Audi has opened its new paint shop in Neckarsulm. The fully automated facility primes all models produced in Neckarsulm and the neighboring Böllinger Höfe. These include the new Audi A5, the upcoming Audi A7, the Audi Sport models and current and upcoming all-electric models.
Corrosion protection without heavy metal
In the cathodic dip coating process, the body is now dipped and rotated upside down in the tank using a new rotation process for Neckarsulm. This is both more space-saving and more thorough, as minimal air bubble formation and dirt deposits can be avoided. For drying the cathodic dip coating, a more energy-efficient transverse drying process is used instead of the usual external drying, in which air is blown into the interior and the bodywork is heated from the inside. This cross-drying process is better suited to electric and hybrid vehicles, which require longer curing times.
Pre-treatment with thin film process
In pre-treatment, the new thin-film process makes the system more efficient and eliminates the need for phosphating. Process steps such as activation and passivation are no longer necessary. A 0.2 micrometer thin layer of zirconium and silicon compounds is applied to the base metal. This serves as corrosion protection and an adhesive base for the primer. The new process helps to save waste, water and energy.
Saving energy in the top coat too
In the top coat, the paint mist was previously collected in water with 100 percent fresh air and disposed of. In the new dry separation process, it is captured by filters so that more than 90 percent of the filtered process air can be reused. In addition, there is no need to use fresh water and chemicals, which is necessary in conventional wet separation. According to Audi, the new paint separation process saves around 50 kilowatt hours per vehicle.
Read fo free: full article published in issue 11/2024 of mo Magazine for Surface Technology