Copyright 2000 Society of Manufacturing Engineers. FUNDAMENTAL MANUFACTURING PROCESSES Painting & Powder Coating

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1 FUNDAMENTAL MANUFACTURING PROCESSES Painting & Powder Coating SCENE 1. CG: FBI warning white text centered on black to blue gradient SCENE 2. CG: disclaimer white text centered on black to blue gradient WARNING federal law provides severe civil and criminal penalties for the unauthorized reproduction, distribution or exhibition of copyrighted videotapes SME Always read the operating manual and safety information provided by the manufacturer before operating any coating equipment. Make sure all machine guards are in place, and follow all safety procedures when working with or near coating equipment. SCENE 3. tape 40, 01:00:00-01:00:12 SME logo, with music CG, SUPER: SCENE 4. tape 25, 01:01:00-01:01:45 fundamental series open, with music tape 582, 01:00:00-01:21:45 peter carey voice-over narration MUSIC UP AND UNDER THE FUNDAMENTAL MANUFACTURING PROCESSES VIDEO SERIES, EXAMINING THE TOOLS AND TECHNIQUES OF PRECISION MANUFACTURING. SCENE 5. program title: CG: Painting & Powder Coating white text centered on black THIS PROGRAM IS AN INTRODUCTION TO PAINTING AND POWDER COATING. SCENE 6. tape 576, 09:13:59-09:14:05 liquid paint application tape 556, 03:08:34-03:08:44 powder coating application THE APPLICATION OF LIQUID PAINTS..., AND POWDER COATINGS ARE PRIMARY FUNCTIONS THROUGHOUT MANUFACTURING.

2 SCENE 7. tape 560, 03:12:37-03:12:50 c.u. liquid paint being applied THESE COATINGS ARE TYPICALLY APPLIED AS THIN FILMS TO PARTS AND SUBSTRATE SURFACES FOR PROTECTION, DURABILITY OR DECORATION. SCENE 8. tape 574, 07:04:02-07:04:12 powder paint being applied CG, SUPER: Organic Coatings PAINTS AND POWDER COATS ARE ORGANIC COATINGS, MEANING THEY ARE MADE-UP OF CHEMICAL COMPOUNDS BASED ON CARBON. SCENE 9. tape 558, 05:03:17-05:03:32 formulated paint poured into container CG, SUPER: Pigments Additives Resins Solvents MOST ORGANIC COATINGS ARE PRODUCED USING ELEMENTS FROM FOUR BASIC CATEGORIES: PIGMENTS, ADDITIVES, RESINS, AND SOLVENTS. SCENE 10. CG, SUPER: Pigments tape 558, 05:28:05-05:28:10 c.u. pile of pigment tape 558, 05:28:48-05:28:53 c.u. pile of pigment tape 558, 05:29:15-05:29:20 c.u. pile of pigment tape 558, 05:29:35-05:29:40 c.u. pile of pigment tape 558, 05:29:55-05:30:00 c.u. pile of pigment tape 573, 06:18:23-06:18:37 pigment added to paint mixture PIGMENTS ARE SMALL PARTICLES OF ORGANIC OR INORGANIC COMPOUNDS ADDED TO INFLUENCE COATING PROPERTIES SUCH AS COLOR, CORROSION RESISTANCE AND MECHANICAL STRENGTH. SCENE 11. CG, SUPER: Additives tape 573, 06:04:51-06:05:03 additives being added to paint mixture tape 558, 05:12:20-05:12:36 tilt of additives ADDITIVES ARE CHEMICALS INCORPORATED INTO A COATING TO PROVIDE SPECIAL PROPERTIES. ADDITIVES MAY INCLUDE THICKENERS OR FLOW AGENTS, ULTRAVIOLET

3 STABILIZERS, ANTI-FOAMING AGENTS, AND FUNGICIDES. SCENE 12. CG, SUPER: Resins tape 558, 05:16:23-05:16:36 zoom out, resins added to paint formulation tape 573, 06:04:15-06:04:27 tilt, resins added to paint mixture RESINS, SUCH AS ACRYLICS AND EPOXIES, ARE THE BINDERS THAT UNITE THE PIGMENTS AND ADDITIVES TOGETHER INTO A SOLID, DURABLE FILM. THE RESINS, ADDITIVES AND PIGMENTS ARE ALSO REFERRED TO AS THE COATING'S SOLIDS. SCENE 13. CG, SUPER: Solvents tape 573, 06:06:58-06:07:16 zoom out, solvents being added to paint formulation tape 558, 05:06:35-05:06:43 viscous coat of paint running slow tape 558, 05:10:10-05:10:16 fluid paint running fast SOLVENTS ARE LIQUIDS USED TO DISSOLVE OR DISPERSE THESE SOLIDS FOR APPLICATION. SOLVENTS ADJUST A COATING'S VISCOSITY, WHICH IS THE PROPERTY OF LIQUID THAT ENABLES IT TO RESIST FLOW. A THICK COATING HAS A HIGH VISCOSITY. LOW VISCOSITY IS CHARACTERIZED BY A THIN COATING. SCENE 14. tape 567, 13:27:32-13:27:56 coating being applied tape 566, 11:06:21-11:06:31 stacks releasing emissions tape 565, 08:15:22-08:15:36 zoom out, stacks with minimal emissions release SOLVENTS EVAPORATE, INFLUENCING THE DRYING TIME OF COATINGS. THIS EVAPORATION RELEASES SOLVENT VOLATILES INTO THE AIR. THESE VOLATILES CAN BE VOLATILE ORGANIC COMPOUNDS OR "VOC'S" WHICH CAUSE POTENTIALLY HARMFUL ATMOSPHERIC REACTIONS. VARIOUS GOVERNMENT REGULATIONS HAVE BEEN ENACTED TO LIMIT THE EMISSION OF THESE "VOC'S". SCENE 15. tape 556, 03:05:10-03:05:20 powder coating being applied POWDER COATINGS BY THEIR NATURE ARE PRODUCED AND APPLIED WITHOUT THE USE OF SOLVENTS. SCENE 16. tape 559, 20:03:40-20:03:50 GRAPHIC: paint can

