Browse Topic: Spraying

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Designing Sensors for Hazardous EnvironmentsTBMG-351969/1/2019
Some of the most common applications for hazardous duty sensors are in the oil and gas industry. Rotary encoders are frequently used to provide crucial feedback about moving machinery on the rig. Flammable agents are common in applications near the wellbore, so most electrical components on the rig require special hazardous area certification. Hazardous duty sensors are also used in applications such as paint spray booths because of the volatiles coming off the paint; grain silos because the dust environment is very explosive; chemical factories; explosives factories; and believe it or not, for cosmetics because the very fine powders that are used are highly explosive.
CONNECTOR RECEPTACLE, REVERSE BAYONET COUPLING, DUMMY STOWAGEAS95234/12 (Current)8/27/2019
AE-8C1 Connectors Committee
LED Lighting Improves Efficiency and ImagingTBMG-343975/1/2019
Rocket engine testing requires a lot of light since all tests are filmed with high-speed cameras to monitor performance; however, those cameras have to adjust to the bright plume from a firing engine, which would black out the rest of the image. Traditionally, that light has been provided by metal halide bulbs.
Does Your Coating System Require Climate Control? What to Look For and What to ExpectTBMG-3342212/1/2018
There is one aspect of the paint and coatings finishing business virtually guaranteed to give the budget director heart failure: climate control. There's no way around it – climate control systems are expensive.
Quick Disconnect for High-Pressure Mate/De-MateTBMG-290536/1/2018
NASA Kennedy Space Center seeks partners interested in the commercial application of the Quick Disconnect for High Pressure Mate/De-Mate. Designed at KSC, this technology is intended for use in dusty environments where dust particles can contaminate high-pressure connectors, resulting in wear on connector surfaces and unreliable connections. The Quick Disconnect (QD) utilizes the gas supplied by the umbilical to spray on, entrain, and remove dust from the connector surfaces prior to mating.
Handling and Packaging of Materials and Components for Emissions TestingJ2989_201804 (Current)4/5/2018
This standard is intended for the automotive industry. Testing methods may specifically define the handling and packaging conditions for the material to be analyzed. In these cases, follow the method as closely as possible. Use this standard as a guide, where the protocol for handling and packaging the samples between part production and testing may be undefined.
Volatile Organic Compounds
Direct Coating Technology for Improved Piano Black Appearance and Scratch Resistance2018-01-13504/3/2018
In this article, a new method for achieving piano black appearance is discussed. Using a technique called Direct Coating, developed by Covestro, components have been produced with a smooth, high-gloss surface, which demonstrates improved scratch resistance and the ability to recover from minor scratches. For this development project, the Hyundai Santa Fe exterior door trim was selected due to the simple geometry and severe performance requirements. This allowed for optimization of molding conditions and comparison of the performance to the current production part. The prototype part demonstrated improved surface quality compared to paint, and passed car wash, chemical, and weathering test specifications. In addition to addressing quality issues, this method offers cost savings by eliminating the traditional painting process, which is expensive due to long cycle time, multi-step processing, and emissions regulations. Furthermore, this technology can be adapted to other substrate materials, different coating colors, and varying surface finishes such as matte and textured patterns within the same mold.
Nummy, Amanda
Black Finishing Low Baking EnamelAMS2503G (Current)2/7/2017
This specification covers the engineering requirements for finishing aircraft parts and assemblies with a black enamel.
AMS B Finishes Processes and Fluids Committee
Development of Paint Booth: “New Paint Mist Collection Method”2016-01-12584/5/2016
1 Inside a paint booth to spray paint on vehicle bodies, bumpers, and other parts (hereinafter referred to as “works”), air whose temperature and humidity are controlled by air-conditioner is supplied by blower fans through filters. Dust-eliminated and regulated air flow is sent downward from top to bottom (hereinafter referred to as “downflow”) in the painting booth. Conventionally, paint which does not adhere to work in spraying (hereinafter referred to as “paint mist”) is collected while flowing at a high speed through a slit opening called venturi scrubber in a mixture of air and water. However, this mist collecting system using venturi scrubber requires a large space with a large amount of pressure loss while consuming substantial energy. By radically changing the mist collecting principle, we developed a new compact system with less pressure loss aiming to reduce energy consumption by 40% in a half-size booth.
