Service.

Self-Study Programme 214

Painting the Vehicle -

Pre-Treatment

Basic Principles
ProCarManuals.com
 Introduction

The topic of v e h i c l e p a i n t i n g continues to gain Self-Study Programmes 214 and 215 were thus
importance in the field of providing customer designed to provide an overview of the current
service. state of the vehicle-painting art.

New technical processes and new materials - ● SSP 214:

especially new paints - significantly increase the Painting the Vehicle - Pre-Treatment
complexity of this specialist area.

The field of vehicle painting is no exception to ● SSP 215

the rule that only services based on fundamental Painting the Vehicle - The Topcoat
knowledge can fully satisfy the demands of the
customer.
ProCarManuals.com

214_001

NEW Caution
Note

The self-study programme Testing, adjustment and repair instructions

is not a workshop manual! may be found in the appropriate
service material.
2
 At a Glance

Vehicle Painting – Basic Principles . . . . . . . . . . . . . . . .4

Steel oxidation (corrosion) . . . . . . . . . . . . . . . . . . . . . . . 4

Abrasive mediums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Prepartory materials and paint . . . . . . . . . . . . . . . . . . .12

The constituents of paint . . . . . . . . . . . . . . . . . . . . . . . . . 15

The paint: classification by drying method . . . . . . . . . . 19

Painting in the Factory . . . . . . . . . . . . . . . . . . . . . . . . .22

ProCarManuals.com

Painting in the Repair Shop . . . . . . . . . . . . . . . . . . . . 28

Repair painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Painting in the workshop . . . . . . . . . . . . . . . . . . . . . . . 29

Pre-treatment of the surfaces to be painted . . . . . . . . 30

The protective primer . . . . . . . . . . . . . . . . . . . . . . . . . . 32

The filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Sanding the filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Application of the primer extender . . . . . . . . . . . . . . 38

Sanding the primer extender . . . . . . . . . . . . . . . . . . . . 42

Check Your Knowledge. . . . . . . . . . . . . . . . . . . . . . . . .44

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3
 Vehicle Painting - Basic Principles

Steel oxidation (corrosion)

The vehicle body is constructed of steel, which is

susceptible to oxidation (corrosion). The body is
galvanised and painted to protect against the Oxidised substance
negative effects of oxidation.

Oxidation

Oxidation is a chemical process by which

electrons are exchanged between two
substances. The atoms which compose the Oxidising substance
oxidised substance release electrons.
214_002
These electrons are then absorbed by the atoms
which compose the oxidising substance. Oxidation
The opposite process is called reduction.
A substance is reduced when it absorbs
ProCarManuals.com

electrons.

The tendency to release or absorb electrons

varies among different substances.

Certain metals, such as iron, tend to release

electrons. Iron is thus said to oxidise.
Other metals, such as copper, have less of a
tendency to release electrons and only oxidise
when they are brought into contact with strongly
reducing substances.
Zinc
Some metals, like gold, only oxidise under
extreme conditions. Oxidation
tendency
Iron
If two substances with varying oxidation
tendencies are brought into contact, the result is
a flow of electrons to the higher oxidation
tendency.
Copper
● The substance which oxidises is called the
anode.
● The substance which reduces is called the
cathode.
● The mutual interaction is called a v o l t a i c Gold
cell.

Flow of
An example of a voltaic cell is a battery, which
electrons
generates a flow of electrons from anode to
cathode. 214_003

Oxidation tendencies
4
 Corrosion protection

Vehicle bodies are constructed largely of steel Galvanised steel panels are thus very well
panels, which have a tendency toward oxidation. protected against oxidation.

Various production measures are taken to ensure Combining the zinc coating with layers of paint
long-lasting corrosion protection. results in optimum protection against corrosion.
These processes provide optimum protection This form of protection is called the d u p l e x
which can be guaranteed for the service life of system.
the vehicle.
The protection against oxidation is a result of the
Processes for protecting body panels against zinc oxide, which is inseparable from the body
corrosion: panel. Oxidation occurs much more slowly with
galvanised steel than with untreated steel.
● Galvanisation There, iron oxide forms and then breaks away
● Painting from the base metal, continually exposing
deeper layers of the steel. Zinc oxidises sooner
ProCarManuals.com

Zinc is the most commonly used protective metal. than iron, but at a much slower pace.
Zinc possesses a greater oxidation tendency than
steel. Galvanised steel will only begin to oxidise
once the zinc has completely oxidised away.

Anodic point (oxidation) Cathodic point (reduction)

Atmospheric
oxygen O2 = Oxygen
Moisture
film H+ = Hydrogen ions

OH- = Hydroxide ions

Steel panel
Fe = Iron

214_004

Electrolytic steel oxidation

5
 Vehicle Painting - Basic Principles

Abrasive mediums Corundum Silicon carbide

Sanding a surface prepares it to receive a tightly

bonding coat of paint.

Basic sanding principles

Sanding a surface removes excess m e c h a n i c a l

material from it.
A hard material is guided with pressure across a
surface, penetrating the surface layers and
214_005
removing small pieces.
Corundum and silicon carbide
The minerals emery, corundum, and silicon
carbide (carborundum) are commonly used
sanding abrasives.
The materials to be sanded, such as extenders or
ProCarManuals.com

fillers, contain soft constituents, such as barium

oxide and lime, which facilitate the sanding
process.

H a r d n e s s is a physical property. 1 - Talc Soft

One substance is said to be harder than another
if it can penetrate it. 2 - Plaster

Various processes are available to determine 3 - Calcite

hardness.
The most simple process was developed by the 4 – Fluorspar
geologist Mohs.
It consists of a 10-stage scale which ranks 5 - Apatite
minerals according to their hardness.
The first mineral in the scale is the softest and the 6 - Felspar
last is the hardest.
7 - Quarz
The hardness of any other mineral is designated
by the Mohs number of that mineral which can 8 - Topaz
etch it.
9 - Corundum

10 - Diamond Hard

Mohs' hardness scale

6
 Structure of abrasive mediums
Abrasive mineral Glue
The abrasive medium consists of an abrasive
mineral bonded to a flat, flexible carrier
material.

