PPG培训阴极电泳漆涂装手册

1、11-3-97ver1 automotive electrocoat reference manual 阴极电泳漆涂装手册阴极电泳漆涂装手册 ppg industries, inc. 3800 w. 143rd street cleveland, oh 44111 216/671-0050 automotive electrodeposition reference manual 11-3-97i ver 1 table of contents 目录目录 1.introduction to electrocoat.2 简介 1.1.history of electrocoat.2 电泳涂装的历

2、史 1.2.why electrocoat.2 为什么要采用电泳涂装 1.2.1. advantages.1-5 优点 1.2.2. limitations .2 局限性 1.3.what is electrocoat.2 什么是电泳涂装 1.3.1. anodic versus cathodic .2 阳极电泳和阴极电泳的区别 1.4.electrochemical reactions .1-16 电化学反应 1.5.components of feed and bath.1-18 槽液及加料祖份 1.6.deionized water.1-21 去离子水 1.7.membranes .1-

3、21 隔膜 automotive electrodeposition reference manual 11-3-97iiver 1 1.7.1. ultrafilter membranes.1-23 超率摸 1.7.2. anolyte membranes .1-23 阳极膜 1.8.section summary .2 本节摘要 2.design considerations .2 设计要素 2.1.introduction.2 简介 2.2.general design .2 总体设计 2.2.1. basic requirements.2 基本要求 2.2.2. sanitary pa

4、ns.2 滴漏盘 2.2.3. carrier design.2-4 吊具设计 2.3.metal preparation.2-4 金属预处理 2.3.1. body shop washer.2-4 车身清洗 2.3.2. phosphating.2-6 磷化 automotive electrodeposition reference manual 11-3-97iii ver 1 2.4.electrocoat tank.2-6 电泳槽 2.4.1. direction of flow .2-6 流动方向 2.4.2. adjustable weir plate.2-8 可调堰 2.4.3

5、. freeboard and overflow .2-8 槽堰超出液面高度和溢流 2.4.4. bottom front end filtration.2-9 槽前端过滤 2.4.5. dimensions: clearance.2-12 尺寸：间隙 2.4.6. effective coating time.2-13 电泳时间 2.4.7. angle of entry.2-13 入槽角度 2.5.materials of construction .2-14 建槽材料 2.5.1. dip tanks.2-14 浸槽 2.5.2. tank enclosure.2-14 槽的间壁 2.5

6、.3. tank lining.2-15 槽衬里 2.6.paint circulation.2-15 automotive electrodeposition reference manual 11-3-97ivver 1 槽液循环 2.6.1. surface flow.2-16 表面液流 2.6.2. pipe velocity.2-17 管路内流速 2.6.3. pumps.2-17 泵 2.6.4piping.2-18 管路 2.6.5. valves.2-19 阀 2.6.6. pressure gauges.2-21 压力表 2.6.7. gasket materials.2-2

7、1 垫圈材料 2.6.8. filtration.2-21 过滤 2.6.9. paint cooling.2-22 槽液冷却 2.7.electrical .2-23 电器 2.7.1. anodes.2-23 阳极 2.7.2. roof anodes.2-24 阳极顶盖 automotive electrodeposition reference manual 11-3-97v ver 1 2.7.3. anolyte cells .2-26 阳极隔膜系统 2.7.4. power supplies.2-28 电源 2.7.5. ultrafilters.2-30 超滤器 2.8.rin

8、ses.2 淋洗 2.8.1. general rinses.2-31 概述 2.8.2. over tank rinses.2-33 槽上冲洗 2.8.3. recirculated rinses #1 and #2 .2-34 第一道和第二道冲洗 2.8.4. drainage between rinses.2-37 各道冲洗之间的沥液 2.8.5. dip rinse .2-37 浸洗 2.8.6. recirculated d i water rinse .2-39 循环去离子水 2.9.di or ro water.2-40 去离子水和渗透水 2.10. temperature pr