Iida, Tatsuya, Mitani, Hiroya, Sato, Mamoru
Effects of Prolonged Exposure to UV and Water on Super-Hydrophobic Surfaces at Ambient and Icing Conditions2015-01-21606/15/2015
The surfaces that shed drops helps with mitigation of icing. Shedding of drop depends on surface hydrophobicity, which becomes affected when exposed to water and/or UV. The hydrophobicity degradation of six (Spray SHS, Etched Al SHS, Hydrobead, Neverwet, Waterbeader, and WX2100) different super-hydrophobic surfaces (SHS), exposed to water or UV, were studied from the drop shedding perspective. Two methods were adopted for the hydrophobicity analysis. Among them, one is to study the contact angles (CA) and contact angle hysteresis (CAH) change at static state (i.e., no airflow) compared to the untreated surface. The other one is to analyze the change in critical air velocity (Uc) for a given drop exposed to airflow, on water/UV treated surfaces at room temperature (22 °C) and icing conditions (−1 and −7 °C). For the water/UV treated surfaces, the static CAH and Uc (for all temperatures tested) for drops on Etched Al SHS, Hydrobead, and Neverwet, were found to be less than the specified value for a surface to deem as under performing. Hence, from the overall analysis, Etched Al SHS, Hydrobead, and Neverwet, are considered retaining their performance fairly well at both room temperature and icing conditions after exposure.
Amirfazli, Alidad
FRP Mold and Panel Manufacturing for FSAE Body Panel and Driver Seat2015-01-07274/14/2015
This paper aims at Fiber Reinforced Panel or FRP mold and panel manufacturing of body panel and driver seat for a Formula Society of Automotive Engineers or FSAE racecar. The competition involves designing a Formula 1 type car that lays the standards for a high performance-racing car [1]. This calls for a high Power: Weight ratio. The rules of the competition ensure a mandatory use of an air restrictor with an engine of a maximum capacity of 600cc to reduce the power of the engines [2]. Hence, to compensate for the loss of power the target now shifts to minimizing the car's weight without compromising the strength. The body panel and driver's seat are two most valuable parts as the first adds elegance and aerodynamics to the car while the latter makes it comfortable for the driver to drive the car under high lateral load shifts. Weight reduction in this area is easier as strength is not the dominating factor. It is preferred because of its low cost, good strength, flexibility and elegance after finishing. To make the fiberglass product of a particular shape, a mold of the same shape is needed. For a smooth outer surface of the product, as in the case of the car body panel, an inside-out or negative mold needs to be made. The mold can be constructed by many ways ranging from using chicken wires and clay to using the MDF (medium density fiberboard), to achieve more accuracy and a smoother surface to obtain a better product.
Rajamanickam, Udayakumar, Singhal, Anshul, Jothi, Miller
Measure of Forming Limit Strain on the Aluminum Sheets Passed Through Draw-Bead by Digital Image Correlation2015-01-05984/14/2015
Accurate determination of the forming limit strain of aluminum sheet metal is an important topic which has not been fully solved by industry. Also, the effects of draw beads (enhanced forming limit behaviors), normally reported on steel sheet metals, on aluminum sheet metal is not fully understood. This paper introduces an experimental study on draw bead effects on aluminum sheet metals by measuring the forming limit strain zero (FLD0) of the sheet metal. Two kinds of aluminum, AL 6016-T4 and AL 5754-0, are used. Virgin material, 40% draw bead material and 60% draw bead material conditions are tested for each kind of aluminum. Marciniak punch tests were performed to create a plane strain condition. A dual camera Digital Image Correlation (DIC) system was used to record and measure the deformation distribution history during the punch test. The on-set necking timing is determined directly from surface shape change. The FLD0 of each test situation is reported in this article. From the results of this study, the draw bead effects (enhanced forming limit behaviors) are found in both aluminums tested. Basic theory, experiment plan, experimental setup, test results and data analysis are shown in detail in this paper.
Li, Xiaona, Du, Changqing, Zhou, Yongjun, Xie, Xin, Chen, Xu, Zheng, Yaqian, Ankofski, Thomas, Narainen, Rodrigue, Xia, Cedric, Stoughton, Thomas, Yang, Lianxiang
Measurement of Aluminum Edge Stretching Limit Using 3D Digital Image Correlation2015-01-05944/14/2015
This paper introduces an industrial application of digital image correlation technique on the measurement of aluminum edge stretching limit. In this study, notch-shape aluminum coupons with three different pre-strain conditions are tested. The edge stretching is proceeded by standard MTS machine. A dual-camera 3D Digital Image Correlation (DIC) system is used for the full field measurement of strain distribution in the thickness direction. Selected air brush is utilized to form a random distributed speckle pattern on the edge of sheet metal. A pair of special optical lens systems are used to observe the small measurement edge area. From the test results, it demonstrate that refer to the notched coupon thickness, pre-tension does not affect the fracture limit; refer to the virgin sheet thickness, the average edge stretch thinning limits show a consistent increasing trend as the pre-stretch strain increased. Test plan, experimental setup, and experimental results are shown in detail in this article.
