advanced materials manufacturing - lbcg · materials conference (mm) thickness (nm) •width of...

Advanced Materials ManufacturingSurface Conditioning Technology for Automotive Lightweight Materials

Andy F. StecherPresident/CEOPlasmatreat North America, Inc.

Global Lightweight VehicleMaterials Conference

• Regulation• Technologies• Business Economics• Market Forces

Automotive Lightweighting


How to achieve these targets?

- MATERIALS- PROCESS- DESIGN


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


Materials of construction• New/dissimilar materials• Lifecycle assessment• Crash testing• Quality• Vehicle safety• Aftermarket, Repairs


Automotive materials of construction• Plastics/Elastomers

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

• EPDM


Automotive materials of construction• Composites

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


Automotive materials of construction• Metals

• Aluminum• Magnesium• Iron• Steel

• Cold Roll• High Strength


Automotive materials of construction• Glass• Ceramics


Assembly methodology• Fewer weld spots • Adhesive bonding• Other joining technologies• Competitiveness• Automation• Safe production environment


Increased Use Automation and

New Technologies

• Process Control• Quality• Safety• Competitiveness


Productivity andWork Safety

Concerns

• OSHA• Competitiveness• Skills• HR Liabilities


Manufacturing processes =Assembly and Joining of Parts


Manufacturing processes =Interfacing Material Surfaces


Important for adhesion of coatings and adhesives.

Low surface energy


Automotive parts affected by oils, mold release agents, and other impurities

Contamination


Contamination

Oil

Dust

Grease

Finger-prints

External SurfaceContamination


Contamination

Anti-oxidants

Cross-linkers

Fillers

UV Modifiers

Pigments

Slip Agents, Waxes

Internal SurfaceContamination


The need for surface preparation

STATIC REMOVAL: Static attracts dust and similar contaminants which interfere with surface processesCLEANING: All surfaces, no matter how clean they seem, have surface contaminants that interfere with bonding and coating applicationsACTIVATION: Advanced engineering polymers tend to be chemically inert – with few or no functional groups on which to bondPASSIVATION: Metals are prone to oxidation and require treatment to stabilize the oxidation processCOATING: Change surface characteristics in a way that improves subsequent coating operations


Traditional surface treatment methods:

•Mechanical: Sanding, Grit Blasting•Fluid: Powerwash, Solvent Wipe•Chemical: Caustic/Acid, Primers


Advantages of non-touch/dry surface treatment:

•Mechanical: Sanding, Grit Blasting•Fluid: Powerwash, Solvent Wipe•Chemical: Caustic/Acid, Primers•Physical: Corona, Flame, Plasma


Purpose of Plasma

Low pressure plasma Atmospheric pressure plasma

batch, full 3D treatment in-line, localized treatment

adhesion promotionachieving reliable bonding

release coatingsimplified CFRP production


Variable parameters Speed Jet-substrate-distance Plasma-cycle-time (PCT) Frequency Voltage (amplitude of pulse) Process-gas (type & amount) Jet-head

Plasma Process Parameters

Additional influences Material, properties & geometry

of the substrate Material & properties of

subsequently applied compounds

Automation


Process Control


Cleaning Aluminum Engine Blocks Plasma-Clean Chaincase Mating Surface

Benefits :

•Added value to product•Quality confirmation•Target is zero oil leaks•Manpower reduction•Reduce warranty claims

Openair® Plasma Applications


FIPG Adhesion Strength increased

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

Openair® Plasma Applications


A comparison plot of plasma cleaned, oven annealed, and acetone wiped aluminum

Cleaning Comparison


Water Contact Angle


Plasma Coating


Coating thickness approx. 100 nm

Plasma Coating Thickness


Plasma coating

improves durability of adhesive bonds longer „open time“ no solvents or other harmful chemicals automated application faster process

Benefits

Applications

adhesive tapealuminum light weight constructioncar windshield bonding

aluminum

plasma polymer

adhesive

aluminum

= adhesion promoter

Primer Replacement


Windhield Bonding


(mm)

Thick

ness

(nm

)Position to middle of track (mm)• Width of treatment up to 30 mm

• Homogenious coating with 4 mm track pitch

Interference colors on a silicon wafer (picture)

Thickness measured byellipsometry

Coating by Openair®-Plasma


Variable parameters with & without polymerization

Speed Jet-substrate-distance Plasma-cycle-time (PCT) Frequency Voltage (amplitude of pulse) Process-gas (type & amount) Jet-head

Additional influences Material, properties & geometry of

the substrate Material & properties of

subsequently applied compounds

Additional parameters for polymerization Precursor (type & amount) Carrier gas (type & amount) Jet-heads for polymerization Temperature of substrate

Plasma Process Parameters


Bonding - Two Urethane Sealants

Peel test results from various pretreatments on aluminum. The adhesive is a urethane. Plasma treatment leads to cohesive failures. Plasma coated aluminum provides the bond line with greater protection through a 96 hour salt spray test


not coated(corrosion)

coated(no corrosion)

Light microscopic magnification of a coated and an uncoated area

Aluminum sheet after 96 h salt spray test (DIN 50021; the corroded area was not protected by the coating by means of using a mask, which was removed after coating and before salt spray test)

Corrosion Protection


Corrosion Protection

Zinc Zinc Plate

Galvanized Steel

Stainless Steel

AlAl Alloy Al/Mg

Post 96 Hour Salt Spray


Checking of impermeability after salt spray test (Swaat-test)

Green: no leakagesRed: leakages (corrosion on the flange with

penetration to inner body)

Highly efficient anti-corrosion coating

Case Study: Automotive Power Steering Pump

50 h 250 h 500 h 750 hWithout corrosion protection pass fail fail fail

With sprayed protective oil pass pass pass fail

With Plasmatreat coating pass pass pass pass


Completely automated in a two-robot-cell

Extensive process control of the PlasmaPlus®-coating permits a high degree of process repeatability

15 cells in production of 1 million parts per year

Coating by Openair®-Plasma

Automation


• Headlamps • Door modules• Dashboard• Door seals• Cameras• Trunk/bumper painting• Aircraft wing bonding• Electronic panels• Back-up/Rearview Cameras• Engine Sealing/Oil pan bonding

Automotive Plasma Applications


48

Employee SafetyReduce Exposure to Toxic Substances

Material CostsSubstrate, Chemicals, Adhesives

Operational CostsLess Labor, More Efficiency

QualityHigher Customer Satisfaction,

Lower Costs from Claims

Environmental StewardshipLess VOC’s & Toxic Wastes

$

$

$

$

Strong Business Considerations


THANK YOU FOR YOUR ATTENTION!

Plasmatreat North AmericaElgin, IL Belmont, CA Ancaster, ON

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

advanced materials manufacturing - lbcg · materials conference (mm) thickness (nm) •width of...

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