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4291 Diploma in Accident Repair paint Principles.<br />

<strong>Substrate</strong> <strong>Identification</strong><br />

A ferrous metal is a metal that contains iron, and it is the iron in steel<br />

and the alloys of steel that causes it to go rusty (corrode). These metals<br />

are also magnetic.<br />

Non-ferrous metals are metals that do not contain iron, so although they<br />

will still corrode they do not go the rusty colour associated <strong>with</strong> ferrous<br />

metals. The corrosive action on each non-ferrous metal will affect each<br />

in a different way.<br />

All steels contain iron and come under the category of ferrous metals. It<br />

is these metals that for years have been the main material for car<br />

manufacturers; however they are being replaced nowadays by other,<br />

stronger, metals.<br />

The main metal for car body panels has been Low Carbon Steel (LCS). It<br />

is this metal that the body repairer has been able to repair <strong>with</strong> great<br />

success. This is much more difficult nowadays due to the stronger and<br />

tougher alloyed steels known as High Strength Steel (HSS), high<br />

strength low alloy steels (HSLA’s) or, more recently, Boron.<br />

It is still important however for the body repairer to have an<br />

understanding of carbon steels. When steel is manufactured there are<br />

many different grades of steel, much depending on the carbon content.<br />

The higher the carbon the harder the steel becomes.<br />

Identify types of substrate and surface coatings.<br />

1<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Carbon steel:<br />

Carbon steel is a metal alloy, a combination of two main elements iron and<br />

carbon. There are other elements present but the quantities are too<br />

small to affect the properties of this material. As the carbon content<br />

rises the metal becomes harder and stronger but less ductile and more<br />

difficult to weld. Higher carbon content lowers steel's melting point and<br />

its temperature resistance in general. It also becomes malleable when<br />

heated, and therefore can be forged into different shapes.<br />

Low Carbon Steel or mild steel is the most common form of steel as its<br />

price is relatively low while it provides properties that are acceptable for<br />

many applications in the automotive industry. Mild steel has a low carbon<br />

content of up to 0.25% and is therefore neither extremely brittle nor<br />

ductile. It is often used where large amounts of steel are needed to be<br />

formed, for example vehicle body panels as it is cheap and malleable.<br />

As low carbon steel is relevantly soft, manganese is often added to<br />

improve the hardness of low carbon steel. Car body panels have only very<br />

low carbon. A maximum of 0.25% and it is impossible to harden or<br />

temper. When heated the metal changes colour. From straw to blue, then<br />

red, then yellow, and when it passes white it melts at approximately 1450<br />

to 1500 o C making it very hot indeed. It has been used to manufacture<br />

cars for years as it has the following properties:<br />

<br />

<br />

<br />

<br />

<br />

Tough, ductile and malleable<br />

Good all round tensile strength<br />

Can be hot and cold formed<br />

It is easily welded by Resistance spot, Oxy-acetylene and MIG<br />

welding<br />

It cannot be hardened by heating and quenching.<br />

Identify types of substrate and surface coatings.<br />

2<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Medium Carbon Steels have between a quarter of one percent (0.25%) to<br />

one half percent (0.55%) carbon. It is stronger and harder than low<br />

carbon steel and can be heat treated to improve its strength. It is used<br />

to make chain wheels, crankshafts, connecting rods, front axle beams,<br />

push rods, gears and transmissions shafts although again it is rarely used<br />

on its own <strong>with</strong>out more modern alloy steels.<br />

High Carbon Steel has a carbon content between 0.50% to 1.5% carbon<br />

and is very strong but is not so ductile as medium or low carbon steel. It<br />

can be heat treated and used to be the main metal for making springs,<br />

axles, gears, and components that require higher hardness and wear<br />

resistance. Steel is heat-treated which allows parts to be fabricated in<br />

an easily- malleable soft state. If enough carbon is present, the alloy can<br />

be tempered to increase strength, wear, and impact resistance. However<br />

high carbon steels have now been replaced by various alloyed steels.<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/9l7JqonyoKA<br />