Xie, Xin, Du, Changqing, Li, Xiaona, Chen, Yi-Hsin, Yang, Guobiao, Zhou, Yongjun, Zhou, Dajun, Zheng, Yaqian, Sia, Bernard, Phillips, Christina, Yang, Lianxiang
Tape, Adhesive, Pressure-Sensitive MaskingAMS3808B (Current)4/13/2015
This specification covers three types of masking in the form of pressure-sensitive adhesive tape.
AMS P Polymeric Materials Committee
Efficient Numerical Simulation of Spray Painting Processes in Automotive Manufacturing2014-36-04189/30/2014
We present an efficient numerical method to simulate the spray painting process in the automotive industry. A framework has been developed based on coupled solvers for the air flow, electromagnetic fields and paint droplets. The applied discretization method allows treating moving boundaries in an efficient way and significantly reduces preprocessing time. Thus the simulation of the painting of a car fender or a truck cab takes only a few hours on a standard computer and gives very good agreement with thickness measurements. These results demonstrate the validity of the method and its applicability to increase product quality and reduce production costs in automotive paint shops. It allows performing systematic analysis of the influence of process conditions on the paint thickness and overspray.
Clément, Zémerli, Fredrik, Edelvik, Andreas, Mark, Oliver, Hermanns
A Lightweighting Solution for Converting an Aluminum Bracket to Plastic Using Long Fiber Thermoplastic Technology2014-28-00104/28/2014
This breakthrough development involves material conversion from aluminum die cast to polypropylene long fiber thermoplastic (40% long glass filled) for a two wheeler bracket of a leading automotive OEM. The plastic bracket was developed working in collaboration with the molder, glass supplier, technology collaborator and the OEM. The new part needed to be designed lighter in weight, easier to process and suitable for painting, outdoor exposure and stringent dynamic conditions. The scope of this study includes the evaluation of the new material from different viewpoints and comparison of the same with the existing material. The submission will go through the intricate analyses carried out in the development process and highlight the key advantages over aluminum. Studies will include static and dynamic analysis, fiber orientation studies, gate location studies, etc.
Bhanshali, Saral
Video Projection Mapping Photogrammetry through Video Tracking2013-01-07884/8/2013
This paper examines a method for generating a scaled three-dimensional computer model of an accident scene from video footage. This method, which combines the previously published methods of video tracking and camera projection, includes automated mapping of physical evidence through rectification of each frame. Video Tracking is a photogrammetric technique for obtaining three-dimensional data from a scene using video and was described in a 2004 publication titled, “A Video Tracking Photogrammetry Technique to Survey Roadways for Accident Reconstruction” (SAE 2004-01-1221). That paper described a method for generating a three-dimensional computer model of a roadway by using video of a drive-through of an accident scene and processing this video footage through available video tracking software.1,2 The benefit of being able to drive through an accident scene to collect data lies in the speed of such a method, but also in safety, as some accident areas are too heavy with traffic, dangerous or otherwise inaccessible. Three-dimensional Camera Projection Mapping is a computer visualization technique of wrapping or mapping video or photographs onto three-dimensional geometry and adjusting the size and shape of the map so it follows the size and shape of the target objects. This rectification process results in a photo-realistic computer model that is accurate in detail, lighting and scale since it is built directly from the photograph. The result of adding the technology of video tracking with three-dimensional camera projection mapping is a scaled computer model of the accident scene that includes photographs of the evidence mapped onto the geometry at the correct scale and location - all from a single video drive-through. Developing both of these concepts into one method of Video Projection Mapping combines the ease of building a three-dimensional accident diagram from a video drive-through, with the accuracy and clarity of analyzing scaled photographic data.
Neale, William T., Marr, James, Hessel, David
Development of Waterborne Conductive Primer for Motorcycles2012-32-008910/23/2012
Most types of paint materials currently used for motorcycles contain large amounts of VOCs (Volatile Organic Compounds). VOCs are environmental load substances, and there is a demand to reduce emissions in recent years. Many of a motorcycle's exterior parts are made of ABS (Acrylonitrile-Butadiene-Styrene) plastics (henceforth ABS) or PA (Polyamid) plastics (henceforth PA). These two plastic materials have different film adhesion mechanisms and adhesion strength. Therefore it was necessary to use different conductive primers and that's was one of the factors which made time and material losses in the painting processes. We solved those two issues, the reduction of VOCs and the common use of the same conductive primer for different parts materials, by combining two kinds of resins originally designed as the conductive primers, i.e., urethane resins with carboxylic acid groups and acrylic resins with amide groups, which are different in properties. Many of the plastic parts used in motorcycles are painted manually because there are difficult portions to be painted by automated painting machines. The viscosity was adjusted to satisfy both the controllability of paint sagging and the surface smoothness to keep the efficiency of paint workers' operations.
