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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$

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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

Global Lightweight Vehicle Manufacturing Conference

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

Global Lightweight Vehicle Manufacturing Conference

Contamination

Oil

Dust

Grease

Finger-prints

External SurfaceContamination

Global Lightweight Vehicle Manufacturing Conference

Contamination

Anti-oxidants

Cross-linkers

Fillers

UV Modifiers

Pigments

Slip Agents, Waxes

Internal SurfaceContamination

Global Lightweight Vehicle Manufacturing Conference

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