Carriers include:

● Paper
● Fabric
● Vulcanised fibre Flexible carrier
● Plastic film 214_007

Structure of abrasive mediums

Hard, fragmented sanding minerals of varying
coarseness are glued to the carrier.
ProCarManuals.com

Abrasive minerals

Corundum and silicon carbide (carborund) are

the most commonly used abrasive minerals. Corundum Used-up corundum

● C o r u n d u m is a very hard mineral composed

primarily of aluminium oxide.
Very pure corundum is white in colour.
When it contains additives, the colour may be
anywhere from pink to brown. 214_008B
When used for sanding, corundum becomes
dull and eventually wears away.
Silicon carbide Used-up silicon carbide

● S i l i c o n c a r b i d e is harder than corundum

but also more brittle.
It is black with a blue shimmer.
When silicon carbide is used for sanding, the
mineral grains break off, resulting in new, 214_008A
oblong and pointed shapes. Wearing away of the abrasive mediums

7
 Vehicle Painting - Basic Principles

Coarseness of the abrasives P180

P12
P220
P16
When abrasive mediums are produced, the P240
P20
sanding compounds are crushed and then sorted P280
P24
according to their particle size (coarseness). P320
P30
P360
P40
The coarseness of the abrasive is categorised P400
P50
based on the average size of the individual P500
P60
grains. P600
P80
P800
P100
The particle size is standardised according to the P1000
P120
FEPA scale. FEPA is the European association of P1200
P150
abrasive-medium manufacturers.
The particle size is designated by a P followed 214_009
by a number. Complete FEPA scale
P12 stands for the coarsest particle size, and
P1200 for the finest.
ProCarManuals.com

The type of grain used for the abrasive is

determined by the:

● Type of sanding job

● Hardness of material to be sanded
● Maximum sanding capacity
● Ambient conditions

An optimum result is only possible if the abrasive

is properly suited to the sanding task at hand.

The carrier material

Flexible carrier materials are an integral part of

the abrasive medium

The elasticity of the abrasive medium depends

on the strength of the carrier material.
The thinner the paper or fabric carrier is, the
more elastic the abrasive medium will be.

The primary factors in the selection of carrier

214_010
type and weight are the surface to be processed
and the hardness of the material to be sanded. Flexible carrier material

8
 The adhesive

Two types of adhesive are used for attaching the

sanding minerals to the carrier:

● Organic adhesive
● Synthetic resins

The o r g a n i c a d h e s i v e s , such as rabbit skin,

are made of natural products of both animal
and vegetable origin.
They are sensitive to water.
This means: The abrasive is ruined when it comes
in contact with water.

Phenol-, epoxy- und carbamide resin are all

examples of s y n t h e t i c r e s i n s .
ProCarManuals.com

They are heat treatable and heat resistant,

enabling the production of abrasive mediums
which are waterproof.

The sanding grain is glued to the carrier in two

stages: Adhesive layer 2
- bond
● First, a layer of glue attaches the individual
abrasive grains to the surface of the carrier Adhesive layer 1
material. - glue

● The second adhesive layer bonds the entire

abrasive mineral to the carrier.

The same or different adhesives may be used for

each step.
The combination is determined by the respective
sanding procedure. Carrier material

214_011

Adhesives and adhesive layers

9
 Vehicle Painting - Basic Principles

Application of the abrasive mineral

The manner of applying the abrasive mineral is The grain quantity per unit surface area is
the decisive factor in the selection of the carrier another important factor in determining the
material. The two types of application are: behaviour of the abrasive medium.

● Gravity application C l o s e d g r a i n e d s t r u c t u r e : The abrasive

● Electrostatic application minerals are packed tightly together.

Gravity application results in a random O p e n g r a i n s t r u c t u r e : Spaces form between

arrangement of the abrasive mineral on the the abrasive particles. The sanding dust is
carrier. carried away more easily and the abrasive
medium does not become clogged.
Electrostatic application aligns the abrasive
mineral in a defined pattern. Additives such as zinc stearate improve
This alignment determines the properties of the lubrication and removal of the abrasive residues.
abrasive medium.
ProCarManuals.com

The texture of the abrasive grain should always

be determined by the surface to be treated.

Gravity deposition of the abrasive mineral Electrostatic deposition of the abrasive mineral

214_012 214_012A

Gravity application and electrostatic application

10
 Form of the abrasive medium

Large abrasive coils are rarely used directly.

The abrasive medium obtains its application
form via stamping processes.
Various types of abrasive medium are available, Disc
depending on the final application:

● Sheet
● Disc
● Roll
Sheet

The abrasive medium - in various sizes and

shapes - may also be perforated for certain
applications.
The perforated holes assist in the extraction of
sanding dust (when used with the appropriate
ProCarManuals.com

sanding tool).
Roll

Perforated sheet

Perforated disc 214_013

Formats of abrasive mediums

Summary:

To ensure optimum bonding of a subsequent coat of paint, the surface requires a certain level
of roughness, which depends on the type of paint as well as the material to be coated.
Non-adhesive surfaces, such as dry painted areas or factory coatings, must therefore be
sanded to the proper degree of roughness.

Sanding the filler and extender assists in producing a smooth, even surface.

11
 Vehicle Painting – Basic Principles

Preparatory materials and paints

Paint coatings protect the underlying metal The coating film serves two purposes:
surfaces and thus lengthen the service life of the
body parts. ● Protection of the surface against harsh
They also produce an attractive surface finish. external influences: humidity, solar rays, heat,
road salt, chemicals, solvents, fuel, etc...
Definition
● Aesthetic treatment of the surface to
Paints are liquid substances of varying viscosity, compensate for irregularities in colour, and to
which are applied to the surfaces by means of provide lustre and various optical and colour
various procedures. effects.

Once they completely harden, they form an even “Technical” refers to paint’s protective functions,
coat which is tightly bonded to the painted and “aesthetic” to ist optical functions.
undercoat.
This layer is called the coating film.
ProCarManuals.com

214_014

Preparatory materials and paints

12
 Terminology

Various types of products fall under the heading

“Preparatory materials and paints”.
The products used in painting the vehicle are
listed below.

Filler Panel

Filler is a plastic composite material which comes

in a paste form.
It is applied with a spatula or similar tool.
Filler compensates for the irregularities in the
surface and seals cracks in the material.
ProCarManuals.com

It must bond very well to the widest variety of

undercoats and also be easy to sand.
214_015

Filler

Panel Primer

Primer

Primers are fluid mixtures that may be

pigmented.
They are applied for the following reasons:

● Undercoat for sealing pores

● Corrosion protection Topcoat
● Bonding layer for the topcoat 214_016

Primer

Panel Primer

Extender

Extenders are pigmented, fluid mixtures rich in

solid particles.
They smooth out the irregularities in the primer
(filling).
Extenders produce a smooth, even surface to Extender
which the topcoat will be applied. Topcoat
214_017

Extender
13
 Vehicle Painting – Basic Principles

Enamel paint

A type of paint which yields an especially smooth

and hard coating film.

Paint colour

Essentially, paint consists of organic pigments

which are soluble in a bonding agent, the base
or the organic medium.
Paint colours are distinguished by their intensity.
They can be more or less transluscent or
ProCarManuals.com

transparent.
214_018

Paint colour

Clear lacquer

Clear lacquer is a liquid, pigmentless compound

which can be applied in a thin layer on the
surface.
After drying, the clear lacquer forms a
transparent coating.

214_019

Clear lacquer

Colourants

Colourants are materials which, once applied to

a surface, penetrate it and change its colour.
They are normally transparent and do not form a
surface film.