Identify types of substrate and surface coatings.<br />

3<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Aluminium:<br />

Aluminium has the advantage of strength yet is about a third of the<br />

weight of steel. The downside of aluminium, and its various alloys, is that<br />

it can be in the region of five times the price of steel. However, its light<br />

weight and resistance to corrosion make it a popular choice particularly<br />

for use as interior and exterior trim items.<br />

Aluminium is a soft, lightweight, malleable metal <strong>with</strong> appearance ranging<br />

from silvery to dull grey, depending on the surface roughness. Aluminium<br />

is remarked for its ability to resist corrosion and for its light weight.<br />

Structural components made from aluminium and its alloys are vital to the<br />

aerospace industry and very important in other areas of transportation<br />

and building. Corrosion resistance is excellent due to a thin surface layer<br />

of aluminium oxide that forms when the metal is exposed to air,<br />

effectively preventing further oxidation. The strongest aluminium alloys<br />

are less corrosion resistant due to galvanic reactions <strong>with</strong> alloyed copper.<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/pMKgD6fHS-4<br />

Identify types of substrate and surface coatings.<br />

4<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Self Assessment:<br />

In groups of two and three, work through these questions on substrates,<br />

if you get stuck use your notes to refresh your memory. These questions<br />

are to assess your OWN knowledge of substrates. If you feel unsure let<br />

your lecturer know so they can help you to understand.<br />

1) What is the percentage of carbon content in low carbon steel?<br />

2) What are the two materials needed to make steel?<br />

3) What are the benefits of low carbon steel?<br />

4) Why does aluminium have excellent corrosion resistance?<br />

5) What are the benefits of aluminium?<br />

Identify types of substrate and surface coatings.<br />

5<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Electro-coating:<br />

Coated Surfaces<br />

The process is also called ELECTRO DEPOSITION. Electro deposition is<br />

a method of using electrical current to deposit organic paint onto a metal<br />

surface, or what is commonly called E-coating. E-coating is based on the<br />

fundamental physics principle that opposites attract. The metal parts<br />

are charged <strong>with</strong> direct current and then immersed in a bath that has<br />

oppositely charged paint particles in it. This allows every corner, crack,<br />

and crevice to have a continuous even coating over the entire surface of<br />

the part. The direct current is controlled to allow the paint solids to<br />

build up to the desired film thickness. Once the part builds up the<br />

desired thickness it then acts as an insulator to stop the deposition<br />

process. This process allows for a very controlled application of paint<br />

solids for a uniformed surface coating <strong>with</strong> typical discrepancy of only 0.1<br />

- 0.02 mil.<br />

What are the Advantages of Electro-coating?<br />

The major advantages are environmental and economic, a few of which<br />

include:<br />

<br />

<br />

<br />

<br />

<br />

The ability to coat complex surfaces evenly.<br />

Maximize performance and minimize costs.<br />

Elimination of drips, runs, and sages.<br />

Hazardous Air Pollutants levels are very low.<br />

There is a minimal amount of solid waste. The waste itself is<br />

considered non-hazardous and to have low environmental impact.<br />

Identify types of substrate and surface coatings.<br />

6<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

<br />

Clean system does not require disposable suits, respirators, and<br />

other costly environmental safety.<br />

<br />

This extremely high efficiency rate translates into lower operation<br />

costs<br />

<br />

A single employee can often manage an electro-coat paint system.<br />

Labour costs are dramatically reduced by eliminating the need for<br />

multiple painters, mixers and technicians.<br />

<br />

Pre-assembly of products is possible since total substrate coverage<br />

is accomplished during application. This can lower reject rates by<br />

eliminating the need for duplicating, mixing or re-handling of<br />

components.<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/JauUjmXlTPE<br />

