Escolar Documentos
Profissional Documentos
Cultura Documentos
Painting
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Stage 6 : Phosphate dip where the car body is coated with a layer
of Zinc phosphate at 49C bath temperature for 3 min.
Phosphate coating prepares the basis for corrosion
protection and better adhesion for Electro coat.
Stage 1 : Pre wash spray rinse in which a chemical (surface active agent surfactant) is
used to loosen oil and wash of contaminants on the body in white .
Cleaner spray rinse 1 where Pressurized hot water (45C) spray loosens the
oil left over in the Pre wash stage and pre-heat the car
body for further processes .
Stage 2 : Cleaner spray 2 containing a Pressurized hot solution(52C) of Factory water
and Degreasing chemical further cleans the car body .
Stage 3 : Cleaner dip containing a hot solution (50C) of Factory water and Degreasing
chemical cleans all the interior portions and box sections of the car body
thoroughly.
Stage 4 : Dip rinse 1 in which factory water is used for removing the Degreasing
chemicals used in the previous two stages.
Stage 5 : Activation dip containing Gardolene ZM solution prepares the surface of the car
body for refined phosphate coating.
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Stage 11 : DI water spray rinse cleans the car finally before E-coat using
new DI water.
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ADVANTAGES
ELECTRO-COAT CURING
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SEALER PROCESS
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Thumbable Sealer
Flowable Sealer or Duplex sealer
Plugs and tapes:
Deadner Pads
Roof Ditch Sealer
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Thumbable Sealer :
Thumbable sealer is a vinyl product which is very
malleable.
It is used to fill the gaps where panels are joined.
Flow able Sealer or Duplex sealer :
Duplex Sealer is used to seal hem
flanges and other similar joints. Its made of very soft vinyl. It is
applied with a Sealer gun to seal various joints in Clinches, Car
body interiors etc. and is applied to the undersides of body using
sealer spray gun to protect them from stone chipping and water
spray.
Plugs and tapes:
Plugs and tapes are used to seal the holes which
were needed during body construction and for drainage in the
Phosphate and Electro-coat processes.
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SEALER CURING
Deadner Pads :
Deadner pads are used to stiffen panels
and therefore reduce vibration and to act as insulators
and absorb noise.
Roof Ditch Sealer :
Roof Ditch Sealer is used to seal
joints between body sides the Roof panel.
It increases the aesthetic effect of the car body.
It is applied with a Special Roof Ditch Sealer gun and
the excess sealer is taken off by using a vacuum
machine which absorbs the excess sealer.
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Once the Plugs and Pads are fitted and all the sealers
are applied, the units leave the sealer deck and pass
through the Sealer Gel Oven at 90 Deg C for 7
minutes.
This fuses the pads into place and partially hardens
the sealers so they are less prone to damage in
subsequent operations.
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DOWNDRAFT
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HUMIDITY
TEMPERATURE
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Primer
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Basecoat
CLEAR COAT
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SURFACE PREPARATION
Types of sanding
Scuff Sanding
Detail Sanding
Orbital Sanding
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DETAIL SANDING :
SCUFF SANDING :
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ORBITAL SANDING :
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CLEANING METHODS
Tack-off
Blow-off
Solvent wipe
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TACK-OFF :
BLOW-OFF :
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SOLVENT WIPE :
In some plants a process called solvent wipe
is carried out.
It also takes place after the sanding.
Solvent
wipe
is
used
to
remove
Contaminations on the unit before painting.
A small amount of polishing compound is put
onto the sanded area and spread around with
the pad before it is started.
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Spot Repair:
WAX OPERATIONS
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CAVITY WAX:
Cavity wax, which is a paraffin wax, is applied
to add further corrosion protection.
The wax is injected into cross members and
box sections of the A Pillars , Rocker panel ,
Hood interiors , Deck lid interiors , Floor
panel.
It is also sprayed into the lower parts of the
door using Wax spray gun.
Different nozzles are used for different
applications and different models.
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