4 CG, SUPER: Pigments tape 559, 20:04:10-20:04:20 GRAPHIC: cutaway of paint can, layer of pigment appears CG, SUPER: Additives tape 559, 20:04:40-20:04:50 GRAPHIC: cutaway of paint can, layer of additives appears CG, SUPER: Resins tape 559, 20:05:10-20:05:20 GRAPHIC: cutaway of paint can, layer of resins appears CG, SUPER: Solvents tape 559, 20:05:40-20:05:50 GRAPHIC: cutaway of paint can, layer of solvent appears tape 559, 20:06:10-20:06:20 GRAPHIC: cutaway of paint can, layers mixed together tape 558, 05:21:23-05:21:47 tilt of formulated paint being mixed and poured CG, SUPER: Primers Sealers Basecoats Clearcoats Topcoats BY COMBINING VARIATIONS OF PIGMENTS, ADDITIVES, RESINS, AND SOLVENTS, A MULTITUDE OF COATING FORMULATIONS ARE CREATED. THESE COMPLEX MIXTURES ARE PRODUCED TO ACCENTUATE SPECIFIC PART PROPERTIES, SUCH AS APPEARANCE AND DURABILITY, AS WELL AS TO MEET END- USE REQUIREMENTS. THESE FORMULATIONS INCLUDE: PRIMERS, SEALERS, BASECOATS, CLEARCOATS, TOPCOATS, AND MANY OTHERS. --- TOUCH BLACK --- SCENE 17. tape 558, 05:22:31-05:22:36 thin resin being poured into formulation tape 558, 05:24:55-05:25:07 zoom in, resin being poured into formulation BECAUSE THEY ACT AS THE BINDER AND FILM FORMER, RESINS CONSTITUTE THE MOST IMPORTANT ASPECT OF PAINT FORMULATION. SCENE 18. continue previous shot tape 559, 20:06:40-20:06:50 GRAPHIC: polymer chain tape 559, 20:07:40-20:07:50 GRAPHIC: polymer chain, highlighted tape 559, 20:07:10-20:07:20 GRAPHIC: monomer enlarged from center of grayed back polymer chain tape 559, 20:01:20-20:02:20 blue background CG: Enamels Lacquers RESINS ARE USUALLY MADE UP OF POLYMERS, WHICH ARE CHAIN LINKAGES OF REPEATING MOLECULAR STRUCTURES KNOWN AS MONOMERS. PAINT POLYMERS CAN BE CATEGORIZED AS EITHER ENAMELS, OR LACQUERS, DEPENDING ON HOW THEY FORM THEIR FILM.

5 SCENE 19. tape 576, 09:25:11-09:25:27 zoom out, application of enamel paint ENAMELS FORM PAINT FILMS THROUGH THE EVAPORATION OF A SOLVENT, WHILE THE RESIN POLYMER UNDERGOES A CHEMICAL PROCESS KNOWN AS CROSSLINKING. SCENE 20. tape 559, 21:00:40-21:00:50 GRAPHIC: enamel #1 drying tape 559, 21:01:10-21:01:20 GRAPHIC: enamel #2 drying tape 559, 21:01:40-21:01:50 GRAPHIC: enamel #3 drying tape 559, 21:02:10-21:02:20 GRAPHIC: enamel #4 drying tape 559, 21:02:40-21:02:50 GRAPHIC: enamel #5 drying tape 559, 21:03:10-21:03:20 GRAPHIC: enamel #6 drying tape 559, 21:03:40-21:03:50 GRAPHIC: enamel #7 drying tape 559, 21:04:10-21:04:20 GRAPHIC: enamel #8 drying tape 559, 21:04:40-21:04:50 GRAPHIC: enamel #9 drying tape 559, 21:05:10-21:05:20 GRAPHIC: enamel #10 drying ADD: solvent evaporation vapor for entire graphic sequence CROSSLINKING IS A PROCESS IN WHICH A POLYMER REACTS WITH ANOTHER CHEMICAL, CALLED A CROSSLINKER, TO FORM LARGER POLYMER CHAINS. THESE CHAINS LINK AND BUNDLE TOGETHER WITH OTHER POLYMER CHAINS TO PRODUCE AN EXTREMELY STRONG BOND. SCENE 21. tape 565, 08:02:17-08:02:45 zoom out, application of lacquer tape 559, 21:05:40-21:05:50 GRAPHIC: lacquer #1 drying tape 559, 21:06:10-21:06:20 GRAPHIC: lacquer #2 drying tape 559, 21:06:40-21:06:50 GRAPHIC: lacquer #3 drying tape 559, 21:07:10-21:07:20 GRAPHIC: lacquer #4 drying tape 559, 21:07:40-21:07:50 GRAPHIC: lacquer #5 drying tape 559, 21:08:10-21:08:20 GRAPHIC: lacquer #6 drying tape 559, 21:08:40-21:08:50 GRAPHIC: lacquer #7 drying tape 559, 21:09:10-21:09:20 GRAPHIC: lacquer #8 drying tape 559, 21:09:40-21:09:50 GRAPHIC: lacquer #9 drying ADD: solvent evaporation vapor for entire graphic sequence LACQUERS, LIKE ENAMELS, FORM THEIR FILMS THROUGH THE EVAPORATION OF A SOLVENT, BUT THEY DON'T UNDERGO ADDITIONAL CROSSLINKING. THE COATING CHARACTERISTICS OF HARDNESS, FLEXIBILITY AND CHEMICAL RESISTANCE ARE DERIVED SOLELY FROM THE EXISTING POLYMER MATRIX. AS THE SOLVENT EVAPORATES, THESE MOLECULES APPROACH EACH OTHER AND BOND TOGETHER TO FORM THE FILM.

