Syllabus

Automotive Surface Finishing - Tutorial Programme

MODULE OBJECTIVES (12 modules)

A. AN OVERVIEW OF SURFACE FINISHING
1.1 Appreciate the evolution and scope of industrial surface finishes based upon historic development.
1.2 Understand the nature of the surface finishing industry and visualise the purpose (end use and service environment) of organic surface finishes.
1.3 Appreciate the economic importance of surface finishing.
1.4 Study a bit of chemistry and appreciate what atoms and molecules are.
1.5 Understand the fundamentals of corrosion.
2.1 Appreciate how chemistry relates to coating technology.
2.2 Understand the roles of polymers, pigments and solvents.
2.3 Understand the principles of coating formulation.
2.4 Appreciate how paints are manufactured and thus understand their behaviour.
2.5 Learn a little about coating powders.
2.6 Be knowledgeable about the properties of coating materials.
3.1 Appreciate the development and important role of automotive primers.
3.2 Understand the critical aspects of surfacers and anti-chip coatings particularly as VOC legislation becomes an issue.
3.3 Learn about the different types of basecoats and consider the possible future development of new materials.
3.4 Appreciate the development and the use of clear coats in basecoat clear systems.
3.5 Anticipate any future role for coating powders in automotive plants.
3.6 Have a basic understanding of the testing that may be required to ascertain the suitability of coatings systems for automotive use.

B. PRE-TREATMENT OF SUBSTRATES
4.1 Have a simple understanding of pre-treatment and the science of adhesion.
4.2 Understand the vital importance of surface preparation, including cleanliness, surface roughness, and chemical modification of the surface.
4.3 Discuss methods of mechanical cleaning and substrate preparation.
4.4 Appreciate the processes and benefits of conversion coatings, phosphating and chromating.
4.5 Predict the problems that may occur with differing non-metallic substrates and suggest possible actions to provide the ideal surface for coating.
4.6 Understand the reasons for handling components for coating application with due care.

C. SERVICES
5.1 Appreciate the meaning and purpose of utilities and prime services in the Paint Shop.
5.2 Realise the importance of water.
5.3 Know what water is.
5.4 Be aware of the properties of water.
5.5 Know about the treatment of water.
5.6 Be aware of the quality of deionised water.
5.7 Appreciate the value of water as a heat transfer fluid for cooling and heating.
5.8 Understand the key properties of utilities and services: steam.
5.9 Understand the key properties of utilities and services: compressed air.
5.10 Understand the key properties of utilities and services: natural gas.
5.11 Understand the key properties of utilities and services: electricity.
5.12 Be knowledgeable of the Factory Coding System.
5.13 Use abbreviations and symbols correctly.

D. COATINGS APPLICATION
6.1 Have an understanding of the basic processes of coating application.
6.2 View the decisions that are made to select the correct process.
6.3 Appreciate the use of simple application processes.
6.4 Have a better understanding of electrophoretic coating.
6.5 Understand the basics of autophoretic coating.
6.6 Compare the processes of ' electro' and ' auto' phoresis.
7.1 Have an understanding of the evolution of basic spray application processes for coatings application.
7.2 Understand the development and design of conventional air atomising equipment and its practical use up to the present day.
7.3 Review the decisions that are made to select the air atomising equipment and appreciate the function, use, and control.
7.4 Appreciate the use of environmentally compliant air atomisation processes.
7.5 Have an understanding of hydraulic atomisation and its variants including air assisted airless techniques.
7.6 Understand the use of ' hot spray' techniques.
7.7 Understanding the practical use of spray application devices.
8.1 Understand the development of the electrostatic painting process.
8.2 Appreciate the benefits of the electrostatic process for the application of paint.
8.3 Understand the principles of electrostatic application.
8.4 Study and compare the various designs of electrostatic paint application equipment.
8.5 List and relate the important variable parameters that provide the quality and efficiency of this coating application:
Equipment set-up.
Coating parameters.
8.6 Understand the powder coating processes:
Fluidised bed dipping
Electrostatic spray application.
8.7 Gun movers, reciprocators/manipulators and robots.
9.1 Appreciate the necessity to handle coating materials with care.
9.2 Review the various methods for feeding liquid materials to application devices.
9.3 Understand the operation of pumps.
9.4 Have a basic understanding of paint circulation systems.
9.5 Review the options for colour change.
9.6 Understand the complexities of plural component systems.
9.7 Have a basic understanding of coating powder handling.
10.1 Understand the importance of air movement in the coating application process.
10.2 Review the operational facilities provided by spray booths and flash-off areas.
10.3 Consider the process of over spray removal.
10.4 Explain the differences between drying and curing.
10.5 Review various types of oven.
10.6 Explain the process of infrared curing.
10.7 Understand the possibilities for new curing technologies in the future.
10.8 Review the curing techniques for coating powders.

E. PROCESS CONTROL IN SURFACE FINISHING
11.1 Understand the factors that influence the performance of coatings designed to meet end user expectations.
11.2 Review current test methods for assessing the visual properties of films and particularly colour.
11.3 Review current test methods for assessing the mechanical properties of films.
11.4 Review current test methods for assessing the performance properties of films, particularly related to longevity.
11.5 Appreciate some practical techniques for process control.
11.6 Review health, safety and environmental guidance associated with the application of coatings.

F. PROBLEM SOLVING IN SURFACE FINISHING
12.1 Adopt some simple techniques for troubleshooting.
12.2 Understand some basic tests for various processes.
12.3 Understand the role of the trouble-shooting auditor.
12.4 Formulate a personal programme to trouble shoot.
12.5 Have reference to some trouble shooting lists.