Automotive Paints and Coatings, Second Edition

506 Pages·2008·14.555 MB·English

AutomotivePaintsandCoatings
Editedby
Hans-JoachimStreitberger
andKarl-FriedrichDo¨ssel
FurtherReading
H.Lipowsky,E.Arpaci
Copperin theAutomotiveIndustry
2007
ISBN:978-3-527-31769-1
G.Pfaff(Ed.)
Encyclopedia ofAppliedColor
2009
ISBN:978-3-527-31551-2
G.Buxbaum,G.Pfaff(Eds.)
IndustrialInorganicPigments
Third,CompletelyRevisedandExtendedEdition
2005
ISBN:978-3-527-30363-2
E.B.Faulkner,R.J.Schwartz(Eds.)
HighPerformancePigments
Second,CompletelyRevisedandExtendedEdition
2008
ISBN:978-3-527-31405-8
S.K.Ghosh(Ed.)
FunctionalCoatings
byPolymerMicroencapsulation
2006
ISBN:978-3-527-31296-2
Automotive Paints and Coatings
Edited by
Hans-Joachim Streitberger
and Karl-Friedrich Do¨ssel
Second,CompletelyRevisedandExtendedEdition
TheEditors AllbookspublishedbyWiley-VCHarecare-
fullyproduced.Nevertheless,authors,editors,
Dr.Hans-JoachimStreitberger andpublisherdonotwarranttheinforma-
Market&Management tioncontainedinthesebooks,includingthis
SustainabilityinBusiness book,tobefreeoferrors.Readersaread-
Patronatsstr.13 visedtokeepinmindthatstatements,data,
48165Mu¨nster illustrations,proceduraldetailsorotheritems
Germany mayinadvertentlybeinaccurate.
LibraryofCongressCardNo.:
Dr.Karl-FriedrichD¨ossel
appliedfor
DupontPerformanceCoatings
Christbusch25
42285Wuppertal BritishLibraryCataloguing-in-PublicationData
Germany Acataloguerecordforthisbookisavailable
fromtheBritishLibrary.
1.Edition1995
2.CompletelyRevisedandExtendedEdition Bibliographicinformationpublishedbythe
2008 DeutscheNationalbibliothek
DieDeutscheNationalbibliothekliststhis
publicationintheDeutscheNationalbibli-
ografie;detailedbibliographicdataareavail-
ableintheInternetat<http://dnb.d-nb.de>.
2008WILEY-VCHVerlagGmbH&Co.
KGaA,Weinheim
Allrightsreserved(includingthoseoftrans-
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Printedonacid-freepaper
ISBN:978-3-527-30971-9
V
Contents
Preface XVII
Abbreviations XIX
ListofContributors XXIII
1 Introduction 1
Hans-JoachimStreitberger
1.1 HistoricDevelopment 1
1.2 Legislation 7
1.3 AutomotiveandAutomotivePaintMarket 9
2 MaterialsandConceptsinBodyConstruction 13
KlausWernerThomer
2.1 Introduction 13
2.2 MethodsofBodyConstruction 15
2.2.1 MonocoqueDesign 15
2.2.2 SpaceFrame 18
2.2.3 HybridTypeofConstruction 19
2.2.4 ModularWayofConstruction 19
2.3 PrinciplesofDesign 20
2.3.1 ConventionalDesign 20
2.3.2 DesignUnderConsiderationofLight-WeightConstruction 22
2.3.3 Bionics 23
2.4 Materials 26
2.4.1 Steel 26
2.4.1.1 GeneralRemarks 26
2.4.1.2 Low-CarbonDeepDrawingSteels 29
2.4.1.3 Higher-StrengthSteels 29
2.4.1.4 High-StrengthSteels 31
2.4.1.5 High-Grade(Stainless)Steels 32
2.4.1.6 Manganese–BoronSteels 32
2.4.1.7 Light-ConstructionSteelwithInducedPlasticity(TWIPSteel) 33
2.4.2 Aluminum 34
AutomotivePaintsandCoatings.EditedbyH.-J.StreitbergerandK.-F.Do¨ssel
Copyright2008WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:978-3-527-30971-9
VI Contents
2.4.2.1 GeneralRemark 34
2.4.2.2 FurtherTreatment 35
2.4.2.3 AluminumAlloys 38
2.4.2.4 AluminumasLight-WeightConstructionMaterial 39
2.4.3 Magnesium 40
2.4.4 Titanium 42
2.4.5 NonmetallicParts – FiberComposites 43
2.5 ManufacturingMethods 47
2.5.1 TailoredProducts 47
2.5.1.1 GeneralRemarks 47
2.5.1.2 TailoredBlanks 47
