jong

Slide1 : Technology Trends in Automotive Surface Coatings Jong Myung Park Buhmwoo Institute of Tech November 15, 2006


Slide2 : CONTENTS Pretreatment System Electro-Coat Pre-sealed System Pre-primed System UV-Curing System Conclusion Introduction Basics of Organic Coating System


Slide3 : 내구성 자동차 강판 요구성능 적용 기술 •DP (Dual Phase) •TRIP (Transformation Induced Plasticity) 경량화 및 강도, 연신율 우수 고속 충돌성 우수한 고강도 강판 •BH STEEL Bake hardening steel 약자로, 차체 성형시 강도가 낮아 가공성 우수하고, 성형 후에는 자동차 도장공정을 거치면서 받는 열에 의하여 강도가 증가되어 최종 자동차 완성된 이후 높은 강도 구현 가능. 고내식성 표면처리 강판 •Presealed •Preprimed •Pre-finished •Pb,Cr-free 표면처리 강판 •고강도강 사용으로 차체무게 감소 – 연비 감소로 인한 환경오염 배출물질 감소 Introduction The Technology of Properties for Automotives


Slide4 : Purpose of Coatings for Automotives Protect from 미관 상품성 향상 방 청 방 음 입체감 평활성 광택감 색 채 SUN LIGHT(UV, IR) Water, Oxygen Sand, Dust Gum, Soot Sea breeze Exhaust gas Improve Introduction


Slide5 : Coating Process of Car Body Introduction


Slide6 : Global Automotive Paint Driving Force Introduction


Slide7 : 코팅 시스템 개론 일반적 코팅 구성 성분 Resin Adhesion & Film formation Key Ingredient for performance Solvent Rheology control Solvation & Dilution Drying behavior Additive Defoaming Rheology control Surface wetting/levelling Pigment Surface protection Special function Decoration/Color Protection Functionality Decoration (Automotive, Heavy-duty, PCM, Industrial) UV protection


Slide8 : 코팅 시스템 개론 코팅용 수지 Applications - Automotive Refinish - Architectural (Emulsions) - Vacuum Metallizing, NC Binder = Film Former = Polymer = Resin * Thermo-plastic Resin (열가소성) - High Mw Polymer에 의하여 생성 - No Functionality for Crosslinking - Low-solid System - Solvent Evaporation에 의하여 도막 형성 - Solvent 및 Heating에 의하여 재용해 특성 - Latex – Aqueous Acrylic Dispersion - High VOC System 소재 표면에 접착 및 부착되어 Film Formation 및 형성된 필름의 물성을 좌우하는 가장 중요한 코팅 성분 Characteristics - Quick Drying - No Chemical Change - Re-dissolved Applications - Automotive OEM - Can Coatings Coil Coatings Appliance Finishes 2K PU Coatings * Thermo-setting Resin (열경화성) - Low Mw Polymer - Crosslinking System - Crosslinker와 반응할 Functional Group 필요 - Solvent 및 Heating에 의하여 재용해 어려움 - Acrylics 및 Polyester, Alkyds, Epoxies 등 - Lower VOC System Characteristics - Heat System - Chemical Change - Not Easily Re-dissolved


Slide9 : 코팅 시스템 개론 Resin Crosslinking 수지의 Reactive Functional Groups과 Crosslinker 간의 화학적 반응에 의하여 생성되는 3차원 Polymer Network * Crosslinking Technology 장점 - Low Mw Resin --- Easily Soluble - High Solids Level 가능 - 범용적인 다양한 수지 및 경화제 군 - Heat 조건에서 용해되지 않음 - 우수한 Solvent Resistance - Low Mw로 인하여 Compatibility 양호 * Crosslink 위한 화학 반응 - Oxidation - Melamine Crosslink - Isocyanate Crosslink - Epoxy Crosslink Resin Functionality Crosslinkers Hydroxyl Group (-OH) Carboxyl Group (-COOH) Epoxies Unsaturated Fatty Acid Amino Resins / Poly-isocyanate Amino Resins / Epoxies Polyamines / Poly-carboxylic Acid Oxygen


Slide10 : 코팅 시스템 개론 코팅용 수지 구분 Thermosetting Resin Air-drying 2-K Reactive Baking Type Stand Oil/Bodied Oil Varnish (Oleoresinous Varnish) Ambient Dried Alkyd Resin Polyurethane Resin Epoxy Resin Alkyd Resin Polyester Resin Thermo-setting Acrylic Resin Melamine Resin Phenol Resin Blocked Isocyanate Urea Resin Thermoplastic Resin Cellulose (NC & CAB) Chlorinated Rubber Thermo-plastic Acrylic Resin Vinyl Resin


