In the automotive manufacturing, the assembled automobile body that emerges from stamping and welding processes is applied 3 to 4 coatings of paint, including an electrodeposited (ED) coating, a primer and a top coating, to ensure appearance quality and rustpreventive quality. With the aim of drastic cost reduction, the authors developed an ultra-short pre-treatment process that reduces four operations, from degreasing to phosphating, to just one operation. The principal issue that has to be addressed in developing this process technology is the development of a new pre-treatment solution for ensuring in one process the pre-treatment quality that has traditionally required four operations. In the course of shortening the auto body pre-treatment from eight conventional operations to five, the pre-treatment solution composition and process conditions were optimized. The use of quality engineering (Taguchi methods) made it possible to maximize the objective reaction and to obtain robust process conditions against the variation in noise factors which present in manufacturing conditions in a short period of time. Accordingly, this technology is greatly expected to bring about large technological innovations in the pre-treatment process, which has not seen any major process reforms in the last twenty or thirty years.
Development of an optimized ultra-short pre-treatment process
Extrem kurzer Vorbehandlungsprozess für die Fahrzeugkarosserie
Review of Automotive Engineering (JSAE) ; 25 , 4 ; 403-408
2004
6 Seiten, 6 Bilder, 3 Tabellen, 3 Quellen
Aufsatz (Zeitschrift)
Englisch
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