Automotive Coating Layers

Coatings are usually applied as multi-layered systems that are composed of primer and topcoat. However, in some cases - for example automotive coating systems -this may vary from four to six layers. Each coating layer is appHed to perform certain specific functions, though its activities are influenced by the other layers in the system. The interactions among different layers and the interfadal phenomenon play an important role in the overall performance of the multi-coat systems [5]. Different properties of coatings are typically associated with specific parts of a coating system (Fig. 1.1) [6]. 

Current automotive coatings are made up of a number of distinct layers (Fig. 7-2), the coatings are either spray applied or electrodeposited. 

Automotive Coating Layers l67 Tab. 7-1 Function and typical thickness of automotive coating layers. 

Automotive Coating Layers 175 Water-borne basecoats... 

Some catalyst supports rely on a relatively low surface area stmctural member coated with a layer of a higher surface area support material. The automotive catalytic converter monolith support is an example of this technology. In this appHcation, a central core of multichanneled, low surface area, extmded ceramic about 10 cm in diameter is coated with high surface area partially hydrated alumina onto which are deposited small amounts of precious metals as the active catalytic species. 

If the rf source is applied to the analysis of conducting bulk samples its figures of merit are very similar to those of the dc source [4.208]. This is also shown by comparative depth-profile analyses of commercial coatings an steel [4.209, 4.210]. The capability of the rf source is, however, unsurpassed in the analysis of poorly or nonconducting materials, e.g. anodic alumina films [4.211], chemical vapor deposition (CVD)-coated tool steels [4.212], composite materials such as ceramic coated steel [4.213], coated glass surfaces [4.214], and polymer coatings [4.209, 4.215, 4.216]. These coatings are used for automotive body parts and consist of a number of distinct polymer layers on a metallic substrate. The total thickness of the paint layers is typically more than 100 pm. An example of a quantitative depth profile on prepainted metal-coated steel is shown as in Fig. 4.39. 

At the heart of an automotive catalytic converter is a catalyzed monolith which consists of a large number of parallel channels in the flow direction whose walls are coated with a thin layer of catalyzed washcoat. The monolith catalyst brick is wrapped with mat, steel shell and insulation to minimize exhaust gas bypassing and heat loss to the surroundings. 

Pearlescent pigments give rise to a white pearl effect often accompanied by a coloured iridescence. The most important pearlescent pigments consist of thin platelets of mica coated with titanium dioxide which partly reflect and partly transmit incident light. Simultaneous reflection from many layers of oriented platelets creates the sense of depth which is characteristic of pearlescent lustre and, where the particles are of an appropriate thickness, colours are produced by interference phenomena. Pearlescent pigments are used in automotive finishes, plastics and cosmetics. 

Salt spray test. The model coatings of Table I are of the high solid type used in automotive top coats. Their primary function is not corrosion protection since this is first of all a matter of phosphate layer, electrocoat and/or primer. However, the topcoats may contribute to corrosion protection by their barrier function for water, oxygen and salts. Therefore their permeability is important as one of the factors in the corrosion protection by the total coating system. We feel that a salt spray test of the model coatings directly applied to a steel surface is of little relevance for their corrosion protection performance in a real system. 

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