| Preface |
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xvii | |
| Abbreviations |
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xix | |
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xxiii | |
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1 | (12) |
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Hans-Joachim Streitberger |
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1 | (6) |
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7 | (2) |
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Automotive and Automotive Paint Market |
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9 | (4) |
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Materials and Concepts in Body Construction |
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13 | (48) |
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13 | (2) |
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Methods of Body Construction |
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15 | (5) |
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15 | (3) |
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18 | (1) |
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Hybrid Type of Construction |
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19 | (1) |
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Modular Way of Construction |
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19 | (1) |
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20 | (6) |
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20 | (2) |
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Design Under Consideration of Light-Weight Construction |
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22 | (1) |
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23 | (3) |
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26 | (21) |
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26 | (1) |
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26 | (3) |
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Low-Carbon Deep Drawing Steels |
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29 | (1) |
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29 | (2) |
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31 | (1) |
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High-Grade (Stainless) Steels |
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32 | (1) |
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32 | (1) |
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Light-Construction Steel with Induced Plasticity (TWIP Steel) |
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33 | (1) |
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34 | (1) |
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34 | (1) |
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35 | (3) |
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38 | (1) |
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Aluminum as Light-Weight Construction Material |
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39 | (1) |
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40 | (2) |
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42 | (1) |
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Nonmetallic Parts -- Fiber Composites |
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43 | (4) |
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47 | (5) |
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47 | (1) |
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47 | (1) |
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47 | (1) |
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48 | (1) |
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48 | (1) |
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48 | (1) |
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49 | (1) |
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49 | (1) |
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50 | (1) |
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50 | (1) |
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51 | (1) |
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52 | (1) |
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52 | (5) |
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53 | (1) |
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54 | (1) |
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55 | (1) |
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55 | (1) |
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56 | (1) |
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56 | (1) |
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57 | (2) |
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59 | (2) |
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59 | (1) |
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Corrosion Prevention in the Design Phase |
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59 | (2) |
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Pretreatment of Multimetal Car Bodies |
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61 | (28) |
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61 | (1) |
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Car Body Construction Materials |
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61 | (4) |
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61 | (2) |
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Surface Conditions/Contaminations |
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63 | (2) |
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65 | (12) |
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65 | (1) |
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65 | (4) |
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69 | (1) |
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70 | (5) |
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75 | (1) |
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Pretreatment of Aluminum -- Steel Structures |
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75 | (1) |
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Pretreatment of Magnesium |
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76 | (1) |
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Pretreatment of Plastic Parts |
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77 | (1) |
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Car Body Pretreatment Lines |
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77 | (8) |
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80 | (1) |
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Continuous Horizontal Spray/Dip Line |
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80 | (1) |
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80 | (1) |
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81 | (1) |
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82 | (1) |
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82 | (1) |
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Details on Process Stages |
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82 | (1) |
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82 | (1) |
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83 | (1) |
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83 | (1) |
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84 | (1) |
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84 | (1) |
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84 | (1) |
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85 | (1) |
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85 | (1) |
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85 | (1) |
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Entering the Electrocoat Line |
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85 | (1) |
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Properties and Specifications of Zinc Phosphate Conversion Layers |
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85 | (1) |
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Environmental Legislations |
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86 | (1) |
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86 | (3) |
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Electrodeposition Coatings |
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89 | (40) |
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Hans-Joachim Streitberger |
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89 | (1) |
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Physico-chemical Basics of the Deposition Process |
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90 | (5) |
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95 | (3) |
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Voltage, Current Density, Bath Temperature, and Bath Conductivity |
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96 | (1) |
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96 | (1) |
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Solid Content, Solvent Content, and pH |
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97 | (1) |
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Resins and Formulation Principles |
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98 | (3) |
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98 | (1) |
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Anodic Electrodeposition Paints |
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99 | (1) |
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Cathodic Electrodeposition Paints |
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99 | (2) |
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Film Performance of Cathodic Electrocoatings |
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101 | (5) |
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101 | (1) |
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102 | (2) |