Identify types of substrate and surface coatings.<br />

7<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

PRE-TREATMENT:<br />

The pre-treatment section is where the<br />

metal surface is cleaned and phosphated<br />

to prepare part for electro-coating.<br />

Cleaning and phosphating are essential in<br />

achieving the performance requirements<br />

desired by the end user. Iron and zinc<br />

phosphate are the most common<br />

materials used in the pre-treatment<br />

systems. Both spray and immersion<br />

stages can be utilized in this section.<br />

ELECTRO-COAT BATH:<br />

The electro-coat bath consists of<br />

80% - 90% water and 10% - 20%<br />

paint solids. The water acts as the<br />

carrier for the paint solids that are<br />

under constant agitation. The paint<br />

solids consist of resin and pigment.<br />

Resin is the backbone of the final<br />

paint film and provides the corrosion<br />

protection, durability, and toughness<br />

of the finish. Pigments are used to<br />

provide the colour and gloss.<br />

Identify types of substrate and surface coatings.<br />

8<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

POST RINSE:<br />

During the electro-coat process, paint<br />

is applied to the part at a controlled<br />

film thickness, and regulated by the<br />

amount of voltage applied to the part.<br />

Once the coating reaches the desired<br />

film thickness, the paint solids begin<br />

to insulate the part and the coating<br />

process slows down. As the part exits<br />

the bath, paint solids cling to the<br />

surface and have to be rinsed off to<br />

maintain efficiency and aesthetics.<br />

The excess paint solids are called<br />

“drag out” or “cream coat”.<br />

BAKE OVEN:<br />

After exiting the post rinses the<br />

coated part which enters the bake<br />

oven. The bake oven cross-links and<br />

cures the paint film to assure<br />

maximum performance properties are<br />

achieved. Bake temperatures range<br />

from 85°C to 204°C based upon the<br />

requirements of the paint that is<br />

used.<br />

Identify types of substrate and surface coatings.<br />

9<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

OEM (Original Equipment Manufacturer) Finishers:<br />

The OEM (Original Equipment Manufacturer) finishers on today’s vehicles<br />

are either “thermo-setting” acrylic enamel, high-solid basecoat and<br />

clearcoat enamels or water-based low emission paints. The difference<br />

between OEM clearcoat and a refinishing clear is how they are activated<br />

and dried. In a refinishing situation the clearcoat can be air-dried and<br />

harden on its own. In an assembly line situation, this would be much too<br />

time consuming. On the assembly line, the vehicles must be painted, dried<br />

and onto the next assembly step in a relatively short period of time<br />

therefore the paints chemical makeup is totally different. There are<br />

basically two types of OEM clearcoat systems. The first is 1K or<br />

melamine; the second is 2K or polyurethane.<br />

1K MELAMINE: In any type of paint system there must be activation, or<br />

something that starts the drying and curing process. With 1K melamine<br />

clear, the activation is started by a baking process. It is activated or<br />

cross-linked by temperature. This type of system is baked at a very high<br />

temperature, typically 265-285 F for about 20-30 minutes.<br />

2K POLYURETHANE: In a polyurethane system, it is a two component<br />

clearcoat that is more of a chemical reaction and is accelerated by heat.<br />

The activation starts when the two components are mixed together at<br />

the sprayer where they are precisely blended, before the paint is<br />

atomized and sprayed on the vehicle. This system is baked at lower<br />

temperatures, typically 140-165 degrees for about 30-40 minutes<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/reC7YE-SYbQ<br />

Identify types of substrate and surface coatings.<br />

10<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Self Assessment:<br />

In groups of two and three, work through these questions on substrates,<br />

if you get stuck use your notes to refresh your memory. These questions<br />

are to assess your OWN knowledge of substrates. If you feel unsure let<br />

your lecturer know so they can help you to understand.<br />

1) Write down two other names for Electro-coating!<br />

2) How is the paint applied to the substrate in Electro-coating?<br />

3) What do the baking temperatures range from <strong>with</strong> Electro-coating?<br />

