearance
105(1)
Design of Cathodic Electrocoating Lines
106(13)
Integration into the Coating Process of Cars and Trucks
106(1)
Pretreatment
107(1)
General Functions and Equipment of an Electrocoat Line
107(1)
Tanks, Filters, Heat Exchanger, and Power Supply
108(3)
Replenishment and Anode Cells
111(3)
Ultrafiltration and Rinsing Zones
114(4)
Baking Oven
118(1)
Defects During Application and their Prevention
119(5)
Dirt
119(1)
Craters
120(1)
Surface Roughness
121(1)
Film Thickness/Throwing Power
122(1)
Other Defects
123(1)
Electrocoating and Similar Processes Used in Automotive Supply Industry
124(1)
Outlook
125(4)
Primer Surfacer
129(46)
Heinrich Wonnemann
Introduction
129(3)
Requirement Profile
132(6)
Legislative Requirement
132(1)
Technological Requirements
133(1)
Film Properties
133(3)
Product Specifications
136(1)
Application
136(2)
Raw Materials
138(14)
Resin Components
139(2)
Pigments and Extenders
141(2)
Titanium Dioxide
143(1)
Barium Sulfate
144(1)
Talc
144(1)
Silicon Dioxide
145(1)
Feldspar
146(1)
Carbon Blacks
146(1)
Additives
146(2)
Pigment Wetting and Dispersion Additives
148(1)
Defoaming and Deaerating Agents
148(1)
Surfactants and Additives for Substrate Wetting
149(1)
Rheology Additives
149(1)
Solvents
150(1)
Aromatic Hydrocarbons: Diluents/Thinners
151(1)
Alcohols, Cellosolves, and Esters: Solvents
151(1)
Tetralin or Pine Oil: Very High Boiling Additive Diluents
152(1)
Liquid Primers
152(8)
Formula Principles
152(1)
Application
152(1)
Rheology
153(3)
Manufacturing Process
156(2)
Application
158(2)
Powder Primer Surfacers
160(10)
Formula Principles
160(2)
Manufacturing Process
162(4)
Application
166(4)
Process Sequence
170(1)
Summary and Future Outlook
171(4)
Top Coats
175(36)
Karl-Friedrich Dossel
Introduction
175(1)
Pigments and Color
175(5)
Single-Stage Top Coats (Monocoats)
180(1)
Base Coats
181(8)
Base Coat Rheology
184(1)
Low and Medium Solids Base Coat
185(1)
High Solids (HS) Base Coats
186(1)
Waterborne Base Coats
186(1)
Global Conversion to Waterborne Base Coat Technology
187(2)
Drying of Base Coats
189(1)
Clear Coat
189(19)
Market
189(1)
Liquid Clear Coats
190(1)
One-Component (1K) Acrylic Melamine Clear Coat
190(2)
Acrylic Melamine Silane
192(1)
Carbamate-Melamine-Based 1K Clear coat
192(1)
One-Component Polyurethane (PUR) Clear Coat
192(1)
One- (and Two-) Component Epoxy Acid Clear Coat
192(1)
Two-Component (2K) Polyurethane Clear Coat
193(1)
Waterborne Clear Coat
194(1)
Powder Clear Coat
195(3)
Top Coat Performance
198(1)
Environmental Etch
198(1)
UV Durability of Clear Coats
199(2)
Scratch Resistant Clear Coats
201(3)
Application Properties
204(2)
Future Developments: UV Curing
206(2)
Integrated Paint Processes (IPP) for Top Coat Application
208(3)
Wet-On-Wet-On-Wet Application (3 Coat 1 Bake) of Primer Surfacer--Base Coat--Clear Coat
208(1)
Primerless Coating Process
209(2)
Polymeric Engineering for Automotive Coating Applications
211(48)
Heinz-Peter Rink
General Introduction
211(3)
Polyacrylic Resins for Coating Materials in the Automotive Industry
214(10)
Managing the Property Profile of the Polyacrylic Resins
214(4)
Manufacturing Polyacrylic Resins
218(1)
Manufacturing Polyacrylic Resins by Means of Solution Polymerization
218(4)
Polymerization in an Aqueous Environment
222(2)
Mass Polymerization
224(1)
Polyester for Coating Materials for the Automotive Industry
224(7)
Managing the Property Profile of Polyesters
224(4)
Manufacturing Polyesters
228(3)
Polyurethane Dispersions in Coating Materials for the Automotive Industry
231(7)
Managing the Property Profile of Polyurethane Resins and Polyurethane Resin Dispersions
232(2)
Manufacturing Polyurethane Resin Dispersions
234(4)
Polyurethane Polyacrylic Polymers in Coating Materials for the Automotive Industry
238(3)
Introduction
238(1)
Managing the Property Profile of Polyurethane Polyacrylic Polymers
239(1)
Manufacturing Polyurethane Polyacrylic Polymers
240(1)
Epoxy Resins
241(3)
Managing the Property Profile
242(1)
Manufacturing Polyepoxy Resins
243(1)
Cross-Linking Agents and Network-Forming Resins
244(15)
Introduction
244(1)
Cross-Linking Agents for Liquid Coating Materials
245(1)
Melamine and Benzoguanamine Resins
245(3)
Tris(Alkoxycarbonylamino)-1,3,5-Triazine