Slide11 : 구성 성분 Acrylic Monomer Initiator Organic Solvents Emulsifier Properties Versatile / Durable Good Color Gloss Retention Good Resistance - UV - Hydrolysis - Oxidation Characteristics Solvent Composition Molecular Weight Tg Solubility Uses Automotives Heavy Industries Industrials Architectures Special Applications Acrylic Resin 코팅 시스템 개론


Slide12 : Acrylic Resin Crosslinking Reaction 코팅 시스템 개론 O O H O O H O H O N C H 2 O R ( R O C H 2 ) 2 N O N R N O O O H H O C N R N C O O H E p o x y I s o c y a n a t e A m i n o - F o r m a l d e h y d e


Slide13 : Amino Resin 코팅 시스템 개론 Urea / Melamine Formaldehyde Alcoholic Solvent Brittleness High Speed Cure Self-condensation Mineral Spirits Tolerance Alkoxy Type & Degrees Solubility & Compatibility Stability Cure Rate Acrylic Polyol Polyester Polyol Alkyd Special Applications Raw Material Characteristics Properties Uses (for Crosslink)


Slide14 : Amino Resin 반응 메커니즘


Slide15 : Polyester Resin 코팅 시스템 개론 Acid Alcohol Solvents Flexibility Good Adhesion Good Chemical Resistance Solvent Composition Molecular Weight Industrials Pre-coated Metal Heavy Industries High Crosslinking Density Automotives Raw Material Properties Characteristics Uses Good Hardness


Slide16 : Polyester Resin 반응 메커니즘 코팅 시스템 개론


Slide17 : Polyester Resin 반응 메커니즘 코팅 시스템 개론


Slide18 : Epoxy Resin 코팅 시스템 개론 Bis-phenol A Epichlorohydrine Solvents Good Reactivity Good Chemical Resistance No Side Products Solvent Composition Molecular Weight Industrials Heavy Industries Automotives UV Sensitivity Floor Coatings Electronics Raw Material Properties Characteristics Uses Good Mechanical Properties


Slide19 : Epoxy Resin 반응 메커니즘 코팅 시스템 개론


Slide20 : Urethane Resin 코팅 시스템 개론 Isocyanates Glycols Solvents Good Adhesion Good Mechanical Properties High Gloss Isocyanate Type Cure Rate Sealants Architectures Industrials Hardener for Acrylics Hardener for Polyesters Raw Material Properties Characteristics Uses Good Electro-isolation Easily Gellation Yellowing


Slide21 : Urethane Resin 반응 메커니즘 A) (Prepolymer) + H2O B) (중간체 Amine 구조) + CO2 ↑ 상온 경화형 A + B 2액 경화형 A) B) (Prepolymer) HO ----------------- OH (Polyol) A + B 코팅 시스템 개론


Slide22 : Pigments 구분 및 역할 코팅 시스템 개론 도막형성 물질과 혼합되어, 색상과 은폐, 투명성 제공 및 기후와 부식에 대한 저항성, 도막 강화 기능 등 부여 Pigments Titanium Dioxide Prime Pigment Extender Pigment High Refractive Index (Scatter Light) High Cost Organic & Inorganic (Oxides) Calcium Carbonate, Talc, Clays Barium Sulphate, Silicas * Reactive Pigments (Rust Protection – Passivation) - Borates - Chromates - Leads - Molybdates - Phosphates - Silicates * Barrier Pigments - Talc - Aluminum - Mica - Silver Paste Color Shade Transparency Hiding Power


Slide23 : Pigment Dispersion 코팅 시스템 개론 Repulsion Attraction


Slide24 : Solvents 역할 코팅 시스템 개론 수지 및 기타 원료의 용해, 원활한 작업 위한 점도 조절 그리고 코팅 안정성 및 흐름성 조절 용도로 사용 Evaporation Rate Solvent Diffusion Solvent Activity Characteristics Viscosity Diffusion Ratio Density Water Solubility Electrical Resistance Total Cost in Use Right Solvency for the Application Evaporation Rate Issues HAPs, VOC Regulation Compliance Odor & Toxicity Solvents Active Solvents Latent Solvents Diluent Solvents Dissolve Resin True Solvent for NC Lower Viscosity High Cost Assist the Active Solvents Reduces Viscosity Poor or Non-solvent Alone Intermediate Cost Diluents the System Non-solvent Low Cost Ketones / Esters Glycol Ethers Glycol Ether Esters Alcohols Water Aromatic Hydrocarbons Aliphatic Hydrocarbons


