More efficiency and sustainability in surface technology

Paint spray test at Fraunhofer IPA: A robot sprays paint onto a collision bumper, and an inline laser detector as well as other sensors record everything. The collected data was used to train an artificial intelligence. © Fraunhofer IPA/Photo: Rainer Bez

A pre-treatment simulated on the computer, a paint process monitored by artificial intelligence, and a water-based zinc primer: Under the motto "Finishing for Compliments," the Fraunhofer IPA will provide insights into current research projects in mid-April at the PaintExpo: Hall 1, Stand 1322.

"Finishing for Compliments – with research and know-how for genuine compliments" – under this motto, the researchers from the Fraunhofer Institute for Production Technology and Automation IPA present their trade fair appearance at this year's PaintExpo. From April 14 to 17, they will provide insights into current research projects that help coating companies achieve more sustainable and smart, AI-supported painting processes – and perhaps even earn compliments from their customers.

The compressed air blasting goes digital

Jörg Schieweck from the Process Modeling and Monitoring research team at Fraunhofer IPA is developing a simulation-supported pre-treatment process in the "DigiStrahl" project. The goal is to digitally model, analyze, and optimize the so-called compressed air blasting.

Similar to a high-pressure cleaner, compressed air blasting involves shooting solid particles at a metallic surface. This creates a uniform roughness, ensuring that the subsequent coating process allows the paint to adhere to the surface. By simulating the compressed air blasting on the computer beforehand, it is possible to assess which abrasive material and which settings on the system deliver the best results. This digitalized compressed air blasting increases efficiency and saves small and medium-sized companies a lot of money because they use less abrasive material and energy and produce less waste.

Flawless painting processes thanks to artificial intelligence

The painting process itself is still considered a complex process to control fully. There is a risk of waste, equipment failures, and rework because, for example, the specified paint layer thickness cannot always be maintained everywhere. Oliver Tiedje, head of the Coatings and Multifunctional Materials division at Fraunhofer IPA, has therefore found ways in the "pAInt-Behaviour" research project to reduce the number of errors and machine downtimes using artificial intelligence.

For this, Tiedje and his team conducted a series of painting tests on plastic components from the automotive and commercial vehicle sectors in the Fraunhofer IPA coating laboratory. Before each test, they deliberately changed the settings on the painting system, accepting errors, and monitored the painting process with 30 different sensors. The collected measurement and process data were analyzed using machine learning methods. This resulted in a detailed behavior model that can detect impending quality deviations early in the painting process and identify their causes.

Environmentally friendly water-based zinc primer

Scientists around Katarzyna Krawczyk from the Testing Technology and Paint Chemistry research team at Fraunhofer IPA have been working on coatings that protect against rust. In the "EcoWaterZinc" research project, they developed a solvent-free zinc primer based on water, solving an environmental and health problem.

Because the zinc-containing coatings currently in use contain health-damaging solvents. When such coatings cure indoors, they release large amounts of volatile organic compounds. These "Volatile Organic Compounds" (VOC) not only smell unpleasant but can also irritate mucous membranes. On the other hand, zinc reacts with water. In the long run, this not only diminishes the anti-corrosive effect but also causes zinc to accumulate in rivers and lakes, endangering the health of humans and animals. The new primer developed at Fraunhofer IPA contains modified zinc particles that do not react with water, forming a durable anti-corrosive coating.

Insights into current research projects at PaintExpo

A pre-treatment simulated on the computer, a paint process free of errors thanks to artificial intelligence, and long-lasting anti-corrosive zinc primers – these are just three examples of current research work at Fraunhofer IPA. Visitors to PaintExpo can gain insights into these and other ongoing or recently completed projects at the Fraunhofer IPA booth: Hall 1, Stand 1322.