6 SCENE 22. tape 576, 09:22:18-09:22:25 liquid paint application tape 555, 02:20:35-02:20:44 powder coating application ALL PAINTS, LIQUID OR POWDER, ARE EITHER AN ENAMEL OR LACQUER, WITH MOST TYPES BEING ENAMELS. --- FADE TO BLACK --- SCENE 23. CG: Liquid Paint Coatings white text centered on black SCENE 24. tape 577, 10:06:27-10:06:44 liquid paint being applied tape 559, 20:01:20-20:02:20 blue background CG: Solution Fluidization Dispersion Fluidization Emulsion Fluidization LIQUID PAINT FORMULATIONS ARE THE MOST COMMON COATINGS APPLIED IN INDUSTRY. ONE OF THE MOST IMPORTANT ASPECTS OF THESE FORMULATIONS IS THE COATING'S METHOD OF LIQUID FLUIDIZATION, INCLUDING: SOLUTION FLUIDIZATION, DISPERSION FLUIDIZATION, AND EMULSION FLUIDIZATION. SCENE 25. CG, SUPER: Solution Fluidization tape 559, 21:10:10-21:10:20 GRAPHIC: solution resin molecules #1 tape 559, 21:10:40-21:10:50 GRAPHIC: solution resin molecules #2, more resin added tape 559, 21:11:10-21:11:20 GRAPHIC: solution resin molecules #3, more resin added tape 559, 21:11:40-21:11:50 GRAPHIC: solution resin molecules #4, more resin added tape 559, 21:12:10-21:12:20 GRAPHIC: solution resin molecules #5, more resin added tape 559, 21:12:40-21:12:50 GRAPHIC: solution resin molecules #6, more resin added tape 559, 21:13:10-21:13:20 GRAPHIC: solution resin molecules #7, more resin added IN SOLUTION FLUIDIZATION, EACH RESIN MOLECULE IS INDIVIDUALLY DISSOLVED IN THE SOLVENT. AS MORE RESIN IS ADDED, THE MOLECULES INTERTWINE, MARKEDLY INCREASING THE PAINT'S VISCOSITY.

7 tape 559, 21:13:40-21:13:50 GRAPHIC: solution resin molecules #8, more resin added Copyright 2000 Society of Manufacturing Engineers SCENE 26. CG, SUPER: Dispersion Fluidization tape 583, 00:00:47-00:01:00 ANI: paint resins molecules clumping together into small clusters as they float around DISPERSION FLUIDIZATION USES SOLVENTS THAT FORCE THE PAINT RESINS INTO SMALL CLUSTERS OF MOLECULES. THIS PERMITS HIGHER VISCOSITIES WHILE REDUCING SOLVENT USE. SCENE 27. CG, SUPER: Emulsion Fluidization tape 583, 00:01:28-00:01:43 ANI: large clusters of resin molecules floating around, each surrounded by an emulsifier keeping the clusters separate EMULSION FLUIDIZATION PRODUCES LARGE CLUSTERS OF RESIN MOLECULES. THESE CLUSTERS ARE EACH SURROUNDED BY AN EMULSIFIER THAT KEEPS THE CLUSTERS SEPARATE FOR FLUIDIZATION. SCENE 28. tape 558, 05:03:44-05:03:52 zoom out, formulated paint being poured tape 559, 20:01:20-20:02:20 blue background CG: Solventborne Coatings Waterborne Coatings LIQUID PAINT FORMULATIONS TODAY ARE OFTEN BROADLY CATEGORIZED AS EITHER: SOLVENTBORNE COATINGS, OR WATERBORNE COATINGS. SCENE 29. CG, SUPER: Solventborne Coatings tape 576, 09:25:54-09:26:13 solventborne coating being applied SOLVENTBORNE COATINGS USE A SOLVENT TO FLUIDIZE OR DISPERSE THE COATING SOLIDS. IN RECENT YEARS, HIGH SOLIDS COATINGS HAVE BECOME THE PRINCIPAL TYPES OF SOLVENTBORNE COATINGS. SCENE 30. tape 567, 13:17:20-13:17:43 high solids paint being applied to part HIGH SOLIDS COATINGS ARE ALSO KNOWN AS LOW "VOC" COATINGS BECAUSE THEY CONTAIN 50 TO 80 PERCENT SOLIDS, WHILE USING MINIMAL SOLVENTS. THESE COATINGS ARE CHARACTERIZED BY THEIR HIGH