Slide25 : Dissolve Film Formers Paint Removers Cleaning Metals Cleaning Fluids Coalescing Aids Uses Solvents 비교 코팅 시스템 개론


Slide26 : 코팅용 Solvents 코팅 시스템 개론


Slide27 : Additives for Coatings 코팅 시스템 개론 Additives Dispersants Wetting Agent Defoamer Control to Pigment Particle Sizes Pigment Stabilization (Electrostatic & Steric Stabilization) Thickener UV Stabilizer Control to Surface Tension (Silicone & Fluoro Chemistry) Control to Foam (Waterborne System) Control to Viscosity (ASE, HASE, HEUR, Bentone, Cellulose) Protection to UV Ray (Hydroxyphenyl triazine, Benzotriazole )


Slide28 : Wetting Agents 특성 코팅 시스템 개론 Wetting Agents Anionic Surfactant Cationic Surfactant Amphoteric Surfactant Hydrophobic Group with Hydrocarbon 12-18 Alkyl Group with –COOH, -SO3H, -OSO3H -COONa, -SO3Na → Salt Shape Non-ionic Surfactant Hydrophilic Group with Cation -CH2N+CH3Cl- Surfactant with Anionic and Cationic both R1-(NH-CH2CH2)2-NH+-CH2-COO- Non-ionic System Polyethylene Oxide Compound Ionic Type Non-ionic Type


Slide29 : Surface Tension 코팅 시스템 개론


Slide30 : Defoaming 코팅 시스템 개론 Polydimethylsiloxanes No Defoamer with Defoamer


Slide31 : Thickener (Rheology) 코팅 시스템 개론 Viscosity Curve Thixotropy Viscosity Profile


Slide32 : UV Stabilizer 코팅 시스템 개론


Slide33 : 2. Pre-treatment system의 기술 특성 및 적용 Fe (Strip) Zn 도금층 도장층 O2 Salt H20 ① O2 Salt H20 ② ③ : ① 표 면 부 식 ② 구 멍 부 식 Corrosion Mechanism


Slide34 : Sacrificial Effect : 도금층 손상 및 부식환경하에서 소재 대비 이온화 경향이 큰 금속 이온이 우선적으로 산화되어 소재가 산화되는 것을 방지.(Zn, Cr6+) Barrier Effect : 소재에 물, 산소 등 부식을 유발시키는 물질이 통과할 수 없는 막을 형성하여 소재가 부식되는 것을 방지.(Sn, Pb, Cr3+) 2. Pre-treatment system의 기술 특성 및 적용 Corrosion Protection


Slide35 : 1)Hot water rinse : rough removal of oil 2)Pre-degreasing : removal of oil, dust and dirt in outer body panel 3)Degreasing : removal of oil on outer and inner bodies 4-5)Water rinse : washing-out of degreasing agent 6)Surface conditioning making the crystal form of zinc phosphate coating more fine-grained 7)Chemical conversion coating treatment : formation of zinc phosphate coating 8-10)Water rinse : washing-out of chemicals 11-12)Deionized water rinse : to prevent blister, and contamination of electro-deposition bath, brought about by miscellaneous ions Process of pretreatment


Slide36 : ▣ 반응형 공정 :탈지-수세-표면조정(activation)-피막형성(spray, dip)-수세-Sealing-순수세-Air blow-건조 표면조정 목적 : 인산염 피막의 반응속도 증가 및 입자 치밀화 (Ti3(PO4)2,TiH4(PO4)4 등의 티탄 콜로이드) ▣ 도포형 : Coating Roll을 사용하여 인산염 피막 형성 A. 처리목적 도장 밀착성 향상 도장후 내식성 향상 가공성 향상 표면 결함 은폐 B. 처리공정 2. Pre-treatment system의 기술 특성 및 적용 Parkerizing


Slide37 : ▣ 나판 내식성, 내 오염성, 도장밀착성 향상 및 표면경도 상향 ▣ 표면경도 상향 → 도금층 밀림 방지 → 마찰계수 감소 → 성형성 향상 ♣ 주용도 : 범용일반, 냉장고, 자동판매기, 전자레인지 (외판 : 고객사 도장후 사용) C. 인산염 피막[Zn3MX(PO4)ㆍ4H20] 역할 Parkerizing 2. Pre-treatment system의 기술 특성 및 적용