214_020

Colourants
14
 The constituents of paint

The following ingredients enable paint to fulfil its The chemical composition of the bonding agent
protective and optical functions: determines the properties of the paint, such as:

● Bonding agent ● Method of drying

● Pigments ● Properties of the topcoat, such as its hardness
● Solvents or lustre
● Additives ● Weather resistance
● Elasticity
The bonding agent ● Adhesion

The bonding agent is that fraction which is A paint is designated by the bonding agent upon
neither volatile nor solid after the paint dries. which it is based.
The bonding agent may also be called a resin. Acrylic paint contains acrylic as a bonding agent
and cellulose paint contains cellulose-based
As the carrier substance for other components of bonding agents.
ProCarManuals.com

the paint, the bonding agent fulfils the most

important role.

Bonding agent

Additives

Paint

Pigments

Solvents

214_021

Constituents of paint
15
 Vehicle Painting – Basic Principles

Pigments

Pigments are solid, very fine particles which are

not soluble in the bonding agent.
They are manufactured by pulverising organic
and inorganic materials.
Pigments mainly endow the paint with the
following properties:
Filler pigments
● Colour
● Opacity

Other pigments, with completely different

functions, may also be added to paint formulae.
Pigments are classified in the following groups:

● Corrosion-protection pigments Waterproofing pigments

ProCarManuals.com

They protect the base or carrier material

(e.g. steel, aluminium, copper) from corrosion.

● Finish pigments
These are opaque particles with a defined
fast colour (e.g. red, green, blue pigments).
They are used to add colour.
Through their composition, these pigments Opaque finish pigments
can yield colour or optical effects.
For example, aluminium and mica pigments
yield metallic and pearl effects, respectively.

● Filler pigments
These pigments do not intriniscally have very
strong covering power.
They complement the finish pigments and give
the paint more “body”. Flame-retardant pigments

● Pigments with special functions

They give the paint certain properties, such as
anti-encrustation (boat paint), fungicide (paint
for damp areas) and flame retardance.
214_022

A few pigments and their properties

16
 Solvents

Solvents are added to the paint to keep the The solvent and the thinner must have a chemical
bonding agent liquid. The purpose is to prevent composition compatible with that of the bonding
coagulation until the moment of application. agent.
After it has been applied, the solvent evaporates
as part of the drying process. Solvents do not A distinction is made between two groups of
remain present in the coating film which bonds paint:
permanently to the base material.
Technically, solvents are referred to as “volatile ● Solvent-based paints
bonding agents”. Solvents and thinners consisting of volatile
organic compounds, such as acetone, petrol
If a paint requires a greater degree of liquidity, it and butyl acetate.
may be thinned.
Additional “volatile bonding agent” (thinner) is ● Water-based paints
then added to the paint. Paints in which water forms the main
Solvents and thinners may have the same or constituent of the solvent and thinner.
ProCarManuals.com

different chemical composition.

Solvent evaporation
Bonding agent Pigment

Coating film
214_0x23

Solvent

17
 Vehicle Painting – Basic Principles

Additives

The overall quality of the paint is determined by

the quality of the main components, the mixture
ratio and the careful selection of additives.
Without additives, the durability of the paint is
restricted, or its properties do not turn out as
desired.

Types of additives:

● Hardeners (drying accelerators) Hardeners

Influence the hardness and curing of the
paint.

● Extenders Extenders
ProCarManuals.com

Influence the features of the surface structure,

such as roughness and filling.

● Softeners (elastifiers) Softeners

Influence the elasticity and flexibility of the
paint.

● Thickeners Thickeners
Improve the consistency of the paint and
prevent runs (thixotropy).

Wetting agents
● Wetting agents
Improve the homogenisation of the other
constituents.

● Dispersion agents Dispersion

Prevent lump formation during storage. agents

● Anti-sedimentation agents
Anti-sedimenta-
(No depositon)
tion agents
Keep the pigments held in suspension.

● Emulsifiers Emulsifiers
Improve the mixing of the ingredients.
214_024

Additives

18
 The paint: classification by drying
method
The way that the paint dries determines many of Drying by evaporation of the solvent.
the properties of the final coating film.
This is the simplest method of drying.
Drying The bonding agent solidifies as the solvent
evaporates.
After the bonding agent, paint may be classified Heat accelerates the process of evaporation.
according to various other criteria.
The most important criterion is the manner in
which the paint dries and hardens.

Depending on the paint, a distinction is made

between t h r e e methods of drying:
Paint dissolves as it comes into contact
1C synthetic resin paint with the solvent (refers to 1C synthetic
ProCarManuals.com

resin paint).
● Drying by evaporation of the solvent.

● Drying by oxidation of the bonding agent.

2C paint

● Drying by a chemical reaction between two or

more constituents.

Dry coating film

Solvent

Bonding agent
214_025

Drying by evaporation of the solvent

19
 Vehicle Painting - Basic Principles

Drying by oxidation of the bonding agent.

Evaporation of the solvent occurs in all methods The chemical properties of dried paint are
of drying. different from those of the original bonding
With drying by oxidation, a reaction with agent.
atmospheric oxygen occurs in addition to a The properties of the coating film are thus not
chemical transformation of the bonding agent. affected by the solvents contained in the paint.
The drying process can be accelerated by the
addition of a hardening agent. The drying process may be accelerated by the
application of heat, which effects a faster
evaporation of the volatile components.
ProCarManuals.com

214_026

Drying by oxidation of the bonding agent

Drying by chemical reaction between two or

more constituents.

The coating film is the result of a chemical reaction If the reaction does not take place until a higher
or by the chemical bonding (polymerisation) of paint temperatures is reached, pre-mixed
components. components may be used.
These paints are known as t h e r m o -
If a reaction occurs at the ambient temperature, hardening.
the components must be mixed immediately
before use.

214_027

Drying by chemical reaction between two or more components

20
 If two components must be mixed before
application, then the paint is known as a two-
component paint (2C paint).
The components are:

● Resin
● Hardener (also catalyst or activator)

The components are kept in separate containers,

each with corresponding solvents.

They are mixed at a specific ratio immediately

before application. The mixing takes place in
cylindrical containers with the aid of measuring
and mixing sticks.

Heat accelerates the drying of the 2C paint.

ProCarManuals.com

The chemical properties of the resulting coating

film are different from those of the original Thinner
constituents. Hardener

2C paint is distinguished by its high resistance to

chemical and physical resistance influences.
Paint

214_028
Measuring and mixing stick

21
 Painting in the Factory

Painting the series bodies

In the factory, vehicle bodies are painted in an

optimally co-ordinated production-line
sequence.

Cleaning and de-greasing Phosphatising

Bath recycling
ProCarManuals.com

Rinsing

Rinsing

Sealing
Washing
Cataphoresis

Under body protection

Primer Topcoat appli-

cation

Inspection

214_029

Sequence of vehicle-body painting in the factory

22
 Pre-galvanised panels

Pre-galvanised panel is zinc-coated steel plate.

The zinc coating protects the metal against
corrosion. Superficial damage to the coating
film, which exposes areas of bare metal, will
result in oxidation of the zinc. Zinc (Zn)
The steel is thus protected by the so-called
Steel
“sacrificial zinc effect”.