Tanaka, Akiko, Inoue, Tomoyuki, Mochizuki, Shinsuke, Inoue, Masanobu
Optimization of Process Parameters for Automotive Paint Application2011-28-007210/6/2011
The quality of the paint application in automotive industry depends on several process parameters. Thus, finding an optimal solution based on experimental configuration is tedious and time consuming. A first step to reduce the effort is to model the application within the framework of a simulation environment. In this study, we present an approach for the systematic variation of design parameters of the paint process to quantify their influence on the quality of the paint application. Using that information the design space is reduced by neglecting the parameters with low impact and later used to predict an optimal set of input parameters for an optimal paint application.
Blum, Stephan, Henkel, Norman, Lehnhaeuser, Thomas, Chittepu, Karthik
TAPE, ADHESIVE, PRESSURE-SENSITIVE MASKINGAMS3808 (Historical)8/9/2011
This specification covers three types of masking material in the form of pressure-sensitive adhesive tape.
AMS P Polymeric Materials Committee
Black Finishing Low Baking EnamelAMS2503F (Historical)4/19/2011
This specification covers the engineering requirements for finishing aircraft parts and assemblies with a black enamel.
AMS B Finishes Processes and Fluids Committee
Silicone Solutions for Lubrication in Medical ApplicationsTBMG-66441/1/2010
For over 50 years, silicones have been used extensively in the design and manufacture of medical devices intended for short- and long-term human implantation. Silicone’s overwhelming success in the healthcare arena is not only due to its proven bio-inertness, but also to silicone chemistry’s dynamic nature, which yields a diversity of raw materials including fluids, gels, adhesives, dispersions, and elastomers. These two assets explain why many therapies rely heavily on silicones and why some medical devices are fabricated entirely of several types of silicone.
Fanuc Painting Robot Boosts Production for Metal FinisherTBMG-957610/1/2009
Classic Metal Finishing, based in Jackson, Mich., supplies components for the aerospace, motorcycle, racing, and medical industries. The plant was purchased in February, 2008 by Classic Metal Finishing and Classic Turning. Classic Turning performs high-end CNC machining of components and Classic Metal Finishing performs anodizing and dry film lubricant applications. Classic Metal Finishing’s anodizing line can anodize with two different types for corrosion inhibitor resistance, and can die aluminum in eight different colors. Dry film lubricant is applied to parts to help with high friction tolerance fits and moving assemblies.
Local Mechanical Property Variations of AZ31B Magnesium Sheet due to Elevated Temperature Forming2009-01-08644/20/2009
The influence of elevated temperature forming on local mechanical properties of AZ31B magnesium (Mg) sheet material was investigated. The Mg sheet was formed into a closure component with high temperature gas pressure at 485°C. Miniature tensile testing specimens were cut from selected areas of the component where different levels of thinning occurred. The specimens were strained in tension to fracture using a miniature tensile stage. The two-dimensional strain distribution in the necking region along with true stress-true strain curves were computed using a digital image correlation technique to assess the influence of the forming-induced thinning on tensile strength and percent elongation at fracture.
Savic, Vesna, Hector, Louis G., Kim, Sooho, Verma, Ravi
High-Temperature Crystal-Growth Cartridge Tubes Made by VPSTBMG-336111/1/2008
Cartridge tubes for use in a crystal-growth furnace at temperatures as high as 1,600°C have been fabricated by vacuum plasma spraying (VPS). These cartridges consist mainly of an alloy of 60 weight percent molybdenum with 40 weight percent rhenium, made from molybdenum powder coated with rhenium. This alloy was selected because of its high melting temperature (≈2,550°C) and because of its excellent ductility at room temperature. These cartridges are intended to supplant tungsten/nickel-alloy cartridges, which cannot be used at temperatures above ≈1,300°C.
Electrodeposition Painting to Outboard Motors2007-32-008610/30/2007
Outboard motors use aluminum die-cast components extensively to cut down their weight. They are also cooled directly by the raw water including saline water. Corrosion protection is the critical issue for outboard motors because of these characteristics. Currently, the coating is the primary measures taken to assure the corrosion resistance and to give originality to the appearance. However, the complicated cooling passages cannot be coated appropriately with the spray-paint process. Such disadvantages can be compensated by the electrodeposition coating technique. In the case of electrodeposition coating, the coating film is generated electrically in the coating material bath by means of deposition. The process is widely applied to the automobile bodies made of steel plate, because it provides higher transfer efficiency and lower VOC (VOLATILE ORGANIC COMPOUNDS) emission. However, the traditional electrodeposition coating material presented various issues when it comes to the application to the aluminum components. These issues are attributable to the behavior of the coating film in the course of deposition process. The new electrodeposition coating material has been developed to deal with these issues, and has been applied to the outboard motor components. The new coating material gives higher anticorrosion property to the components, and also allows the reduction of VOC emission and the elimination of hexavalent chromium. This report describes the efforts made to work out the engineering issues for applying the new electrodeposition coating material to the actual production process.