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104 | (1) |
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Surface Smoothness and Appearance |
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105 | (1) |
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Design of Cathodic Electrocoating Lines |
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106 | (13) |
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Integration into the Coating Process of Cars and Trucks |
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106 | (1) |
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107 | (1) |
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General Functions and Equipment of an Electrocoat Line |
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107 | (1) |
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Tanks, Filters, Heat Exchanger, and Power Supply |
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108 | (3) |
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Replenishment and Anode Cells |
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111 | (3) |
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Ultrafiltration and Rinsing Zones |
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114 | (4) |
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118 | (1) |
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Defects During Application and their Prevention |
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119 | (5) |
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119 | (1) |
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120 | (1) |
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121 | (1) |
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Film Thickness/Throwing Power |
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122 | (1) |
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123 | (1) |
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Electrocoating and Similar Processes Used in Automotive Supply Industry |
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124 | (1) |
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125 | (4) |
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129 | (46) |
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129 | (3) |
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132 | (6) |
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132 | (1) |
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Technological Requirements |
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133 | (1) |
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133 | (3) |
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136 | (1) |
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136 | (2) |
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138 | (14) |
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139 | (2) |
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141 | (2) |
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143 | (1) |
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144 | (1) |
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144 | (1) |
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145 | (1) |
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146 | (1) |
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146 | (1) |
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146 | (2) |
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Pigment Wetting and Dispersion Additives |
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148 | (1) |
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Defoaming and Deaerating Agents |
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148 | (1) |
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Surfactants and Additives for Substrate Wetting |
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149 | (1) |
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149 | (1) |
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150 | (1) |
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Aromatic Hydrocarbons: Diluents/Thinners |
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151 | (1) |
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Alcohols, Cellosolves, and Esters: Solvents |
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151 | (1) |
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Tetralin or Pine Oil: Very High Boiling Additive Diluents |
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152 | (1) |
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152 | (8) |
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152 | (1) |
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152 | (1) |
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153 | (3) |
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156 | (2) |
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158 | (2) |
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160 | (10) |
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160 | (2) |
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162 | (4) |
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166 | (4) |
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170 | (1) |
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Summary and Future Outlook |
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171 | (4) |
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175 | (36) |
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175 | (1) |
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175 | (5) |
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Single-Stage Top Coats (Monocoats) |
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180 | (1) |
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181 | (8) |
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184 | (1) |
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Low and Medium Solids Base Coat |
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185 | (1) |
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High Solids (HS) Base Coats |
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186 | (1) |
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186 | (1) |
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Global Conversion to Waterborne Base Coat Technology |
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187 | (2) |
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189 | (1) |
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189 | (19) |
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189 | (1) |
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190 | (1) |
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One-Component (1K) Acrylic Melamine Clear Coat |
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190 | (2) |
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192 | (1) |
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Carbamate-Melamine-Based 1K Clear coat |
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192 | (1) |
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One-Component Polyurethane (PUR) Clear Coat |
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192 | (1) |
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One- (and Two-) Component Epoxy Acid Clear Coat |
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192 | (1) |
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Two-Component (2K) Polyurethane Clear Coat |
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193 | (1) |
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194 | (1) |
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195 | (3) |
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198 | (1) |
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198 | (1) |
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UV Durability of Clear Coats |
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199 | (2) |
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Scratch Resistant Clear Coats |
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201 | (3) |
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204 | (2) |
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Future Developments: UV Curing |
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206 | (2) |
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Integrated Paint Processes (IPP) for Top Coat Application |
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208 | (3) |
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Wet-On-Wet-On-Wet Application (3 Coat 1 Bake) of Primer Surfacer--Base Coat--Clear Coat |
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208 | (1) |
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Primerless Coating Process |
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209 | (2) |
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Polymeric Engineering for Automotive Coating Applications |
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211 | (48) |
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211 | (3) |
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Polyacrylic Resins for Coating Materials in the Automotive Industry |
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214 | (10) |
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Managing the Property Profile of the Polyacrylic Resins |
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214 | (4) |
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Manufacturing Polyacrylic Resins |
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218 | (1) |
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Manufacturing Polyacrylic Resins by Means of Solution Polymerization |
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218 | (4) |
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Polymerization in an Aqueous Environment |
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222 | (2) |
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224 | (1) |
