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


Economics impact• Reduction of vehicle platforms• Productivity• Skilled Labor• Automation• Manufacturing costs• ROI


Market impact• Safety• Quality• Design/Appearance• Service/Aftermarket• Costs


How to achieve these targets?

- MATERIALS- PROCESS- DESIGN


Materials of construction• Lightweighting materials• Lifecycle assessment• Crash testing• Quality• Safety


Manufacturing methodology• Less welding • More adhesive bonding• Joining of dissimilar materials• New technologies• Automation• Re-Shoring


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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

$

$

$

$


Steel is easy to clean, easy to bond to, and easy to paint.


Automotive materials of construction

• Plastics/Elastomers• Thermosets/Thermoplastics• PA6, PA66, PA11, PA12• PEEK• PPS, PPA• ….

• EPDM



• Composites• CFRP• SMC• GFRP• Graphene• New material compositions



• Metals• Aluminum• Magnesium• Iron• Steel• Cold Roll• High Strength



• Glass• Ceramics


Increased Use Automation and

New Technologies

• Process Control• Quality• Safety• Competitiveness


Productivity and

Work Safety Concerns

• OSHA Reqs• Competitiveness• Skills• HR Liabilities


The interface of any of manufacturing processes happens on

material surfaces


Plastics have a low surface energy: Important for adhesion of coatings and adhesives.


Automotive parts are always subject to surface contamination by oils, mold release agents, and

other impurities


Contamination

Oil

Dust

Grease

Finger-prints

External SurfaceContamination


Contamination

Anti-oxidants

Cross-linkers

Fillers

UV Modifiers

Pigments

Slip Agents, Waxes

Internal SurfaceContamination


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


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


Openair Plasma


• 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


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


Plasma & RTV application.avi

Plasma & RTV application.avi


FIPG Adhesion Strength increased

Replaced manual wipe down:• cleaner• more accurate• save labor• better adhesion



Process Development

• Feasibility/Samples

• Engineering/ Process Development

• Rental Units

• Purchase

• Service


THANK YOU FOR YOUR ATTENTION!

Plasmatreat North America

Elgin, IL Belmont, CA Ancaster, ON

Tel. (855) 4TH-STATEwww.plasmatreat.com

automotive lightweighting - lbcg · 2015. 4. 15. · automotive lightweighting surface conditioning...

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