Slide38 : ▶ 부식반응(부반응) : 양극반응 Zn (Fe) → Zn 2+ (Fe 2+) + 2e- 음극반응 2H+ + 2e- → H2↑ ▶ 피막형성반응(주반응, 침전반응) : 3Zn2+ + 2H3PO4 → Zn3(PO4)2 H2O + 6H+ 3Zn(H2PO4)2 → Zn3(PO4)2 H2O + 4H3PO4 Zn 용출 → H+소비 → 계면 PH 상승 → 용액중 Zn(H2PO4)해리→ Zn3(PO4)2ㆍ4H2O 석출 D. 인산염 피막형성 반응순서 E. 피막형성 이론 Parkerizing 2. Pre-treatment system의 기술 특성 및 적용


Slide39 : F. 인산염 피막의 종류 및 특성 인산철 : 우수한 도막 밀착성, 광택 에 유리한 매끈한 화성처리표면, 내열성 우수, 처리비용 저렴, 아연계에 비해 내식성 열세 인산아연: 피막은 반응초기 강판표면의 음극부위에 석출된 후 결정 화와 성장을 통하여 수 많은 장방형 박판형 결정으로 성장 Parkerizing Phosphate surface 2000X


Slide40 : Cr Spray Water Rinse Applicator Roll A. 크롬처리 목적: 내식성 향상 및 상층의 수지/도장층과 밀착성 향상 Chromate 2. Pre-treatment system의 기술 특성 및 적용 Cr Spray Water Rinse


Slide41 : B. 피막형성 반응 (전해크롬) : 아연 부식생성물인 백청,흑청을 방지키 위해 표면에 크롬산화물 형성 (내식성 향상이 주목적) ▶ CrO3가 물과 반응하여 분해 : 2CrO3 + H2O → Cr2O72- + 2H+ (용액속에 존재) ▶ 전극반응 - 음극반응 : Cr2O72- + 14H+ + 6e- → 2Cr3+ + 7H2O - Cr 전착반응 : 2Cr3+ + 3e- → 2Cr (Cr3+ 일부가 강판 표면에 선 전착) - 음극반응 : 2Cr3+ + 60H- → 2Cr(OH)3 Cr2O72- + H2O → 2CrO42- + 2H+ Cr(OH)3 + 2CrO42- → Cr(OH)3Cr(OH)CrO4 (전해크롬 피막) ▶ 강판 표면에서의 pH 상승에 의한 수산화물을 형성으로 강판에 전착됨. C. 크롬제품 피막층 구조 Strip Cr (5~50mg/㎡) Zn (20g/㎡) * 주용도 : 일시 방청성 요구 범용 및 도장하지용 세탁기, 냉장고(도장후 사용), 전자레인지 밑판 Chromate 2. Pre-treatment system의 기술 특성 및 적용


Slide42 : Advantages and disadvantages of present Pretreatment system 2. Pre-treatment system의 기술 특성 및 적용


Slide43 : Trend of New Pretreatment system 1. Environmental regulation 2. Cost reduction 3. Quality improvement 2. Pre-treatment system의 기술 특성 및 적용 What is Driving the new Trends?


Slide44 : 1. Environmental New Pretreatment system 2. Pre-treatment system의 기술 특성 및 적용 환경 대책 변화 Past Present 잠재적인 유해성을 가능한 한 미연에 방지 대기오염 및 수질오염 방지 등과 같은 공해방지 대책


Slide45 : 1. Environmental


Slide46 : 2. Pre-treatment system의 기술 특성 및 적용 국가별 자동차 중금속 규제 현황


Slide47 : 2. Pre-treatment system의 기술 특성 및 적용 EU 자동차 환경 법규(Directive 2000/53/EC) 세부 법규 내역 EU 전기/전자제품 환경법규


Slide48 : 2. Pre-treatment system의 기술 특성 및 적용 2. Cost reduction


Slide49 : New Pretreatment system 2. Pre-treatment system의 기술 특성 및 적용 3. Quality Environmentally-friendly or lower-cost processes can come with a drop in robustness and an increase in complexity Solutions are needed which don’t up costs


Slide50 : 2. Pre-treatment system의 기술 특성 및 적용 Trends


Slide51 : Silane : Basic chemistry Hydrolysis Reaction 2. Pre-treatment system의 기술 특성 및 적용


Slide52 : Silane : Basic chemistry Condensation reaction Siloxane reacts with OH- on metal surface 2. Pre-treatment system의 기술 특성 및 적용


Slide53 : Crosslinking of Silane Coating(schematic) Metal (M) 2. Pre-treatment system의 기술 특성 및 적용


Slide54 : Self Assembling Monolayer (SAM) 2. Pre-treatment system의 기술 특성 및 적용 Paint Paint Bonding End of SAM Metal Bonding End of SAM Metal Oxide / Hydroxide Metal · Ti / Zr plus SAM · High-performance · Commercialized on aluminum wheels