2.5.1.3 TailoredTubes 48
2.5.1.4 TailoredStrips 48
2.5.1.5 PatchworkBlanks 48
2.5.1.6 Future 49
2.5.2 Hydroforming 49
2.5.3 PressHardening 50
2.5.4 MetalFoam 50
2.5.5 SandwichStructures 51
2.5.6 RollFormingtoShape 52
2.6 JoiningMethods 52
2.6.1 Bonding 53
2.6.2 LaserWelding 54
2.6.3 Others 55
2.6.3.1 Clinching 55
2.6.3.2 Riveting 56
2.6.3.3 RollerHemming 56
2.7 Outlook 57
2.8 SurfaceProtection 59
2.8.1 PrecoatingofSheets 59
2.8.2 CorrosionPreventionintheDesignPhase 59
3 PretreatmentofMultimetalCarBodies 61
HorstGehmecker
3.1 Introduction 61
3.2 CarBodyConstructionMaterials 61
3.2.1 SheetMaterials 61
3.2.2 SurfaceConditions/Contaminations 63
3.3 PretreatmentProcess 65
3.3.1 SequenceofTreatment 65
3.3.2 Degreasing 65
3.3.3 Activation 69
3.3.4 ZincPhosphating 70
3.3.5 Passivation 75
3.3.6 PretreatmentofAluminum – SteelStructures 75
Contents VII
3.3.7 PretreatmentofMagnesium 76
3.3.8 PretreatmentofPlasticParts 77
3.4 CarBodyPretreatmentLines 77
3.4.1 SprayLines 80
3.4.2 ContinuousHorizontalSpray/DipLine 80
3.4.3 RoDip3Line 80
3.4.4 VarioShuttleLine 81
3.4.5 OtherTypesofLines 82
3.4.6 ConstructionMaterials 82
3.4.7 DetailsonProcessStages 82
3.4.7.1 PrecleaningStage 82
3.4.7.2 Spraydegrease 83
3.4.7.3 DipDegrease 83
3.4.7.4 Rinsing 84
3.4.7.5 Activation 84
3.4.7.6 Phosphating 84
3.4.7.7 Rinsing 85
3.4.7.8 Passivation 85
3.4.7.9 Deionizedwaterrinsing 85
3.4.7.10 EnteringtheElectrocoatLine 85
3.5 PropertiesandSpecificationsofZincPhosphateConversionLayers 85
3.6 EnvironmentalLegislations 86
3.7 Outlook 86
4 ElectrodepositionCoatings 89
Hans-JoachimStreitberger
4.1 HistoryandIntroduction 89
4.2 Physico-chemicalBasicsoftheDepositionProcess 90
4.3 DataforQualityControl 95
4.3.1 Voltage,CurrentDensity,BathTemperature,andBath
Conductivity 96
4.3.2 WetFilmConductivity 96
4.3.3 SolidContent,SolventContent,andpH 97
4.4 ResinsandFormulationPrinciples 98
4.4.1 GeneralRemarks 98
4.4.2 AnodicElectrodepositionPaints 99
4.4.3 CathodicElectrodepositionPaints 99
4.5 FilmPerformanceofCathodicElectrocoatings 101
4.5.1 PhysicalFilmData 101
4.5.2 CorrosionProtection 102
4.5.3 ChipResistance 104
4.5.4 SurfaceSmoothnessandAppearance 105
4.6 DesignofCathodicElectrocoatingLines 106
4.6.1 IntegrationintotheCoatingProcessofCarsandTrucks 106
4.6.2 Pretreatment 107
VIII Contents
4.6.3 GeneralFunctionsandEquipmentofanElectrocoatLine 107
4.6.4 Tanks,Filters,HeatExchanger,andPowerSupply 108
4.6.5 ReplenishmentandAnodeCells 111
4.6.6 UltrafiltrationandRinsingZones 114
4.6.7 BakingOven 118
4.7 DefectsDuringApplicationandtheirPrevention 119
4.7.1 Dirt 119
4.7.2 Craters 120
4.7.3 SurfaceRoughness 121
4.7.4 FilmThickness/ThrowingPower 122
4.7.5 OtherDefects 123
4.8 ElectrocoatingandSimilarProcessesUsedinAutomotiveSupply
Industry 124
4.9 Outlook 125
5 PrimerSurfacer 129
HeinrichWonnemann
5.1 Introduction 129
5.2 RequirementProfile 132
5.2.1 LegislativeRequirement 132
5.2.2 TechnologicalRequirements 133
5.2.2.1 FilmProperties 133
5.2.2.2 ProductSpecifications 136
5.2.2.3 Application 136
5.3 RawMaterials 138
5.3.1 ResinComponents 139
5.3.2 PigmentsandExtenders 141
5.3.2.1 TitaniumDioxide 143
5.3.2.2 BariumSulfate 144
5.3.2.3 Talc 144
5.3.2.4 SiliconDioxide 145
5.3.2.5 Feldspar 146
5.3.2.6 CarbonBlacks 146
5.3.3 Additives 146
5.3.3.1 PigmentWettingandDispersionAdditives 148
5.3.3.2 DefoamingandDeaeratingAgents 148