4) What does the abbreviation OEM stand for?<br />

5) Why do we need OEM paint systems and refinishing paint systems?<br />

Identify types of substrate and surface coatings.<br />

11<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Pre-Primed Panels:<br />

These panels can come <strong>with</strong> two different types of primers. E-coating<br />

this is where the metal panels are charged <strong>with</strong> direct current and then<br />

immersed in a bath that has oppositely charged paint partials in it. This<br />

allows every corner, crack, and crevice to have a continuous even coating<br />

over the entire surface of the panel. Transport Primer this is a 1K<br />

primer that has no etching or adhesive qualities. The only purpose of this<br />

primer is to protect the panel from corrosion whilst being stored or<br />

transported to the body-shop. It is necessary for all of this primer to be<br />

removed and replaced <strong>with</strong> an acid etch primer before applying any<br />

foundation or topcoats. A simple test to identify the type of pre-primed<br />

panel is a solvent test. Use a solvent impregnated cloth to wipe over the<br />

substrate, if the primer reacts, softens and wipes off, this identifies it<br />

as Transport primer and as such must be removed.<br />

Identify types of substrate and surface coatings.<br />

12<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Zinc Coated Steel:<br />

All model vehicles are now constructed mainly from zinc coated steels.<br />

Zinc coatings provide excellent corrosion resistance in most atmospheres.<br />

Widely used to protect motor vehicle products ranging from vehicle<br />

chassis and structural body shells, to nuts and bolts. The zinc is usually<br />

electroplated onto the steel because this gives a smoother coating than<br />

can be obtained if the steel is simply dipped into hot zinc.<br />

Hot dip galvanizing: Individual steel components or fabrications are<br />

chemically cleaned by acid to remove rust before being immersed in a<br />

bath of molten zinc at a temperature of about 450°C. As the steel is<br />

<strong>with</strong>drawn, a layer of molten zinc remains on the surface.<br />

Zinc plating (Electro-galvanizing): The zinc coating is electro-deposited<br />

onto prepared steel from a solution of zinc salts. The metal parts are<br />

charged <strong>with</strong> direct current and then immersed in a bath that has<br />

oppositely charged zinc particles in it. This allows every corner, crack,<br />

and crevice to have a continuous even coating over the entire surface of<br />

the part.<br />

Zinc-rich paints: These are paints in which very high levels of fine zinc<br />

dust have been incorporated. Zinc dust paints can be applied to any rust<br />

and scale-free steel surface by brushing, spraying or dipping. They are<br />

mainly used to protect car bodies and also to repair damage areas where a<br />

zinc layer has been removed.<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/8QmcrtClly0<br />

Identify types of substrate and surface coatings.<br />

13<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Repaired panels:<br />

The ability to identify a repaired substrate can sometimes be easy and<br />

other time’s is extremely difficult. Understanding what the substrate is<br />

made from or what materials have been used, will change the preparation<br />

procedures needed. Most refinishing involves filling, priming and painting<br />

onto existing paint coatings so it is important to know something about<br />

the type of substrate you are working on. There are three main aspects<br />

to consider:<br />

<br />

<br />

The type of finish material already on the surface.<br />

The condition of that finish and the substrate below, and the<br />

depth of the coatings.<br />

<br />

The material on the vehicle will determine which type of finish or<br />

sealing coat should be applied if complete stripping is not an option.<br />

This can be carried out by a solvent test. A small piece of cloth is soaked<br />

in cellulose thinner and wiped across a part of the body that will be<br />

sanded down:<br />

<br />

<br />

Immediate dissolving indicates a cellulose finish.<br />

Slow dissolving after a short, covered soak indicates that it is<br />

probably a thermoplastic acrylic.<br />

<br />

No reaction means that the paint is a two-pack acrylic or<br />

equivalent.<br />

Thermoplastic acrylics must be treated particularly carefully because the<br />

finish can reflow when heated, as well as being affected by some<br />

solvents.<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/U7kvYwsQQKQ<br />