8 VISCOSITIES, AND ARE EXTREMELY POPULAR IN INDUSTRY BECAUSE OF THEIR REDUCED SOLVENT EMISSIONS. SCENE 31. tape 576, 09:09:29-09:09:57 high solids paint being applied to part CG, SUPER: Alkyds Polyesters Epoxies Urethanes Acrylics Silicones THE LEADING TYPES OF RESINS USED TO PRODUCE HIGH SOLIDS COATINGS ARE ALKYDS, POLYESTERS, EPOXIES, URETHANES, ACRYLICS, AND SILICONES. SCENE 32. CG, SUPER: Waterborne Coatings tape 577, 10:20:43-10:20:54 waterborne paint being applied to part, dissolve to next shot tape 577, 10:20:56-10:20:58 waterborne paint being applied to part, freeze on last frame WATERBORNE COATINGS USE MOSTLY WATER AS THE FLUIDIZING MEDIUM, AS WELL AS SOME LIMITED SOLVENTS. AS A GROUP THESE FORMULATIONS ARE IDEAL FOR COMPLYING WITH "VOC" REGULATIONS. SCENE 33. tape 575, 08:20:07-08:20:20 waterborne paint being applied to part CG, SUPER: Water-Reducible Alkyds Modified Alkyds Polyurethanes Latexes Acrylic Latexes & Epoxy Hybrids A WIDE RANGE OF COATING FORMULATIONS FALL INTO THIS BROAD CATEGORY, INCLUDING: WATER-REDUCIBLE ALKYDS, MODIFIED ALKYDS, POLYURETHANES, LATEXES, AND ACRYLIC LATEXES AND EPOXY HYBRIDS. --- TOUCH BLACK --- SCENE 34. tape 577, 10:13:11-10:13:20 painting line tape 559, 20:01:20-20:02:20 blue background CG: Part Pretreatment & Cleaning ALL PAINTING PROCESSES CAN BE BROKEN DOWN INTO THREE FUNDAMENTAL SEQUENCES:

9 Paint Application Paint Curing PART PRETREATMENT AND CLEANING, PAINT APPLICATION, AND PAINT CURING. SCENE 35. tape 576, 09:07:19-09:08:33 parts being cleaned before liquid paint application CG, SUPER: Part Pretreatment & Cleaning CG, SUPER: Nature & Composition Of The Contaminants To Be Removed Composition Of The Part Or Substrate To Be Coated Paint Application Process End-Use Part Requirements PART PRETREATMENT AND CLEANING ARE CRITICAL TO SUCCESSFUL APPLICATION OF COATINGS. CLEANING PROCESSES ARE SELECTED ON THE BASIS OF THE NATURE AND COMPOSITION OF THE CONTAMINANTS TO BE REMOVED, THE COMPOSITION OF THE PART OR SUBSTRATE TO BE COATED, THE PAINT APPLICATION PROCESS, AND END-USE PART REQUIREMENTS. SCENE 36. tape 574, 07:20:44-07:20:54 chemical cleaning of parts CG, SUPER: Chemical Cleaning tape 571, 09:14:57-09:15:02 ultrasonic cleaning of parts CG, SUPER: Ultrasonic Cleaning tape 570, 02:15:31-02:15:37 vapor degreasing of parts CG, SUPER: Vapor Degreasing THE PRIMARY TYPES OF PRETREATMENT CLEANING PROCESSES INCLUDE: CHEMICAL CLEANING..., ULTRASONIC CLEANING..., AND VAPOR DEGREASING. SCENE 37. continue previous shot tape 567, 13:12:33-13:12:42 chemical cleaning of parts tape 571, 09:16:33-09:16:40 ultrasonic cleaning of parts BECAUSE OF THE VARIABLES, NO CLEANING METHOD IS BEST FOR ALL COATING APPLICATIONS. ADDITIONALLY, SURFACE PREPARATION OFTEN REQUIRES MORE THAN ONE TYPE OF CLEANING METHOD TO BE SUCCESSFUL. --- TOUCH BLACK --- SCENE 38. CG, SUPER: Paint Application tape 563, 03:21:24-03:21:37 pan of spray enclosure MOST INDUSTRIAL PAINT APPLICATION IS PERFORMED IN SEGREGATED, WELL VENTILATED ENCLOSURES OR BOOTHS.

10 THESE ENCLOSURES ARE DESIGNED TO PROVIDE A SAFE AND CLEAN ENVIRONMENT FOR PAINTING. SCENE 39. tape 560, 03:16:58-03:17:45 c.u. painting operation CG, SUPER: The Type of Paint Material Applied Paint Thickness & Final Properties Required Quantity & Size of Parts Being Coated Transfer Efficiency of Application Method THERE ARE MANY FACTORS USED TO DETERMINE THE PROPER PAINTING METHOD FOR A GIVEN APPLICATION. THESE FACTORS INCLUDE: THE TYPE OF PAINT MATERIAL APPLIED, THE PAINT THICKNESS AND FINAL PROPERTIES REQUIRED, THE QUANTITY AND SIZE OF PARTS BEING COATED, AND THE TRANSFER EFFICIENCY OF THE APPLICATION METHOD. TRANSFER EFFICIENCY REFERS TO THE PERCENTAGE OF PAINT SOLIDS THAT ACTUALLY COAT THE PART, THE REMAINDER BEING THE POTENTIAL PAINT WASTE. SCENE 40. tape 567, 13:18:13-13:18:35 zoom out, painting process CG, SUPER: Conventional Air Spraying Airless Spraying Air-Assisted Airless Spraying High Volume, Low Pressure Spraying Electrostatic Spraying Electrocoating THERE ARE MANY METHODS AND SYSTEMS USED FOR THE APPLICATION OF LIQUID PAINT COATINGS, WITH THE PRIMARY TYPES INCLUDING: CONVENTIONAL AIR SPRAYING, AIRLESS SPRAYING, AIR-ASSISTED AIRLESS SPRAYING, HIGH VOLUME, LOW PRESSURE SPRAYING, ELECTROSTATIC SPRAYING, AND ELECTROCOATING. SCENE 41. CG, SUPER: Conventional Air Spraying tape 562, 00:04:31-00:04:42 conventional air spraying operation, yellow truck cab tape 562, 00:03:49-00:04:07 CONVENTIONAL AIR SPRAYING IS THE MOST COMMON MEANS OF APPLYING PAINT. IN THIS METHOD, HIGHLY

