Automotive Paints and Coatings

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.

Preface xvii

Abbreviations xix

List of Contributors xxiii

1 Introduction 1
Hans-Joachim Streitberger

1.1 Historic Development 1

1.2 Legislation 7

1.3 Automotive and Automotive Paint Market 9

2 Materials and Concepts in Body Construction 13
Klaus Werner Thomer

2.1 Introduction 13

2.2 Methods of Body Construction 15

2.3 Principles of Design 20

2.4 Materials 26

2.5 Manufacturing Methods 47

2.6 Joining Methods 52

2.7 Outlook 57

2.8 Surface Protection 59

3 Pretreatment of Multimetal Car Bodies 61
Horst Gehmecker

3.1 Introduction 61

3.2 Car Body Construction Materials 61

3.3 Pretreatment Process 65

3.4 Car Body Pretreatment Lines 77

3.5 Properties and Specifications of Zinc Phosphate Conversion Layers 85

3.6 Environmental Legislations 86

3.7 Outlook 86

4 ElectrodepositionCoatings 89
Hans-Joachim Streitberger

4.1 History and Introduction 89

4.2 Physico-chemical Basics of the Deposition Process 90

4.3 Data for Quality Control 95

4.4 Resins and Formulation Principles 98

4.5 Film Performance of Cathodic Electrocoatings 101

4.6 Design of Cathodic Electrocoating Lines 106

4.7 Defects During Application and their Prevention 119

4.8 Electrocoating and Similar Processes Used in Automotive Supply Industry 124

4.9 Outlook 125

5 PrimerSurfacer 129
Heinrich Wonnemann

5.1 Introduction 129

5.2 Requirement Profile 132

5.3 Raw Materials 138

5.4 Liquid Primers 152

5.5 PowderPrimerSurfacers 160

5.6 Process Sequence 170

5.7 Summary and Future Outlook 171

6 TopCoats 175
Karl-Friedrich Dössel

6.1 Introduction 175

6.2 Pigments and Color 175

6.3 Single-Stage Top Coats (Monocoats) 180

6.4 Base Coats 181

6.5 Clear Coat 189

6.6 Integrated Paint Processes (IPP) for Top Coat Application 208

7 Polymeric Engineering for Automotive Coating Applications 211
Heinz-Peter Rink

7.1 General Introduction 211

7.2 Polyacrylic Resins for Coating Materials in the Automotive Industry 214

7.3 Polyester for Coating Materials for the Automotive Industry 224

7.4 Polyurethane Dispersions in Coating Materials for the Automotive Industry 231

7.5 Polyurethane Polyacrylic Polymers in Coating Materials for the Automotive Industry 238

7.6 Epoxy Resins 241

7.7 Cross-Linking Agents and Network-Forming Resins 244

8 Paint Shop Design and Quality Concepts 259
Pavel Svejda

8.1 Introduction 259

8.2 Coating Process Steps 260

8.3 General Layout 266

8.4 Coating Facilities 268

8.5 Paint Drying 288

8.6 Quality Aspects 290

8.7 Economic Aspects 298

9 Coatings for Plastic Parts 305

9.1 Exterior Plastics 305
Guido Wilke

9.2 Interior Plastics 334
Stefan Jacob

10 Adhesive Bonding – a Universal Joining Technology 351
Peter W. Merz, Bernd Burchardt and Dobrivoje Jovanovic

10.1 Introduction 351

10.2 Fundamentals 351

10.3 Bonding in Car Production 366

10.4 Summary 374

11 In-plant Repairs 377
Karl-Friedrich Dössel

11.1 Repair After Pretreatment and Electrocoat Application 377

11.2 Repair After the Primer Surfacer Process 378

11.3 Top-Coat Repairs 378

11.4 End-of-Line Repairs 380

12 Specifications and Testing 381

12.1 Color and Appearance 381
Gabi Kiegle-Böckler

12.2 Weathering Resistance of Automotive Coatings 405
Gerhard Pausch and Jörg Schwarz

12.3 Corrosion Protection 427
Hans-Joachim Streitberger

12.4 Mechanical Properties 434
Gerhard Wagner

13 Supply Concepts 467
Hans-Joachim Streitberger and Karl-Friedrich Dössel

13.1 Quality Assurance (QA) 467

13.2 Supply Chain 468

14 Outlook 475
Hans-Joachim Streitberger and Karl-Friedrich Dössel

14.1 Status and Public Awareness of the Automotive Coating Process 475

14.2 Regulatory Trends 476

14.3 Customer Expectations 478

14.4 Innovative Equipments and Processes 479

14.5 New Business Ideas 481

Index 483

"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

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. 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.