Mega Trends in Automotive supported by Coatings• Weight reduction Paint consumption Low density products Treatment of Aluminum• Environmental Waste water, chemical foot print consumption, energy saving, lower toxicity of used ingredients• Reduced complexity Shorter process, less and capital investment process steps
PretreatmentDrivers and Status for Alternatives to Tri-Cationic Phosphate
Pretreatment Market Outlook• Continued growth in thin film (zirconium) based pretreatments• Tri-cationic ZnPO4 pretreatment still significant technology through 2020.• Growth of alternate ZnPO4 technologies to deal with high aluminum content• Performance to OEM requirements for Green Pretreatment is required• Pretreatment elimination system expected in market by 2015
Drivers for Technology Change to Green PretreatmentDrivers• Shorter process – 7 stages versus 10 stages• Substantial reduction of energy, waste water, chemicals and man power – Ni free, Phosphate free, 90% less sludge – Less heavy metal salts – Simplified waste and sludge management• No limitation of Aluminum per vehicle• Shorter processCurrent Limitations• Corrosion performance versus zinc phosphate controls• Results depend on substrate and corrosion test used
Zircobond® Market Status/ Experience• 12 commercial lines operating (first in 2007)• Light vehicle and commercial vehicle (HDT) operations (including immersion, spray and 100% aluminum)• Multiple electrocoat and topcoat systems• PPG is leader in thin film pretreatment with over 2.0MM vehicles coated globally
ElectrocoatDrivers for new developments in coming years
Main Drivers for Electrocoat Development• Performance – Compatibility with Green Pretreatments – Compatibility with Compact Top Coat Systems – Throw Power and optimized consumption – Bake temperature• Environmental – Avoid and minimize risk for EH&S – Energy and waste water reduction• Economics – Work on alleviating escalating raw material costs
Role of Electro coat with Green Pretreatment? Electrocoat Countermeasures• Throw Power Electrocoat deposition & thickness deviation characteristics and wet film resistance• Visibility of Increased robustness pretreatment defects via e-coat formulation• Performance Excellent cross linking providing best adhesion and corrosion
Dynamic Voltage measurements Deposition on Phosphate pretreatment Deposition on Green pretreatment 350 350 300 300 250 250Voltage (V) Voltage (V) 200 200 150 150 100 100 50 50 0 0 0 50 100 150 200 0 50 100 150 200 Deposition time (s) Deposition time (s) • Dynamic measurement of local potential differences in exterior surfaces and inner surfaces were measured with a submarine device on phosphatation or green pretreatment. • The reached potential differences in the box sections are low in the case of the green pretreatment, the electrocoat has to compensate this difference.
Throw Box Set Up 4 panels with 2.0 cm spacing between each panel Goal: Maximize film build “G/A face“
Throw power optimization with formulation Optimized ecoat On Phosphatation Optimized ecoat On green PT• Optimization of the electrocoat makes possible an improvement of the throwpower and a decrease of the sensitivity to substrate resistivity.
Deposition results of inner sectionsBody treated Body treated withwith standard Zircobond®phosphatation PPG ElectrocoatPPGElectrocoat • With suitable electrocoat formulation, appropriate process optimization, same film build distribution outside and inside can be reached.
Role of Electrocoat in Compact Top Coat Processes?Electrocoat Electrocoat Countermeasures• Appearance Electrocoat smoothness and maintained good edge coverage• Less Sanding Process Robustness (no primer surfacer sanding deck)• Less cure Excellent cure response (no primer surfacer cure)
Industrial experience• European lines Running in Compact processes with PPG electrocoat: BMW Oxford Daimler Rastatt L1 & L2 Daimler Kesckemet PSA Trnava Ford Craiova PSA Sochaux (SOP Q1 2012) RSA Valladolid (SOP Q1 2012)• Compact process top-coats are a reality, all car manufacturers are going in this direction.
Electrocoat adaptation• PPG is running successfully the electrocoat at different customers where compact top-coats are used.• Key parameters are the robustness of the couple product- process, on a given line: – Good levelling of substrate roughness – No dirt – No mapping – No external contamination (Oil, phosphate, …) To avoid sanding operations
Impact of the structure of the substrate 40 100 LW SW/2 DOI 35 95 30 25 90 W S I &20 O D W L 85 15 10 80 5 0 75The final appearance is also depending of the substrate smoothness
HyperThrow Concept in Enviro-Prime® 7000Electrocoat Electrocoat Countermeasures• Reduced High Throw concept Consumption to reduce outside film builds at same inside film builds. Reduced energy and water Reduced weight Loss• Improved For difficult designed areas Throw To eliminate interior anodes To allow higher through put
Enviro-Prime® 7000Electrocoat Optimize Usage: The Innovation Description PPG developed a Hyper Throw Electrocoat Coating via use of the following Design Principles : Increased Wet Film Resistivity which allows the paint to insulate with less film build (i.e. lower exterior film build) Increased Deposition Speed which increases time for coating of recessed areas (i.e. increase interior film build) High Throw Electrocoat is driven by deposition dynamics!!!
Enviro-Prime® 7000 Design Intent – Reduce Excessive Film Build ED7 vs Traditional ED ‐ Film Build Distribution ED7 Std ED Required for Appearance A = Verticles, Hood V B = Roof, Underbody e h C = Floor Pan i c l D = Recessed e A E = Recessed Excessive Film Builds r e a F = Recessed G = RockerRequired for 0 5 10 15 20 25 Film Build (Microns)Corrosion Resistance
Enviro-Prime® 7000 Project StatusElectrocoat • Commercial at 2 global car manufacturers • 20 production lines (NA, EU and Asia Pacific) − 15-20 additional lines planned in coming 6-12 months • Approved at 3 other global OEM’s • In use over both zinc phosphate and green pretreatments • Development nearing completion with non-heavy metal catalyst system
Enviro-Prime® 7000 AttributesAdvantages of Hyper-Throwpower Electrocoat• Lower Overall Electrocoat Usage – High Throwpower Technology – Low Weight Loss & Low P/B Technology• Factory Savings / Potential Benefits – Lower Power Consumption – Lower DI Water Consumption – Potential Additional Areas for Savings – Potential for Increased Throughput – Potential for improved overall corrosion performance due to better inner recess coverage• Environmental Benefits – Lower Vehicle Emissions – Lower Water Usage
Thanks for your attention !In case of questions:Philippe BoudenTechnical Manager Electrocoat Europebouden@ppg.com+33 327 193 815