11 conventional air spraying operation, red truck cab COMPRESSED AIR IS USED TO ATOMIZE THE PAINT WHICH IS APPLIED USING A SPRAY GUN. AIR PRESSURE MAY RANGE FROM ROUGHLY 30 TO 100 PSI OR 200 TO 700 KILO-PASCAL'S. SOME LOW PRESSURE AIR SPRAYING SYSTEMS USE UNDER 10 PSI OR 70 KILO-PASCAL'S OF PRESSURE FOR ATOMIZATION. SCENE 42. tape 575, 08:06:04-08:06:18 zoom out, conventional air paint delivery system, paint being applied manually tape 562, 00:04:17-00:04:24 zoom out, automatic conventional air spraying THE PAINT IS FED TO THE GUN THROUGH EITHER A GRAVITY, SIPHON OR PRESSURE SYSTEM. THE PAINT MAY BE APPLIED MANUALLY..., OR AUTOMATICALLY FOR HIGH VOLUME OPERATIONS. SCENE 43. CG, SUPER: Airless Spraying tape 581, 01:02:04-01:02:19 airless spraying operation tape 581, 01:01:09-01:01:24 special airless spray gun being used to spray cabinet AIRLESS SPRAYING USES HYDRAULIC PRESSURE TO SHARPLY INCREASE THE PAINT'S FLUID PRESSURE, TYPICALLY IN THE RANGE OF 900 TO 1200 PSI OR 6,200 TO 8,300 KILO-PASCAL'S. SPECIAL SPRAY GUNS ARE USED TO ATOMIZE AND APPLY THE PAINT WITHOUT USING COMPRESSED AIR ASSIST. SCENE 44. CG, SUPER: Air-Assisted Airless Spraying tape 579, 00:03:01-00:03:11 zoom out, air-assisted airless spraying operation tape 579, 00:03:27-00:03:41 air-assisted airless spraying operation AIR-ASSISTED AIRLESS SPRAYING USES BOTH COMPRESSED AIR AND PRESSURIZED FLUID TO ATOMIZE THE PAINT FOR APPLICATION. FLUID PRESSURE IS USUALLY BETWEEN 800 TO 1000 PSI OR 5,500 TO 6,900 KILO-PASCAL'S, WHILE THE AIR PRESSURE IS THE SAME OR A LITTLE LESS THAN CONVENTIONAL AIR SPRAY. SCENE 45. CG, SUPER: High Volume/Low Pressure Spraying tape 568, 15:02:29-15:02:38 HIGH VOLUME/LOW PRESSURE, OR "HVLP", SPRAYING IS

12 High volume/low pressure spraying tape 563, 03:16:39-03:16:49 High volume/low pressure spraying AN AIR ATOMIZATION SYSTEM THAT USES LESS THAN 10 PSI OR 69 KILO-PASCAL'S OF AIR PRESSURE TO APPLY PAINT. "HVLP" PRODUCES A SOFTER, MORE CONTROLLABLE SPRAY, REDUCING OVERSPRAY AND PAINT WASTAGE. SCENE 46. CG, SUPER: Electrostatic Spraying tape 577, 10:12:12-10:12:16 wide, electrostatic spraying operation, cut to next shot tape 577, 10:10:21-10:10:41 c.u. of same electrostatic spraying operation ELECTROSTATIC SPRAYING INVOLVES ELECTRICALLY CHARGING THE PAINT PARTICLES AS THEY ARE ATOMIZED. THESE CHARGED PARTICLES ARE THEN ATTRACTED TO THE PART, WHICH IS GROUNDED AND HAS THE OPPOSITE POLARITY. SCENE 47. continue previous shot ELECTROSTATIC SPRAYING PROVIDES VERY GOOD TRANSFER EFFICIENCY, MINIMIZING PAINT WASTE. SCENE 48. CG, SUPER: Electrocoating tape 578, 11:15:03-11:15:27 parts going into electrocoating operation tape 578, 11:17:08-11:17:27 c.u. pan, parts coming out of electrocoating operation ELECTROCOATING, ALSO CALLED ELECTRODEPOSITION OR E-COATING, IS A DIP METHOD OF ELECTRICALLY APPLYING PAINT. THE COATINGS ARE WATERBORNE AND CHARGED. THE GROUNDED PARTS ARE DIPPED, AND BECAUSE THEY HAVE AN OPPOSITE POLARITY, ATTRACT THE PAINT TO THEIR SURFACE. ELECTROCOATING IS EXTREMELY EFFICIENT, PROVIDING UNIFORM PAINT COVERAGE. --- TOUCH BLACK --- SCENE 49. CG, SUPER: Paint Curing tape 575, 08:24:58-08:25:27 zoom out, parts going into oven ONCE A PART HAS BEEN COATED IT IS TRANSFORMED INTO A FINISHED SOLID PAINT FILM BY CURING AT ROOM TEMPERATURE, OR IN SOME TYPE OF OVEN.