5.3.3.3 SurfactantsandAdditivesforSubstrateWetting 149
5.3.3.4 RheologyAdditives 149
5.3.4 Solvents 150
5.3.4.1 AromaticHydrocarbons:Diluents/Thinners 151
5.3.4.2 Alcohols,Cellosolves,andEsters:Solvents 151
5.3.4.3 TetralinorPineOil:VeryHighBoilingAdditiveDiluents 152
Contents IX
5.4 LiquidPrimers 152
5.4.1 FormulaPrinciples 152
5.4.1.1 Application 152
5.4.1.2 Rheology 153
5.4.2 ManufacturingProcess 156
5.4.3 Application 158
5.5 PowderPrimerSurfacers 160
5.5.1 FormulaPrinciples 160
5.5.2 ManufacturingProcess 162
5.5.3 Application 166
5.6 ProcessSequence 170
5.7 SummaryandFutureOutlook 171
6 TopCoats 175
Karl-FriedrichDo¨ssel
6.1 Introduction 175
6.2 PigmentsandColor 175
6.3 Single-StageTopCoats(Monocoats) 180
6.4 BaseCoats 181
6.4.1 BaseCoatRheology 184
6.4.2 LowandMediumSolidsBaseCoat 185
6.4.3 HighSolids(HS)BaseCoats 186
6.4.4 WaterborneBaseCoats 186
6.4.5 GlobalConversiontoWaterborneBaseCoatTechnology 187
6.4.6 DryingofBaseCoats 189
6.5 ClearCoat 189
6.5.1 Market 189
6.5.2 LiquidClearCoats 190
6.5.2.1 One-Component(1K)AcrylicMelamineClearCoat 190
6.5.2.2 AcrylicMelamineSilane 192
6.5.2.3 Carbamate-Melamine-Based1KClearcoat 192
6.5.2.4 One-ComponentPolyurethane(PUR)ClearCoat 192
6.5.2.5 One-(andTwo-)ComponentEpoxyAcidClearCoat 192
6.5.2.6 Two-Component(2K)PolyurethaneClearCoat 193
6.5.2.7 WaterborneClearCoat 194
6.5.3 PowderClearCoat 195
6.5.4 TopCoatPerformance 198
6.5.4.1 EnviromentalEtch 198
6.5.4.2 UVDurabilityofClearCoats 199
6.5.4.3 ScratchResistantClearCoats 201
6.5.4.4 ApplicationProperties 204
6.5.5 FutureDevelopments:UVCuring 206
X Contents
6.6 IntegratedPaintProcesses(IPP)forTopCoatApplication 208
6.6.1 Wet-On-Wet-On-WetApplication(3Coat1Bake)ofPrimer
Surfacer–BaseCoat–ClearCoat 208
6.6.2 PrimerlessCoatingProcess 209
7 PolymericEngineeringforAutomotiveCoatingApplications 211
Heinz-PeterRink
7.1 GeneralIntroduction 211
7.2 PolyacrylicResinsforCoatingMaterialsintheAutomotive
Industry 214
7.2.1 ManagingthePropertyProfileofthePolyacrylicResins 214
7.2.2 ManufacturingPolyacrylicResins 218
7.2.2.1 ManufacturingPolyacrylicResinsbyMeansofSolution
Polymerization 218
7.2.2.2 PolymerizationinanAqueousEnvironment 222
7.2.2.3 MassPolymerization 224
7.3 PolyesterforCoatingMaterialsfortheAutomotiveIndustry 224
7.3.1 ManagingthePropertyProfileofPolyesters 224
7.3.2 ManufacturingPolyesters 228
7.4 PolyurethaneDispersionsinCoatingMaterialsfortheAutomotive
Industry 231
7.4.1 ManagingthePropertyProfileofPolyurethaneResinsand
PolyurethaneResinDispersions 232
7.4.2 ManufacturingPolyurethaneResinDispersions 234
7.5 PolyurethanePolyacrylicPolymersinCoatingMaterialsforthe
AutomotiveIndustry 238
7.5.1 Introduction 238
7.5.2 ManagingthePropertyProfileofPolyurethanePolyacrylic
Polymers 239
7.5.3 ManufacturingPolyurethanePolyacrylicPolymers 240
7.6 EpoxyResins 241
7.6.1 ManagingthePropertyProfile 242
7.6.2 ManufacturingPolyepoxyResins 243
7.7 Cross-LinkingAgentsandNetwork-FormingResins 244
7.7.1 Introduction 244
7.7.2 Cross-LinkingAgentsforLiquidCoatingMaterials 245
7.7.2.1 MelamineandBenzoguanamineResins 245
7.7.2.2 Tris(Alkoxycarbonylamino)-1,3,5-Triazine 248
7.7.2.3 PolyisocyanatesandBlockedPolyisocyanates 249
7.7.2.4 OtherCross-LinkingAgentsforLiquidCoatingMaterials 252
7.7.3 Cross-LinkingAgentsforPowderCoatingsintheAutomotive
Industry 252