Automotive Lightweighting - LBCG · 2015. 4. 15. · Automotive Lightweighting Surface Conditioning...
Transcript of Automotive Lightweighting - LBCG · 2015. 4. 15. · Automotive Lightweighting Surface Conditioning...
Automotive Lightweighting
Surface Conditioning via Openair® Plasma
Andy F. StecherPresident/CEOPlasmatreat North America, Inc.
Global Lightweight Vehicle Manufacturing Conference
Regulatory impact• CAFE• VOC reduction• Reduction of manufacturing
energy consumption • Worker health and safety
Global Lightweight Vehicle Manufacturing Conference
Economics impact• Reduction of vehicle platforms• Productivity• Skilled Labor• Automation• Manufacturing costs• ROI
Global Lightweight Vehicle Manufacturing Conference
Market impact• Safety• Quality• Design/Appearance• Service/Aftermarket• Costs
Global Lightweight Vehicle Manufacturing Conference
How to achieve these targets?
- MATERIALS- PROCESS- DESIGN
Global Lightweight Vehicle Manufacturing Conference
How to achieve these targets?
- MATERIALS- PROCESS- DESIGN
Global Lightweight Vehicle Manufacturing Conference
Materials of construction• Lightweighting materials• Lifecycle assessment• Crash testing• Quality• Safety
Global Lightweight Vehicle Manufacturing Conference
Manufacturing methodology• Less welding • More adhesive bonding• Joining of dissimilar materials• New technologies• Automation• Re-Shoring
Global Lightweight Vehicle Manufacturing Conference
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Employee Safety
Reduce Exposure to Toxic Substances
Material Costs
Substrate, Chemicals, Adhesives
Operational Costs
Less Labor, More Efficiency
Quality
Higher Customer Satisfaction,
Lower Costs from Claims
Environmental StewardshipLess VOC’s & Toxic Wastes
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Global Lightweight Vehicle Manufacturing Conference
Steel is easy to clean, easy to bond to, and easy to paint.
Global Lightweight Vehicle Manufacturing Conference
Steel is easy to clean, easy to bond to, and easy to paint.
Global Lightweight Vehicle Manufacturing Conference
Steel is easy to clean, easy to bond to, and easy to paint.
Global Lightweight Vehicle Manufacturing Conference
Automotive materials of construction
• Plastics/Elastomers• Thermosets/Thermoplastics• PA6, PA66, PA11, PA12• PEEK• PPS, PPA• ….
• EPDM
Global Lightweight Vehicle Manufacturing Conference
Automotive materials of construction
• Composites• CFRP• SMC• GFRP• Graphene• New material compositions
Global Lightweight Vehicle Manufacturing Conference
Automotive materials of construction
• Metals• Aluminum• Magnesium• Iron• Steel• Cold Roll• High Strength
Global Lightweight Vehicle Manufacturing Conference
Automotive materials of construction
• Glass• Ceramics
Global Lightweight Vehicle Manufacturing Conference
Increased Use Automation and
New Technologies
• Process Control• Quality• Safety• Competitiveness
Global Lightweight Vehicle Manufacturing Conference
Productivity and
Work Safety Concerns
• OSHA Reqs• Competitiveness• Skills• HR Liabilities
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The interface of any of manufacturing processes happens on
material surfaces
Global Lightweight Vehicle Manufacturing Conference
Plastics have a low surface energy: Important for adhesion of coatings and adhesives.
Global Lightweight Vehicle Manufacturing Conference
Automotive parts are always subject to surface contamination by oils, mold release agents, and
other impurities
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Contamination
Oil
Dust
Grease
Finger-prints
External SurfaceContamination
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Contamination
Anti-oxidants
Cross-linkers
Fillers
UV Modifiers
Pigments
Slip Agents, Waxes
Internal SurfaceContamination
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The need for surface preparation
STATIC REMOVAL: Static attracts dust and similar contaminants which interfere with surface processes
CLEANING: All surfaces, no matter how clean they seem, have surface contaminants that interfere with bonding and coating applications
ACTIVATION: Advanced engineering polymers tend to be chemically inert – with few or no functional groups on which to bond
PASSIVATION: Metals are prone to oxidation and require treatment to retard the oxidation process
COATING: Change surface characteristics in a way that improves subsequent coating operations
Global Lightweight Vehicle Manufacturing Conference
Traditional surface treatment methods:
•Mechanical: Sanding, Grit Blasting
•Fluid: Powerwash, Solvent Wipe
•Chemical: Caustic/Acid, Primers
Plasmatreat / Plasma Technology Systems: All Rights Reserved
Advantages of non touch surface treatment:
•Mechanical: Sanding, Grit Blasting
•Fluid: Powerwash, Solvent Wipe
•Chemical: Caustic/Acid, Primers
•Physical: Corona, Flame, Plasma
Plasmatreat / Plasma Technology Systems: All Rights Reserved
May 2013
Global Lightweight Vehicle Manufacturing Conference
Openair Plasma
Global Lightweight Vehicle Manufacturing Conference
• Headlamps • Door modules• Dashboard• Door seals• Cameras• Trunk/bumper painting• Aircraft wing bonding• Electronic panels• Back-up/Rearview Cameras• Engine Sealing/Oil pan bonding
Openair® Plasma Applications
Global Lightweight Vehicle Manufacturing Conference
Cleaning Aluminum Engine Blocks Plasma-Clean Chaincase Mating Surface
Benefits :
•Added value to product•Quality confirmation•Target is zero oil leaks•Manpower reduction•Reduce warranty claims
Openair® Plasma Applications
Global Lightweight Vehicle Manufacturing Conference
FIPG Adhesion Strength increased
Replaced manual wipe down:• cleaner• more accurate• save labor• better adhesion
Openair® Plasma Applications
Global Lightweight Vehicle Manufacturing Conference
Process Development
• Feasibility/Samples
• Engineering/ Process Development
• Rental Units
• Purchase
• Service
Global Lightweight Vehicle Manufacturing Conference
THANK YOU FOR YOUR ATTENTION!
Plasmatreat North America
Elgin, IL Belmont, CA Ancaster, ON
Tel. (855) 4TH-STATEwww.plasmatreat.com