Substrate Identification Booklet with QR codes
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
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