9、otection.2-42 温度防护 2.11. line stops.2-42 automotive electrodeposition reference manual 11-3-97viver 1 停线 2.12. baking.2-43 烘干 2.13. paint storage tanks.2-44 涂料储备槽 2.14. tank feed.2-44 槽液配制 2.14.1.resin component.2-45 树脂组份 2.14.2.pigment component.2-46 颜料组份 2.14.3.acid injection.2-48 加酸 3.system oper

10、ation.2 系统操作 3.1.introduction.2 简介 3.2.metal cleaning and phosphating .3-2 金属清洗及磷化 3.2.1. precleaning.3-2 预清洗 3.2.2. phosphating.3-3 磷化 3.3.tank design and construction.3-4 automotive electrodeposition reference manual 11-3-97vii ver 1 槽的设计和结构 3.4.paint circulation.3-6 槽液循环 3.5.tank electrification.

11、3-8 电泳槽加电装置 3.5.1. anodes.3-8 阳极 3.5.2. rectifiers.3-8 整流器 3.6.ultrafiltration .3-9 超滤 3.7.rinse systems .3-11 清洗系统 3.8.baking.3-12 烘干 4.analytical tests.2 分析试验 4.1.electrocoat solids (non-volatile) .2 电泳漆固体份（不挥发份） 4.2.electrocoat ph.4-5 电泳漆 ph 值 4.3.electrocoat conductivity.4-9 电泳漆的电导率 4.4.panels a

12、nd panel ratings .4-13 automotive electrodeposition reference manual 11-3-97viiiver 1 试板及试板评价 4.5.measurement of dry film thickness.4-16 干膜厚度测量 4.6.sandwich compatibility test.4-18 相容性试验 5.terminology.2 专有名词 automotive electrodeposition reference manual 11-3-97section 1 ver 1 introduction to electro

13、coat 电泳漆简介电泳漆简介 1.1.history of electrocoat 电泳涂装的历史电泳涂装的历史 research directed toward the development of a paint which could be deposited electrophoretically was begun in 1957 at the ford motor company under the direction of dr. george brewer. this research was designed to develop a method for improvin

14、g corrosion protection on hard-to-reach parts of car bodies. 在美国福特车厂 george brewer 博士的领导下，福特汽车公司从 1957 年就着 手研究电泳涂装。 这个计划是开发一种改善车身难涂部位防腐蚀性的方法。 automobile manufacturers were well aware that rust occurred in interior recessed areas, also noting that flat exposed areas, such as roofs, were often rust fr

15、ee. although dip coatings penetrated into the recessed areas, they were usually washed off by solvent vapors during baking. thus, dr. brewers group strove to create a paint in which the solvents could be removed from the film during the application process. their work led to the development of elect

16、rocoat. 汽车制造厂商们早已注意到汽车内部隐蔽处的锈蚀，但暴露在外的平面部位， 如车顶却不易锈蚀。虽然浸涂法能使涂料进入汽车内部，但是在烘干过程中， 油漆因溶剂蒸发而被洗掉。于是 brewer 博士领导小组努力去开发一种在施工 过程中溶剂可以从涂膜中被排除掉的涂料，他们的工作开创了电泳涂装。 the first ford production tank began operation on july 4, 1961 to coat wheels. the wixom tank for auto bodies was installed in 1963. both of these tan

17、ks used anodic electrodeposition. 福特公司的第一个用于车轮涂装的生产槽在 1961 年 7 月 4 日开始运行，用来 涂装汽车车身的 wixom 槽建于 1963 年， 这两个槽所用的均是阳极电泳漆。 automotive electrodeposition reference manual 11-3-97section 2ver 1 although market growth for electrodeposition steadily increased immediately after introduction, not until 1973, wh

18、en cathodic products were introduced, did the market literally boom. in 1965, only one car in 100 was primed with electropaint; by 1970, ten of 100 were electropainted; now, almost 90% are primed with cathodic electrocoat. 开发电泳涂装后，虽然市场的需求稳定增长，但直到 1973 年阴极电泳漆问世 时，市场需求才真正繁荣起来。1965 年只有 1%轿车用电泳底漆，到 1970