The coating of the steel plate with zinc is Zinc (Zn)

performed either electrolytically or by immersion
in molten zinc.
It may be coated on one or both sides. The
thickness of the zinc layer is between 5 - 10 µm,
depending on the area of application.
214_030
ProCarManuals.com

Hot galvanisation can always be recognised by

its surface structure (zinc blooms). Double-sided galvanised steel panel
Exterior panels to be painted are electrolytically
galvanised.

Pre-treatment of panels: cleaning and de-

greasing

The first step in the series painting process is the

cleaning and de-greasing of the unpainted body.
The body is submerged in a cleaning bath and
then sprayed with de-greasing solutions.
After rinsing and drying, all fatty residues are
removed from the bodywork.

Phosphatising

Phosphatising is a process in which the body is

submerged in a bath containing various
phosphate salt solutions.
The result is the formation of a crystalline metal
phosphate on the body panel. This means:
optimum adhesion base and corrosion
protection. 214_031

Cleaning and de-greasing

23
 Painting in the Factory

Priming by cataphoretic dipping

After phosphatising, the bodywork is

cataphoretically dipped, which provides
excellent protection against oxidation.

Cataphoresis (= migration of positively charged

particles in a liquid) is an electrical process
which is also called electrophoresis (= transport
of electrically charged particles by electrical
current).

The body is completely dipped in a bath of

paint-electrolyte solution.
It is then connected to a the negative pole of a
direct-current source. The positive pole forms a
series of anodes arranged around the basin.
ProCarManuals.com

The field forces deposit the positively charged

paint particles onto the negatively charged body
panelling.

Advantages:

● Coating of all external surfaces, internal

surfaces and hollow spaces.
● Even coating thickness.

Cataphoretic dipping can deposit a layer of

primer up to 20 µm thick onto the body.

In the subsequent rinsing zone, non-adhesive

paint residues are removed.
The last rinsing cycle is then performed using
completely desalinated water.

The body - now free of water droplets - is placed

in the dryer. There the primer hardens at 180 °C.

The factory-supplied spare parts are also primed

by the cataphoretic-dipping process. 214_032

Priming by cataphoretic dipping

24
 Sealant and fine sealing

Metal sheet overlappings, metal edges, grooves,

butt joints and weld seams are bonded with
sealant.
The sealant compound is a highly viscous
polyurethane material.

The sealant is sprayed on the aforementioned,

highly corrosion-susceptible areas.

214_033

Application of the sealant

Protection against stone impact

ProCarManuals.com

Areas susceptible to stone strikes are protected

by means of a stone impact protection base.

A stone impact protective base is a highly

viscous, elastic paint.

The chassis pan and the wheel housings are

normally coated with a protective stone impact
base.

Primer 214_034
Stone impact protection base
The next coat on the body is the primer. Its
function is to smooth out any surface blemishes
and to provide a uniform surface for the topcoat.

Special jets spray the electrostatically charged

paint particles onto the likewise electrostatically
charged body.
The advantage of this procedure is the
economical use of material.

The primer is dried at 170 °C. After hardening

and cooling at room temperature, all areas
which need to be evened out may be sanded.
The body is then cleaned of all residues.

25
 Painting in the Factory

Topcoat

The last coat of paint is the topcoat. It provides: Single-coat painting

● Colour
● Lustre
● Special effects Single-coat
● Hardness paint

The topcoat is applied in a one-coat or two-coat Primer

process.
With two-coat processes, first the base paint is
Cataphoresis
applied and then a clear lacquer.
(dipping base)

The two-coat topcoat - with its colours and Phosphatising

effects (uniform, metallic, pearl effect) -
combines with the clear lacquer to form a hard, Zinc
ProCarManuals.com

shiny film.

With single coating, the paint itself acts as the

protective layer; with two-coating, the clear
Double-coat painting
lacquer serves this purpose.
Clear lacquer
The application of the topcoat is carried out
similarly to the application of the primer in the
electrostatic coating procedure. This process Two-coat
offers advantages over the usual spray-gun base
application.
Primer

Cataphoresis
(dipping base)
Phosphatising

Metallic paint is applied in the factory

Zinc
using an automated spray gun.

Electrostatic application results in the

specific alignment of the aluminium
particles. This alignment cannot be
reproduced in the repairshop using
conventional techniques. 214_035

One-coat and two-coat paints

26
 Wax and corrosion-protection agents

Sealing the cavities with liquid wax concludes the

painting process.
This seal provides the cavities with effective,
long-term protection against corrosion.

In addition to the wax treatment, polyurethane

foam may be used in specially defined cavities to
improve the acoustics and reduce disagreeable
external odours.
ProCarManuals.com

Vehicle
cavities

HKV spray
guns
214_036

Cavity-conservation gun

27
 Painting in the Repair Shop

Repair painting

A big difference exists between painting in the The paint used in a workshop must dry at lower
factory and painting in the workshop. temperatures, because plastics, sub-assemblies
and the vehicle electronics c a n n o t be exposed
In production, the body is painted by itself, to temperatures over 60 - 70 °C.
without the engine, interior panels, upholstery
etc. In order to carry out such work, the correct
In repair, these parts are not removed (except in equipment, aids and tools must be available.
the case of body replacement). For more detailed information, refer to Self-
All parts not to be painted must therefore be Study Programmme 215, “Painting the Vehicle -
covered. The Topcoat”.

Painting in production always has a constant

structure. Effect painting yields a constant
arrangement of the aluminium or mica pigments.
Repair painting always displays the signature of
ProCarManuals.com

the tradesmen, in both its structure and

appearance.

214_037

Repair painting

28
 Painting in the workshop

The workshop painting process consists of two Topcoat

phases:
The topcoat forms the outermost protective layer
● Pre-treatment for corrosion protection and to of the paint.
compensate for surface irregularities.
● Application of the topcoat to restore the
original appearance.

If a vehicle is brought into a shop with body Information on the application of the
damage, the sheet-metal parts will either be topcoat may be found in the ‘Basic
restored or replaced. principles’ chapter.
The repair paint job protects the damaged parts
against corrosion, smoothes out irregularities in Self-Study Programme 215, “Painting
restored parts and re-creates the original the Vehicle - The Topcoat” provides
appearance. instructions for the correct application
ProCarManuals.com

of the topcoat.
Pre-treatment

The preparatory materials prepare the base for

the application of the topcoat.
In no event may the topcoat be directly applied
to the metal section.

The following preparatory materials are used for

the repair paint job:

● Filler
● Primer
● Extender

The topcoat is applied to the primer, the extender

or existing coats of paint.
These must first be sanded using the abrasive
medium suitable for the topcoat.

214_038

Painting in the workshop

29
 Painting in the Repair Shop

Pre-treatment of the surfaces to be

painted
The base material must be pre-treated according
to instructions to ensure that the paint bonds
perfectly.
Cleaning, removal of corrosion and sanding are
the key phases of the pre-treatment.

