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    Electrodeposition Andreas Tolz PPG

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    Andi Musdalifah
    The document discusses a new chrome-free electrocoat primer called Aerocron for the aviation industry. Aerocron provides corrosion protection equivalent to conventional spray primers while offering environmental, productivity, and performance advantages over traditional spray application methods. Testing has shown Aerocron performs well in various corrosion and mechanical tests.

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    Electrodeposition Andreas Tolz PPG

    Uploaded by

    Andi Musdalifah
    121 views14 pages
    The document discusses a new chrome-free electrocoat primer called Aerocron for the aviation industry. Aerocron provides corrosion protection equivalent to conventional spray primers while offering environmental, productivity, and performance advantages over traditional spray application methods. Testing has shown Aerocron performs well in various corrosion and mechanical tests.

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    13. Electrodeposition; Andreas Tolz; PPG

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    The document discusses a new chrome-free electrocoat primer called Aerocron for the aviation industry. Aerocron provides corrosion protection equivalent to conventional spray primers while offering environmental, productivity, and performance advantages over traditional spray application methods. Testing has shown Aerocron performs well in various corrosion and mechanical tests.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    121 views14 pages

    Electrodeposition Andreas Tolz PPG

    Uploaded by

    Andi Musdalifah
    The document discusses a new chrome-free electrocoat primer called Aerocron for the aviation industry. Aerocron provides corrosion protection equivalent to conventional spray primers while offering environmental, productivity, and performance advantages over traditional spray application methods. Testing has shown Aerocron performs well in various corrosion and mechanical tests.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 14

    Electrodeposition paint

    A breakthrough chrome-free automatic tank


    process for the aviation industry

    IMFair June 15th 2011

    PPG Confidential Andreas Tolz, PPG Aerospace


    Enhanced Coating Systems for the Aerospace Industry

    Todays environmental regulations combined with new substrates


    used for aircrafts present challenges to develop new materials
    and / or processes for painting.

    As a coatings manufacturer PPG Aerospace provides Cr(VI)-free


    solutions via two pathways:

    Elimination of Cr(VI) in conventional coating systems


    Cr(VI)-free conversion coating
    Cr(VI)-free sol-gel surface treatment
    Spray primer containing novel corrosion inhibitor pigments
    New Technology
    Electrocoat primer - Aerocron

    PPG Confidential
    Electrocoat Primers for the
    Aerospace Industry

    Agenda

    Electrocoat Principles
    Advantages for the Aerospace Industry

    Test Results

    Conclusions

    PPG Confidential
    Technology Maturity
    Electrocoat has a long history of use for corrosion
    prevention in both the automotive and industrial
    industries.
    Currently >95% of all automobiles produced
    worldwide use electrocoat
    8 out of 10 electrocoat tanks worldwide
    use PPG technology
    First automotive electrocoat tank in 1971 at Ford Wixom
    First low-cure / high-gloss, exterior durable electrocoat in 1980
    First ultra-white, non-yellowing epoxy electrocoat for appliances in 1989
    Introduced ENVIROPRIME lead-free electrocoat

    Winner of Presidential Green Chemistry Award in 2001

    PPG Confidential
    Electrodeposition Process
    Method of applying a coating which uses electrical current to deposit
    aqueous dispersed resins and pigments onto a conductive substrate
    Coatings can be applied via anodic or cathodic deposition
    Several screening studies proved Anodic Electrocoat to be best choice for
    Aluminum and their alloys in terms of paint adhesion and corrosion protection

    Coated part is the anode


    Surface oxidation, Deposition of paint film

    Polymerization of paint film through oven curing


    Actual development allows temperature
    cure 100 - 120 C

    PPG Confidential
    Electrodeposition Process
    Covering of part surface with small paint film in first seconds high electricity
    transfer on surface
    Uniform paint film build over part during application time part becomes
    more and more insulated