Identify types of substrate and surface coatings.<br />

14<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

It may also be necessary to check for the presence of a clear coat,<br />

particularly on metallic finishes. Dark, solid colours are also often clear<br />

coated to preserve their appearance and add depth. There are two tests<br />

that may be used.<br />

<br />

Taking some shavings from the surface <strong>with</strong> a very sharp blade is<br />

one. If the shavings are white, it is a clear over base.<br />

<br />

Alternatively, rub the surface <strong>with</strong> a burnishing compound. Colour<br />

will be removed if it is solid colour. If the cloth does not discolour<br />

it is a clear over base.<br />

The depth of paint film will also determine how the repair is undertaken.<br />

Most paint makers are unhappy <strong>with</strong> finishes that exceed between 250<br />

microns and 350 microns in total depth. Most car factories produce<br />

finishes ranging between 80 and 120 microns. A typical repair process is<br />

likely to add between 40 and 80 microns. If the panel has already been<br />

repainted, the paint depth could already be in the region of 200 microns.<br />

It may be considered worthwhile in such a case to reduce all the paint to<br />

a depth suitable for the new coatings.<br />

Identify types of substrate and surface coatings.<br />

15<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Self Assessment:<br />

In groups of two and three, work through these questions on substrates,<br />

if you get stuck use your notes to refresh your memory. These questions<br />

are to assess your OWN knowledge of substrates. If you feel unsure let<br />

your lecturer know so they can help you to understand.<br />

1) Write down two different types of primers on pre-primed panels!<br />

2) What is the purpose of Transport Primer?<br />

3) Name three different methods of coating steel <strong>with</strong> zinc.<br />

4) What is another word for zinc coated steel?<br />

5) How do you carry out a solvent test?<br />

Identify types of substrate and surface coatings.<br />

16<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Powder coating:<br />

Powder coating is a dry finishing process, using finely ground particles of<br />

pigment and resin which are electro-statically charged and sprayed onto a<br />

part to be coated. The main difference between a conventional liquid<br />

paint and a powder coating is that the powder coating does not require a<br />

solvent to keep the binder and pigment parts in a liquid suspension form.<br />

The parts to be coated are electrically grounded (earthed) so that the<br />

charged powder particles projected at them adhere to the parts and are<br />

held there until melted and fused into a smooth coating in the curing<br />

oven. This results in a uniform, durable, high quality and attractive finish.<br />

The Powder Coating process offers another advantage – it’s<br />

environmentally friendly. The colour selection is virtually unlimited <strong>with</strong><br />

high and low gloss, metallic and clear finishes available. Texture<br />

selections range from smooth surfaces to a wrinkle or matte finish, and<br />

rough textures. It is usually used to create a hard finish that is tougher<br />

than conventional paint. Powder coating is mainly used for coating of<br />

metals, such as steal, aluminium, and automobile and bicycle parts.<br />

Identify types of substrate and surface coatings.<br />

17<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

The curing process, called cross-linking, requires a certain degree of<br />

temperature for a certain length of time in order to reach full cure and<br />

establish the full film properties for which the material was designed.<br />

Normally the powders cure at 200°C in 10 minutes. The curing schedule<br />

could vary according to the manufacturer's specifications.<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/vWxm3459ibE<br />

Aftermarket finishers:<br />

Custom painting can involve using multiple colours, metal flake paints,<br />

multilayer masking, and special spraying techniques to produce a<br />

personalised look. Multicolour stripes, flames, murals, and other artwork<br />

can be added to the finish. Custom painting requires considerable talent,<br />

skill, and knowledge. You need to plan the custom job carefully. This will<br />

let you determine how to mask and spray or apply each colour. Custom<br />

painters are good at using airbrushes, striping tools, and masking<br />

materials. Before custom painting, make sure the base finish is in good<br />

condition. You do not want to waste your time trying to paint over a<br />

weathered or problem finish<br />

There are a number of different aftermarket finishers that you need to<br />

take into account before repairing an aftermarket finish:<br />

Stencils and images.<br />

Flames.<br />

Metal flake finishers.<br />

Polly chromatic finishers.<br />

Marbleisation.<br />

Identify types of substrate and surface coatings.<br />

18<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Airbrushing: this is an artistic<br />