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Polyester for Coating Materials for the Automotive Industry |
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224 | (7) |
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Managing the Property Profile of Polyesters |
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224 | (4) |
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228 | (3) |
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Polyurethane Dispersions in Coating Materials for the Automotive Industry |
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231 | (7) |
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Managing the Property Profile of Polyurethane Resins and Polyurethane Resin Dispersions |
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232 | (2) |
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Manufacturing Polyurethane Resin Dispersions |
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234 | (4) |
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Polyurethane Polyacrylic Polymers in Coating Materials for the Automotive Industry |
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238 | (3) |
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238 | (1) |
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Managing the Property Profile of Polyurethane Polyacrylic Polymers |
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239 | (1) |
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Manufacturing Polyurethane Polyacrylic Polymers |
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240 | (1) |
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241 | (3) |
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Managing the Property Profile |
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242 | (1) |
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Manufacturing Polyepoxy Resins |
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243 | (1) |
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Cross-Linking Agents and Network-Forming Resins |
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244 | (15) |
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244 | (1) |
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Cross-Linking Agents for Liquid Coating Materials |
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245 | (1) |
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Melamine and Benzoguanamine Resins |
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245 | (3) |
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Tris(Alkoxycarbonylamino)-1,3,5-Triazine |
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248 | (1) |
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Polyisocyanates and Blocked Polyisocyanates |
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249 | (3) |
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Other Cross-Linking Agents for Liquid Coating Materials |
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252 | (1) |
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Cross-Linking Agents for Powder Coatings in the Automotive Industry |
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252 | (7) |
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Paint Shop Design and Quality Concepts |
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259 | (46) |
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259 | (1) |
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260 | (6) |
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261 | (1) |
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261 | (1) |
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Sealing and Underbody Protection |
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262 | (1) |
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263 | (1) |
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Function Layer and Primerless Processes |
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263 | (1) |
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264 | (1) |
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265 | (1) |
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266 | (2) |
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268 | (20) |
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268 | (1) |
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Automation in the Paint Application |
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269 | (1) |
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270 | (1) |
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271 | (1) |
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272 | (3) |
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275 | (2) |
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Paint Dosing Technology for Liquid Paints |
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277 | (1) |
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Paint Dosing Technology for Powder Paints |
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278 | (1) |
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279 | (1) |
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Paint Supply Systems for the Industrial Sector |
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280 | (1) |
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280 | (1) |
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280 | (2) |
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282 | (1) |
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Basic Principles for the Design of the Pipe Width for Circulation Lines |
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282 | (1) |
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Paint Supply Systems for Small Consumption Quantities and Frequent Color Change |
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283 | (1) |
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Small Circulation Systems |
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283 | (1) |
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Supply Systems for Special Colors |
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284 | (1) |
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285 | (1) |
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Voltage Block Systems with Color-Change Possibility |
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285 | (1) |
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Installations for the High Viscosity Material Supply |
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286 | (1) |
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287 | (1) |
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288 | (2) |
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290 | (8) |
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290 | (2) |
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Process Monitoring and Regulation |
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292 | (1) |
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Automated Quality Assurance |
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293 | (3) |
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Process Optimization in Automatic Painting Installations |
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296 | (2) |
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298 | (7) |
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298 | (1) |
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Full Automation in Vehicle Painting |
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298 | (2) |
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Exterior Application of Metallic Base Coats with 100% ESTA High-Speed Rotation |
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300 | (1) |
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Robot Interior Painting with High-Speed Rotation |
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301 | (4) |
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Coatings for Plastic Parts |
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305 | (46) |
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305 | (29) |
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305 | (1) |
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305 | (1) |
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Technical and Design Aspects |
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306 | (1) |
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307 | (1) |
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307 | (1) |
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Offline, Inline, and Online Painting |
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307 | (1) |
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Process-Related Issues, Advantages, and Disadvantages |
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307 | (3) |
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Exterior Plastic Substrates and Parts |
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310 | (1) |
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310 | (1) |
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Basic Physical Characteristics |
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311 | (4) |
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Part Processing and Influence on Coating Performance |
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315 | (1) |
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315 | (3) |
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Plastic-Coating Materials |
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318 | (1) |
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Basic Technical Principles of Raw-Material Selection |
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318 | (2) |
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320 | (4) |
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Contrast Color and Clear Coat on Plastic Systems |