AOKI, Tetsuya
Sprayed Metal Finish, AluminumAMS2450G (Current)6/13/2007
This specification covers the procedure to be used for spraying metallic parts with aluminum and the properties of the coating.
AMS B Finishes Processes and Fluids Committee
Increasing Durability of Flame-Sprayed Strain GaugesTBMG-17835/1/2007
Thermally sprayed dielectric ceramic coatings are the primary means of attaching strain and temperature gauges to hot-section rotating parts of turbine engines. As hot-section temperatures increase, lifetimes of installed gauges decrease, and seldom exceed one hour above 2,000 °F ( ≈1,100 °C). Advanced engine components are expected to operate at temperatures approaching 2,200 °F ( ≈1,200 °C), and the required high-temperature lifetime is 10 hours minimum.
Protective Skins for Aerogel MonolithsTBMG-11892/1/2007
A method of imparting relatively hard protective outer skins to aerogel monoliths has been developed. Even more than aerogel beads, aerogel monoliths are attractive as thermal-insulation materials, but the commercial utilization of aerogel monoliths in thermal-insulation panels has been inhibited by their fragility and the consequent difficulty of handling them. Therefore, there is a need to afford sufficient protection to aerogel monoliths to facilitate handling, without compromising the attractive bulk properties (low density, high porosity, low thermal conductivity, high surface area, and low permittivity) of aerogel materials. The present method was devised to satisfy this need.
Test Methods for Cleanroom Apparel and Related Indirect Materials in Automotive Paint Spray2006-01-07494/3/2006
As automotive paint spray processes have adopted cleanroom philosophies in the past several years, it has become increasingly apparent as to the impact of indirect materials on the final product. Historically, less reliable methods such as panel tests and tape tests were utilized to determine product cleanliness. These methods suffered from environmental interference, with an inability to isolate variables unrelated to the product’s cleanliness. As a result, new test methods for particle release have evolved, which are more reliable, and scientifically repeatable. Some examples are Readily Releasable testing and Bidirectional Shake Testing for particulates. Though originally intended for testing of particle release of wiping materials, automotive OEMs have expanded the use of these tests for Cleanroom-type coveralls, wipes, gloves and automation covers. The test criterion encompasses both new and reusable products. The laundry can no longer rely solely upon test methods such as ASTM F51-68, or Helmke Drum testing as a means to determine particulate release for an individual batch of product. Though the tests are both effective and acceptable for other critical manufacturing environments. The ensuing paper will investigate these test methods, and the impact and the validity to measure contamination from indirect materials on automotive paint finishes.
Nightingale, Robert
A Framework for CAD and Scanner-based Robotic Coating Automation2006-01-01564/3/2006
Coating automation of a complex product family with unknown features is investigated. A CAD and scanner-based robotic coating system is proposed. The system is capable of creating robotic programs for different products automatically. Unpredicted features are detected by sensors when a product is loaded into the system. Other features are known from the product CAD model. All of the features are merged together to create an accurate surface model. The system generates robotic paths and trajectories based on the surface model. A system framework and methodology for path and trajectory generation is proposed.
Lang, Sherman Y. T., Bi, Z. M.
Optical Inspection Methods Synchronizing with Computer Design and Simulation2005-01-08914/11/2005
Full-field optical methods are replacing many of the traditional test measurement methods for verification and iteration of computer models and simulations. This paper will discuss the development of these technologies and their impact on the testing and FEM worlds for solving many typical measurements, and some measurements considered here to fore impossible.
Tyson, John, Schmidt, Timothy, Coe, David, Galanulis, Konstantin
Precision Stages Enable Analytical Measurement of Jet-Able FluidsTBMG-291614/1/2005
Precision X-Y stages were developed for integration into a new analytical measurement tool for use in the development of digital inks or other fluids to be jetted from ink jet print heads. The Drop Watcher III system provides repeatable and exact measurements of drop formation (e.g., distance and time from the start of the drop ejection), drop size, and flight characteristics of opaque or transparent fluid drops. In addition to X-Y stages, the system consists of a monochrome CCD camera with a zoom lens providing magnification from 0.75X to 4X. Magnification from 2.5X to 10X is achievable when using the high-magnification option, yielding fields of view from 640 µm to 2.56 mm.