248(1)
Polyisocyanates and Blocked Polyisocyanates
249(3)
Other Cross-Linking Agents for Liquid Coating Materials
252(1)
Cross-Linking Agents for Powder Coatings in the Automotive Industry
252(7)
Paint Shop Design and Quality Concepts
259(46)
Pavel Svejda
Introduction
259(1)
Coating Process Steps
260(6)
Pretreatment
261(1)
Electrocoating (EC)
261(1)
Sealing and Underbody Protection
262(1)
Paint Application
263(1)
Function Layer and Primerless Processes
263(1)
Powder
264(1)
Cavity Preservation
265(1)
General Layout
266(2)
Coating Facilities
268(20)
Process Technology
268(1)
Automation in the Paint Application
269(1)
Painting Robot
270(1)
Application Technology
271(1)
Atomizer
272(3)
Paint Color Changer
275(2)
Paint Dosing Technology for Liquid Paints
277(1)
Paint Dosing Technology for Powder Paints
278(1)
Paint-Material Supply
279(1)
Paint Supply Systems for the Industrial Sector
280(1)
Paint Mix Room
280(1)
Container Group
280(2)
Circulation Line System
282(1)
Basic Principles for the Design of the Pipe Width for Circulation Lines
282(1)
Paint Supply Systems for Small Consumption Quantities and Frequent Color Change
283(1)
Small Circulation Systems
283(1)
Supply Systems for Special Colors
284(1)
Voltage Block Systems
285(1)
Voltage Block Systems with Color-Change Possibility
285(1)
Installations for the High Viscosity Material Supply
286(1)
Conveyor Equipment
287(1)
Paint Drying
288(2)
Quality Aspects
290(8)
Control Technology
290(2)
Process Monitoring and Regulation
292(1)
Automated Quality Assurance
293(3)
Process Optimization in Automatic Painting Installations
296(2)
Economic Aspects
298(7)
Overall Layout
298(1)
Full Automation in Vehicle Painting
298(2)
Exterior Application of Metallic Base Coats with 100% ESTA High-Speed Rotation
300(1)
Robot Interior Painting with High-Speed Rotation
301(4)
Coatings for Plastic Parts
305(46)
Exterior Plastics
305(29)
Guido Wilke
Introduction
305(1)
Ecological Aspects
305(1)
Technical and Design Aspects
306(1)
Economical Aspects
307(1)
Process Definitions
307(1)
Offline, Inline, and Online Painting
307(1)
Process-Related Issues, Advantages, and Disadvantages
307(3)
Exterior Plastic Substrates and Parts
310(1)
Overview
310(1)
Basic Physical Characteristics
311(4)
Part Processing and Influence on Coating Performance
315(1)
Pretreatment
315(3)
Plastic-Coating Materials
318(1)
Basic Technical Principles of Raw-Material Selection
318(2)
Car-Body Color
320(4)
Contrast Color and Clear Coat on Plastic Systems
324(1)
Technical Demands and Testing
324(1)
Basic Considerations
324(1)
Key Characteristics and Test Methods
325(4)
Trends, Challenges, and Limitations
329(1)
Substrates and Parts
329(1)
Paint Materials
330(2)
Processes
332(2)
Interior Plastics
334(17)
Stefan Jacob
Introduction: the `Interior' Concept
334(1)
Surfaces and Effects
335(2)
Laser Coatings
337(2)
Substrate Requirements
339(1)
Requirements to Be Fulfilled by the Paint Systems and Coating
339(1)
Demands Expected by the Inscription Technique
340(1)
Performances of Interior Coatings
341(1)
Mechanical and Technological Demands
341(1)
Substrates and Mechanical Adhesion
342(1)
Ecological and Economical Requirements
343(1)
Equipment for the Application of Interior Paint Systems
344(2)
Raw-Material Basis of Interior Paints
346(1)
Summary/Outlook
347(4)
Adhesive Bonding -- a Universal Joining Technology
351(26)
Peter W. Merz
Bernd Burchardt
Dobrivoje Jovanovic
Introduction
351(1)
Fundamentals
351(15)
Basic Principles of Bonding and Material Performances
351(1)
Types of Adhesives
351(4)
Adhesives are Process Materials
355(1)
Advantages of Bonding
356(3)
Application
359(1)
Surface Preparation
359(2)
Substrates
361(1)
Adhesion
361(1)
Durability and Aging of Bonded System
362(4)
Bonding in Car Production
366(8)
Body Shop Bonding
367(1)
Antiflutter Adhesives
367(1)
Hem-Flange Bonding
368(1)
Spot-Weld Bonding
369(1)
Crash-Resistant Adhesives/Bonding
369(1)
Paint Shop
370(1)
Trim Shop
371(1)
Special Aspects of Structural Bonding in the Trim Shop
371(1)
`Direct Glazing'
371(1)
Modular Design
372(1)
Other Trim Part Bondings
372(2)
Summary
374(3)
In-plant Repairs
377(4)
Karl-Friedrich Dossel
Repair After Pretreatment and Electrocoat Application
377(1)
