自泳漆涂装工艺介绍.ppt

自泳漆工艺介绍及成本分析,Dr.2006年5月17日,AutophoreticCoatingPresentation,2,自泳漆涂装工艺全球情况,全球拥有50多个专利北欧，北美及日本有生产和研发力量每年涂装面积5000万平方米100多个用户，上千种工件20多个国家推广,AutophoreticCoatingPresentation,3,什么是自泳漆,自泳漆：依靠与铁基材的化学反应沉积过程化学反应过程，不是电沉积过程铁离子和水性树脂在铁基体表面的反应勿需磷化或铬化,L-,Acid,Fe+,电泳,OH-,R+,+,-,自泳,AutophoreticCoatingPresentation,4,自泳漆的特性,膜厚均匀：即使是对于电泳等涂装方式不容易涂装到的区域也能均匀形成涂层,SEM电镜照片显示自泳漆涂装方式没有边缘效应，在边角处、螺纹波谷处涂层均匀.,AutophoreticCoatingPresentation,5,自泳漆成膜机理,FeFx3-x,FeFx3-x,H+,颜料树脂粒子-,Fe,F-,FeFx3-x,H+,H+,颜料树脂粒子-,颜料树脂粒子-,F-,F-,Fe+,Fe+,Fe,AutophoreticCoatingPresentation,6,反应机理方程式,自泳漆涂层成膜机理,AutophoreticCoatingPresentation,7,涂装时间与膜厚的关系,自泳漆膜厚在涂装时间达定值时，膜厚将维持不变，一般为25分钟。,AutophoreticCoatingPresentation,8,自泳漆ACC700,800和900系列产品,PVDC(ACC866)良好的抗腐蚀性能无重金属离子有机挥发物为零热稳定性较差,Acrylic(ACC703)良好的抗腐蚀性能含铬的反应水洗低含量有机挥发物良好的热稳定性,Epoxy(ACC900),AutophoreticCoatingPresentation,9,ACC700系列（ACC705，基材为丙稀酸）良好的抗腐蚀性能含铬的反应水洗低含量有机挥发物良好的热稳定性（烘干温度170度）外观为亚光，较差，主要由于黑体件涂装由于工艺比较早，槽液维护比较困难，目前不再推荐,自泳漆ACC700,800和900系列产品,AutophoreticCoatingPresentation,10,自泳漆ACC700,800和900系列产品,ACC800系列（ACC866，基材为聚二氯乙烯）良好的抗腐蚀性能无重金属离子有机挥发物为零烘干温度105110度外观为亚光，主要用于黑体件涂装，如反应水洗采用价格较高的ACC3414，则外观将有所改善由于800系列环境友好，烘干温度低，节省能源，目前为主要推荐工艺。,AutophoreticCoatingPresentation,11,自泳漆ACC700,800和900系列产品,ACC900系列（ACC915，基材为环氧树脂）良好的抗腐蚀性能无重金属离子有机挥发物为零烘干温度160170度外观良好，目前正在研制其它颜色的ACC900系列产品，但成本较高。由于900系列外观好，可推荐进行外观要求较高的零部件涂装,AutophoreticCoatingPresentation,12,ACC涂层的基本性能,划格：单边扩蚀3mm，盐雾实验达600小时不划格：盐雾实验可达1000小时以上,其它性能指标请见下页幻灯片,AutophoreticCoatingPresentation,13,自泳漆与电泳漆膜性能比较,AutophoreticCoatingPresentation,14,ACC性能比较,AutophoreticCoatingPresentation,15,自泳漆与粉末喷涂、电泳漆膜工艺控制参数比较,ACCSeriesProducts清洗段分析氧化还原电位ORP氟离子含量101铁离子含量温度固体分,PowderCoat清洗段分析磷化段分析工作电荷流率空气压力空气运动空气温度环境湿度,E-Cocat清洗段分析磷化段分析颜基比颜料固体分温度%固体分酸的毫克当量pH值,AutophoreticCoatingPresentation,16,自泳漆与传统工艺过程比较,上图中可见，ACC涂装不需要表调和磷化工序，只在ACC后增加反应水洗工位,AutophoreticCoatingPresentation,17,自泳漆涂装工件范围,所有汽车零部件黑体件，尤其是形状不规则的、结构复杂的、带有内腔的零部件，ACC涂装具有明显优势。车架底盘减震器座椅骨架各种螺栓、螺母标准弹簧、板簧热轧件铸铁件农用车零部件。,AutophoreticCoatingPresentation,18,AutophoreticCoatingProcedures典型自泳漆涂装工艺步骤,AutophoreticCoatingPresentation,19,自泳漆设备,烘干,反应水洗,水洗,自泳涂装,纯水洗,水洗,碱洗,碱洗,AutophoreticCoatingPresentation,20,WhySoHot?自泳漆-超值的涂装方式,涂装综合运营成本考虑因素:不应该单纯考虑材料成本本身.过程效率设备尺寸/复杂性能源消耗直接或间接的劳动力消耗维护成本高低涂装线对整个制造过程的影响库存及周转期等,AutophoreticCoatingPresentation,21,AutophoreticProductionLine自泳漆生产线,AutophoreticCoatingPresentation,22,AutophoreticApplications自泳漆涂装应用,零部件ACC涂装应用,千斤顶加拿大，美国，澳大利亚.