13 SCENE 50. continue previous shot tape 559, 20:01:20-20:02:20 blue background CG: Heat Crosslinking Radiation Curing THERE ARE VARIOUS METHODS USED TO CURE COATINGS, WITH THE PRIMARY TYPES INCLUDING: HEAT CROSSLINKING, AND RADIATION CURING. SCENE 51. CG, SUPER: Heat Crosslinking tape 577, 10:24:49-10:25:02 parts cured using heat crosslinking HEAT CROSSLINKING IS USED FOR COATINGS THAT ARE EITHER TOO SLOW OR UNABLE TO CROSSLINK AT LOW OR ROOM TEMPERATURE. SCENE 52. CG, SUPER: Radiation Curing tape 565, 08:21:43-08:21:56 parts cured using radiation curing RADIATION CURING IS THE PROCESS BY WHICH COATINGS ARE CURED RAPIDLY, USUALLY WITHIN SECONDS, BY A RADIATION ENERGY SOURCE, SUCH AS ULTRAVIOLET LIGHT. --- FADE TO BLACK --- SCENE 53. CG: Powder Coatings white text centered on black SCENE 54. tape 554, 01:20:24-01:20:38 powder coating being applied to parts tape 555, 02:02:47-02:02:53 parts coming out of oven SINCE THEIR DEVELOPMENT IN THE 1960'S, POWDER COATINGS HAVE BECOME VIABLE ALTERNATIVES TO LIQUIDS. POWDER COATINGS ARE APPLIED DRY, AND MOST CROSSLINK TO FORM A CONTINUOUS FILM WHEN HEATED. SCENE 55. tape 556, 03:11:08-03:11:15 zoom out, powder being draw up for application tape 583, 00:02:12-00:02:19 ANI: powder particle, various elements floating then integrating together POWDER COATINGS CONSIST OF FINELY GROUND HOMOGENEOUS PLASTIC PARTICLES, EACH CONTAINING THE PROPER PROPORTION OF RESINS, PIGMENTS, BINDERS,

14 FLOW AIDS, FILLERS AND HARDENERS. SCENE 56. tape 556, 03:14:25-03:14:38 c.u. particles being applied THESE PARTICLES ARE ELECTROSTATICALLY CHARGED AND, WHEN SPRAYED, CLING TO THE PARTS, WHICH ARE GROUNDED. SCENE 57. tape 583, 00:02:46-00:02:54 ANI: particles heating up and melting into continuous film tape 583, 00:03:15-00:03:20 ANI: heated up continuous film cooling to room temperature WHEN EXPOSED TO HEAT, THESE PLASTIC PARTICLES MELT, FORMING A CONTINUOUS FILM THAT IS HIGHLY DURABLE AND CHEMICALLY RESISTANT. SCENE 58. tape 554, 01:27:45-01:28:04 parts being powder coated, pan to powder being reclaimed POWDER COATINGS ARE OFTEN MORE ENVIRONMENTALLY FRIENDLY THAN LIQUID COATINGS BECAUSE THEY HAVE NO SOLVENT CONTENT AND EMIT SMALL QUANTITIES OF VOC'S. ADDITIONALLY, THERE IS LITTLE WASTE BECAUSE MOST OVERSPRAY IS RECOVERABLE. SCENE 59. tape 554, 01:04:36-01:04:55 powder being applied to parts CG, SUPER: Epoxy Polyester Acrylic Silicone Hybrid Powder Combinations THE PRIMARY TYPES OF POWDER RESINS INCLUDE: EPOXY, POLYESTER, ACRYLIC, SILICONE, AND HYBRID POWDER COMBINATIONS. SCENE 60. tape 556, 03:20:28-03:20:38 wide shot, pan of powder coating process tape 554, 01:14:45-01:14:59 pretreatment of powder coated parts tape 554, 01:18:33-01:18:44 powder being applied to parts tape 554, 01:23:41-01:23:52 POWDER COATING PROCESSES REQUIRES SEVERAL SUB- SYSTEMS. THESE SUB-SYSTEMS INCLUDE: A PRETREATMENT METHOD TO PREPARE THE PART SURFACE FOR COATING...,

15 powder booth's powder recovery system tape 557, 04:01:18-04:10:23 parts conveyed out of curing oven tape 556, 03:16:20-03:16:32 parts on conveyor AN APPLICATION SYSTEM TO APPLY THE POWDER..., A BOOTH WITH A POWDER RECOVERY SYSTEM TO CONTAIN THE PROCESS..., A CURING OVEN..., AND, A CONVEYOR OR OTHER MEANS OF MOVING THE PART THROUGH THE PROCESS. SCENE 61. tape 557, 04:05:08-04:05:46 pretreatment of powder coated parts CG, SUPER: Mechanical Processes Chemical Processes PRETREATMENT PROCESSES FOR POWDER COATING TYPICALLY INCLUDE: MECHANICAL PROCESSES, AND OR CHEMICAL PROCESSES. SCENE 62. continue previous shot CG, SUPER: Wire Brushing Abrasive Blasting Grinding Sanding Vibratory Polishing MECHANICAL PROCESSES INCLUDE: WIRE BRUSHING, ABRASIVE BLASTING, GRINDING, SANDING, AND VIBRATORY POLISHING. THESE PROCESSES CAN BE PERFORMED MANUALLY OR AUTOMATICALLY. SCENE 63. tape 554, 01:09:20-01:09:35 tilt, zoom in, parts going into wash tanks tape 554, 01:11:57-01:12:15 zoom out, parts coming out of wash tanks CG, SUPER: Alkaline Acid Neutral Solvent Emulsion CHEMICAL PRETREATMENT IS ACCOMPLISHED BY USING EITHER AN AQUEOUS SPRAY OF, OR IMMERSION DIP IN A CLEANING SOLUTION, OR A COMBINATION OF BOTH. THIS SOLUTION CAN BE EITHER AN ALKALINE, ACID, NEUTRAL, SOLVENT,

