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Coloring and resistance to corrosion of cars

 

Automotive paint is paint used on automobiles for both protective and decorative purposes.^[1][2] Water-based acrylic polyurethane enamel paint is currently the most widely used paint for reasons including reducing paint's environmental impact.

Modern automobile paint is applied in several layers, with a total thickness of around 100 μm (0.1mm). Paint application requires preparation and primer steps to ensure proper application. A basecoat is applied after the primer paint is applied. Following this, a clearcoat of paint may be applied that forms a glossy and transparent coating. The clearcoat layer must be able to withstand UV light.

History

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In the early days of the automobile industry, paint was applied manually and dried for weeks at room temperature because it was a single component paint that dried by solvent evaporation. As mass production of cars made the process untenable, paint began to be dried in ovens. Nowadays, two-component (catalyzed) paint is usually applied by robotic arms and cures in just a few hours either at room temperature or in heated booths.

Until several decades ago lead, chromium, and other heavy metals were used in automotive paint. Environmental laws have prohibited this, which has resulted in a move to water-based paints. Up to 85% of Lacquer paint can evaporate into the air, polluting the atmosphere. Enamel paint is better for the environment and replaced lacquer paint in the late 20th century.^[1] Water-based acrylic polyurethane enamels are now almost universally used as the basecoat with a clearcoat.^[3]

Processes and coatings

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Preparation

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High-pressure water spray jets are directed to the body. Without proper pretreatment, premature failure of the finish system can almost be guaranteed. A phosphate coat is necessary to protect the body against corrosion effects and prepares the surface for the E-Coat.

The body is dipped into the Electro-Coat Paint Operation (ELPO/E-Coat), then a high voltage is applied. The body works as a cathode and the paint as an anode sticking on the body surface. It is an eco-friendly painting process. In E-Coat, also called CED paint, use is approximately 99.9% and provides superior salt spray resistance compared to other painting processes.^[4]

The primer is the first coat to be applied. The primer serves several purposes.

• It serves as a leveler, which is important since the cab often has marks and other forms of surface defect after being manufactured in the body shop. A smoother surface is created by leveling out these defects and therefore a better final product.
• It protects the vehicle from corrosion, heat differences, bumps, stone-chips, UV-light, etc.
• It improves ease of application by making it easier for paints to stick to the surface. Using a primer, a more varied range of paints can be used.

The base coat is applied after the primer coat. This coat contains the visual properties of color and effects, and is usually the one referred to as the paint. Base coat used in automotive applications is commonly divided into three categories: solid, metallic, and pearlescent pigments.

• Solid paints have no sparkle effects except the color. This is the easiest type of paint to apply, and the most common type of paint for heavy transportation vehicles, construction equipment and aircraft. It is also widely used on cars, trucks, and motorcycles. Clear coat was not used on solid colors until the early 1990s.
• Metallic paints contain aluminium flakes to create a sparkling and grainy effect, generally referred to as a metallic look. This paint is harder to manage than solid paints because of the extra dimensions to consider. Metallic and pearlescent paints must be applied evenly to ensure a consistent looking finish without light and dark spots which are often called "mottling". Metallic basecoats are formulated so that the aluminium flake is parallel to the substrate. This maximises the "flop". This is the difference in the brightness between looking perpendicularly at the paint and that at an acute angle. The "flop" is maximised if the basecoat increases in viscosity shortly after application so that the aluminium flake which is in a random orientation after spraying is locked into this position while there is still much solvent (or water) in the coating. Subsequent evaporation of the solvent (or water), leads to a reduction in the film thickness of the drying coating, causing the aluminium flake to be dragged into an orientation parallel to the substrate. This orientation then needs to be unaffected by the application of the clear coat solvents. The formulation of the clear coat needs to be carefully chosen so that it will not "re-dissolve" the basecoat and thus affect the orientation of the metallic flake but will still exhibit enough adhesion between the coatings so as to avoid delamination of the clear coat. A similar mode of action occurs with pearlescent pigmented basecoats.
• Pearlescent paints contain special iridescent pigments commonly referred to as "pearls". Pearl pigments impart a colored sparkle to the finish which works to create depth of color. Pearlescent paints can be two stage in nature (pearl base color + clear) or 3 stage in nature (basecoat + pearl mid-coat + clear-coat).^[5]

