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Special Issue "Innovative Coatings for Automotive Industry"

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A special issue of Coatings (ISSN 2079-6412).

Deadline for manuscript submissions: closed (31 October 2017) | Viewed by 88565

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Special Issue Editor

Dr. Nelson Akafuah

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Guest Editor

Mechanical Engineering Department, University of Kentucky, Lexington, KY 40506, USA
Interests: spray painitng; heat transfer & combustion; manufacturing processes & systems

Special Issue Information

Dear Colleagues,

Automotive coatings have two important purposes—to protect the underlying metal or synthetic body panels from the harsh environment to which they are exposed, and to improve the appearance quality. The coating achieves these objects with only approximately 0.1 mm of coating film thickness. Factors, such as the chemistry and material composition of the paint, influence the quality of the coating. The appearance (color, gloss, and texture) of a coated surface greatly affects a customer’s perception of product quality. Appearance is very important in judging the quality of a car, and color is one of the most important considerations in determining appearance. Coating composition, together with the application procedures, paint film formation processes, and coated surface characteristics determine the appearance of a coating film. Automotive coating processes represent the cutting edge of application technology and paint formulation. However, the process remains very expensive, energy and time intensive, and highly wasteful (in terms of material). There are also associated environmental impacts to consider. New and emerging technologies must introduce sustainable multi-functional products, while improving the above shortcomings. Such innovations must streamline the coating process and reduce manufacturing costs.

Dr. Nelson K. Akafuah
Guest Editor

Manuscript Submission Information

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Keywords

multifunctional coatings
self-cleaning/healing coatings
energy generating coatings
paintshop dust/dirt control methods
low energy usage ovens
automated surface finish inspection methods
low cost cleaning methods and/or materials for paint booths, conveyors, and fixtures
new paint atomization technology

Published Papers (6 papers)

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Research

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Open AccessArticle

Nucleation and Growth of Intermetallic Compounds Formed in Boron Steel Hot-Dipped in Al–Ni alloy

and

Coatings 2017, 7(11), 195; https://doi.org/10.3390/coatings7110195 - 10 Nov 2017

Cited by 6 | Viewed by 3716

Abstract

The formation mechanism of intermetallic compounds formed in boron steel hot-dipped in Al–7Ni (wt %) at 690 °С for 10–120 s was studied by identifying the intermetallic phases and investigating the growth process. Initially, a Fe₃O₄ oxide layer formed on the steel. The oxide layer separated into multiple layers sporadically; following this, the Al–Ni molten alloy permeated into the region of the oxide layer breakdown and formed the Al₉FeNi (T, monoclinic, space group: P21/c) phase on the steel surfaces. The Al₉FeNi (T) phase formed from the reaction between the Al–Ni molten alloy and Fe eluted from the steel; this phase not only acts as an Al interdiffusion channel, but also as a barrier for Fe; and facilitates only grain growth without a significant change in thickness. Inside the steel, the Fe₂Al₅ (η, orthorhombic, space group: Cmcm) phase grows along the c-axis in the [001] direction; and has a long columnar structure. The Fe₃AlC (κ, Cubic, space group: Pm3m) phase is formed owing to a reduction in the Al concentration and the simultaneous diffusion and discharge of C toward the steel interface, as C cannot dissolve in the Fe₂Al₅ (η) phase. Full article

(This article belongs to the Special Issue Innovative Coatings for Automotive Industry)

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Open AccessArticle

Study on the Formation of Reaction Phase to Si Addition in Boron Steel Hot-Dipped in Al–7Ni Alloy

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Coatings 2017, 7(11), 186; https://doi.org/10.3390/coatings7110186 - 04 Nov 2017

Cited by 9 | Viewed by 3828

Abstract

In order to reduce the intermetallic compounds formed during the application of an Al–7Ni wt % hot-dip multifunctional coating on boron steel, developed for Tailor Welded Blanks (TWB) and hot stamping, 2–6 wt % Si was added to the coating to change the reaction layer. The coating was run at 690 °C for 120 s. Al₉FeNi phases were formed on the steel interface, Fe₂Al₅ was formed on the steel, FeAl₃ was generated between the existing layers, and flake-type Al₂Fe₃Si₃ was formed in the Fe₂Al₅ phase, depending on the Si content. In addition, as Si was added to the coating, the thickness of the Fe₂Al₅ phase decreased and the thickness of the Al₉FeNi phase and Al₂Fe₃Si₃ increased. The decrease in the thickness of the Fe₂Al₅ phase was mainly due to the effect of the Si solid solution and the Al₂Fe₃Si₃ formation in the Fe₂Al₅ phase. The reason for the growth of Al₉FeNi is that the higher the Si content in the coating, the more the erosion of the interface of the steel material due to the coating solution. Therefore, the outflow of Fe into the coating liquid increased. Full article

(This article belongs to the Special Issue Innovative Coatings for Automotive Industry)