    Film thickness can be


    controlled by Voltage
    and/or application time

    PPG Confidential
    A new direction for Aerospace
    Use of Electrocoat as Corrosion Resistant Primer
    Immersion vs. Spray Process
    Technology Reduction in overall process cycle time
    Shift Thermal vs. Air Cure
    Low Cure Technology

    Performance Equivalent to
    Performance Conventional Spray Primer
    Weight savings

    Elimination of Chrome
    Environmental Reduced worker exposure

    PPG Confidential 7
    Advantages for the Aerospace Industry

    Environmental, Health and Safety Considerations Electrocoat bath


    Aqueous based low solvent emission Breakdown
    Minimal waste discharge closed loop process
    Minimal exposure of workers to hazardous materials Deionized
    Water
    70 - 80%
    Productivity / Efficiency
    Resin
    Automated process increased productivity 15 - 20%

    90-95% material utilization / no overspray Organic


    Solvent
    Immediate part handling after thermal cure 0 - 5% Pigment
    2 - 5%
    Do not have dry to touch, dry to tape, dry to fly restrictions

    Application / Performance
    Uniform film across entire surface including recessed areas
    Throwpower capability (holes/gaps) due to dip process
    Excellent barrier / corrosion resistance properties
    PPG Confidential
    Substrate Preparation
    Initial electrocoat application tested on fresh anodized pretreatment (CAA and TSA)
    Mechanical and Corrosion Performance equal to Cr6 spray primer

    New approach : no anodization treatment clean and deoxidize only


    Anodic process leads to thin compact oxide layer on surface when paint is applied
    Alkaline degreasing

    Rinsing Alkaline degreasing

    Acid deoxidation Rinsing

    Rinsing Acid deoxidation

    Anodization (CAA or TSA) Rinsing

    Rinsing Aerocron Electrocoat

    Aerocron Electrocoat Rinsing

    Rinsing Curing

    PPG Confidential Curing


    Aerocron Chrome Free Test Data
    TM

    Application parameters

    Bath parameter: pH : 9 - 9,5 / Temperature : 24 26 C

    Application: Time : 2min (incl. Ramp-up phase) / Voltage: 180 V


    Curing: 30 min @ 110 C (object temperature)
    Paint film thickness: 18 to 22m

    PPG Confidential
    Aerocron Chrome Free Test Data
    TM

    Performance over alkaline degreased and deoxidized Al 2024 bare / clad


    (no anodization)
    Mechanical performance
    Cross hatch Adhesion : PASS (G=0)
    Fatigue tests
    equal to or better than Alodine 1200 + sprayable primer

    Chemical resistance
    Water immersion (2 weeks @ 23C): PASS (G=0), no blistering
    Resistance to phosphate ester hydraulic fluids (Skydrol LD4)
    1000 h @ 23C : PASS
    1000 h @ 70C : PASS

    Corrosion resistance
    Filiform (960h): <2mm on either side of the scratches
    Salt Spray (3000h): average creep <1 mm on either side of the
    scratches, no face blistering
    PPG Confidential
    Long term testing 2 years Beach exposure

    Aerocron Electrocoat Spray Chrome primer


    over clean & DeOx over clean & DeOx
    10 Rating 10 Rating
    PPG Confidential
    AEROCRON Application trials
    TM

    Successfully application of multiple test series for Aerospace customers


    between 2009 2010
    No anodization used (clean and deoxidize only)
    Over 1500 parts/panels already coated and tested
    Test panels and parts (up to 3 m long)
    tested Al-alloys 2024 / 2214 / 5xxx-6xxx-7xxx Series

    Intense discussions with several OEMs for industrialization


    First electrocoat tank at a customer site scheduled for 2011

    PPG Confidential
    Conclusions

    Electrocoat Primers for the Aerospace Industry

    Aerocron CF is the first breakthrough in the Aerospace


    TM

    paint activity as it combines:

    Outstanding corrosion protection properties


    Increased material utilization / No overspray
    Uniform coating of complex parts / Throwpower
    capability
    Overall weight reduction
    Fully automated process
    PPG Confidential

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