approach often using stencils and<br />

using multiple colours to achieve<br />

detail art work.<br />

Painted flames are a custom<br />

painting technique often used on<br />

“hot rods”. Different shades of<br />

red and yellow are used to give a<br />

realistic look.<br />

Metal flake is best described as<br />

large flakes added to the clear<br />

coat to give a glitter affect. They<br />

are made from ultra fine<br />

polyester, which makes the flakes<br />

light and easy to use.<br />

Pinstripe two tone effects: this<br />

technique splits the car into two<br />

different colours and is often<br />

highlighted <strong>with</strong> a vinyl or hand<br />

painted strip.<br />

Identify types of substrate and surface coatings.<br />

19<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Self Assessment:<br />

With the new skills and knowledge you have gained, work in groups of two<br />

and three, to identify the substrates provided. Use the identification test<br />

to also identify the surface coatings. If you get stuck, use your notes to<br />

refresh your memory. These tests are to assess your OWN knowledge of<br />

substrates identification. If you feel unsure let your lecturer know so they<br />

can help you to understand.<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> A<br />

Test used:……………………………………………<br />

Surface coating:…………………………………<br />

Test used:……………………………………………<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> B<br />

Test used:…………………………………………..<br />

Surface coating:…………………………………<br />

Test used:……………………………………………<br />

Identify types of substrate and surface coatings.<br />

20<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> C<br />

Test used:…………………………………………..<br />

Surface coating:…………………………………<br />

Test used:……………………………………………<br />

<strong>Substrate</strong>:……………….………………………….<br />

Test used:…………………………………………..<br />

<strong>Substrate</strong> D<br />

Surface coating:…………………………………<br />

Test used:……………………………………………<br />

<strong>Substrate</strong>:……………….………………………….<br />

Test used:…………………………………………..<br />

<strong>Substrate</strong> E<br />

Surface coating:…………………………………<br />

Test used:……………………………………………<br />

Identify types of substrate and surface coatings.<br />

21<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Plastic Panels<br />

Plastic materials are produced synthetically from raw materials like mineral<br />

oil, natural gas, coal, lime, air and water. They are organic materials usually<br />

carbon compounds and are very light in weight they have very poor thermal<br />

conductivity and high electrical resistance. The working properties of<br />

plastics are varied and depend on the type and the specific material. They<br />

can be hard or soft, brittle or tough have excellent elastic properties and<br />

generally low tensile strength. They are not electrically or thermally<br />

conductive and many are resistant to acids.<br />

Thermoplastic and Thermosetting plastic, the molecular structures of<br />

these two types of plastic are different. Thermo-plastics can be softened<br />

by the application of heat and reformed or shaped many times over.<br />

Thermo-setting plastic, when set form a chemical reaction and make this<br />

material set once and for all. Once it is set, it cannot be reformed or<br />

shaped as the re-application of heat only damages or destroys it.<br />

When considering the repair of plastic materials, is it important to note that<br />

only thermoplastic materials are able to be welded as this category has the<br />

capacity to be softened, and joined by heat. Different repair techniques are<br />

used in the repair of thermosetting plastics, for example, the use of resins<br />

and filling agents to join the plastic. A simple test can be used to find out<br />

which type of plastic you are working on. Using a razor blade, cut a thin<br />

slither of plastic on an unseen part of the substrate, if the slither begins to<br />

Identify types of substrate and surface coatings.<br />

22<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

curl, it is thermoplastic and if it cuts straight and is brittle, it is thermosetting.<br />

The use of plastics has grown significantly during recent years and many<br />

components, even body structures, are now made from certain plastic<br />

materials. One of their main attributes is the ability to be easily formed.<br />

There are a number of alternative variants in this:<br />

<br />

<br />

<br />

<br />

<br />

Compression moulding<br />

Injection moulding<br />

Extrusion moulding<br />

Blow moulding<br />

Vacuum forming<br />

Other attributes of using plastics to make motor vehicle parts are as<br />

follows:<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

Weight saving where fuel consumption can be reduced.<br />

Improved resistance to corrosion<br />

Attractive appearance<br />

Less noise than steel panels<br />

Durability<br />

Low component cost <strong>with</strong> ease of creating assemblies<br />

Greater design scope<br />

Better active and passive safety for occupants and pedestrians due to<br />

their impact-absorbing properties<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/T01i_vp2mJE<br />