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Open AccessArticle

Novel Electrodeposited Ni-B/Y₂O₃ Composite Coatings with Improved Properties

Moinuddin Mohammed Yusuf

and

Anwarul Hasan

Coatings 2017, 7(10), 161; https://doi.org/10.3390/coatings7100161 - 29 Sep 2017

Cited by 27 | Viewed by 4517

Abstract

Ni-B/Y₂O₃ composite coatings were developed through an electrodeposition process to study the effect of addition of Y₂O₃ particles on structure, surface, thermal, mechanical, and anticorrosion properties of Ni-B coatings. It is revealed that parent crystal structure of Ni-B matrix is preserved by addition of Y₂O₃, however, a noticeable improvement in crystallinity is observed. The analysis of the surface exhibits formation of dense and nodular deposits in the two types of coatings, but incorporation of Y₂O₃ particles in Ni-B matrix has resulted in a noteworthy change in grain size and surface roughness. Thermal analysis of the surfaces indicates that Ni-B-Y₂O₃ composite coatings demonstrate superior thermal stability compared to Ni-B coatings. The nanoindentation analysis shows a significant enhancement in the mechanical characteristics of the Ni-B matrix by addition of Y₂O₃ particles. This may be contemplated as the result of grain refinement and dispersion hardening of the Ni-B matrix by the presence of hard Y₂O₃ particles. A decent improvement in the corrosion protection efficiency (73.6%) is also observed by addition of Y₂O₃ particles into Ni-B matrix. Simultaneous improvement of mechanical and anticorrosion properties suggests potential applications of Ni-B-Y₂O₃ coatings in oil and gas, automobile, and many other industries. Full article

(This article belongs to the Special Issue Innovative Coatings for Automotive Industry)

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Open AccessArticle

Trajectory Optimization of Electrostatic Spray Painting Robots on Curved Surface

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Coatings 2017, 7(10), 155; https://doi.org/10.3390/coatings7100155 - 25 Sep 2017

Cited by 15 | Viewed by 7404

Abstract

In this paper, a new practical electrostatic rotating bell (ESRB) cumulative rate model of painting is derived, and an experimental study on painting is carried out. First, the experimental method is used to obtain the radial thickness profile function of the spatial paint distribution of static spray. Then, a spatial trajectory-planning scheme for a spray-painting robot based on a rectangular model is presented. This method designs the spatial path of the spray-painting robot by using the cuboid model method after the optimal value is taken as the width d of the overlapping area of the two spray-painting strokes in the plane. The experimental results illustrate that the paint thickness basically meets the requirements, and the experimental results verify the effectiveness of the trajectory optimization method. Full article

(This article belongs to the Special Issue Innovative Coatings for Automotive Industry)

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Open AccessArticle

Effects of Bell Speed and Flow Rate on Evaporation of Water Spray from a Rotary Bell Atomizer

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Coatings 2015, 5(2), 186-194; https://doi.org/10.3390/coatings5020186 - 29 May 2015

Cited by 6 | Viewed by 6194

Abstract

A phase doppler anemometer (PDA) was used to determine the effects of evaporation on water spray for three rotary bell atomizer operational variable parameters: shaping air, bell speed and liquid flow. Shaping air was set at either 200 standard liters per minute (L/min) or 300 L/min, bell speed was set to 30, 40 or 50 thousand rotations per minute (krpm) and water flow rate was varied between 100, 200 or 300 cubic centimeters per minute (cm³/min). The total evaporation between 22.5 and 37.5 cm from the atomizer (cm³/s) was calculated for all the combinations of those variables. Evaporation rate increased with higher flow rate and bell speed but no statistically significant effects were obtained for variable shaping air on interactions between parameters. Full article

(This article belongs to the Special Issue Innovative Coatings for Automotive Industry)

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Review

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Open AccessReview

Evolution of the Automotive Body Coating Process—A Review

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Coatings 2016, 6(2), 24; https://doi.org/10.3390/coatings6020024 - 13 Jun 2016

Cited by 141 | Viewed by 61809

Abstract

Automotive coatings and the processes used to coat automobile surfaces exemplify the avant-garde of technologies that are capable of producing durable surfaces, exceeding customers’ expectations of appearance, maximizing efficiency, and meeting environmental regulations. These accomplishments are rooted in 100 years of experience, trial-and-error approaches, technique and technology advancements, and theoretical assessments. Because of advancements directed at understanding the how, why, when, and where of automobile coatings, the progress in controlling droplets and their deposition attributes, and the development of new technologies and paint chemistries, a comprehensive and up-to-date review of automobile coatings and coating technologies was considered to be of value to industrial practitioners and researchers. Overall, the critical performance factors driving the development and use of advanced automotive coatings and coating technologies are (a) aesthetic characteristics; (b) corrosion protection; (c) mass production; (d) cost and environmental requirements; and (e) appearance and durability. Although the relative importance of each of these factors is debatable, the perfection of any one at the expense of another would be unacceptable. Hence, new developments in automotive coatings are described and discussed in the following review, and then related to improvements in production technologies and paints. Modern automotive coating procedures are also discussed in detail. Finally, an extrapolation into the future of automotive coating is offered with a view of the developments and technologies needed for an increasingly efficient and more sustainable coatings industry. Full article

(This article belongs to the Special Issue Innovative Coatings for Automotive Industry)

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