Fundamental Painting Procedures

FOREWORD Encouraged by a growing demand among consumers for high- er-grade automobiles and a progress of technical development in the industry, automakers today have reached a surprisingly high level in their paint quality. To give only a few examples, modern cars look shinier and car- makers are using, more generously than ever, flip-flop and two- tone paints containing a variety of pigments and particles. Such trends are likely to continue as automakers are competing with each other in gaining higher technological advantages in the market. The same applies to repair and repainting for automobiles.

Research and development efforts are being made constantly so that all the modern color and painting tech- nologies can be maintained after repair and repainting opera- tions . . Similarly, many work methods and equipment types are being proposed in order to improve productivity, especially of paint- ing, at bodywork stations. Under these circumstances, we reviewed the entire contents of the previous publication, Lexus Fundamental Body Painting Manual (Publication No. BRM019U) to reflect all these new developments in the industry and pub- lish a new one accordingly.

This revised manual contains all the technologies, materials and equipment that are most up-to- date at the time of publication. We sincerely hope that the new manual proves to be helpful for your painting work and educa- tional purposes. TOYOTA MOTOR CORPORATION

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BASIC KNOWLEDGE ABOUT PAINTS AND PAINTING 1-1 1. BASIC KNOWLEDGE ABOUT PAINTS AND PAINTING page .. [1] DEFINITION AND PURPOSES OF PAINTING- 1. Definition ............................................ 1 -2 2. Purposes ............................................. 1-2 [2] PAINT COMPONENTS 1. Pigm~nts ... ; ........................................ 1-4 2. Resins ....... ., ................................. _...... 1-5 3. Solvents and Thinners .. .. .. .. .. .. . .. .. . .. . .. .. . 1 -6 [3] PAINT DRYING __ 1. Solvent Evaporation Type (Air Drying) . . . 1 -7 2. Reaction Type .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. . 1 -8 [4] AUTOMOTIVE PAINTS 1. Performance of Automotive Paints . .

. . . . . . 1 - 11 2. Classification of Automotive Paints 1 -12 [~] METHODS OF APPLICATION 1·. Spraying .... -.... ..... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 1 -19 2. Immersion Coating ............................... 1-21 [6] PAINTING FOR NEW VEHICLES 1. Coat Formation on Body Parts .. . .. .. .. .. . .. . 1 - 23 2. Painting Process for New Vehicles ........ 1-25 -3-

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1-2 BASIC KNOWLEDGE ABOUT PAINTS AND PAINTING 1 DEFINITION AND PURPOSES OF PAINTING 1. DEFINITION Painting is a process in which a liquid called "paint" is applied to form a thin film which, when dried and hardened, turns into a very hard coat. DEFINITION OF PAINTING 2. PURPOSES OF PAINTING ( 1) Protection Automobiles, ships, bridges, etc., are main- ly made of iron, a material that tends to rust easily when exposed to air. When rust develops on iron, those structures lose their original physical strength or shape. Rust can be prevented, however, by paint- ing the iron so that the original perfor- mance of the structures can be maintained over a longer period of time.

Painting may be applied also to lumber. Wood can be protected from such defects as surface scratching, decay and worms if they are coated with a paint that contains rust pre- ventive and insecticide. In summary, the major purpose of painting is to protect the object from external ele- ments of damage. PROTECTION FROM DAMAGE (2) Cosmetic improvement Painting gives colors and luster to vehicles and enhances their cosmetic appearance. They look better, and their commercial value increases, if they are painted well. Bumpers may be painted in the same color as the body itself and door sashes may be painted black to improve the quality of the vehicle. These are also important purposes of painting.

(3) Identification by painting Fire engines and police cars are often painted red. Painting is also used to differentiate certain vehicles from all others. COSMETIC IMPROVEMENT -4-

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PAINT COMPONENTS 1 -3 PAINT COMPONENTS Paint is a highly viscous liquid consisting of pigments, resins, and solvents that are mixed evenly. Nor- mally, a thinner is added to the paint to lower its viscosity to a practical level before use. PIGMENT A powder which gives color and filler to the paint finish. It will not dissolve in water or solvent. RESIN A clear liquid which binds the pigment and adds luster, hard- ness and adhesion to the paint. SOLVENT A liquid which dissolves the resin and allows for easier blend- .. ing of the pigment and resin. ... l-_T_H_I_N_N_E_R___,, ...... A diluent, containing a blend of various solvents, which gives the paint a viscosity that is easier to apply.

PIGMENT RESIN SOLVENT PAINT Among several kinds of paints, a clear paint is a colorless and transparent paint that contains resins and solvents but not pigments. A clear paint is applied over the top coat to give an added luster to metallic or pearl mica painting while protecting metallic and mica pigments. ~--------- -------------------------------------------------. · Viscosity is a technical term that expresses hardness (tackiness) of a fluid. A tacky paint has a "high" viscosity while thinned or diluted paint has a "low" viscosity.

· Paint is contained in cans together with certain additives that are designed to maintain the originai per- formance of the paint and stability during storage. Additives range from plasticizers to desiccants, pig- ment dispersants, mildewcides, ultraviolet absorbers, anti-skinning agents, etc., and they are mixed with paint selectively to best suit the need. -5-

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