Identify types of substrate and surface coatings.<br />

23<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Fabrication of Plastics<br />

Extrusion: Using this processing it is possible to produce a wide range of<br />

different forms of plastic, such as tubes, sheets and films, structural parts,<br />

etc. Plastic pellets are placed in a feed hopper which feeds into the system.<br />

A turning screw pushes the plastic into the barrel where heaters increase<br />

the temperature and a melted polymer is obtained. The melted plastic is<br />

forced through a shaping die. Depending on the particular shape of this<br />

element, a continuous shape is formed and pulled out of the extrusion<br />

machine. Solidification occurs by cooling<br />

Compression molding:This is a similar process to extrusion. In compression<br />

molding, plastic pellets, sometimes called molding powder, are placed in the<br />

feed hopper and pushed to the gate by the action of the turning screw. It is<br />

heated and compressed while it passes through the barrel. After the gate,<br />

the molten charge is quickly transferred to a press where it is molded while<br />

still hot. The part is removed after sufficient cooling.<br />

Identify types of substrate and surface coatings.<br />

24<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Injection molding: Plastic pellets flow, due to gravity, from the feed hopper<br />

onto a turning screw. They are converted into a melted plastic by the action<br />

of heaters situated along the barrel. The screw moves the molten plastic<br />

forward, forcing the plastic through a gate into the cooled mould. The mould<br />

is opened once the plastic has solidified and the piece is pushed from the<br />

mould by automatic ejector pins. After we get the manufactured piece, the<br />

mould is closed and clamped and the process begins again.<br />

Blow molding Plastic grocery bags, bottles and similar items are made using<br />

this processing. As in compression processing, plastic pellets are melted and<br />

the plastic is forced through a gate into the blow pin camera. The plastic<br />

substance is expanded and cooled by being made to flow around a massive air<br />

bubble. After a few seconds, the mould is opened and the manufactured<br />

product is ready.<br />

Identify types of substrate and surface coatings.<br />

25<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Vacuum forming is a popular deforming process. It works by removing air,<br />

thereby creating a vacuum underneath a soft and flexible thermoplastic<br />

sheet and allowing atmospheric pressure to push the plastic down onto a<br />

mould. The vacuum forming process may start <strong>with</strong> a ‘blow’ that stretches<br />

the plastic or it may be started by raising the mould, on the plate, to create<br />

a draping form. On some machines a combination of these processes is used.<br />

The aim is always to create a high definition outcome <strong>with</strong>out any excessive<br />

thinning having taken place.<br />

Identify types of substrate and surface coatings.<br />

26<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Glass reinforced plastic:<br />

Fibre-glass or GRP (glass<br />

reinforced plastic), is a composite<br />

material made of glass fibres and<br />

plastic polyester resins. The glass<br />

fibres bring high tensile<br />

(stretchable/flexible) strength to<br />

this product. The plastic provides<br />

the opposite quality of strong<br />

compressive strength (to support<br />

heavy loads). Such a combination<br />

makes fibre-glass a truly<br />

remarkable production material.<br />

Fibre-glass has a wide spectrum of<br />

properties these include:<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

High tensile and compressive<br />

strength.<br />

Fire resistant.<br />

Un-reactive to chemicals.<br />

Insulator to heat,<br />

electricity and sound.<br />

Hard and smooth surface.<br />

Impervious to water.<br />

Easily moulded <strong>with</strong> long<br />

lasting colour.<br />

Identify types of substrate and surface coatings.<br />

27<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

The strength and enhanced protection is achieved by including chopped<br />

strand glass matting and acid resistant glass flakes during different<br />

stages of its application. They have a high strength to weight ratio,<br />

excellent impact. Unlike metals, GRP is weatherproof and virtually<br />

maintenance free, thus it is well suited for external applications as it will<br />

not corrode. GRP Glass reinforced plastic is not used much nowadays but<br />

there are many vehicles on the road using panels made of plastic resin and<br />

glass fibres.<br />

Peugeot 206 Complete Modified Bonnet (One piece GRP).<br />

Scan the <strong>QR</strong> code for video clips or http://youtu.be/eS_Sqnn2rlc<br />

