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 Dossel
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 Dossel
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-Bockler
12.2 Weathering Resistance of Automotive Coatings 405
Gerhard Pausch and Jorg 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 Dossel
13.1 Quality Assurance (QA) 467
13.2 Supply Chain 468
14 Outlook 475
Hans-Joachim Streitberger and Karl-Friedrich Dossel
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