Cleaning the vehicle

If a vehicle is brought into the workshop to be

painted, all the surfaces must be thoroughly
cleaned.
The vehicle must be washed before the start of
servicing.
ProCarManuals.com

Silicone cleaner and a dust cloth are used to give 214_039A

the parts to be painted a final cleaning. Cleaning the vehicle

Removal of corrosion

If protective layers are removed during body Passivation materials may only applied to bare
restoration, the exposed areas will be susceptible or galvanised steel panels.
to corrosion. This treatment is not suitable for aluminium or
This is especially true if the paint is not applied other materials.
immediately after the body is restored. The protective primer must be applied within 20
minutes after the passivation agents are applied,
If any corrosive areas are already present on the or the desired effect will be lost (a counter-
vehicle, they must be sanded away. reaction may even take place).
The abrasive medium must be applied to the
surface in such a way that the corroded area is
completely removed without any unnecessary
reduction of sheet metal strength.

After sanding, there may still be some invisible

areas of corrosion.
Passivation (= treatment using acid zinc
phosphates or similar corrosion protective
primers) creates a protective film and prevents
further corrosion.

30
 De-greasing surfaces
De-greasing
To ensure that the paint bonds optimally, the agent (Silicone
respective surfaces must be blow-dried with cleaner)
compressed air and then de-greased.
A de-greasing solvent (silicone cleaner) is
applied over small areas. Before the solvent
evaporates, the treated area must be rubbed
with a clean, dry cloth.
The solvent used (silicone cleaner) must loosen
impurities but may not react with the base.
To optimise the de-greasing result, let the solvent
evaporate slowly while rubbing it off.
Simply allowing the solvent to dry has no
cleaning effect; it instead results in the deposition
of impurities.
De-greasing, besides being important b e f o r e
ProCarManuals.com

t h e p a i n t a p p l i c a t i o n , is also i m p o r t a n t
b e f o r e s a n d i n g , for two reasons:

● Sanding a greasy surface can result in lumps

formed by greasy sanding dust.
Sanding tracks will be left on the surface, and
the abrasive will soon become unusable.

● The abrasive grains force the fat and oil

inwards, making them difficult to remove
later.

214_039

De-greasing the surface

Preparatory sanding Sanding the edges

In order to achieve optimal adhesion, the base

must exhibit the proper degree of roughness.
Selection of the correct sanding coarseness is
thus extremely important.
Before After
For smooth transitions from the painted surface
to the bare metal, all the painted edges must be
sanded.
The paint edges are smoothed using a vibrating
sander and P80 or P100 sandpaper. 214_040

Preparatory sanding

31
 Painting in the Repair Shop

The protective primer

Primer for bare metal

Acid-harde-
The production-standard corrosion protection Extender
ning primer
should, as far as technically possible, be
observed for all repair paint jobs.

If the pre-treatment exposes bare metal, one of

the following protective primers must be used
before application of the paint.

● Acid-hardening (phosphatising) protective

primer

● Epoxy-resin based protective primer

ProCarManuals.com

Acid-hardening protective primer

Panel
Acid-hardening protective primer, also called 214_041
w a s h p r i m e r, is a two-component product.
Once the components have been mixed, the Acid-hardening primer
primer has a potlife of 24 hours at 20 °C.

The primer extender is applied after the wash

primer has dried but still retains its corrosive
properties.

Acid-hardening protective primer is easy to sand.

Sanding should be carried out in a dry-sanding
process with P400 sandpaper.
A polyester filler cannot be applied to
The ventilation time between spraying cycles an acid-hardened protective primer,
should be about 5 minutes. Two to three coats because the still-wet filler will loosen
can be applied, depending on requirements. the primer from the base. In this case,
The drying time before application of the extender without primer is the better
extender is 30 to 90 minutes at 20 °C. option.

The reverse, that is the application of

an acid-hardened protective primer to
hardened filler, is permissible because
the filler is no longer chemically
active.

32
 Epoxy-resin based primer

Primers with an epoxy resin basis are compatible Extender Epoxy-resin based
with polyester filler, regardless of the thickness of primer
the layer.

The drying film may be very thick, enabling the

primer to act as an extender.
The drying time of approx. 4 hours at 20 °C is
relatively long.

This primer serves as corrosion protection for the

area to be filled, so that the filler is not applied
directly to the bare metal.

Sheet metal
ProCarManuals.com

Polyester filler
214_042

Epoxy-resin based primer

Note:

Both paint and primer retain their c o r r o s i v e

p r o p e r t i e s until they have dried. An additional
coat of compatible paint can be applied without
any intermediate sanding (wet-on-wet
application).
If the paint has lost its corrosive properties, fine
sanding will be necessary.

The d r y i n g t i m e is divided into three phases:

● D u s t d r y i n g : Dust no longer sticks to the

paint. Imprints can still be made by applying
light pressure.
● A s s e m b l y d r y i n g : The painted part can be
installed. Imprints can only be made by
applying strong pressure. The paint has not
yet hardened.
● D r i e d t h r o u g h : The painted part can be put
to its proper use or sanded.

33
 Painting in the Repair Shop

The filler

Polyester filler

The polyester filler may only be applied in thin Mixed filler has a short potlife - only about 5 to
layers. Layers which are too thick - due to 10 minutes.
defective panel restoration - can lead to a poor It must therefore be applied quickly and
quality finish. precisely.
The filler tools may be cleaned with a universal
Polyester filler consists of two components which solvent.
must be mixed directly before application. Only mix as much filler as required. With time,
Resin and hardener (catalyst). the filler loses its ability to be spread as well as
Hardener must always be added in the amounts its bonding properties.
prescribed by the manufacturer, normally 2 to 3
grams per 100 grams of filler (2 to 3 percent of ● Not enough hardener (catalyst)
the weight). The filler does not harden within the planned
time. Sanding is made more difficult, the
ProCarManuals.com

Filler and the red-coloured hardener are mixed abrasive medium becomes clogged and
with a spatula until the mixture (homogenization) leaves behind sanding tracks and drag lines.
is optimal and no traces of red hardener are ● Too much hardener (catalyst)
visible. The filler does not harden more quickly. The
active hardener is left over to react with the
resin, the extender and topcoat pigments. The
result is changes in colour and the formation
of spots or contours.

Working sequence

Polyester filler

Hardener (catalyst)

214_043

Mixing polyester filler

34
 Application of filler

The quality of the repair paint job is determined Note on preparing filler:
in large part by how well the quality of the filler
application. During storage, solid particles in the filler may
Motto: sink to the bottom, and resin may rise to the top.
The more time spent applying the filler, Always stir the contents of the container
the less time spent sanding. thoroughly in order to ensure proper mixing of
resin and solid extenders.
Restored sheet metal areas must first be de- The extenders would not otherwise take part in
greased and sanded. the reaction, resulting in an altered mixing ratio
Post-sanded filler layers thicker than 400 to with the hardener.
500 µm are not acceptable. Use only clean tools to remove the filler from the
container. Residues of filler or hardener cause a
Polyester filler may only be used on bare steel, reaction in the container, rendering its contents
because it has insufficient adhesive properties on unusable.
galvanised steel.
ProCarManuals.com

Universal filler is the better option in that case,

since it adheres excellently to both steel and
galvanised steel.
Another possibility is the application of polyester
filler on a coat of epoxy-resin primer.