16 OR EMULSION CLEANING SOLUTION. --- TOUCH BLACK --- SCENE 64. tape 555, 02:10:45-02:10:54 application of powder using electrostatic spraying THE MOST COMMON METHOD OF APPLYING POWDER COATINGS IS BY ELECTROSTATIC SPRAYING. SCENE 65. tape 555, 02:01:22-02:01:34 c.u. particles suspended in feed hopper tape 554, 01:24:51-01:25:24 c.u. powder pumped through tip of spray gun IN THIS METHOD, A FEED HOPPER HOLDS AND SUSPENDS THE POWDER PARTICLES IN AN AIR STREAM. THIS IS KNOWN AS FLUIDIZATION. THIS FLUIDIZED POWDER IS PUMPED TO THE TIP OF A SPRAY GUN THROUGH THE USE OF COMPRESSED AIR. SCENE 66. continue previous shot THE SPRAY GUN IMPARTS AN ELECTROSTATIC CHARGE TO THE POWDER MATERIAL AS THE POWDER IS DIRECTED TOWARDS THE WORKPIECE. --- TOUCH BLACK --- SCENE 67. tape 555, 02:13:17-02:13:37 wide spray booth as parts are powder coated THE SPRAY BOOTH CONTAINS THE POWDER PARTICLES DURING THEIR APPLICATION. APPROXIMATELY 50 PERCENT OF THE POWDER ADHERES TO THE PART DURING APPLICATION, SO EFFICIENT RECOVERY OF OVERSPRAY IS AN IMPORTANT ASPECT OF THE POWDER COATING SPRAY SYSTEM. SCENE 68. tape 554, 01:26:31-01:26:59 zoom out, excess powder directed to a bank of filters A TYPICAL RECOVERY SYSTEM INCLUDES: A POWERFUL FAN TO DIRECT THE EXCESS POWDER TO A

17 BANK OF FILTERS, WHERE THE POWDER IS CAPTURED AND SIEVED FOR REUSE, AND A FINAL FILTER TO CAPTURE THE LAST OF THE POWDER. --- TOUCH BLACK --- SCENE 69. tape 555, 02:25:31-02:25:42 powder parts coming out of oven CG, SUPER: Convection Cure Ovens Infrared Cure Ovens THE CURING OF POWDER COATED PRODUCTS IS ACCOMPLISHED BY USING EITHER CONVECTION CURE OVENS, OR INFRARED CURE OVENS. SCENE 70. tape 574, 07:13:25-07:14:02 zoom out, convection curing oven used to cure powder coated parts CONVECTION OVENS USE A HEAT SOURCE, USUALLY A GAS BURNER, AND A FAN TO HEAT THE INTERIOR OF AN OVEN. THE POWDER IS HEATED BY THE CIRCULATING HOT AIR AND MUST REACH AND BE HELD AT A SPECIFIC TEMPERATURE FOR A PREDETERMINED LENGTH OF TIME TO ACHIEVE FULL CURE. THIS CURE TIME IS DEPENDENT UPON THE SIZE AND MASS OF THE PART AND THE RATE AT WHICH THE PART ACCEPTS HEAT USING CONVECTION HEATING. SCENE 71. tape 580, 12:05:50-12:06:02 zoom out, parts going in infrared curing oven tape 580, 12:08:56-12:09:34 zoom out, cured powder coated parts coming out of infrared curing oven INFRARED CURING USES AN EMITTING SOURCE TO DIRECTLY TRANSMIT INFRARED ENERGY TO THE COATED PART. THIS DIRECT ENERGY TRANSFER CREATES AN IMMEDIATE REACTION IN THE COATING, BEGINNING CROSSLINKING AS SOON AS THE SURFACE IS EXPOSED. SCENE 72. continue previous shot

18 INFRARED CURING OVENS CAN CURE A COATING MUCH FASTER THAN CONVECTION OVENS, BUT SINCE THE ENERGY IS DIRECTIONAL, EVEN DISTRIBUTION OF ENERGY CAN BE DIFFICULT FOR COMPLEX PARTS WITH RECESSED SURFACES. --- FADE TO BLACK --- SCENE 73. CG: Review white text on black tape 63, 12:00:15-12:03:49 review music MUSIC UP AND UNDER LET S REVIEW THE MATERIAL CONTAINED IN THIS VIDEOTAPE. SCENE 74. tape 576, 09:13:59-09:14:05 liquid paint application tape 556, 03:08:34-03:08:44 powder coating application THE APPLICATION OF LIQUID PAINTS..., AND POWDER COATINGS ARE PRIMARY FUNCTIONS THROUGHOUT MANUFACTURING. SCENE 75. tape 560, 03:12:37-03:12:50 c.u. liquid paint being applied THESE COATINGS ARE TYPICALLY APPLIED AS THIN FILMS TO PARTS AND SUBSTRATE SURFACES FOR PROTECTION, DURABILITY OR DECORATION. SCENE 76. tape 574, 07:04:02-07:04:12 powder paint being applied CG, SUPER: Organic Coatings tape 573, 06:18:23-06:18:37 pigment added to paint mixture CG, SUPER: Pigments tape 573, 06:04:51-06:05:03 additives being added to paint CG, SUPER: Additives tape 558, 05:16:23-05:16:36 zoom out, resins added to paint CG, SUPER: Resins tape 573, 06:06:58-06:07:16 solvents being added to paint CG, SUPER: Solvents PAINTS AND POWDER COATS ARE ORGANIC COATINGS, AND MOST ARE FORMULATED USING ELEMENTS FROM FOUR BASIC CATEGORIES: PIGMENTS..., ADDITIVES..., RESINS..., AND SOLVENTS.