Usually sprayed on top of a colored basecoat, clearcoat is a glossy and transparent coating that forms the final interface with the environment. For this reason, clearcoat must be durable enough to resist abrasion and chemically stable enough to withstand UV light. Clearcoat can be either solvent or water-borne.^[6]

One part and two part formulations are often referred to as "1K" and "2K" respectively.^[7] Car manufacturer (OEM) clear coats applied to the metal bodies of cars are normally 1K systems since they can be heated to around 140 °C to effect cure. The clear coats applied to the plastic components like the bumpers and wing mirrors however are 2K systems since they can normally only accept temperatures up to about 90 °C. These 2K systems are normally applied "off line" with the coated plastic parts fixed to the painted metallic body. Owing to the difference in formulation of the 1K and 2K systems and the fact they are coated in different locations they have a different effect on the "redissolving" of the metallic base coat. This is most easily seen in the light metallic paints like the silver and light blue or green shades where the "flop" difference is most marked.

The terminology for automotive paints has been driven by the progression of technologies and by the desire to both distinguish new technologies and relate to previous technologies for the same purpose. Modern car paints are nearly always an acrylic polyurethane "enamel" with a pigmented basecoat and a clear topcoat. It may be described as "acrylic", "acrylic enamel", "urethane", etc. and the clearcoat in particular may be described as a lacquer. True lacquers and acrylic lacquers are obsolete, and plain acrylic enamels have largely been superseded by better-performing paints.^[8] True enamel is not an automotive paint. The term is common for any tough glossy paint but its use in the automotive industry is often restricted to older paints before the introduction of polyurethane hardeners.^[9]

Modern car paint is typically made from acrylic-polyurethane hybrid dispersions, which are a combination of two different plastics.^[10] They were developed during the 1970's and 80's as a water-soluble replacement for enamel paints, following health concerns over their high VOC content. Acrylic is less expensive and can hold more pigment, but has poor scratch resistance, whereas polyurethanes are harder but more costly. Combining both types gives a material which can contain a lot of color and be hard-wearing. Simply mixing the materials is not sufficient, as this give heterogeneous coating with separate acrylic and polyurethane domains. Instead, the starting chemicals for each plastic (monomers) are combined and partially polymerized to give an interpenetrating polymer network. Within this the polymer-chains are not chemically bonded to one another, but instead become entangled and interwoven and as they form. This is possible because they polymerize in different ways, which are incompatible with each other. Polyurethane is formed by step growth polymerization involving polycondensation, whereas acrylic is formed by chain growth polymerization featuring free radicals. The resulting product is homogeneous and tough, with superior properties to the individual plastics.

Innovations are taking place in paint industry as well. These days, automotive paints come in liquid form, spray form, and powder forms:-

• Liquid: Usually polyurethane paints. Compressor is needed to apply.
• Spray: This is as same as perfume in spray bottle. Made for DIYer.
• Powder or additive: Paints in powder form applied after mixing in paint thinner.

Types of automotive paints

• Removable: These kinds of paints are made for giving custom appearance to vehicle.
• Non-removable: Made for touch-ups and painting vehicle.

• Fordite, automotive paint which has been layered and dried over time

• Automotives Paints and Coatings, Streitberger & Dössel, 2008
• Hans-Joachim Streitberger; Karl-Friedrich Dossel (31 March 2008). Automotive Paints and Coatings. John Wiley & Sons. ISBN 978-3-527-30971-9.
• Universal Motorcars (24 April 2020). Automotive body Paints and repair. Universal Motorcars.
• Paint Materials and Processes from an Automotive OEM Perspective

Facility used to clean the exterior of motor vehicles

For other uses, see Car wash (disambiguation).