Repair After the Primer Surfacer Process
378(1)
Top-Coat Repairs
378(2)
End-of-Line Repairs
380(1)
Specifications and Testing
381(86)
Color and Appearance
381(24)
Gabi Kiegle-Bockler
Visual Evaluation of Appearance
381(1)
Specular Gloss Measurement
382(3)
Visual Evaluation of Distinctness-of-Image (DOI)
385(1)
Measurement of Distinctness-of-Image
385(1)
Visual Evaluation of `Orange Peel'
386(2)
Instrumental Measurement of Waviness (Orange Peel)
388(2)
The Structure Spectrum and its Visual Impressions
390(2)
Outlook of Appearance Measurement Techniques
392(1)
Visual Evaluation of Color
393(1)
Solid Colors
393(4)
Metallic and Interference Colors
397(1)
Color Measurement of Solid Colors
398(3)
Color Measurement of Metallic and Interference Coatings
401(1)
Typical Applications of Color Control in the Automotive Industry
402(1)
Color Measurement Outlook
403(2)
Weathering Resistance of Automotive Coatings
405(22)
Gerhard Pausch
Jorg Schwarz
Introduction
405(1)
Environmental Impact on Coatings
406(2)
Natural Weathering
408(6)
Artificial Weathering
414(7)
New Developments
421(2)
Standards for Conducting and Evaluating Weathering Tests
423(3)
Correlation Between Artificial and Natural Weathering Results
426(1)
Corrosion Protection
427(7)
Hans-Joachim Streitberger
Introduction
427(2)
General Tests for Surface Protection
429(3)
Special Tests for Edge Protection, Contact Corrosion, and Inner Part Protection
432(1)
Total Body Testing in Proving Grounds
433(1)
Mechanical Properties
434(33)
Gerhard Wagner
General Remarks
434(1)
Hardness
435(1)
Pendulum Damping
435(1)
Indentation Hardness
436(3)
Scratch Hardness
439(2)
Adhesion and Flexibility
441(1)
Pull-Off Testing
441(1)
Cross Cut
441(3)
Steam Jet
444(1)
Bending
445(1)
Cupping
446(2)
Impact Testing by Falling Weight
448(1)
Stone-Chip Resistance
449(1)
Standardized Multi-Impact Test Methods
450(1)
Single-Impact Test Methods
451(3)
Abrasion
454(1)
Taber Abraser
454(1)
Abrasion Test by Falling Abrasive Sand
455(1)
Scratch Resistance
456(1)
Crockmeter Test
456(1)
Wet-Scrub Abrasion Test
457(1)
Simulation of Car Wash
458(2)
Nanoscratch Test
460(2)
Bibliography, Standards
462(5)
Supply Concepts
467(8)
Hans-Joachim Streitberger
Karl-Friedrich Dossel
Quality Assurance (QA)
467(1)
Supply Chain
468(7)
Basic Concepts and Realizations
468(5)
Requirements and Limitations of a System Supply Concept
473(2)
Outlook
475(8)
Hans-Joachim Streitberger
Karl-Friedrich Dossel
Status and Public Awareness of the Automotive Coating Process
475(1)
Regulatory Trends
476(2)
Customer Expectations
478(1)
Innovative Equipments and Processes
479(2)
New Business Ideas
481(2)
Index 483
After receiving his PhD in organic chemistry from the University of Munster, Germany, Hans-Joachim Streitberger began his technical career at BASF Coatings in Munster. Following positions in cathodic electrocoating development and central paint research, he became director of the European research group. He led the technical automotive OEM group in Southfield, Michigan, USA, for three years, before returning to Munster in charge of the European technical groups for automotive OEM development and technical service. He later became vice president of a business group for industrial coatings with responsibility for Europe, during which time he was a member of the advisory board at BASF Coatings AG as well as head of the industrial business group of the German Paint Association, VdL. Dr. Streitberger's final position at BASF Coatings was head of Corporate Industrial Management before he became a self-employed consultant.

Karl-Friedrich Dossel studied chemistry in Kiel, Germany and Reading, UK, obtaining his PhD in physical chemistry in 1978. He joined the R&D department at Hoechst AG in the area of photoresist / microelectronic applications and became manager of coating resins R&D in 1992. In 1995 he was made Director of Technology for Automotive Coatings at Herberts, which later became DuPont, where he is currently the Director for Strategic Technology and Global Product Management. Dr. Dossel has global experience in the automotive industry as well as authoring over 100 patents, publications, and conference presentations in the field of automotive coatings.