Selective Galvanizing Using Kinetic Spraying2003-01-12373/3/2003
General corrosion protection of sheet materials such as steel used in automobile construction has reached a high level of performance, due primarily to the incorporation of mill-applied treatments such as electrogalvanizing, galvannealing and other coil-coating processes developed over the last half century. While such treatments have greatly extended the corrosion resistance of steel and its various body constructs, attention is now focused on aspects of the manufacturing process wherein these intended protections are compromised by such features as weldments, joins, cut edges and extreme metal deformations such as hems. A novel metal deposition process, based on high-velocity impact fusion of solid metal particles, has been used to extend the corrosion resistance of base steel and pre-galvanized sheet, by selectively placing highly controlled depositions of zinc and other sacrificial materials in close proximity to critical manufacturing details. The technology of this process is reviewed and preliminary results are reported for hem flange construction.
McCune, Robert C., Ricketts, Mark S., Gao, Guilian, Neiser, Richard A., Puskar, Joseph, Roemer, Timothy J.
Improvements in the Use of Water Washes in Testing for NVRTBMG-64016/1/2002
Some improvements have been made to enhance the role of water as a test solvent for determining the amount of hydrocarbon nonvolatile residue (NVR) present on an item of hardware that is required to be totally or nearly devoid of such residue. Water is now used as an NVR-testing solvent because (1) even highmolecular- weight hydrocarbon greases are at least slightly soluble in water, (2) water is safer and less expensive than are chlorofluorocarbon solvents [in particular, 1,1,2- trichloro-1,2,2-trifluoroethane (also known as CFC-113), which was used previously in testing for hydrocarbon NVR], and (3) CFC solvents are expensive and are now recognized as environmentally harmful.
Deposition of Hard Coating Film on Polymer Surface by Plasma CVD2002-01-02943/4/2002
Polycarbonate (PC) resin is widely used for automobile parts. In order to improve its abrasion-proof and ultraviolet (UV) shielding abilities, we studied the effects of applying SiO2/ZnO two-film-coating to polycarbonates by using a RF plasma CVD method with hexamethyldisilane (HMDS) and diethylzinc (DEZ). We found that both the deposition rate of ZnO thin films and the characteristics of the film depended on the substance temperature. Deposition rates of the ZnO thin films decreased, and the ultraviolet shielding ability improved, as the substance temperature rose. We also found ZnO-coated PC plates to show a remarkable protection against UV radiation; their surfaces remained smooth and suffered less discoloration even after a 1000-hour-irradiation of UV light in a xenon arc weatherability test. SiO2 films deposited on ZnO films using HDMS with oxygen had very hard surface characteristics and we feel that they may be used in coating hard films on automotive headlamp lenses.
Anma, Hidetaka, Yoshimoto, Yuuji, Tanaka, Mariko, Takatsuka, Hiroyuki, Hatanaka, Yoshinori
Polyorganosiloxanes for Coating Porous Ceramic InsulationTBMG-73185/1/2001
Liquid and paste polyorganosiloxane formulations (which become high-temperature- and oxidation-resistant organosilicone-based ceramics upon curing) have been invented for use in (1) protecting porous, lightweight ceramic thermal insulation materials against aeroconvective thermal degradation and (2) repairing and bonding such materials. These formulations were originally intended especially for application to the fibrous refractory composite insulation (FRCI) tiles that protect parts of the space shuttles during re-entry into the terrestrial atmosphere; they may also be suitable for application to similar insulating tiles in laboratory and industrial furnaces.
Plasma-Sprayed Selective Emitters for ThermophotovoltaicsTBMG-296729/1/2000
Plasma spraying has been shown to be an effective means of depositing thin films of various oxides for use as wavelength-selective emitters for thermophotovoltaic devices (see Figure 1). Wavelength-selective emitters are needed to increase the overall efficiencies of such devices. A suitable emitter material for a given thermophotovoltaic device is one that, when heated to incandescence, emits light with a spectral peak or peaks that preferably lie within the wavelength band of peak response of the photovoltaic cell in the device; more specifically, what is desired is low emissivity at photon energies less than the band gap and high emissivity at photon energies above the band gap of the photovoltaic cell.
Environmentally Conscious Manufacturing of TPO Instrument Panel Skins2000-01-00233/6/2000
Thermoplastic polyolefin (TPO) instrument panel skins are in demand in Europe and Asia as a solution to final product disposition environmental concerns. In North America TPO is valued for its durability characteristics (particularly heat and UV aging) and capability for deployment of seamless airbags at cold temperatures. Desiring to have an environmentally “green” system to create the “green” product, Delphi designed a manufacturing process with in-plant closed loop recycling of 100% offal directly back into the skin and the use of waterbased coating system for combating concerns with solvents. Delphi's development of recyclable TPO skin for instrument panels was introduced on 1997 production of Mercedes-Benz M-class. The paper will describe how the systems approach was used in overcoming the challenges involved in closed loop recycling of engineered offal during sheet manufacturing and thermoforming processes and the implementation of waterbased primer and topcoat systems.