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324 | (1) |
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Technical Demands and Testing |
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324 | (1) |
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324 | (1) |
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Key Characteristics and Test Methods |
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325 | (4) |
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Trends, Challenges, and Limitations |
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329 | (1) |
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329 | (1) |
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330 | (2) |
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332 | (2) |
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334 | (17) |
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Introduction: the `Interior' Concept |
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334 | (1) |
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335 | (2) |
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337 | (2) |
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339 | (1) |
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Requirements to Be Fulfilled by the Paint Systems and Coating |
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339 | (1) |
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Demands Expected by the Inscription Technique |
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340 | (1) |
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Performances of Interior Coatings |
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341 | (1) |
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Mechanical and Technological Demands |
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341 | (1) |
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Substrates and Mechanical Adhesion |
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342 | (1) |
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Ecological and Economical Requirements |
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343 | (1) |
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Equipment for the Application of Interior Paint Systems |
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344 | (2) |
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Raw-Material Basis of Interior Paints |
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346 | (1) |
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347 | (4) |
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Adhesive Bonding -- a Universal Joining Technology |
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351 | (26) |
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351 | (1) |
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351 | (15) |
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Basic Principles of Bonding and Material Performances |
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351 | (1) |
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351 | (4) |
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Adhesives are Process Materials |
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355 | (1) |
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356 | (3) |
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359 | (1) |
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359 | (2) |
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361 | (1) |
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361 | (1) |
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Durability and Aging of Bonded System |
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362 | (4) |
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Bonding in Car Production |
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366 | (8) |
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367 | (1) |
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367 | (1) |
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368 | (1) |
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369 | (1) |
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Crash-Resistant Adhesives/Bonding |
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369 | (1) |
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370 | (1) |
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371 | (1) |
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Special Aspects of Structural Bonding in the Trim Shop |
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371 | (1) |
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371 | (1) |
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372 | (1) |
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372 | (2) |
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374 | (3) |
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377 | (4) |
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Repair After Pretreatment and Electrocoat Application |
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377 | (1) |
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Repair After the Primer Surfacer Process |
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378 | (1) |
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378 | (2) |
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380 | (1) |
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Specifications and Testing |
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381 | (86) |
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381 | (24) |
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Visual Evaluation of Appearance |
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381 | (1) |
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Specular Gloss Measurement |
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382 | (3) |
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Visual Evaluation of Distinctness-of-Image (DOI) |
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385 | (1) |
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Measurement of Distinctness-of-Image |
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385 | (1) |
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Visual Evaluation of `Orange Peel' |
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386 | (2) |
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Instrumental Measurement of Waviness (Orange Peel) |
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388 | (2) |
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The Structure Spectrum and its Visual Impressions |
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390 | (2) |
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Outlook of Appearance Measurement Techniques |
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392 | (1) |
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Visual Evaluation of Color |
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393 | (1) |
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393 | (4) |
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Metallic and Interference Colors |
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397 | (1) |
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Color Measurement of Solid Colors |
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398 | (3) |
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Color Measurement of Metallic and Interference Coatings |
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401 | (1) |
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Typical Applications of Color Control in the Automotive Industry |
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402 | (1) |
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Color Measurement Outlook |
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403 | (2) |
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Weathering Resistance of Automotive Coatings |
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405 | (22) |
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405 | (1) |
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Environmental Impact on Coatings |
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406 | (2) |
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408 | (6) |
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414 | (7) |
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421 | (2) |
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Standards for Conducting and Evaluating Weathering Tests |
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423 | (3) |
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Correlation Between Artificial and Natural Weathering Results |
|
|
426 | (1) |
|
|
|
427 | (7) |
|
Hans-Joachim Streitberger |
|
|
|
|
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) |
|
|
|
434 | (33) |
|
|
|
|
|
434 | (1) |
|
|
|
435 | (1) |
|
|
|
435 | (1) |
|
|
|
436 | (3) |
|
|
|
439 | (2) |
|
|
|
441 | (1) |
|
|
|
441 | (1) |
|
|
|
441 | (3) |
|
|
|
444 | (1) |
|
|
|
445 | (1) |
|
|
|
446 | (2) |
|
Impact Testing by Falling Weight |
|
|
448 | (1) |
|
|
|
449 | (1) |
|
Standardized Multi-Impact Test Methods |
|
|
450 | (1) |
|
Single-Impact Test Methods |
|
|
451 | (3) |
|
|
|
454 | (1) |
|
|
|
454 | (1) |
|
Abrasion Test by Falling Abrasive Sand |
|
|
455 | (1) |
|
|
|
456 | (1) |
|
|
|
456 | (1) |
|
|
|
457 | (1) |
|
|
|
458 | (2) |
|
|
|
460 | (2) |
|
|
|
462 | (5) |
|
|
|
467 | (8) |
|
Hans-Joachim Streitberger |
|
|
|
|
|
|
467 | (1) |
|
|
|
468 | (7) |
|
Basic Concepts and Realizations |
|
|
468 | (5) |
|
Requirements and Limitations of a System Supply Concept |
|
|
473 | (2) |
|
|
|
475 | (8) |
|
Hans-Joachim Streitberger |
|
|
|
|
Status and Public Awareness of the Automotive Coating Process |
|
|
475 | (1) |
|
|
|
476 | (2) |
|
|
|
478 | (1) |
|
Innovative Equipments and Processes |
|
|
479 | (2) |
|
|
|
481 | (2) |
| Index |
|
483 | |