Universal filler
Galvanisation Paint

Filler application

Steel

Area to be filled

Standard filler Epoxy-resin based

primer
214_044

Application of filler on a galvanised panel

35
 Painting in the Repair Shop

Sanding the filler

Polyester filler dries and hardens relatively

quickly - in about 30 minutes at 20 °C. The Polyester filler may only be sanded
sanding work can thus be carried out shortly after it has dried completely.
Water may not be used.
after the filler has been applied.
Insufficient drying of the filler - like incorrect Polyester filler tends to absorb
admixture of hardener - leads to the following moisture, resulting in the formation of
sanding problem: “bubbles” during the heat-drying of
The abrasive becomes clogged with sticky resin the topcoat.
residue. Wet-sanding also increases the risk of
Cleaning the surface with a cleaning solution corrosion.
makes the sanding process faster, more
comfortable and more effective.

Medium-grain sandpaper, P80 or P120, is the

best choice for the main sanding procedure.
ProCarManuals.com

Then sanding tracks can then be removed with

fine-grain P240 sandpaper.
Pneumatic
The sanding work can be performed manually
sander
with a sanding block and plane, or with the aid
of an electric sander.
For large, smooth surfaces, the most appropriate
tool is the vibrating sander.
214_045A
The eccentric sander is a better match for
Orbital sander
irregular surfaces.

214_045B

Vibrating sander

214_045C

Orbital-vibrating
sander

214_045 214_045D

Manual sanding tools Sanding tools

36
 If more filler needs to be applied after the
sanding process, the sanding residue may be
removed with a compressed-air gun, solvent and Sanded filler
paper towels.
As a rule, only two applications of filler should
be necessary.

To protect against damage and soiling during

the application of filler - and especially during
sanding, securely cover all adjacent areas.

Once the filler has been sanded, the areas of

bare steel receive an application of protective
primer and then extender.
The extender must be applied over a larger area
than the filler, since the filled area must be
completely covered with extender.
ProCarManuals.com

The painted areas bordering the filled areas are

finely sanded or m a t - s a n d e d .
This area is 15-cm wide surrounding the entire
filled surface.

Matting tools include:

Area to be matted
● Abrasive pad 214_046
● Conventional abrasive medium
● Sanding machine Matting

37
 Painting in the Repair Shop

Application of the primer extender

The primer extender forms an undercoat onto The primer extender is a dual-component
which the topcoat will be applied. The topcoat product with an acrylic base and a composition
may only be applied onto the primer extender or similar to that of 2C paint. The type of
the existing coat of paint. pigmentation varies.

Tasks of the primer extender Solid matter content

The primer extender, a preparatory material for The filling capacity of the primer extender
painting, has the following tasks: depends on its solid matter content.
The solid matter content is classified as follows:
● Smoothing out restored areas.
● Covering the filler and primer layers. ● Standard:
● Providing an undercoat for the topcoat, in Standard solid matter content
order to achieve optimum bonding and shine. ● M S (medium solid):
Medium solid matter content
ProCarManuals.com

The topcoat may n o t be applied directly to the ● H S (high solid):

filler or primer. The results would be poor surface High solid matter content
quality and application problems such as
topcoat absorption.

Covering pigment Bonding agent

Bonding agent

Solvent
Solvent

Filler pigment

2C Acrylic- 2C Single-coat
based extender acrylic paint

214_047

Dual-component primer extender

38
 Application procedure Formulas

One option is the w e t - i n - w e t p r o c e d u r e . The The type of primer extender to be used depends
primer extender is used as an intermediate or upon the type of repair, i.e. the area to be
insulation layer, without compensation for painted.
surface irregularities. Various application properties may be achieved
The topcoat is applied while the primer extender through the selective use of the hardener, thinner
still possesses its corrosive properties. and additives, as well as the mixing ratio.

S a n d a b l e e x t e n d e r is the most commonly The most important factor is the selection of

used application procedure. The primer extender hardener and thinner according to the
hardens completely and is then sanded smooth. processing temperature.

C o l o u r a b l e e x t e n d e r is used to avoid - “Fast” for temperatures under 18 °C

numerous topcoat sprayings, which can result in - “Medium” for temperatures between
colour variations. 18 and 25°C
Topcoat paint is added to the undercoat to give it - “Slow” for temperatures under 25 °C
ProCarManuals.com

the same colouring as the topcoat.

The potlife of acrylic-based primer extenders is
30 to 60 minutes.
Do not use more extender than needed!

Guidelines for Using Primer Extenders

Area to be painted Suitable primer extender

Replaced panels Standard or MS

Panel with small repair spots MS

Restored panels HS

Interior parts Wet-in-wet

Normal surface quality (finish) Wet-in-wet

High surface quality (finish) Sandable

Colours with low covering capacity Colourable

39
 Painting in the Repair Shop

Application of the primer extender

For replaced parts or large-surface damages, To avoid problems resulting from insufficient
the primer extender is applied to the entire drying, the prescribed evaporation times must be
panel. observed - especially with medium and high coat
For small damages, the primer extender must thicknesses.
cover the filled and primed area(s). The evaporation time between two coats is
between 5 and 10 minutes.
The primer filler is applied with a spray gun
whose nozzle is adjusted to the type of extender.
The best results are attained in a spray chamber.

An HVLP spray gun (= high volume-low

pressure) is the best choice for ensuring an even
distribution of the primer extender.
Adjacent areas must be securely
covered during application of the
ProCarManuals.com

primer extender.

Filling a partial area

Filler Extender

Filling the entire surface

Filler Extender

Filler Extender

214_048

Primer extenders
40
 Spraying cycles

Sandable extenders require more than one The reason

spraying cycle in order to fully compensate
deformations. With each spraying cycle, mist from the
For small repairs, the coat of primer extender extender material settles on the edge of the
must be thicker on the filled surface than in the coated area.
surrounding area. If the next spraying cycle covers this deposit, the
sanding process will expose it again,
When spraying cycles of sandable extender, leading to absorption problems during
each cycle must cover a larger surface area than application of the topcoat..
the subsequent cycle.
ProCarManuals.com

Correct spraying sequence

Extender deposits

Sanding

Incorrect spraying sequence

Extender deposits
Application problems
Sanding (Absorption of the topcoat)

214_038

Spraying cycles
41
 Painting in the Repair Shop

Sanding the primer extender

The primer extender must be sanded carefully. Incorrect procedure for sanding the primer
Errors in the primer-extender layer are visible extender.
even through the topcoat.

The primer extender may only be sanded after it

has completely dried through. Abrasive medium
This factor is especially important when working
P80 P240
with thick extender layers.

Sanding incompletely dry primer extender will

leave sanding tracks on the surface and can also Sanding in stages – incorrect sequence
clog the abrasive medium.