19、 年 增加到 10%，现在几乎 90%用电泳底漆。 1.2.why electrocoat 为什么要电泳涂装为什么要电泳涂装 because of the marked advantages of electrodeposition, the process has, during the last two decades, become the dominant method for priming automobiles. a listing of the advantages of electrodeposition clearly explains the reasons for it

20、s spectacular success. 由于电泳涂装具有明显的优点， 此工艺在过去的 20 年中已成为汽车涂底漆 的最主要方法。以下的电泳涂装优点清楚地说明了它获得惊人成功的原因。 1.2.1.advantages 优点优点 1formation of protective films in highly recessed areas such as flanges and box sections provides critical corrosion protection. 2 电泳漆在非常隐蔽的部位，如翻边以及箱式结构，仍能形成完整的保护 膜，从而得到较高的防腐蚀性。 3trans

21、fer efficiencies of better than 95% result in reduced paint waste, especially when compared with spray-applied coatings. automotive electrodeposition reference manual 11-3-97section 3 ver 1 4 尤其与喷涂法相比，涂料利用率能达到 95%以上，减少了涂料的浪费。 5use of water as practically the only carrier virtually eliminates fire ha

22、zard, materially reduces water and air pollution, and markedly reduces the cost of facilities for controlling these conditions. 6 使用水做载体，免除了火灾危险。 大大降低了水和空气的污染，明显地 减少了环保设备费用。 7the low paint bath viscosity (approximately equal to that of water) results in ease of pumping and allows drainage of the coa

23、ted vehicle. 8槽液粘度低（大约等于水的粘度），泵送容易，也利于被涂车身的沥干。 9freshly-deposited paint is insoluble in water, permitting complete rinsing and recovery of dragged-out material. 10刚沉积电泳上的漆不溶于水， 允许彻底清洗， 且 可回收带出的槽液。 11uncured paint is dry enough to allow some handling. 12 未固化的漆膜不粘手，甚至可以作某些处理。 13unlike spray coatings,

24、electrodeposited paint will not sag during baking. 14不象喷涂的涂膜，电泳沉积的涂膜在烘干时不 流掛。 15unlike dip coatings, electrodeposited paint is not washed off in enclosed areas by hot vapors during curing. 16与浸法涂装不同，电泳沉积在内腔部位的涂 膜，在烘干过程中不会被热蒸汽 洗掉。 17since the process is automated, direct labor costs are markedly redu

25、ced. 18由于生产过程自动化， 大大降低了直接劳动成本。 19the deposited film is reproducible from part to part and from day to day. automotive electrodeposition reference manual 11-3-97section 4ver 1 20 电泳工艺稳定，可保证漆膜均一涂于工件上。 the electrochemical process of depositing paint appears, at first examination, quite complicated; how

26、ever, it is actually more trouble-free than other paint application processes for several reasons: 电泳涂装法问世后，第一次考验是相当复杂的，但由于下列几个理由，实 际上掌握它并不比其它涂装方法难。 21the large tank volume tends to minimize variations in paint or process. 22槽的容量很大， 使涂料或工艺参数的波动减少到最小。 23the operating parameters are well defined and a

27、re based on extensive experience. 24 操作工艺参数已有明确的规定，且是以丰富的经验为基础。 25samples from the tank, which are tested weekly at the ppg electrocoat laboratory, often predict problems before they appear on the line. 26ppg 电泳漆实验室每周从槽中取的样品做实 验，常常是在生产线上出现问题 之前就能预报。 since the ppg electrocoat laboratory constitutes a

28、 controlled environment, the following controls permit close monitoring of the commercial-scale process: 由于 ppg 电泳漆实验室时监控实验室，可以实现以下对工业规模的工艺 过程的严密控制。 27a variety of metal substrates can be coated to permit extensive examination of differing conditions. 28可以涂装各种各样的金属底材，且可进行不同 条件的严格考验。 29several tanks