Slide55 : Reduce Processing Time 2. Pre-treatment system의 기술 특성 및 적용 Degrease Water rinsing Activation Spray & dip coating Water rinsing Sealing DI water rinsing Air blow Drying Degrease Water rinsing Spray, dip, roll coating Water rinsing Drying Present New Pretreatment


Slide56 : 3. Electro Deposition coating (cathodic)


Slide57 : (+) cathode (+) cathode (+) anode Electrolysis Electrophoresis Electrodeposition Electroosmosis Process of ED coating


Slide58 : Major current flow Start Stage 1 Major current flow Stage 2 Major current flow Major current flow Stage 3 Major current flow Current flow of ED coating METAL Electro coat


E-coat technology Roadmap : E-coat technology Roadmap Lead free E-coat Development P/B ratio = 0.4 Application for Automobile part line Low density E-coat P/B ratio = 0.2 Reinforce Edge coverage UV Durable E-coat No Primer surfacer for Truck & Chassis Frame EMMAQUA 1yr pass Appearance & Adhesion Environomic E-Coat ▪ Economical: Low P/B ratio (P/B = 0.10 ~ 0.15) Low oven weight loss (below 7%) Lower Cure (below 165℃) ▪ Environmental: Lead & Tin Free HAPs Free Lower VOC Super UV Durable E-Coat Eliminate need for primer surface Applying to Automotive Car Body Top coat Film appearance and adhesion


Slide60 : The Basics of Lead In Electrocoat Pb How much? Functions of lead Overcoming the elimination of lead About 1 ounce (28 grams) per typical car Corrosion resistance Catalyst (cure response) Coat out properties Alternative Anti-Corrosion Agents Stronger polymers


Dual E-Coat : Dual E-Coat First Coat Second Coat - Corrosion Resistance - Sharp Edge Coverage - High Throwpower - Film Build Uniformity - Conductivity (after bake) - Stone-chip Resistance - UV Light Resistance and Hiding Opacity - LOW Throwpower - Excellent Appearance (Enhanced Verticals) - Zero VOC


Slide62 : New process : RoDip3


Global Electrocoat Trends : Global Electrocoat Trends 2000 2005 2010 Final Conversion to Lead-free will continue in small plants. All Major plants have been converted. New ED Processes to minimize Investment & Space Global CED, lead and heavy metal free, edge coverage, high throwing power Desire New Anti-corrosion Processes 2009 Electro coat 2009 All Many With Lead Lead Free User Focus


Slide64 : Electrocoat Development Objectives


Slide65 : 4. Pre-sealed steel sheet for car body What are the Driving Forces for the use of Coil Coating in Automotive Applications? Improved Corrosion Resistance Pre-sealed Potential to Reduce Cost Elimination of Process Steps Steel Suppliers can add Value Supply of systems which Enhance quality and eliminate Process Steps Outsource Painting Processes Minimize Volatiles Eliminate paint Process


Slide66 : 자동차 소재 구성 4. Pre-sealed steel sheet for car body


Slide67 : 자동차 강판 요구 성능 및 적용 기술 내구성 자동차 강판 요구성능 적용 기술 •DP(Dual Phase) •TRIP(Transformation Induced Plasticity) 경량이며, 강도와 연신율이 우수 고속 충돌성이 우수한 고강도 강판 •BH STEEL Bake hardening steel의 약자로 차체 성형시 강도가 낮아 가공이 잘되고, 성형 후에는 자동차 도장공정을 거치면서 받는 열에 의해 강도가 증가하여, 자동차가 최종 완성된 이후에는 높은 강도를 갖게 된다. 고내식성 표면처리 강판 •Presealed •Preprimed •Pre-painted •Pb,Cr free 표면처리 강판 •고강도강 사용으로 차체무게 감소 – 연비 감소로 환경오염 물질 배출 감소 4. Pre-sealed steel sheet for car body


Slide68 : Evolution of Pre-sealed Cr Pretreat & Preseal Weldable 2K Pretreat/Preseal < 2 µm Corrosion Resistance Nissan Inner Door Cr Pretreat Preseal Weldable 2-4 µm, 10 cycles cyclic corrosion Corrosion Resistance Daimler-Chrysler Inner Door ~1996 Non Cr Pretreat Preseal Weldable 5-7 µm, 20 cycles cyclic corrosion Corrosion Resistance Daimler-Chrysler Inner Door Phase II No Pretreat Preseal Weldable ? µm, 20 cycles cyclic corrosion Corrosion Resistance Daimler-Chrysler No Pretreat Low Bake Preseal Weldable ? µm, 20 cycles cyclic corrosion Corrosion Resistance Daimler-Chrysler Bake Hardenable Eliminate Pretreat 4. Pre-sealed steel sheet for car body