Kakarala, Norm, Anim, Jacqueline, Beasley, Sam, Clock, Jason, Spuck, Brian
Designing an Interior AppliedWaterborne Coating for Use in Automotive Paint Shops to Replace Sound Deadening Pads2000-01-13913/6/2000
This paper describes a waterborne, bakeable thick-film coating that is designed for use as an interior sound pad replacement. The product is applied using a swirl spray application to reduce overspray and maintain uniform coverage. The product has a nonvolatile content of 82% utilizing a resin system based on an acrylic dispersion. This product shows acoustic properties comparable to melt down sound pads. This chemistry withstands a pregel/primer oven up to 150°C, 20 minutes in length, prior to topcoat application and the associated topcoat bakes by maintaining good surface drying and integrity. Utilization of this type of system allows an automotive NVH engineer to specify a cost effective automated coating system that totally eliminates the use of manual applied mastic pads.
Hussaini, Akbar
Maturing Fiber Reinforced Thermoplastic Technology for Automobile Body Structural Applications1999-01-32449/28/1999
With the increasing emphasis on fuel efficiency and environmentally friendly vehicles, much effort is being directed by the auto industry to develop efficient, lightweight and alternative-powered vehicles. One of the ongoing research programs at DaimlerChrysler's Liberty and Technical Affairs is not only aimed at reducing the overall weight of the automobile body structure, but also reducing the cost of manufacturing it. In addition, an automobile body structure needs to meet the requirements of noise, vibration and harshness (NVH), durability, crashworthiness and recyclability. The objective of this paper is to provide a review of the ongoing research and development activities leading to an automobile body structure that meets the above objectives. The paper highlights the many different technology development challenges faced during the process. Discussions of the choice of material systems, injection molding of very large body structural panels using these material systems, their applications to different products, cost implications and supplier issues are included in this paper.
Argeropoulos, John G., Fielding, Russell C., Oswald, Lawrence J.
A Protocol for Testing and Evaluation of Paint Spray Applicators for the Automotive Industry9822899/29/1998
In this paper we discuss the development of a paint applicator system test protocol developed by Ford Motor Company. The test protocol involves spraying commercially available automotive primers, basecoats and clearcoats with known characteristics onto 90 cm long by 30 cm wide phosphated panels (36 in by 12 in) at application conditions necessary to obtain a typical range of film builds. The film builds are then measured at frequent intervals to obtain build averages, standard deviations, and spray pattern sizes. From these, transfer efficiency and pattern uniformity are obtained. In addition, the quality of the applied paint is measured at well defined film builds using several instruments to determine whether the application system being tested is capable of achieving the superb appearance demanded by our customers. Details of the required test matrix, the measurement templates and some comparative results obtained using the Ford protocol will be presented.
Braslaw, J., Altermatt, C. K., Mehta, M., Purcell, J. M.
Globalization of Waterborne Coatings in the Automotive Industry9823779/29/1998
10 years ago Opel and VW Germany were the first to use waterborne basecoats in regular car production because of environmental reasons. Today waterborne metallic basecoats have a market share of 90% in German car manufacturing, 50% in Europe, and are used in 85 OEM plants worldwide. New developments show improvements of appearance and process window, making waterborne coatings usable at temperatures from 20 - 30 °C, relative humidities of 70 ± 10 %, and altitudes from sea level to 2000 m. A novel low cost conversion concept was developed for the introduction of waterborne basecoats into existing (solventborne) paint shops.
Dössel, Karl-F.
An Experimental Investigation of Spray Transfer Processes in an Electrostatic Rotating Bell Applicator9822909/29/1998
A better understanding is needed of the electrostatic rotating bell (ESRB) application of metallic basecoat paint to automobile exteriors in order to exploit their high transfer efficiency without compromising the coating quality. This paper presents the initial results from experimental investigation of sprays from an ESRB which is designed to apply water-borne paint. Water was used as paint surrogate for simplicity. The atomization and transport regions of the spray were investigated using laser light sheet visualizations and phase Doppler particle analyzer (PDPA). The experiments were conducted at varying levels of the three important operating parameters: liquid flow rate, shaping-air flow rate, and bellcup rotational speed. The results show that bellcup speed dominates atomization, but liquid and shaping-air flow rate settings significantly influence the spray structure. The visualization images showed that the atomization occurs in ligament breakup regime. Measurements in the spray transport zone, using PDPA, showed that drops tend to segregate according to size, with the larger drops on the outer periphery of the spray.
Loch, Thomas, Nivi, Hossein, Liu, Yi, Lai, Ming-Chia, Im, Kyoung-Su
Tapes, Pressure-Sensitive Adhesive, Masking, Non-Staining - for Aircraft Painting ApplicationsAMST21595 (Historical)9/1/1998
This specification covers pressure sensitive adhesive tape designed for masking and color separation application during aircraft painting operations. It is designed for use with all common finishes but is especially designed for use with polyurethane coating systems conforming to MIL-C-83286.