29、can be easily cross-compared. 30 可以容易的对几个槽进行相互比较。 31close anode-cathode distances in the coating tubes that are used in the electrocoat automotive electrodeposition reference manual 11-3-97section 5 ver 1 laboratory can be employed to magnify problems experienced in the field. 32在电泳实验室使用的试验槽中，调近阳极-阴

30、极间距可用来放大在这方面经常 出现的问题。 1.2.2.limitations 电泳涂装的局限性电泳涂装的局限性 although the advantages of the electrodeposition process far outweigh disadvantages, some limitations exist. electrodeposition can take place only on electrically-conductive substrates. when a unit is coated and baked, the electrodeposition of

31、 a second coat is impossible with standard electrocoat products. thus, electrodeposition is used mainly for the application of prime coats. application of a variety of color coats requires separate dip tanks. 虽然电泳的优点比缺点多，但是还是有一些局限性。电泳工艺只能用在导 电的底材上；当涂装的物体烘干后。 不可能进行第二次电泳涂装。因此， 电泳涂装主要被用来涂底漆；涂不同的颜色涂膜要在不

32、同的槽中进行。 1.3.what is electrocoat 什么是电泳涂装什么是电泳涂装 1.3.1.anodic versus cathodic 阳极沉积法和阴极沉积法的区别 based upon the method of deposition, two types of electropaint have been developed: anodic and cathodic. the anodic types were commercialized first for two reasons: 基于沉积的电泳方式，已经开发了阳极电泳漆和阴极电泳漆两种类型的电 泳漆阳极电泳漆首先投入

33、正式生产有两个原因： 33the earlier resin technology was based on resins which contained acid groups. automotive electrodeposition reference manual 11-3-97section 6ver 1 these could be neutralized to allow them to become soluble in water. 34 早期的树脂制造技术都是以含酸基团的树脂为基础，中和后，他们可以 溶于水。 35when the solubilized resin was

34、 deposited, it regained its acidic function. this acidity permits ready crosslinking (curing) when the coating is baked. 36 当水溶性树脂沉积后，它可以恢复其酸性基团的功能。当此涂层被烘干 时，这种酸性基团可使漆膜其迅速交联（固化）。 the ability to produce a cathodic-type resin was available long before the resins were introduced commercially in 1975. t

35、wo major problems had to be overcome before commercialization became possible: 阴极电泳漆的树脂在 1975 年阳极型树脂商品化之前很长一段时间内就有 能力制造了，但其正式投产之前要克服以下两个主要的问题。 37a method was needed to make alkaline polymers cure at temperatures low enough to ensure body integrity. 38 降低碱性聚合物固化的温度，同时还要确保漆膜的均一性。 39the corrosivity of

36、the bath solution had to be reduced. 40 必须降低槽液的腐蚀性。 the process of curing thermosetting resins is called crosslinking. during this process, which is driven by heat, the relatively small molecules deposited are chemically intertwined to form a single uniform film. 热固型树脂的固化过程称为交联， 这个过程是以热为动力，较小分子的 沉积膜

37、经化学交联形成一个完整的表面。. the reactions involved in crosslinking deposited film depend upon the films chemical environment. the structures that are obtained by these curing reactions are essential for the practical value of the coating. reaction conditions automotive electrodeposition reference manual 11-3-9

38、7section 7 ver 1 also determine bake time, temperature and, therefore, energy consumption. 电泳漆膜交联的反应取决于涂膜的化学反应环境，靠这些固化反应获得的 涂膜结构，对其防腐性能具有真正的实际价值。反应的条件也决定了烘 干时间及温度，以及消耗能源。 anodic electrocoats usually have a ph of approximately 9.0; however, the deposited film is, in contrast, highly acidic. acid cata

39、lyzed crosslinking reactions can be used with little difficulty. 阳极电泳槽液一般 ph 约为 9，可沉积涂层却是高酸性。酸催化的交联反 应比较容易进行。 the situation is somewhat different for cathodic materials. as with anodic resins, the crosslinking can be either internal or external. because of the alkaline nature of the uncured cationic