Identify types of substrate and surface coatings.<br />

28<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Flexible plastics:<br />

Flexible plastic components have<br />

been developed to be pedestrian<br />

friendly and to limit damage to a<br />

vehicle involving low impact<br />

crashes. The most common<br />

example of this is a front bumper<br />

as most accidents involving<br />

pedestrians are at low speed, and<br />

<strong>with</strong> a flexible bumper the<br />

pedestrian has more chance of<br />

walking away from the accident.<br />

Modern Renaults has flexible<br />

plastic front wings which have a<br />

plastic built in memory and as<br />

such limits damage to them.<br />

Rigid plastics:<br />

Rigid plastic components have<br />

been developed for structural<br />

parts of a vehicle where the<br />

mould-ability and strength for<br />

complex shapes is needed.<br />

Examples of this are headlight<br />

housings, accelerator pedals and<br />

door handles.<br />

Identify types of substrate and surface coatings.<br />

29<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Textured and smooth surface plastics:<br />

Textured and smooth surface plastic components have been developed for<br />

there aesthetic appearance. The texture, or lack of it, is incorporated into<br />

the plastic moulding process and a number of different finishes can be<br />

achieved. A textured finish is normally applied to components that are not<br />

going to be painted; the texture is the finished surface. Smooth finishers<br />

are often painted to match the vehicles colour; i.e. colour coated bumpers.<br />

Due to the poor adhesion qualities of plastic on both flexible and ridged<br />

finishes, a plastic primer must be used. Also, a flex agent can be added that<br />

allows primers and colours to flex or bend <strong>with</strong>out cracking.<br />

Identify types of substrate and surface coatings.<br />

30<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Self Assessment:<br />

In groups of two and three, work through these questions on plastics, if you<br />

get stuck, use your notes to refresh your memory. These questions are to<br />

assess your OWN knowledge of plastics. If you feel unsure let your<br />

lecturer know so they can help you to understand.<br />

1) What’s the difference between thermoplastic & thermosetting plastic?<br />

2) Name two methods of plastic fabrication used?<br />

3) What does the abbreviation GRP stand for?<br />

4) Give two benefits of using GRP?<br />

5) Why do we use flexible plastics for the front bumper?<br />

Identify types of substrate and surface coatings.<br />

31<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Self Assessment:<br />

With the new skills and knowledge you have gained, work in groups of two<br />

and three, to identify the plastic substrates provided. If you get stuck, use<br />

your notes to refresh your memory. These tests are to assess your OWN<br />

knowledge of plastic substrates identification. If you feel unsure let your<br />

lecturer know so they can help you to understand.<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> A<br />

Test used:……………………………………………<br />

Result from test:………………………………<br />

....................……………………………………………<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> B<br />

Test used:……………………………………………<br />

Result from test:………………………………<br />

....................……………………………………………<br />

Identify types of substrate and surface coatings.<br />

32<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> C<br />

Test used:……………………………………………<br />

Result from test:………………………………<br />

....................……………………………………………<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> D<br />

Test used:……………………………………………<br />

Result from test:………………………………<br />

....................……………………………………………<br />

<strong>Substrate</strong>:……………….………………………….<br />

<strong>Substrate</strong> E<br />

Test used:……………………………………………<br />

Result from test:………………………………<br />

....................……………………………………………<br />

Identify types of substrate and surface coatings.<br />

33<br />

Bill Milestone


4291 Diploma in Accident Repair paint Principles.<br />

Summary<br />

On the completion of identifying types of substrate, and surface coatings<br />

task book, you should be aware of:<br />

<br />

Ferrous and Non-ferrous<br />

metals.<br />

<br />

Surface coating.<br />

<br />

Plastic substrates.<br />

<br />

Plastic fabrication.<br />

<br />

<strong>Substrate</strong> identification<br />

tests.<br />

<br />

Surface coating<br />

identification tests.<br />

Identify types of substrate and surface coatings.<br />

34<br />

Bill Milestone

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