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A car wash,^[1] or auto wash, is a facility used to clean the exterior,^[2] and in some cases the interior, of cars. Car washes can be self-service, full-service (with attendants who wash the vehicle), or fully automated (possibly connected to a filling station). Car washes may also be events where people pay to have their cars washed by volunteers, often using less specialized equipment, as a fundraiser.^[3]

History

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The first U.S. patent for a mechanized car wash was filed in 1900 and soon followed by "auto laundries".^[4] The Automobile Laundry in Detroit, Michigan, opened in 1914 by Frank McCormick and J.W. Hinkle, is considered the first business in the U.S. to adopt the name "car wash" for their services.^[5] Manual car wash operations, which used manpower to push or move the cars through stages, peaked at 32 drive-through facilities in the United States. The first semi-automatic car wash in the United States debuted in 1946 at a facility in Detroit, which used automatic pulley systems and manual brushing.^[6][4]

Dan Hanna, encouraged by car washers in Detroit, founded a car wash in 1955 called the Rub-a-Dub in Oregon. He later formed Hanna Enterprises and reached about 31 locations. Hanna operated his wash rack until adopting a mechanized car washing system in 1959.^[7] The company became one of the leading manufacturers of car washing equipment and materials, including brushes, conveyor belts, tire washes, and recirculating water systems.^[7] In the late-1960's, some car washes began to adopt "flex-serve" models to accommodate customers who did not want a full interior and exterior cleaning, in which facilities such as vacuuming and hand detailing are constructed near the exit as an optional service.^[6]

The car wash industry in the U.S. remained primarily led by small businesses that distinguished themselves through playful signage or building architecture.^[4] At the turn of the 21st century, the "express exterior" business model—first developed by a chain in Baton Rouge, Louisiana—began to emerge, in which computerized point of sale and queueing systems are used to manage customer throughput via automation, reducing the amount of staff required.^[6] In the 2010s, this model began to be combined with subscription-based car wash services, which offer convenience and potentially lower costs for car owners compared to traditional pay-per-wash models.^[6][4]

Due to their turnkey nature and lower staffing requirements, express exterior washes became an ubiquitous business model for the industry, resulting in many operators and private equity firms investing in opening larger chains of locations.^[4][6] As of 2024, the United States is estimated to have approximately 60,000 car washes that constitute a $14 billion industry.^[4] It has experienced steady growth, with an average annual expansion of 5% in recent years; some market analysts project the industry to double in size by 2030, partly attributed to the growth of subscription-based services.^[4] Additionally, the market share of professional car washes has grown significantly, from 50% in 1996 to an estimated 79% in 2021.^[4] This suggests a decline in the number of individuals washing their cars themselves. The average revenue per car wash location is reported to be around $1.5 million.^[4]

Some municipalities in the United States have enacted saturation bans due to the number of new car wash locations being constructed in clusters.^[4]

The following are forms of car washing.