Slide69 : E-Coat Primer Basecoat Clearcoat Conventional layers Additional layer for corrosion protection Steel Substrate Pretreatment Coatings for BH steel 3 in 1 system (E-coat, Pretreatment, Presealed) 4 in 1 system (Primer, E-coat, Pretreatment, Presealed) Substitution all Conventional layer Presealed 1st Presealed 2nd Pre Primed (weldable) Pre Primed (non-weldable) Pre Coated Presealed 1st Presealed 2nd Pre Primed (weldable) Pre Primed (non-weldable) Pre Coated 1.5-2.5 µm 18-25 µm 30-40 µm 12-18 µm 35-45 µm 1 - 2 µm 3 - 7 µm 4. Pre-sealed steel sheet for car body Future Trends in Automotive coatings


Slide70 : 4. Pre-sealed steel sheet for car body Driving Forcasts toward Coil Coatings


Slide71 : 4. Pre-sealed steel sheet for car body Reduction of manufacturing Range at the car manufacturer by use of organic Pre-coated steel sheet Press shop Cleaning Pretreatment ED Paint Primer Top coat Secondary Corrosion Protection Press shop Cleaning Pretreatment ED Paint Primer Top coat Press shop Top coat Press shop Cleaning Pretreatment ED Paint Primer Top coat Press shop Module Production


Slide72 : 4. Pre-sealed steel sheet for car body Pre-sealed Coatings Give Assistance in Solving Problems Design and Crash requirements lead to more complex constructions- corrosion protection of the car-body gets more difficult – corrosion protection should be delivered “within” the steel sheets. Sheet thickness decreases due to weight saving demands but warranties against perforation corrosion are prolonged Sealing measures can be transferred from the paint shop to the body-shop and assembling lines. This leads to significant higher “first-o.k.-rates” in the paint shop due to less paint failures.


Slide73 : 4. Pre-sealed steel sheet for car body Requirements for Presealed coated car-body sheets Product properties Forming Cups Impact Erichsen Draw bead Corrosion Cup Flat Flanges Real parts Spot weldability Working range Electrode life time Transition resistance Adhesive bonding Shear strength Peel strength


Slide74 : Flange/Hemming area (Fender, Door, Wheel cover, etc.) : Easy to corrosive parts Cavity Cavity Wax Hem Sealer Flange NO WAX NO SEALER < Conventional> 4. Pre-sealed steel sheet for car body Application of Pre-sealed steel sheet < Using Pre-sealed steel sheetl>


Slide75 : Blue : Pre-sealed (SS) Dark Yellow : Pre-sealed (DS) Yellow : Pre-sealed (SS) + Zn Pink : Zn (SS) Green : Zn (DS) 4. Pre-sealed steel sheet for car body Application of Pre-sealed steel sheet


Slide76 : Mercedez-Benz C-Class Right Side : Without Pre-sealed With Sealer/Wax Left Side : With Pre-sealed Without Sealer/Wax Red Rust Appeared No Red Rust (Using EG 75/75, After Stuttgart Corrosion Test) Performance of Pre-sealed steel sheet 4. Pre-sealed steel sheet for car body


Slide77 : 4. Pre-sealed steel sheet for car body Pre-sealed car-body steel sheet 1st Generation 2nd Generation Organic coating(3~5㎛) with Zinc powder Cr-free pretreatment (no-rinse) Organic coating (2~2.5㎛, no conductive pigment) Cr-free pretreatment (no-rinse) Organic coating(3~5㎛) with conductive pigments (Ironphosphide) Cr-free pretreatment (no-rinse) Aims for development of the 2nd Generation: Improved corosion protection in comparison to 1st Generation Very good spot weldability Curing temperature(PMT) ≤ 160℃ (Bake Hardening steel) 10 cycles VDA 621-415 10 cycles VDA 621-415 20 cycles VDA 621-415


Slide78 : ※VDA : 독일 자동차공업협회 규격 [Verband der Automobilindustrie] Corrosion test method of Pre-sealed steel sheet overlapping 120 µm gap glass 100 100 100 4x10cm photo Henkel & Daimler Chrysler 4. Pre-sealed steel sheet for car body


Slide79 : 4. Pre-sealed steel sheet for car body Corrosion test method of Pre-sealed steel sheet