The drying time varies according to the type and

coat thickness of the primer extender.
Surface to be sanded
ProCarManuals.com

It is normally between 3 and 12 hours at 20 °C.

The sanding process consists of two steps:

● Coarse sanding 1. Sand with P80

● Fine sanding

In the first step, a coarse-grain abrasive

smoothes the primer-extender layer down to the
level of the panel surface.

The fine-sanding step creates the surface

structure necessary to cover sanding tracks and
ensure that the topcoat bonds tightly. A fine- 2. Sand with P240
grain abrasive is used for this step.

3. Paint coat

Visible sanding tracks

214_047A

Visible sanding tracks

42
 Sanding in stages

Correct procedure for sanding the primer The stage-sanding process starts with a coarse
extender abrasive and ends with a fine one.

If the jump from one coarseness to the next is too

great, the channels left by the sanding passes
Abrasive medium will not be sufficiently covered by the next stage.

P80 P150 P240 According to the FEPA norm (see Page 8), no
more than three levels towards a finer grain may
Sanding in stages - correct sequence be skipped.

Finish sanding for one-coat and two-coat

topcoats

Surface to be sanded The selection of a finish-sanding grain size

ProCarManuals.com

depends on whether the subsequent painting is

to proceed with one coat or two.

The film thickness of one-coat paint is greater

1. Sand with P80 than that of two-coat.
With two-coat paint, only the base paint - and
not the clear lacquer - contributes to covering the
sanding tracks.
2. Sand with P150
One-coat paint thus covers deeper sanding
tracks.

Dry sanding and wet sanding

3. Sand with P240 Primer extender may be sanded wet or dry.

Dry sanding, however, achieves the same
surface quality more quickly than wet sanding.
Wet sanding is performed manually and
4. Paint coat produces large amounts of sanding residue.
Dry sanding is performed with sanding machines
equipped with a suction system.
Wet sanding permits the use of finer abrasives
than dry sanding, because the water provides an
No visible sanding tracks additional sanding effect.

214_047B

No visible sanding tracks

43
 Check Your Knowledge

1.) What is oxidation?

A A chemical reaction of water with a metal surface.

B A chemical reaction by which electrons are exchanged between two substances.

C A chemical reaction of atmospheric oxygen with a metal surface.

2.) What is a voltaic cell?

A The mutual interaction of anode and cathode.

B The mutual interaction of two cathodes.

C The mutual interaction of two anodes.

ProCarManuals.com

3.) Why is zinc used to coat steel panels in vehicle production?

A Because it has a higher oxidation tendency than steel.

B Because it has a lower oxidation tendency than steel.

C Because it increases the rigidity of the panel.

4.) Which minerals are used in abrasives?

A Emery, corundum, quartz

B Emery, corundum, silicon carbide

C Emery, corundum, carborund

D Corundum, silicon carbide, diamond

44
 5.) Which of the following statements about abrasive coarseness are true?

A The particle size is standardised according to the FEPA scale.

B The particle size is designated by a number, followed by a P, followed by a number.

C The coarseness of the abrasive is determined according to the average size of the individual
grains.

6.) What is a primer?

A A base coat for sealing pores

B A base coat for compensating irregularities

ProCarManuals.com

C A bonding layer for the topcoat

D A layer for corrosion protection

7.) What are the primary components of paint?

A Bonding agents, solvents, extenders

B Bonding agents, pigments, solvents, additives

C Pigments, solvents, hardeners

D Bonding agents, hardeners, additives

8.) Which methods are available for drying vehicle paint?

A Drying by evaporation of the solvent.

B Drying by chemical reaction of the solvent with the bonding agent.

C Drying by oxidation of the bonding agent.

D Drying by bonding of the components (polymerisation).

45
 Check Your Knowledge

9.) What is 2C paint?

A Paint consisting of two main components: bonding agent and pigment.

B Paint created by mixing two components before application.

C Paint containing the two components catalyst and activator.

10.) Which is the correct sequence for body painting in the factory?

A Phosphatising, cataphorese, primer, topcoat.

B Phosphatising, galvanisation, cataphorese, primer, topcoat.

C Galvanisation, cataphorese, phosphating, primer, topcoat.

ProCarManuals.com

11.) What is cataphorese?

A A protective coat for the replacement parts for storage.

B A protective primer for bodies and spare parts.

C A dull black coat of paint.

12.) Which primer is the best choice for the bare areas of a replaced panel without filler?

A Acid hardening primer.

B An epoxy-resin based primer.

C None of the above.

46
 13.) What is the difference between the sanding process for filler vs. extender?

A Extender must always be sanded when dry, filler may also be sanded when wet.

B Filler must always be sanded when dry, extender must be sanded when wet.

C Filler must always be sanded when dry, extender may also be sanded when wet.

14.) What is an HS type of primer extender?

A A material with high solid matter content.

B A material with high pigmentation.

C A material with high bonding agent content.

ProCarManuals.com

15.) MS extender is best suited to which type of surface?

A Replaced panels

B Panels with small repair surfaces.

C Restored panels.

D Interior parts.

16.) Which of the following describes the correct stage-sanding sequence for primer extenders?

A Coarse sanding with P80, finish sanding with P240

B Coarse sanding with P80, fine sanding with P150, finish sanding with P240

C Both of the above.

47
 Glossary

Absorption Latex Paint

1) Physics: The partial or complete absorption of electroma- Paint made from a bonding-agent dispersion and pigments.
gnetic waves or particle radiation while passing through
matter. The energy of the absorbed rays is converted to heat
(absorption heat).
2) Chemistry: The absorption of gases and vapours through
liquids or solid bodies and the even distribution within the Duplex
absorbing substance. Modifier of composite words with the meaning ‘double’.
3) Biology: The absorption of liquids, vapours, etc. via the
cells.

Electrochemical elements
Acetone Electrical sources in which chemical energy is converted
directly into electrical energy. Non-chargeable primary or
Colourless, aromatic, flammable liquid; important solvent galvanized elements create electrolytic tension, whereby a
and extraction medium. solid conductor (metal/carbon rod) which is submerged in a
conductive (watery) solution of an electrolyte; the dry ele-
ment (ZnMn-, Alkali-Mn-, HgZn-, AgZn-cells) yields 1.5 volts;
used in flashlights and small appliances. The most important
rechargeable secondary element is the lead accumulator.
Acrylic resin
Synthetic resin made of polymerized acrylic acid derivati-
ves: colourless, thermoplastic masses.
Electrodes
ProCarManuals.com

Conductive, usually metallic parts which either bridge elec-

trical charge carriers between 2 mediums or create an elec-
trical field. The positive electrode is called the anode, the
Acrylic acid negative is called the cathode.
Pungent-smelling carbonic acid; base material for polyacry-
lic acid and mixed polymerides (especially paints).

Electrolytic
Conducts electrical current and is decomposed by it (of
[aqueous] solutions)
Activator
Substance which increases the effectiveness of a catalyst.