19 SCENE 77. tape 576, 09:22:18-09:22:25 liquid paint application tape 555, 02:20:35-02:20:44 powder coating application ALL PAINTS, LIQUID OR POWDER, ARE EITHER AN ENAMEL OR LACQUER, WITH MOST TYPES BEING ENAMELS. SCENE 78. tape 576, 09:25:54-09:26:13 solventborne coating being applied CG, SUPER: Solventborne Coatings tape 577, 10:20:43-10:20:54 waterborne paint being applied to part CG, SUPER: Waterborne Coatings LIQUID PAINT FORMULATIONS TODAY ARE OFTEN BROADLY CATEGORIZED AS EITHER: SOLVENTBORNE..., OR WATERBORNE HIGH SOLIDS COATINGS. SCENE 79. tape 576, 09:07:19-09:08:33 parts being cleaned before liquid paint application CG, SUPER: Chemical Cleaning tape 571, 09:14:57-09:15:02 ultrasonic cleaning of parts CG, SUPER: Ultrasonic Cleaning tape 570, 02:15:31-02:15:37 vapor degreasing of parts CG, SUPER: Vapor Degreasing PART PRETREATMENT AND CLEANING ARE CRITICAL TO SUCCESSFUL APPLICATION OF COATINGS. THE PRIMARY TYPES OF PRETREATMENT CLEANING PROCESSES INCLUDE: CHEMICAL CLEANING..., ULTRASONIC CLEANING..., AND VAPOR DEGREASING. SCENE 80. tape 567, 13:18:13-13:18:35 zoom out, painting process CG, SUPER: Conventional Air Spraying tape 562, 00:04:31-00:04:42 conventional air spraying operation, yellow truck cab CG, SUPER: Airless Spraying tape 581, 01:02:04-01:02:19 airless spraying operation CG, SUPER: Air-Assisted Airless Spraying tape 579, 00:03:27-00:03:41 air-assisted airless spraying operation CG, SUPER: High Volume/Low Pressure Spraying tape 568, 15:02:29-15:02:38 High volume/low pressure spraying CG, SUPER: Electrostatic Spraying tape 577, 10:06:31-10:06:38 THERE ARE MANY METHODS AND SYSTEMS USED FOR THE APPLICATION OF LIQUID PAINT COATINGS, WITH THE PRIMARY TYPES INCLUDING: CONVENTIONAL AIR SPRAYING..., AIRLESS SPRAYING..., AIR-ASSISTED AIRLESS SPRAYING..., HIGH VOLUME, LOW PRESSURE SPRAYING..., ELECTROSTATIC SPRAYING..., AND ELECTROCOATING.

20 electrostatic spraying operation CG, SUPER: Electrocoating tape 578, 11:17:08-11:17:27 c.u. pan, parts coming out of electrocoating operation Copyright 2000 Society of Manufacturing Engineers SCENE 81. tape 575, 08:24:58-08:25:27 zoom out, parts going into oven ONCE A PART HAS BEEN COATED IT IS TRANSFORMED INTO A FINISHED SOLID PAINT FILM BY CURING AT ROOM TEMPERATURE, OR IN SOME TYPE OF OVEN. --- TOUCH BLACK --- SCENE 82. tape 554, 01:20:24-01:20:38 powder coating being applied to parts SINCE THEIR DEVELOPMENT, POWDER COATINGS HAVE BECOME VIABLE ALTERNATIVES TO LIQUID COATINGS. SCENE 83. continue previous shot tape 583, 00:02:12-00:02:19 ANI: powder particle, various elements floating then integrating together POWDER COATINGS CONSIST OF FINELY GROUND HOMOGENEOUS PLASTIC PARTICLES, EACH CONTAINING THE PROPER PROPORTION OF RESINS, PIGMENTS, BINDERS, FLOW AIDS, FILLERS AND HARDENERS. SCENE 84. tape 556, 03:14:25-03:14:38 c.u. particles being applied THESE PARTICLES ARE ELECTROSTATICALLY CHARGED AND, WHEN SPRAYED, CLING TO THE PARTS, WHICH ARE GROUNDED. SCENE 85. tape 556, 03:20:28-03:20:38 wide shot, pan of powder coating process tape 554, 01:12:05-01:12:15 pretreatment of powder coated parts tape 554, 01:18:33-01:18:44 powder being applied to parts tape 554, 01:23:42-01:23:52 powder booth's powder recovery system tape 557, 04:01:18-04:10:23 POWDER COATING PROCESSES REQUIRES SEVERAL SUB- SYSTEMS. THESE SUB-SYSTEMS INCLUDE: A PRETREATMENT METHOD TO PREPARE THE PART SURFACE FOR COATING..., AN APPLICATION SYSTEM TO APPLY THE POWDER...,

21 parts conveyed out of curing oven tape 556, 03:16:20-03:16:32 parts on conveyor A BOOTH WITH A POWDER RECOVERY SYSTEM TO CONTAIN THE PROCESS..., A CURING OVEN TO MELT THE PLASTIC PARTICLES INTO A CONTINUOUS FILM..., AND, A CONVEYOR OR OTHER MEANS OF MOVING THE PART THROUGH THE PROCESS. --- FADE TO BLACK --- SCENE 86. CG, ROLL: credits white text on black, fade up mid-screen Produced By: The Society Of Manufacturing Engineers Executive Producer: Steven R. Bollinger Producer/Director/Cameraman: Jerome T. Cook Written By: Clark Pardee Jerome T. Cook Graphics By: Dennis Summers, Quantum Dance Works Jerome T. Cook Equipment Access Provided By: Dee-Blast Industries Detroit Electro-Coatings Co., L.L.C. Kentwood Powder Coat, Inc. MacDonald Industrial Products North American Coatings Inc. Parker Hannifin Corporation, Pneumatic Division North America X-CEL Industries Inc.

22 Video Footage Provided By: Graco Inc. Nordson Corporation Technical & Editorial Consulting: Vincent Cook, BASF Coating Corporation Gerald L. Schneberger, G.L. Schneberger & Associates Steve Smith, BASF Coating Corporation Rodger Talbert, R. Talbert Consulting, Inc. Production Assistance Provided By: Patrick Fitzpatrick Lance Rosol Video Editing: Communicore SCENE 87. CG: disclaimer white text centered on black Some machinery in this program had safety equipment removed to allow better recording of certain processes. Always read the safety information provided in the manufacturers' manual before machine operation. SCENE 88. tape 40, 01:00:00-01:00:12 SME logo, with music CG, SUPER: