GENERAL PAINT SYSTEM LAYERING FOR

PLASTICS

2k CLEAR COAT / TOP COAT

BASECOAT

PRIMER
SUBSTRATE TREATEMENT

SUBSTRATE
 3C2B Paint System-
‘
Clean, Pretreated Bake

Cool
Body-in-White E-Coat Rinse Cycle

Primer Sealer Sanding

Bake [155/20] 8 mints F/off
Cool

Sanding Base Coat 8 mints F/off

Inspection Cool 8 mints F/off Clear Coat

Bake [155/20]
 Rodip system - Pretreatment & CED Line

Fresh Indl. Fresh DM

Spray Spray

Name : Deluge Spray Degrease Dip & Degrease Dip II Ind. Water Rinse Surface Phosphate DM Water DM Water Passivation DM Water Tilting
Spray I Activation Rinse Rinse Rinse Empty to
Spray
Spray Immersion Immersion rotate
60 m3 52 m3 52 m3 7 m3 45 m3 82 m3 7 m3 45 m3 45 m3 45 m3 45 m3
Capacity :

Temp. : 60 deg 60 deg 60 deg Ambient Ambient 55 deg Ambient. Ambient. 55 deg. Ambient .

Fresh DM
Spray

Cooling 45 deg
Sealing line

Name : CED Tilting Empty to UF 3 UF 2 UF 1 CED

Dripping
Baking rotate
oven
12 mins 45 m3 45 m3 45 m3 7 m3 218 + 20 m3
Capacity :

Temp. : 10 mins 90 – 110 deg Ambient 60 deg. 60 deg. 60 deg 60 deg 60 deg.
15 mins 160 deg
 VWIPL Paint Shop Process Flow – Sealing, UBS & Painting

Name :

Flash Off

CED sanding Sealing 1 Under Body Sealing 2 Tag Rag Wiping Primer booth Primer
Spray Baking
oven

Area Inner body Under body Outer body Outer body Robotic 15 mins 160 deg
Covered : Outer body Sealing Operation Sealing Operation Sealing Operation Operation

Flash Off Flash Off

Cooling
Insp. &
Polishing
Name : Baking Clear Coat Clear Coat Base Coat Base Coat Base Coat Tag Rag Primer Sanding
oven Booth Manual booth Booth Manual Wiping

10 mins 90 – 110 deg Robotic Inner Side Robotic Robotic Inner Side Outer body Outer body
Area
20 mins 160 deg Operation Painting Operatio Operation Painting Wiping Sanding
Covered :
n
ATOMIZED NON ATOMIZED

Conventional Air Spray Dip

HVLP Electro deposition
Airless Flow Chart
Air Assisted Airless Roller Coat
Electrostatic Spray Curtain Coat
Electrostatic High Speed Rotary
Powder
Sr. Application Method % General Transfer
No. Efficiency

1. Conventional air spray 30 – 50

2. Airless 55 – 75
3. Air assisted airless 55 – 75
4. HVLP 55 – 75
5. Electrostatic spray 55 – 75
6. Electrostatic Rotary 75 – 95
7. Powder 75 – 95
8. Dip 90 +
9 Electro deposition 90 +
BAKING WINDOW

Recommended
Baking Schedule
 Bell elements
Block of nano values (solvent –air, Interior plastic Shaping air device
simple or double paint system) configuration
Atomizer extension
Turbine with magnetic
air bearing

Spray Bell

Repulsion ring Bell-to-turbine rotor

connection system by clip
Internal high voltage supply
Exterior aluminium shaping air device
 3C-1B Paint System
‘
Clean, Pretreated Bake

Cool
Body-in-White E-Coat Rinse Cycle

Primer Sealer Sanding

8 min F/off at Room Temp

Interior B/coat Base Coat 8 min F/off

Inspection Cool Bake [140/30] 8-10 min F/off Clear Coat

 Automotive Plastic Parts

Why Use Plastic Parts in Automobiles?