40、 film, external linking reactions are sluggish. 对阴极电泳就有所不同了，阳离子树脂的交联反应可以在内部或外部进行， 但因未固化阴离子涂膜具有碱性，所以外部交联反应较缓慢。 internal crosslinking is carried out by urethane groups mixed with the cathodic resin. these crosslinkers are stable in water at normal bath temperature but become reactive at curing tempera

41、tures. special procedures are used to ensure that these crosslinkers will not react at bath temperature to cause instability. 内部的交联是靠与阳离子树脂混合的氨基甲酸脂基团进行的。这些交联剂 于正常槽液温度下在水中很稳定，但在固化温度下就变得活泼起来。通过 采用一些特殊的处理工艺，确保这些交联剂不会在槽液温度起反应而引起 槽液的不稳定性。 although numerous types of resins may be suitable for electrodepos

42、ition, the most common ones are thermosetting. thermosetting resins fuse or melt when baked into a hard, uniform, solvent-resistant film. 虽然多种树脂都可以适用于电泳涂装，但最常见的是热固型的 热固型的树脂在烘干时融合或融化成为一坚硬，均匀的耐溶剂涂膜。 resin chemists must ensure that the resin has particular properties of hardness, automotive electrodepo

43、sition reference manual 11-3-97section 8ver 1 flexibility, adhesion, water-and-chemical resistance, pigment wetting, and others. to be used as an electropaint, the resin must also have the following characteristics: 研发人员必须确保树脂具有硬度，柔韧性，附着力，耐水及化学品性，颜 料湿润性及其它特性。用于制造电泳漆的树脂还必须具备如下特性： 41it must be soluble

44、 or dispersible to form a stable solution even when subjected to a wide variety of production conditions. 42树脂必须可溶解或分散成一种稳定的溶液，可以适应多种生产条件。 43it must deposit onto an electrode to form a smooth, dense, insulating, wet film which also contains pigment. 44树脂必须能沉积在一个电极上，形成一光滑，致密，绝缘，并含有颜料的湿 涂膜。 45it must

45、be able to coat a part which is complex in shape. 46必须能够泳涂外形复杂的工件。 47it must resist re-dissolution when rinsed. 48 必须在冲洗时不再被溶解掉。 49it must become mechanically and chemically stable upon baking so that the resulting film can fulfill its protective and/or decorative requirements. 50经烘干后的涂膜具有机械及化学稳定性，以

46、满足保护和（或）装饰的需要。 although the principle of electrodeposition gained acceptance with the anodic systems, it was not until the cathodic method was developed that electrodeposition became the common method for priming automobiles. the cathodic method has the following advantages: 虽然电泳涂装的原理是从阳极电泳系统获得的， 但是

47、直到开发出了阴极 电泳涂装法以后， 电泳涂装才成为汽车涂底漆普遍采用的方法。阴极电 automotive electrodeposition reference manual 11-3-97section 9 ver 1 泳漆有以下优点： 51it achieves corrosion resistance at low film thickness. 52 较低的膜厚具有良好的防腐蚀性。 53it permits throwpower to interior surfaces without penalty of over-build on exterior surfaces. 54保证工件

48、内表面泳透力的同时，外表面上涂膜也不会过厚。 55it achieves bimetallic joint corrosion resistance required by the increased use of galvanized metal. 56双金属复合层也能获得良好的防腐蚀性， 可适应日益扩大的镀锌钢板用量的 需求。 57it possesses saponification resistance and long-term adhesion retention over an entire galvanized body panel. 58它具有耐皂化性， 在全镀锌的车身板上可

49、长期保持其附着力。 59it requires substantially less electrical consumption for deposition and, as a result, less refrigeration for cooling. 60电泳本身耗电量少，从而用于冷却的冷量也少。 61it achieves gloss and hold-out with and without spray primers. 62本身具有足够的光泽度，可喷涂或不喷涂中涂， 同时在没有中涂的情况下也 不影响面漆的亮度。 the prime advantage for cathodic