AMS G8 Aerospace Organic Coatings Committee
An Environmentally Conscious Decision Support System for the Automotive Industry9821038/11/1998
As a part of the Global Green Engineering Initiative at the US-Japan Center for Technology Management at Vanderbilt University, an Internet-based Environmentally Conscious Decision Support tool (EcoDS) has been developed for life-cycle management. EcoDS is used to compare different alternatives for manufacturing processes or product designs with regards to cost and residual risk, and includes a user-defined value system. This tool uses a vertical streamlining approach applied prior to the data input, to reduce data collection efforts and to speed the life-cycle assessment process. The output is condensed into a single summary matrix. It has been deemed useful to create a version of EcoDS designed specifically for the automotive industry (AutoEcoDS). This program will involve multiple modules each related to a different aspect of the manufacture of automobiles and automotive products. Each module will include an easy-to-use question format to determine the significant life-cycle information. The output will be useful in decision-making about different manufacturing processes for the automotive industry.
LoBosco, Gina, Dhingra, Rajive
Conductive TPO9807092/23/1998
Conductively modified thermoplastic olefins (TPOs) have been developed using low levels of conductive carbon fillers, <6 wt.%, without sacrificing the favorable mechanical and rheological properties exhibited by these materials for the automotive market. The bulk electrical properties of these materials exhibit traditional percolation behavior when the samples are compression molded. However, conductively modified injection molded materials exhibit a high surface resistivity, typically greater than 1016 ohm cm, which is compensated by a relatively low resistance interior, defined as a core resistance, of less than 109 ohm/cm. The threshold for electrostatic paintability has been identified based on core resistance measurements, electrostatic dissipation results, and electrostatic painting transfer efficiency data. The core resistance must be less that 109 ohm/cm for charge dissipation to occur and for any significant increase in paint film builds to be observed. Electrostatic painting of representative production rear bumper fascias at Visteon - Utica Plant have shown transfer efficiency increases relative to non-conductive parts for adhesion promoter, primer, basecoat, and clearcoat when conductive TPO resins are employed. This is true even with the use of conductive adhesion promoter and primers. Recent advancements in chemistries and processes which eliminate adhesion promoters, such as olefinic topcoats, plasma or flame surface treatments, or directly paintable TPO formulations, are targeted towards cost savings associated with process and/or coating elimination. However, by elimination of conductive surface coatings prior to electrostatic application of basecoat and clearcoat over non-conductive TPO parts, these potential cost savings are more than offset by a loss in painting efficiency. The use of conductive TPO parts enables these promoterless system approaches by maintaining the highest possible transfer efficiency levels in electrostatic painting processes.
Helms, Jeffrey H., Blais, Edmund J.
Effects of Atomization on the Particle Size, Appearance, and Composition of Automotive OEM Basecoats9809792/1/1998
Color uniformity in the automotive paint industry is a very important attribute. Previous work to better understand the factors responsible for basecoat color variation has concluded that dried film composition is the most important factor. This work continues to support that conclusion, and in addition, describes quantitatively how final film composition can be modified by small changes in the atomization of the basecoat. Using an air-blast paint spray atomizer and a silver (aluminum flake containing) waterborne basecoat, sixteen (16) spray applied films were analyzed by inductively coupled plasma - atomic emission spectroscopy (ICP-AES) for pigment content. Analysis found that the ratio of “effect” to “color” pigments in the films (i.e., metallic flakes vs. colored pigments) changed by more than 60% when changes were made to the conditions of spray application; fluid flow [100 vs. 400 g/min.], shaping air flow [25 vs. 50 psi cap], and atomizing air flow [40 vs. 60 psi cap]. These results are significant as perceived color is highly correlated to the concentration of aluminum in the film. Formulation specialists can typically detect color differences in coatings when films vary in composition by less than 2%. For the casual observer, this lower limit is approximately 5%.
Miller, Richard C., Brooks, Gayle F.
Self-Lubricating Composite Coating for High-Temperature UseTBMG-321491/1/1998
PS300 is a self-lubricating solid coating material for use in sliding contacts at temperatures up to 800°C. PS300 is a composite of metal-bonded chromium oxide with barium fluoride/calcium fluoride eutectic and silver as solid lubricant additives. The "PS" in the name of this and other self-lubricating, high-temperature composite materials that have been reported in NASA Tech Briefs signifies that the material is applied to a substrate by plasma spraying of a powder blend of its constituents.
BLACK FINISHING Low Baking EnamelAMS2503E (Historical)5/1/1995
This specification covers the engineering requirements for finishing aircraft parts and assemblies with a black enamel.
AMS B Finishes Processes and Fluids Committee
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