•Effective Weight Reduction of Vehicle
give better mileage.
•Metal parts susceptible to corrosion are
replaced by plastic parts.
•Aesthetics
 Plastic Parts in a Car
Mirror Housing Radiator Grill
ABS ABS

Wheel Caps Door handles Bumpers

Nylon PC/PBT, PPO TPO
 Plastic Roof Rail
( Tube, Cover, Stay ) Side Step
( AL, ABS, PA 66) (PC+PBT/ABS,RIM) Bumper (PP,ABS ,PC/PBT,TPO)
Radiator Grill (ABS )
• Air Spoiler Door Mirror Housing (ABS)
(ABS,RIM) Door Handle
(Noryl / PA66) Lighting
(PC,PBT,PMMA)

15
BUMPER PAINTING PROCESS WITHOUT FLAMMING IN INDIA-APPG

IPA SOLVENT WIPE/POWER WASH

TACK O RAG WIPE

IONIZED AIR BLOW

APPLICATION OF ADHESION PROMOTOR (FLASH

PRIMER)
DFT of 7 –8 mic. Followed by flash off of 4-5 mins.

APPLICATION OF BASE COAT

Use Solid/Met base coat .DFT 16±2 mic.in two coats
followed by flash off 4-5 mins.

APPLICATION OF 2K CLEAR COAT

DFT of 30-35 mics in two coats followed by flash off
of 8-10 mins.

BAKE AT 80°C FOR 30 MINS.

SANDING/BUFFING/POLISHING
After bumper reaches ambient temp.
 What’s metallic coating
Solid color
- Uniformly colored and opaque coat film .
- The tint of this kind of paint varies the film thickness .

Metallic & mica color

- The brightening agent ( Metallic or mica flake ) is extremely
disturbed .

- The same paint may appear quite differently .

Base coat film

Metal flake

① ②
 1.2 Finishing of metallic color

Metal flake Base coat film

① ② ③

① : It lack the characteristic glare of metallic coat film .

It look like an aluminum foil .

② : It has an adequate brightness and glare . ( Irregular reflection )

③ : The orientation ( arrangement ) of metal flake include the

following points.

The film ② is the best .

 Paint particle speed & atomization
- When particle speed is slow
The metal flake overlaps and appears to be small in quantity .

- When atomization is excellent

The number of metal flake elements in one paint particles is smaller .
The metal flake hardly overlap .
 Atomization mechanism
In the atomization method of the bell type atomizer .

By rotating the bell cup at high speed , the paint is transformed into
particles .

Thick liquid string Thin liquid string

Paint particles

Liquid strings
Bell rotating direction Bell rotating direction

The tearing manner differs with the properties of the paint .

 Atomization mechanism
The atomization method of the Metallic Bell type atomizer .

Bell type Gun type

Paint particles

Liquid strings
+
Atomizing air
Paint
Bell rotating direction Pattern air

Paint particles
Liquid strings Bell rotation
Shaping air

Metallic Bell type Shaping air ring

 Flight state of paint particles
STD. Bell type Metallic Bell type Gun type

Direction of paint particle Direction of paint particle

Centerifugal force Atomizing air
Electric field Fan air
Shaping air Electric field
 Transfer efficiency
Transfer efficiency

Conventional air spray gun 20 to 30%

Electrostatic air spray gun 35 to 50%

Metallic bell 70 to 80%

- The transfer efficiency depends on the coating condition .

- The transfer efficiency of the metallic bell is better than that of gun type by
20 or 30% .
 Basecoat Components
Solvent: Added to paint for ease of application

UV Absorber: Protects paint from UV rays of sun

PCA: Pattern control additive produces proper flake orientation

during spraying and prevents sagging during initial bake

Melamine: Cross linker - binds resins together to form film

Acrylic Resin: Hardness and durability

Polyester Resin: Flexibility

Anti-Settling Agent: Prevents pigment from settling

Aluminum Pigment: Imparts metallic appearance

Mica Pigment: Imparts metallic appearance and color

Alcohol: Stability protection

Acid Catalyst: Aids in cure

24
Hand Spray Variation
This would be an
example of a uniform
distribution across
the pattern. The
filmbuild is uniform.
If the film thickness
and size is right, the
mass film deposit is
similar to the original
application.

25
Hand Spray Variation
This would be an
example of a wetter
center of the spray
pattern with a dry
outer edge. If you
move slower, the
wetness and
filmbuild increases.
The mass film
deposit is different.

