3. 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
5. 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
6. Drivers for Technology Change
to Green Pretreatment
Drivers
• 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 process
Current Limitations
• Corrosion performance versus zinc phosphate controls
• Results depend on substrate and corrosion test used
7. 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
9. 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
11. 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
12. Dynamic Voltage measurements
Deposition on Phosphate pretreatment Deposition on Green pretreatment
350
350
300
300
250 250
Voltage (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.
13. Throw Box Set Up
4 panels with
2.0 cm spacing
between each panel
Goal: Maximize film build “G/A face“
14. 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.
15. Deposition results of inner
sections
Body treated Body treated with
with standard Zircobond®
phosphatation PPG Electrocoat
PPG
Electrocoat
• With suitable electrocoat formulation, appropriate process
optimization, same film build distribution outside and inside can be
reached.
17. 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)
18. 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.
19. 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
20. 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 75
The final appearance is also depending of the substrate smoothness
22. HyperThrow Concept
in Enviro-Prime® 7000
Electrocoat
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
23. Enviro-Prime® 7000
Electrocoat
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!!!
24. 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 = Rocker
Required for 0 5 10 15 20 25
Film Build (Microns)
Corrosion Resistance
25. Enviro-Prime® 7000 Project
Status
Electrocoat
• 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
26. Enviro-Prime® 7000 Attributes
Advantages 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
27. Thanks for your attention !
In case of questions:
Philippe Bouden
Technical Manager Electrocoat Europe
bouden@ppg.com
+33 327 193 815
