May. 06, 2024
At the inception of the automotive industry roughly a century ago, cars were coated using a varnish-like substance applied by brush. This coating was subsequently sanded, smoothed, and re-applied multiple times to achieve several layers. The final step involved polishing the vehicles for a glossy finish. Manufacturers like Ford, with its Model T line, utilized brushing, dipping, and pouring techniques to comprehensively cover and protect various car parts. All these steps were manual, and the entire process could take up to 40 days from start to finish.
In the period between the 1920s and the 1940s, advancements in automotive coating technologies shifted towards spray equipment and alkyd-based stoving enamels. These methods significantly reduced application and drying times to about a week or less, resulting in more uniform finishes that required less sanding.
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By 1923, nitrocellulose lacquer systems were developed by E.I. DuPont De Nemours. These lacquers, applied using spray paint guns, required 3 to 4 coats to achieve the desired finish. However, they offered poor resistance to chemical solvents like hydrochloric acid, limiting their durability in acidic conditions.
The early 1930s witnessed the introduction of alkyd enamel paints, which formed durable films due to molecular bonding after curing in an oven. These enamel paints, with 2 to 3 application steps, offered high chemical resistance but were prone to oxidation and fading under sunlight.
Durability improved in the 1960s with the advent of acrylic stoving enamels, which provided a glossy, resilient finish. However, the manual spray application could result in uneven coating thickness. Various layers were applied for specific purposes: primers for corrosion protection, primer surfacers for smoothness and chip resistance, and topcoats for color and weather resistance.
In the 1950s, dip coating processes were fraught with safety and environmental issues, including explosions and fire hazards. Anodic electrodeposition paints emerged in the mid-1960s, followed by cathodic deposition coatings in the mid-1970s, which offered superior corrosion protection and process reliability.
Further innovation in the late 1970s saw the introduction of the wet-on-wet finish, consisting of a thin basecoat and a thicker clearcoat. This method initially found use in high-end automobiles but became widespread by the late 1980s due to cost reductions.
By the 1980s, water-based basecoats were introduced, followed by primer surfacers in the 1990s, leading to automotive coating processes that met the high throughput demands of the industry. These coatings were durable and effective, with current clear coats in Europe based primarily on two-component formulations.
Novel developments in paint pigments have been achieved alongside advancements in processing and chemistries. Flake-based and interference pigments have enhanced the appearance and customer satisfaction of automotive coatings. Despite initial challenges, new spray gun technologies have been developed to accommodate these advanced pigments.
Manual spray painting required significant craftsmanship to achieve even coating thickness, whether on flat or curved surfaces. Today, computer-controlled spray guns have minimized this need, ensuring worker safety and optimizing paint-to-surface deposition ratios.
It's crucial to note that automotive paint shops are major energy consumers, accounting for 30% to 50% of an automobile assembly plant's total costs. These expenses are tied to HVAC, paint drying, and emission treatments, with significant energy allocated to booth ventilation.
Today, automotive painting processes are highly standardized, incorporating inorganic pretreatments, cathodic electrodeposition, liquid or powder primer surfacers, and solvent-borne clear coats. High-quality powder coatings, now used in various car manufacturing processes, meet stringent environmental regulations, coinciding with the increased use of materials like aluminum and high-strength steel in car bodies.
Automotive coatings continue to evolve, meeting customer expectations and regulatory demands while reducing manufacturing and ownership costs. Smart coatings offer potential improvements in surface durability and additional functionalities like self-healing, super-hydrophobicity, and self-sensing capabilities.
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Self-stratifying coatings, which comprise compatible polymer blends, could simplify the current complex painting processes by enabling the simultaneous application of basecoat and clearcoat. These novel coatings must maintain desired attributes such as appearance, gloss, and durability while potentially offering new benefits like high infrared reflectivity and customizable inscriptions.
This discussion provided an overview of the history and evolution of automotive body coatings. It highlighted the recent trends and potential future developments. The next sections will offer a comprehensive look at modern automotive coating methods, assessment tools, and alternative processes.
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By Cynthia Challener, CoatingsTech Contributing Writer
While digitalization might initially be linked to smartphones and IoT devices, it is now influencing all industries, including the paint and coatings sector. Companies are adopting digital strategies to enhance customer experiences, improve manufacturing processes, and introduce new business models.
The World Economic Forum, in collaboration with Accenture, identified three digital themes in its 2016 white paper on the digital transformation of the chemicals sector. These themes focus on enterprise digitalization, new digitally enabled offerings, and collaborative innovation ecosystems.
Efficiency, productivity, and safety in the paint and coatings supply chain will improve with digitalization, driving operational excellence. Enhanced R&D productivity through advanced data management and analysis will lead to significant innovations. Companies will better understand customer needs, facilitating quicker product launches and improved customer service.
Digitalization encompasses various transformational changes, with a broad range of definitions. Many companies focus on enhancing customer value as a core principle, encompassing internal processes, customer interactions, and new business models based on digital technologies.
Consumers increasingly rely on digital interfaces for product research, which impacts the architectural coatings industry. Digital commerce and online tools for color and product selection play crucial roles, and digitalization helps connect professionals with customers more efficiently.
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Various technologies and tools are being employed to achieve digitalization in the paint and coatings industry. These include automation technologies, data analytics, collaboration systems, and virtual and augmented reality capabilities.
Specific examples include Evonik's use of data management tools and Covestro's artificial intelligence applications in R&D. Collaboration among companies facilitates the development of digitalization tools, and access to diverse technologies presents interconnectivity challenges.
Digitalization is essential for future success, despite its complexities. It involves significant changes at multiple levels, requiring a comprehensive strategy that incorporates change management. Digitalization offers opportunities for growth and innovation, and companies must adopt it to stay competitive.
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