26
 Bell Cups (Atomizer Geometry)
Cup Edge Serrations
or Smooth Edge
Cup Diameter

Annular Fluid Feed to

Annular Fluid Feed to Cup Surface
Cup Surface
Cup Surface Cup Fluid Well

Cup Center
Flush Port
Fluid Tube
Cup Center Feed
Splash Plate
Hub Mounting Shaft

Cup Center
Splash Plate
External Cup Edge

27
Cup Geometry (Centrifugal Force Fz)

Fz=M 2r
Fz
The (Fz) Applied
• Squeezes the Coating
• Causes Sheet Thinning Fz
• Forces to the Edge

28
 APPLICATION CONTROLS
PAINT VISCOSITY / PAINT TEMPERATURE

PAINT VISCOSITY & PAINT TEMPERATURE ARE

INVERSELY PROPORTIONAL

BOOTH TEMPERATURE [25 - 30 ° C]

LOW - MOTTLING ON METALLIC BASECOATS, CLEARCOAT

SOAK IN / SAGGING, LESS CLARITY.
HIGH - ORANGE PEEL, MORE DRY SPRAY, LESS DOI.

BOOTH HUMIDITY [60 - 70 %]

HIGH - MOTTLING ON METALLIC BASECOATS, CLEARCOAT

SOAK IN, LOW IMAGE CLARITY, DARKENING OF COLOUR.
LOW - ORANGE PEEL, DRY SPRAY, LESS DOI.
 DIRT
•Booth & oven maintenance,

•Dirty spray equipments/ paint mixers /jigs

•Dirty or ruptured paint filters ,

•Surface dirt - Poor preparation in sanding or Tack off

•Booth under negative pressure resulting in external dirt

•Lint free cover alls, hand gloves & wipe cloth

•Paint finish not OK or Paint/Thinner contaminated

•Poor house keeping.

 COLOUR MISMATCH
• Wrong batch of paint used

•Poor paint opacity

•Proper B/C ; T/C DFT not applied

• Intermixing of colors (CCV leakage/improper bell flushing)

• Untinted paint used

• Wrong Primer shade applied

• Wrong thinner used

• Wrong application viscosity/ ford cup used

 SAGS & RUNDOWN

•Gun distance too close

•Temperature of the paint may be low

• Booth Temperature too low / Relative humidity too high .

• Air atomizing pressure too low.

• Application viscosity may be low

• Fan width pattern may be too narrow

• Fluid delivery may be high

 BLISTERS / SOLVENT POP

• High dft

• Low flash off between B/C & C/C.

• Solvent imbalance

• Fluid delivery may be high

• Application viscosity may be high

• Fan width pattern may be too narrow

• Temperature of the B/C paint may be low

 CISSING / CRATERING

• Water & Oil in air line

• Paint contamination by oil , water etc

• Surface contamination because of improper wiping, greasy or

wet hands of operator, or dirt / sanded particles.

• Spray booth environment may be contaminated [Welding

operation]

• Booth air supply may be contaminated.

• Overspray falling may not merge properly

 ORANGE PEEL
•Gun distance too far ,

•Low film build

•Temperature of the paint may be high

• Booth Temperature too high / Relative humidity too low .

• Air atomizing pressure too high.

• Application viscosity may be high

• Fan width pattern may be too wide

• High Application viscosity

PS- The above factors can also lead to Dry Spray.

 MOTTLING specific to METALLICS

•B/C Film build may be high

•B/C Gun distance too close

•Insufficient flash off time between B/C & C/C.

•Booth Temperature too low / Relative humidity too high .

•Temperature of the B/C paint may be low ,

•B/C Air atomizing pressure too low.

•B/C application viscosity may be low

•B/C Fan width pattern may be too narrow

 SAND SCRATCHES

•Appropriate sand paper may not be used

•Under baked primer

•Dried [polishing compound] Buffing pads

•Underneath defect not filled/ sanded properly

•Low film thickness [ particularly in Metallic basecoats ]

•Moist-Circular sanding pattern not followed

•Under baked Topcoat system will lead to sand marks when buffed &
polished for removing dirt.
 HAZINESS

• Basecoat setting

•Too dry - Rough finish/overspray

•Too wet – Soak in

.Basecoat dft too high (>20 microns)

•Less Topcoat dft

•Wrong thinner

•Low humidity (< 45%), high paint/ booth temperature

 SPITTING – Metallic flakes
•Basecoat too dry

•Booth Temperature too high / Relative humidity too low .

