Two-day Course Tentative Outline

Wednesday October 8, 2008

(08:00-08:10)

Greetings by K. Saito - Director of PTC and IR4TD

(08:10-10:00)

Changes in Automotive Painting - I

by K. Toda
Fundamental mechanism of the quality issues:
   - Atomization
   - Solvent Evaporation
   - Viscosity Change
   - Film Thickness vs. Transfer Efficiency
   - Appearance Quality
Changes in the application equipment:
   - (Electrostatic) Spray Gun
   - No.2 Process Bell
   - Mini-Bell
   - Metallic Bell
   - Multi-feed Bell
   - Cartridge Bell

(10:00-10:10)

Morning Break

(10:10-12:00)

Process Improvement Tools - I: CFD and Applications

by A. J. Salazar
Introduction to Computational Fluid Dynamics (CFD):
   - Engineering analysis and traditional approaches
   - CFD as the third complementary approach
   - Four basic steps in CFD analysis
Application of CFD to paint overspray capturing:
   - Applying four basic steps of CFD analysis
Application of CFD to VOC's calculation:
   - Applying four basic steps of CFD analysis
Application of CFD to sprayer cup simulation:
   - Applying four basic steps of CFD analysis

(12:00-01:00)

Lunch Break

(01:00-02:50)

Process Improvement Tools - II: Infrared NDT and Applications

by B. Gharaibeh
Non-Destructive Testing (NDT) techniques for coated surfaces:
   - Introduction and terminology, Contact vs. non-contact methods
Infrared Thermography (IRT) for NDT applications:
   - Introduction to IRT testing
   - IRT principles of operation
Five fundamental steps in IRT applied to coated surface inspection:
   - Properly defining an IRT problem
   - Identifying the most suitable IRT technique
   - Implementing the process and collecting data
   - Reducing noise and data errors
   - Post-processing and analyzing the data
Case studies - Defect detection in automotive manufacturing:
   - Substrate integrity (scratches, scale, dust, etc.)
   - Disbonding
   - Foreign objects (metallic and non-metallic) in a coating system
   - Gas pop-ups, thick layer and paint overspray defects

(02:50-03:00)

Afternoon Break

(03:00-04:50)

Changes in Automotive Painting - II

by K. Toda
Changes in the automatic application system:
   - Reciprocator
   - Old Robot Painting
   - Modular Robot Painting
   - New Robot Painting
Reduction of VOCs emissions, energy usage:
   - Difference between Japanese and American/European way
   - Kaizen: Continuous improvement

(05:00-06:00)

Reception

Thursday October 9, 2008

(08:10-10:00)

Changes in Automotive Painting - III

by K. Toda
Application of Waterborne Paints:
   - Evaporation rate of water
   - Rheology control
   - Electrostatic spray equipment for waterborne paints
Application of Powder:
   - Mechanism of powder coating
   - Transfer efficiency and paint recovery
   - Paint delivery system

(09:50-10:00)

Morning Break

(01:00-03:00)

Changes in Automotive Painting - IV

by K. Toda
Compact Coating Process in the Plant Site:
   - Rastatt
   - Mazda
   - Daihatsu/Toyota
   - Others
Future

(12:00-01:00)

Lunch Break

(01:00-01:10)

Adjourn