Slide80 : 48hrs 72hrs 96hrs 96hrs 72hrs 72hrs 4. Pre-sealed steel sheet for car body Corrosion test – Plate, Pretreatment, ASTM B117


Slide81 : 688 hr 816 hr 1150 hr 1150 hr 456 hr 264 hr Corrosion test – Plate, Pretreatment + Presealed, ASTM B117 4. Pre-sealed steel sheet for car body


Slide82 : 1150 hr 1150 hr 480 hr 456 hr 264 hr 4. Pre-sealed steel sheet for car body Corrosion test – Cup, Pretreatment + Presealed, ASTM B117


Slide83 : 100 Electrode lifetime test 4. Pre-sealed steel sheet for car body 100 1,500 1,700


Slide84 : 1150 hrs 816 hrs 1080 hrs 4. Pre-sealed steel sheet for car body 2nd Pre-sealed corrosion test : ASTM B117


Slide85 : 4. Pre-sealed steel sheet for car body 2nd Pre-sealed electrode lifetime test


Slide86 : 5. Pre-primed steel sheet for car body Reduction of manufacturing Range at the car manufacturer by use of organic Precoated steel sheet Press shop Cleaning Pretreatment ED Paint Primer Top coat Secondary Corrosion Protection Press shop Cleaning Pretreatment ED Paint Primer Top coat Press shop Top coat Press shop Cleaning Pretreatment ED Paint Primer Top coat Press shop Module Production


Slide87 : 5. Pre-primed steel sheet for car body Top coat(15~20㎛) Primer (5㎛) Pretreatment Pre-primed coating Cr-free pretreatment and primer Previous New state Pre-primed car-body steel sheet


Slide88 : 5. Pre-primed steel sheet for car body Corrosion Behavior of Pre-primed Steel Sheet (Undercreepage at Cut Edges) ZE 75/75 + ED paint ZE 75/75 + Pre-primed


Slide89 : 5. Pre-primed steel sheet for car body BTM Tog-L-Loc Clinching of Pre-primed steel sheet


Slide90 : Mechanically joined Nuts and Bolts on a Dash Panel Made of Pre-primed Steel Sheet 5. Pre-primed steel sheet for car body


Slide91 : 6. Pre-finished steel sheet for car body Reduction of manufacturing Range at the car manufacturer by use of organic Precoated steel sheet Press shop Cleaning Pretreatment ED Paint Primer Top coat Secondary Corrosion Protection Press shop Cleaning Pretreatment ED Paint Primer Top coat Press shop Top coat Press shop Cleaning Pretreatment ED Paint Primer Top coat Press shop Module Production


Slide92 : 6. Pre-finished steel sheet for car body State of Development of Pre-finished Car-body Sheets Regarding OEM paint Requirements Esthetic properties General usage properties Processing properties Chemical resistance Scratch resistance Stone chip resistance Adhesion Corrosion : -surface -cut edge Weathering resistance Gloss, DOI, structure Color matching Metallic effect paint Number of point defects Loss of gloss due to forming operations Formability Adhesive bonding Application of mechanical joining techniques Evaluation state of development Requirements fulfilled Requirements not fulfilled, Solution not yet available Requirements not fulfilled, Solution available


Slide93 : Vision of a Possible Future Scenario for a Modular Car Production Press shop Cleaning Pretreatment ED Paint Press shop Module Production Reduction of painting costs for modules Elimination of spray painting processes at the car manufacturer High variability of shape of a model series Reduction of cost and space in favor of core competence processes 6. Pre-finished steel sheet for car body


Slide94 : Possible Concepts for the Application of Organic Pre-coated Car-body Sheets = supplied by Coilcoater = processes made by car producer Weldable organic coatings Non - weldable organic coatings ED primer add-on parts Closures, roofs 6. Pre-finished steel sheet for car body


Slide95 : Layers & Resins compositions and Chemistries Base Metal Electrocoat Primer Surfacer Cationic modified epoxy resins Water borne Automotive Coatings


Global Automotive Paint Driving Forces : Global Automotive Paint Driving Forces Higher Quality Lower Cost Environmental Compliance Shorter Development Times Product Differentiation by Vehicle Models, Colors Appearance, Durability, Color Process Consolidation


Many Car Body Design Concepts : Many Car Body Design Concepts No Clear Trend Full Body Concept is the current standard Space frame with hang-on-parts Preassembled modules in body color