• Hand car wash Vehicles are cleaned manually by attendants using cloths, brushes, and buckets or hoses. These facilities may offer basic exterior washing or full detailing services, including interior cleaning.
• Self-service facilities, generally coin-operated, where the customer manually washes the car with a water-dispersing wand and low-pressure brushes, including pressurized "jet washing".^[8]
• In-bay automatics involve the customer parking and an automatic wash machine rolling back and forth over the stationary vehicle. Housed at filling stations and stand-alone wash sites.^[9]
• Conveyor or tunnel washes involve the car moving on a conveyor belt through a series of fixed cleaning mechanisms while the customer waits outside. Friction (brushes or curtains) or frictionless (high-pressure nozzles and touches wash) are used.^[10]
• Mobile car washes Operators travel to the customer’s location with equipment mounted on vans, trailers, or trucks. Services may include exterior washing, waxing, and interior cleaning. Many operators use water tanks, pressure washers, generators, vacuums, and buffers.
• Car wash lift systems, where cars are placed on a lift platform that can be used to wash under the car.
• Touch-free (or touchless) car washing technology is the modern car wash system that reduces water consumption, chemical solutions, and time. Washing machinery uses high-pressure jets that measure the length and width of the vehicle.^[11]
• Steam car wash: Steam cleaning uses high-temperature steam to remove dirt and grime from both the exterior and interior surfaces. This method is water-efficient and often used for sanitization purposes.
• Waterless car wash: This technique uses high-lubricity cleaning agents and microfiber cloths to clean the vehicle without the need for rinsing with water. It is favored in areas with water restrictions or where mobility is prioritized.

In modern car wash facilities, whether tunnel, in-bay automatic, or self-serve, detergents and other cleaning solutions are designed to loosen and eliminate dirt and grime. This is in contrast to earlier times, when hydrofluoric acid, a hazardous chemical, was commonly used as a cleaning agent in the industry by some operators.^[12] There has been a move in the industry to shift to safer cleaning solutions. Most car wash facilities are legally required to treat and/or reuse their water and may be required to maintain wastewater discharge permits. This is in contrast to unregulated facilities or even driveway washing (at one's home), where wastewater can end up in the storm drain and, eventually, in streams, rivers, and lakes.

A chemical car wash, or waterless car wash, uses chemicals to wash and polish car surfaces. This method is claimed to be eco-friendly,^[13] but is recommended only for cars with light dirt accumulation to avoid paint damage.^[14]

Mechanized car washes, especially those with brushes, may risk damaging the exterior finish. Paint finishes and car washing processes have improved. More facilities utilize "brushless" (cloth) and "touch-free" (high-pressure water) equipment, as well as modern "foam" washing wheels made of closed-cell foam.

A self-serve car wash is a simple and automated type of car wash that is typically coin-operated or token-operated self-service system. Newer self-service car washes offer the ability to pay with credit cards or loyalty cards. The vehicle is parked inside a large, sometimes covered, bay equipped with a trigger gun and wand (a high-pressure sprayer) and a foam brush for scrubbing. When a customer inserts coins or tokens into the coin box, they can choose options such as soap, tire cleaner, wax, or clear water rinse, all dispensed from the sprayer, or scrub the vehicle with the foam brush. The number of coins or tokens inserted determines when customers operate the equipment; in most instances, a minimum number of coins is necessary to start the equipment. These facilities are often equipped with separate vacuum stations that allow customers to clean the upholstery and rugs inside their cars. Some self-service car washes offer hand-held dryers.

While self-service car washes offer flexibility and cost savings, they can also present challenges. In colder climates, water runoff can freeze in and around the bay, creating potential safety hazards.Moreover, self-serve vacuum stations may harbor various bacteria, including Staphylococcus aureus, Pseudomonas aeruginosa, Listeria monocytogenes, and coliforms such as Escherichia coli. These microorganisms can pose health risks, particularly to individuals with compromised immune systems, and may lead to the transfer of contaminants onto vehicle interiors during cleaning.

The first conveyor-driven automatic car wash appeared in Hollywood, California, in 1940.^{[citation needed]} Conveyor-driven automatic car washes consist of tunnel-like buildings into which customers (or attendants) drive.

Before entering the automated section of the wash tunnel, attendants may prewash customers' cars.

The car wash typically starts cleaning with chemicals called presoaks applied through special arches. CTAs, or "chemical tire applicators", apply specialized formulations, which remove brake dust and build-up from the surface of the wheels and tires.

A high-pressure arch may direct water at the vehicle's surface at the end of a car wash's presoak.