Electrophoresis
Aesthetic General motion of electrically loaded particles in resistant
mediums (e.g. filter paper) under electrical voltage.
Stylistically beautiful, tasteful, provocative

Carborundum Emulsifier
Extremely hard abrasive made of silicon carbide or alumi- Agent (e.g. gum arabic) which facilitates the formation of an
nium oxide. emulsion.

Coil Epoxy resin

Thin, wound-up wire Epoxy resin, a liquid or solid artificial resin which can har-
den and which contains the epoxy groups; used as cast
resins, paints.

Dispersion
Physics: (disperse system) a matter system (mixture) of two or
more existing phases, where the one component (disperse
phase) is distributed inside another (dispersing agent) in its
finest form. The disperse phase as well as the disperse
system can be solid, liquid or gaseous. Examples of disper-
sion include suspended solids, emulsions, aerosols (mist)
and smoke.

48
 Fungicides
Substances which even in low concentration can destroy Perforation
fungi. The transition to a fungistat, which only stems the fun- General: A series of holes punched successively through a
gal growth, without killing is variable and is often only a substance.
question of the dosage and duration of application.

Phenol
Catalyst
Benzol derivative with a hydroxyl group, colourless crystal-
1) Chemistry: Substance which even in slight amounts chan- line substance with a characteristic odour
ges the speed of a chemical reaction (catalyse), usually
accelerating, without itself being used up. Important cata-
lysts include vanadiumoxide, platinum, nickel, peroxide,
activated carbon, organometallic complex compounds and Phosphates
ion exchangers.
2) Technical: Catalytic converter. Salts of the phosphoric acids

Cataphoresis Pigment
Electrophoresis-positively charged particle in the direction Granular shaped colouring substance which is deposited in
of the cathode. the cells, especially those of the skin. The pigment determi-
nes the colour of the tissue.

Components
ProCarManuals.com

Constituents which can compose a whole, or into which the Polymerisation

whole can be broken down, e.g. the components of a com-
posite substance. The most important of the three reactions in manufacturing
macro-molecules via the joining of unsaturated monomers
or monomers with an unstable ring system e.g. epoxide, lac-
tame, where no sub-molecular reaction product is split off.
The products of polymerisation (polymers) consist of a mix-
Crystalline ture of polymers distinguished by their varying levels of
Exhibiting crystal structure; certain minerals and stones polymerisation

Paints Polyurethane
Spreadable substances, of a certain quality, true or colloi- Multi-purpose synthetics (fibres, paints, foam material) pro-
dal solutions of solid substances in volatile solvents, which duced via the polyaddition of isocyanates and alcohols
after application and drying form upon the base a closed,
bonding film.
Reduction
Chemistry: The opposite reaction to oxidation, by which a
chemical element or a compound absorbs electrons which
Mohs have been released by another substance ( the reduction
Mohs, Friedrich, German mineralogist. Introduced a stan- medium, which is thereby oxidised).
dard of mineral classification and in 1812 developed a scale
of hardness which was named after him (Mohs' hardness)
Sandpaper
Solid paper (or linen cloth) on which abrasive grains are
Oxidation glued; varies according to the abrasive: glass, sand, emery
Oxidation is the reaction of chemical elements or com- etc. Waterproof sandpaper is used for wet-sanding primers
pounds with oxygen (e.g. burning); from the standpoint of and paints.
electron theory, oxidation is a procedure by the chemical
elements or compounds release electrons which are absor-
bed by other substances (thus reducing the oxidation mate-
rial). The opposite (and always coupled) process is called Sedimentation
reduction. Process of stone formation through the deposit of stone
fragments, the separation of dissolved components in soluti-
ons, enrichment of plants and animals.
Passivation
Chemistry: The formation of a electrochemical state (passi-
vity) of a metal surface by which the metal becomes rela-
tively resistant to chemical attack (dissolution, corrosion). A
very thin, invisible pore-free oxide layer forms via anodic
current or the oxidation medium, which protects the metal
e.g. iron, aluminium, chrome.

49
 Glossary

Silicon carbide
Silicon carbide, silicon-carbon compound; serves both as an
abrasive (Carborundum ®) and as a fire-proofing material.

Silicones
Synthetic, polymer silicon-organic compounds. Silicones are
thermally and chemically very stable and water resistant,
they are multi-purpose, e.g. the silicone oils (with short
molecular chains) are used as hydraulic liquids, lubricants,
foam separator and to impregnate textiles and paper; the
silicone greases (with longer molecular chains) are used as
lubricants and ointment bases;
Silicon caoutchouc (with long, vulcanised e.g. with peroxide
diluted molecular chains) are used as a durable, elastic,
weather-resistant, acid and lye-proof sealants and the sili-
cone resin (with spatially strong diluted molecules) as elec-
tric insulation and as a raw material for temperature-
resistant paints.

Silicone
Extremely heat- and water-resistant synthetic containing sili-
ProCarManuals.com

con

Stearate
Salts of the stearic acids (chemical).

Viscosity
Viscosity, inner friction, those properties of a liquid or a
gaseous medium (fluids), which, during deformation, yield
friction tension in addition to thermodynamic pressure and
cause the displacement of mutually reacting liquid or gase-
ous particles.

Cellulose
The primary component of the vegetable cell wall

Zinc
Chemical symbol Zn, metallic chemical element from
subgroup II of the periodic table of elements; atomic
number 30;

50
ProCarManuals.com

Solutions to the test questions:

1: B/ 2: A/ 3: A/ 4: B/ 5: A, B, C/ 6: A, C, D/ 7:
B/ 8: A, C, D / 9: B/ 10: A / 11: B/ 12: A, B/ 13:
C/ 14: A/ 15: A, B/ 16: B

51
 214
2:1 2:1 2:1 2:1 2:1

10 +10% 10 10 +10% 10

+5% +5%
9 10 9 +20% 10 9 10 9 +20% 10

+20% 8
+10% +10%
9 9 9 9
8 8 8 8
+20%

10 +5% 7 10
8 8 8 8 8
7 7 7 7
9 9
6
ProCarManuals.com

7 7 7 7 7
10 6 0 6
9 10 8 10 6 0 6
9 10 8

9 9 6 9 6 6 5 9 9 6 9 6
7 7
5 5 5 5
2 8 8 8 2 8 8
5 6 5 5 5 6 5
7 7 7 4 7 7
7 7
4 4 4 4
5 5
6 6 4 6 4 6 4 6 6 4 6 4
3
5 3 5 3 5 4 5 5 3 5 3 5 4
3 3 3 3 3
4 4 4 4 4 4 4
3 2 3
2 2 2 2
3 3 2 3 2 3 2 3 3 2 3 2
2 2
2 2 2 2 2 2 2
1
1 1 1 1 1
1 1 1 1
1 1
1 1 1 1 1 1 1

000.5010.41.00 000.5010.70 00 000.5010.41.00 000.5010.70 00

Only for internal use © VOLKSWAGEN AG, Wolfsburg

All rights reserved
940.2810.33.20 Issued 03/99

❀ No chlorine was used to bleach this paper

during manufacture.

52