Slide98 : Definition of UV Coatings UV Coating System UV Cure Process UV Light Electron Beam UV uses UV light to activate a photo-initiator (PI) that functions to propagate the reaction of the unsaturated monomers or oligomers EB uses an electron gun that emits actual electrons that initiate the reaction Environmental Friendly Short Curing Times High Quality Surface High Cost for the Equipments High Raw Material Costs Advantage Disadvantage Short Production Cycle No Pot-life Limits No Place needed for after Curing


Slide99 : UV Coating System 개념 UV Coating System Energy (E) = h ν = h c / λ Characterized in bundles called Photons Longer wavelength equates to lower energy and lower frequency Wavelength (λ) Intensity (W) Frequency (ν) * Efficient use of UV energy Longer wavelength equates to lower energy and increase penetration * Drives formulation Reflected in PI and photo-stabilizer selection Awareness of pigment particle size


Slide100 : UV Coating System UV Coating System Oligomer (resin) Determines coating film properties Mn = 500 ~ 3000 and 2 or more reactive groups Reactive Monomer(s) Reduce viscosity Determines cure speed Photo-initiator(s) Produces radicals &/or cations Additives Including inhibitors for pot life stability * Ingredients of UV Coatings


Slide101 : UV Coating 반응 메커니즘 UV Coating System Liquid Phase Solid Phase * Phase Change by Photo-initiated Polymerization


Slide102 : Driving Forces towards UV Cure System UV Coating System High Space Consumption for Traditional Processes Limitations of Line Speed of Traditional Processes Complex Control of Traditional Processes Energy Consumption of Traditional Processes Solvent Emissions & Treatment in Traditional Processes CO2 Emission Limits Low Cost Fast Production High Quality Zero VOC Eco-concept UV Cure System


Slide103 : UV System for Coil Coatings UV Coating System


Slide104 : UV System for Coil Coatings UV Coating System * Conventional Process


Slide105 : Coil Primer for UV Coatings UV Coating System Additional Functionality of the Primer Primer Application Directly on only Cleaned Metal (No Pre-treatment Required) Good Adhesion Substrate Good Corrosion Protection To be Overcoated with Topcoats * Requirements for an Innovative Coil Coating UV-Primer


Slide106 : UV Pre-treatment-Primer UV Coating System Water Thinable * Properties of UV Curing System Includes Pre-treatment Conventional Application Water Evaporation + UV Crosslinking Dry Film Thickness >/=5 Micron Good Adhesion to Galvanised Steel Good Corrosion Protection 2-Comonent UV Primer System (Primer Base + Activator) Water Containing Application - Dry Film Thickness: 5 Micron - Water Evaporation: 100~120℃ - Crosslink Energy: 500 mJ/cm2


Slide107 : Benefits for Coil Coating Process UV Coating System Saving of Process Steps * Included Pre-treatment Function Saving of Space Curing Section much smaller * Only Water Flash-off + UV Curing at Primer Lower Energy Consumption


Slide108 : Coil Coating Process using the UV Primer UV Coating System


Slide109 : Coil Coating Process using the UV Primer UV Coating System No extra Pre-treatment Section Shorter Line Layout - Save 70~80% of Space for the Oven - Save Space of Pre-treatment Section Emission-free Primer Section * Innovation for a New Coil Coating Line Integration into Pre-treatment Section * Innovation for an Existing Coil Coating Line Primer Application in Pre-treatment Section Enhance Line to 3-Coat Application Thick-film Technology will be available New Markets through new Product Profiles


Slide110 : Coil Coating Process using the UV Primer UV Coating System Easy to Apply with Roller Coater * Applied on Rolling & Galvanizing Lines No Solvents Emission-free Strip becomes not so hot


Slide111 : Coil Coating Process using the UV Primer UV Coating System Organic Primer Application with Low Complexity Organically Coated Steel (Pre-primed Steel) with Permanent Corrosion Protection with inherent Lubrication New Products from Rolling or HDG Line New Market Opportunities through New Products * Innovation for a Rolling Mill or HDG Line


Slide112 : UV Coating Applications For 3-D Car Body UV Coating System UV Plasma Coatings UV Dual Cure Coatings


Slide113 : Conclusion Future Trend of Automotive Coatings System Cavity wax/Hem sealer Pre-sealed ED-coat Pre-primed, weldable Primer surfacer Pre-primed, non-weldable Top coat Pre-finished Conventional system Pre-coated system Pretreatment UV Durable E-coat Silane product Environmental Cost Quality Present Coating system


Technology Roadmap : Technology Roadmap UV Durable E-coat Environomic E-Coat Super UV Durable E-Coat Chromate Phosphate Silane product Pre-sealed Pre-primed, Weldable Pre-primed, Non-weldable Pre-finished Conclusion