Mitters are ribbon-like components that suspend cloth strips or sheets over the tunnel

The car is rinsed with fresh water immediately, followed by extra services if required. In many car washes, the first of these services is a polish wax. After the polish, the wax application is typically a retractable mitter or top brush and, in some cases, side brushes or wrap-around brushes. Next is a protectant, which creates a thin protective film over a vehicle's surface. Protectants generally repel water, which assists in drying the car and aiding in the driver's ability to see through their windshield during rain. A low-end wax or clear coat protectant follows the primary protectant. A drying agent is typically applied at the end of the tunnel to remove water from the vehicle's surface before forced air drying. After the drying agent, there may be a "spot-free" rinse of soft water that has been filtered of the salts usually present and sent through semi-permeable membranes to produce highly purified water that will not leave spots.

Dryers may be present in various forms, such as stationary gantries with a contouring roof jet or small circular assemblies with nozzles of different shapes and sizes mounted on arches. Mitters, side brushes, top brushes, and/or wraps outfitted with chamois- or microfiber-based material may follow the dryers.

At "full-service" car washes, the car's exterior is washed mechanically, by hand, or using a combination of both, with attendants available to dry the vehicle manually and clean the interior. Many full-service car washes also provide "detailing" services, which may include polishing and waxing the car's exterior by hand or machine, shampooing,^[15] and steaming interiors as well as other services to provide thorough cleaning and protection to the car.

Like soft-touch car washes, touchless car washes are automated, with the vehicle passing through a tunnel where it is cleaned. However, touchless car washes do not use the foam or cloth applicators that soft-touch washes use; instead, they rely on high-pressure washers to clean and rinse the vehicle. Sensors utilized by these washes allow for a more precise clean along with the vehicle's exact shape.^[16] To compensate for not physically contacting the vehicle, touchless washes use higher pressures and more caustic detergents than ordinary car washes.^[17] Because the vehicle is not physically touched during a touchless wash, the vehicle is at a lower risk of being damaged. However, touchless washes have a harder time cleaning off tougher materials or reaching difficult-to-reach locations on vehicles, and their usage of stronger chemicals can potentially damage a vehicle's paint finish.^[16][18]

The primary environmental considerations for car washing are:

• Use of water and energy resources;
• Contamination of surface waters;
• Contamination of soil and groundwater.

The use of water supplies and energy is self-evident since car washes are users of such resources. The professional car wash industry has made strides in reducing its environmental footprint, a trend that will continue accelerating due to regulation and consumer demand. Many car washes use water reclamation systems to significantly reduce water usage and a variety of energy usage reduction technologies.^[19] These systems may be mandatory where water restrictions are in place.

Contamination of surface waters may arise from the rinse discharging to storm drains, which eventually drain to rivers and lakes. Chief pollutants in such wash-water include phosphates; oil and grease; and lead. This is almost exclusively an issue for home/driveway washing and parking lot-style charity washes. Professional carwashing is a point source of discharge that can capture these contaminants, generally in interceptor drains, so the contaminants can be removed before the water enters sanitary systems. (Water and contaminants that enter stormwater drains are not treated and released directly into rivers, lakes, and streams.)

Soil contamination is sometimes related to such surface runoff and is associated with soil contamination from underground fuel tanks or auto servicing operations which commonly are ancillary uses of car wash sites — but not an issue for car washing.

For these reasons, countries like Switzerland and Germany have banned citizens from washing their cars at home.^[20] In the US, some state and local environmental groups (the most notable being the New Jersey Department of Environmental Protection) have begun campaigns to encourage consumers to use professional car washes as opposed to driveway washing, including moving charity car wash fundraisers from parking lots to professional car washes. Poland, Portugal, Italy, and many other countries have no regulations regarding wastewater from car washing.^[20]

 

An abandoned self-serve car wash in Houston, Texas

• Auto detailing
• Automobile repair shop
• Car costs
• Jetwash
• LaserWash, a brand of touchless in-bay automatic car wash

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