•Temperature of the paint may be high

• High RPM

• Low Shaping air

• High application viscosity

•Conveyor stoppage during B/C Bell spray

•Low flow rate

WATER SPOT
 Water Spot
Causes Counter Measures

1. Pretreatment water not drained 1. Check pretreatment drying oven

totally. temperature.

2. Water drops from water curtain. 2. Water Curtain is not mal-functioning .any
obstacle in water curtain ?
3. Masking paper absorb water which comes out
in baking. 3. Check masking process and quality of
paper.
4.Pretreated components not dried completely.
4. Wipe the components with dry soft cloth
before painting
5.Water accumulation on Jigs and conveyor
during water-rinse stages.
5. Check all possibilities of water
accumulation on Jigs, conveyors and air-
6.Water condensation on surface during very line
cold environment
6. Regular checks on Air-line filters.
7. Water in Airline.

8.Very high Humidity in spray Booth

UNCOVER
 UNCOVER
Causes Counter Measures
1. Fan width too broad. 1. Check the fan width and spray distance.

2. Painter is not overlapping the strokes 2. Train the painter properly.

properly
3. Observe the spray pattern and see actual
3. Difficult to reach portion coverage during spraying.

4. No contrast in substrate colour and paint 4. Check the Air pressure/paint pressure.

5. Air/paint pressure too low or too high 5. Check Reciprocator movements are
smooth
6. Components vibrating on jigs
6. Check air-velocity and adjust as specified.
7. Spray distance too long
7. Confirm that painter can reach gun to all
8. Reciprocator malfunctioning parts.

9. Air velocity too high 8. Check jig design and loading so that
there is no obstacle during spraying
10. Improper jig design and heavy loading 9. Increase paint flow.
11. Low emission volume
LIFTING
 Lifting
Causes Counter Measures
1.Undercoat remains uncured . 1. Check oven temperatures and conveyor
speed
2.Low film thickness of under coat /
Base coat. 2. Check thickness of individual coat.

3.Strong solvent in clear coat 3. Check viscosity of base coat & clear
coat adjust as specified
4.Sanding up to bare-plastic
before recoating the components 4. Check air pressure/paint pressure

5.Low viscosity of base coat / clear 5. Do not recoat the components

coat immediately after first coat is baked.

6.Very high air pressure 6. Check fan width and adjust.

7.Narrow fan width 7. Increase thickness of basecoat.

8.Conveyor stoppage during painting 8. Consult paint supplier for low attacking
thinner in clear coat
9.Insufficient time gap for recoating
OIL SPOT
 Paint Peel Off
Causes Counter Measures
1.Under cure or over curing of paint 1.Check pretreatment quality and rinsing
efficiency.
2.Very hard undercoat
2.Check oven temperatures.
3.Incompatibility of undercoat and topcoat
3.Do proper sanding all over before
4.Silicon content in paint is high repainting

5.Difference in hardness of undercoat 4.If different suppliers for undercoat and top
and topcoat coat confirm compatibility in a lab

6.Pretreatment quality not Okay. 5.Check hardness of individual layer

7.Same Isopropanol (IPA) used for 6.Change IPA and wiping cloth after
plastic components throughout the specified period.
shift
7. Check for any contamination on
8.Improper sanding before recoating. surface. Do not touch the surface with
bare hands.
9.Oil/ grease contamination on surface
8.Contact paint supplier.
10.Very low thickness of paint

11.Pretreatment residue remained on

surface.
PAINT PEEL OFF
BLISTER
Scratch marks testing
 ELECTROCOAT HISTORY

Sustained Leadership through Innovation

1995 –
Lead Free
1990 – CED CED
with Environment
New friendly,
solubilizing
Enhanced
1985 – Acid
Technology
Throw power
CED with & lower
New X-linker pigment content
Improved for Improved
shrinkage Throw power,
HB CED -1981 & Non Reduced dirt
with Yellowing
improved effect
CED - 1976 film
smoothness,
chip Res. &
AED-1963 Greatly
improved reduced VOC.
Improved corrosion
corrosion resistance
Resistance
compared to
dip primers

GEN-I GEN - II GEN - III GEN - IV GEN V GEN VI