50、systems, however, is superior corrosion protection. with anodic electrodeposition, metallic ions from the part being coated often become included in the deposited film. this condition results from anode reactions when current is applied. the presence of the iron ion in the film automotive electrodep

51、osition reference manual 11-3-97section 10ver 1 provides a readily available site for rust to start. in addition, when deposited, cationic resins are alkaline in nature and tend to be natural corrosion inhibitors. 其实， 阴极电泳的最主要优点还是防腐蚀性非常优良。材用阳极电泳时， 由于通电时的阳极反应从被涂工件上溶下的金属离子常常包含在漆膜中， 。在漆膜中存在的铁离子就成了开始生锈的

52、诱因。另外，沉积时，阳粒子 树脂呈碱性， 这样就成为天然的缓蚀剂。 1.4.electrochemical reactions 电化学反应电化学反应 to this point, we have discussed anodic and cathodic paint and have used the terms anionic and cationic as well. although the terms cathodic and cationic may be used as synonyms, they refer to two different aspects of the sub

53、ject. 到此为止， 我们已经讨论了阳极漆和阴极漆，并且已使用了阳离子，阴 离子等术语，虽然阳极和阴离子可以作为同义词使用， 其实他们是用于 表示一个事物的两个不同方面的。 positively charged electrodes are called anodes while negatively charged ones are called cathodes. a water solution contains charged particles which are called ions. ions are atoms or molecules with charges. anio

54、ns have negative charges, and cations have positive charges. if one remembers that opposites attract, the problem simplifies. the cathode is negative: thus, it repels negative charges and attracts positive charges. 带正电荷的电极称为阳极，带负电荷的电极成为阴极，水溶液中含有的带 电粒子称为离子，离子是带电荷的原子和分子，阴离子带负电荷，阳离子 带正电荷，如果大家都明白异性相吸的道理

55、，问题就简单了，阴极带负电： 所以它排斥负电荷而吸引正电荷。 the positively-charged ions in the solution are called cations, and the negatively-charged particles are called anions. thus, by the principle of opposites attracting, the cations (positive charges) are attracted to the cathode (which is negative in charge). since the

56、cathode is relatively fixed in position, automotive electrodeposition reference manual 11-3-97section 11 ver 1 the cations move toward it. this movement is called migration. 溶液中带正电荷的离子称为阳离子， 带负电荷的离子称为阴离子。这样， 根据异性相吸的原理，阳离子（带正电荷）与阴极（带负电荷）相互吸引， 由于阴极位置相对固定，故此阳离子便移向阴极，这种运动称为迁移。 negatively-charged ions ke

57、ep the positively-charged resin molecules in a cathodic system in solution. the solubility of the resin depends on the critical balance of positively and negatively charged ions. 带负电荷的离子把带正电的树脂分子存在于阴极系统的溶液中。树脂的溶 解性取决于阴，阳离子的电平衡。 when paint is deposited at the cathode, the process is called cathodic,

58、and paint with a positive charge is called cationic paint. thus, the terms cathodic and cationic refer, respectively, to where the paint is deposited and the type of charge of the deposited paint. the two terms are often used interchangeably. 电泳漆沉积在阴极上时，此工艺称为阴极电泳，带正电荷的漆称为阳离子 型电泳漆。故此“阴极的”极“阳离子的”两个术语即

59、分别表示漆的沉积对象 及沉积漆的带电类型。这两个术语常可互换使用。 the electrocoating process is known by several names: 电泳涂装工艺在英语中有以下几个名词： elpo e-coat electropainting electrodeposition electrophoretic painting electrocoating is similar in process to that of electroplating, such as the application of chrome on automobile bumpers. t

60、he two processes are alike in that both use the passage of electric current for deposition. they differ, however, because electroplating deposits metallic ions whereas electrocoating deposits organic resin molecules. automotive electrodeposition reference manual 11-3-97section 12ver 1 跟电镀工艺相似，比如汽车保险