可涂装集成的零部件ACC800series,AutophoreticCoatingPresentation,23,零部件ACC涂装应用实例,AutophoreticApplications自泳漆涂装应用,车灯德尔浮车灯灯罩ACC800Series,AutophoreticCoatingPresentation,24,AutophoreticApplications自泳漆涂装应用,零部件ACC涂装实例,刹车零件均匀的ACC涂层ACC700and900SeriesSeries,AutophoreticCoatingPresentation,25,AutophoreticApplications自泳漆涂装应用,AutoSuspension,AutoInterior(Seating/Safety-Restraint),ElectricMotors/Compressors,SteelWheels,AutoFrames/Chassis,AutophoreticCoatingPresentation,26,AutophoreticApplications自泳漆涂装应用,MetalFurniture,MotocycleFrames,AG/ConstructionComponents,HomeRadiators,AutophoreticCoatingPresentation,27,AutophoreticApplications自泳漆涂装应用,AutomotivePartsApplications,车架国家：土耳其，埃及，印度车型：SUV,军车自泳漆：ACC800系列ACC900系列,AutophoreticCoatingPresentation,28,AutophoreticApplications自泳漆涂装应用,农机零部件ACC实例,做为底漆和面漆ACC800、ACC900系列,AutophoreticCoatingPresentation,29,AutophoreticApplications自泳漆涂装应用,金属家具ACC涂装应用实例,抽屉滑边组合件ACC800系列,AutophoreticCoatingPresentation,30,当前自泳漆在中国主要客户,上海昆山SHIMANO自行车零部件（日资）ACC866ACC915（新建线）无锡中杰减震器ACC866武汉十堰轿车弹簧ACC866苏州车架线ACC866,AutophoreticCoatingPresentation,31,AutophoreticCoatingChemicals主机厂认可情况GeneralMotors（通用）,998-4132MaterialSpecificationGradeB-ACC800Series(20.0-25.4Microns)GradeC-ACC800Series(12.7-17.3Microns)InteriorGradeD-ACC900Series(12.7-25.4Microns)GradeB,C,DMeet:4350-M(A336)PerformanceSpecificationGradeB&DMeet:500-600HoursSaltsSpray,ScribedCosmeticCorrosionRequirements2Year5%RedRustGM9540P40cyclesSubstrateDependent,AutophoreticCoatingPresentation,32,AutophoreticCoatingChemicals主机厂认可情况Hyundai/Kia（现代/起亚）,MS-630-17MaterialSpecificationAutodepositedCoatingChemicalMetalProductsScopeofApplicationAllModelAwardedMarch2005Type1(FAP-1)GeneralPartsType2(FAP-2)PartsthatneeddurabilityType3(FAP3)PartsthatneedhighdurabilityType4(FAP-4)PartsthatneedspecialcorrosionresistanceMostlyappliestoACC800SeriesTypeCoatingsFutureMaterialSpecificationforACC900SeriesTypeCoatingsexpectin2006.,AutophoreticCoatingPresentation,33,AutophoreticCoatingChemicals主机厂认可情况DaimlerChrysler（奔驰）,PS-6061(ProcessStandard)TypeII(ACC800),TypeIII(ACC900)SaltSpray-240hrs,Humidity-240hrs,Gravel-1pt.70psiPF-8871(PerformanceStandard)PurchasedPaintedPartsPassClassS96,S168,S240,S240E,S336,S500E,I48,I100PF-9968(PerformanceStandard)UnderhoodandChassisPartsHumidity-240hrs,Corrosion-Cyclic,FluidResistance,ChipResistance,ThermalStability,FinishAppearance,HighPerformanceGravel,SaltSprayResistance,AutophoreticCoatingPresentation,34,AutophoreticCoatingChemicals主机厂认可情况FordMotor（福特）,ESB-M64J27EngineeringMaterialSpecificationA1-(20.4MicronsMin.coatingfilmthickness)-ZeroVOC100degCcure.(referencetoACC800Series)B1-(20.4MicronsMin.coatingfilmthickness)-LowVOC160degCcure.(referencetoACC900Series)WSS-M2P187EngineeringMaterialSpecificationA-1(non-visibleinterior)15micronsminimumcoatingfilmthicknessA-2(non-visibleexterior)20micronsminimumcoatingfilmthicknessESB-M2P133-1EngineeringMaterialSpecification(willexpire)Nonvisibleautoparts20to30microncoatingfilmthicknessPerformanceStandardsfor:WaterImmersion-240hrs,Corrosion-Cyclic,StoneChipResistance,Adhesion,FinishAppeara