Automotive Paints and Coatings

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.

"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)

• Preface xviiAbbreviations xixList of Contributors xxiii1 Introduction 1Hans-Joachim Streitberger1.1 Historic Development 11.2 Legislation 71.3 Automotive and Automotive Paint Market 92 Materials and Concepts in Body Construction 13Klaus Werner Thomer2.1 Introduction 132.2 Methods of Body Construction 152.3 Principles of Design 202.4 Materials 262.5 Manufacturing Methods 472.6 Joining Methods 522.7 Outlook 572.8 Surface Protection 593 Pretreatment of Multimetal Car Bodies 61Horst Gehmecker3.1 Introduction 613.2 Car Body Construction Materials 613.3 Pretreatment Process 653.4 Car Body Pretreatment Lines 773.5 Properties and Specifications of Zinc Phosphate Conversion Layers 853.6 Environmental Legislations 863.7 Outlook 864 ElectrodepositionCoatings 89Hans-Joachim Streitberger4.1 History and Introduction 894.2 Physico-chemical Basics of the Deposition Process 904.3 Data for Quality Control 954.4 Resins and Formulation Principles 984.5 Film Performance of Cathodic Electrocoatings 1014.6 Design of Cathodic Electrocoating Lines 1064.7 Defects During Application and their Prevention 1194.8 Electrocoating and Similar Processes Used in Automotive Supply Industry 1244.9 Outlook 1255 PrimerSurfacer 129Heinrich Wonnemann5.1 Introduction 1295.2 Requirement Profile 1325.3 Raw Materials 1385.4 Liquid Primers 1525.5 PowderPrimerSurfacers 1605.6 Process Sequence 1705.7 Summary and Future Outlook 1716 TopCoats 175Karl-Friedrich Dössel6.1 Introduction 1756.2 Pigments and Color 1756.3 Single-Stage Top Coats (Monocoats) 1806.4 Base Coats 1816.5 Clear Coat 1896.6 Integrated Paint Processes (IPP) for Top Coat Application 2087 Polymeric Engineering for Automotive Coating Applications 211Heinz-Peter Rink7.1 General Introduction 2117.2 Polyacrylic Resins for Coating Materials in the Automotive Industry 2147.3 Polyester for Coating Materials for the Automotive Industry 2247.4 Polyurethane Dispersions in Coating Materials for the Automotive Industry 2317.5 Polyurethane Polyacrylic Polymers in Coating Materials for the Automotive Industry 2387.6 Epoxy Resins 2417.7 Cross-Linking Agents and Network-Forming Resins 2448 Paint Shop Design and Quality Concepts 259Pavel Svejda8.1 Introduction 2598.2 Coating Process Steps 2608.3 General Layout 2668.4 Coating Facilities 2688.5 Paint Drying 2888.6 Quality Aspects 2908.7 Economic Aspects 2989 Coatings for Plastic Parts 3059.1 Exterior Plastics 305Guido Wilke9.2 Interior Plastics 334Stefan Jacob10 Adhesive Bonding – a Universal Joining Technology 351Peter W. Merz, Bernd Burchardt and Dobrivoje Jovanovic10.1 Introduction 35110.2 Fundamentals 35110.3 Bonding in Car Production 36610.4 Summary 37411 In-plant Repairs 377Karl-Friedrich Dössel11.1 Repair After Pretreatment and Electrocoat Application 37711.2 Repair After the Primer Surfacer Process 37811.3 Top-Coat Repairs 37811.4 End-of-Line Repairs 38012 Specifications and Testing 38112.1 Color and Appearance 381Gabi Kiegle-Böckler12.2 Weathering Resistance of Automotive Coatings 405Gerhard Pausch and Jörg Schwarz12.3 Corrosion Protection 427Hans-Joachim Streitberger12.4 Mechanical Properties 434Gerhard Wagner13 Supply Concepts 467Hans-Joachim Streitberger and Karl-Friedrich Dössel13.1 Quality Assurance (QA) 46713.2 Supply Chain 46814 Outlook 475Hans-Joachim Streitberger and Karl-Friedrich Dössel14.1 Status and Public Awareness of the Automotive Coating Process 47514.2 Regulatory Trends 47614.3 Customer Expectations 47814.4 Innovative Equipments and Processes 47914.5 New Business Ideas 481Index 483