The automotive industry is continuously evolving, with consumers demanding high-performance, durable and eco-friendly vehicles. Manufacturers must use lightweight materials and advanced plastics, which require special treatment.
Plasma technology has become a game changer for automotive manufacturers. Using plasma to clean, activate, or coat surfaces ensures better adhesion of paints and coats. Plasma treatment improves material performance and bonding without altering its basic properties.
Protective layers due to the plasma coatings help to resist corrosion due to extreme temperatures. Plasma treatment enhances the bonding of paints and adhesives for various materials such as plastics, metals, and composites. We highlight the applications and benefits of plasma treatments in the automotive industry, in this article.
Understanding Plasma Treatment Machines in the Automotive Industry
Plasma treatment is a process that alters the material surface of various automotive components to enhance their properties. The most standard materials in the automotive industry are plastics, composites, metals, and rubber.
Plasma treatment creates a low-temperature plasma field where gas molecules are ionized (by an electric filed) into highly reactive particles. The plasma interacts with the material surface and either cleans, etches, or activates.
In the automotive industry, you can apply different types of plasma treatments. Atmospheric plasma treats large surfaces at atmospheric pressure. Low-pressure plasma occurs in a vacuum and is ideal for sensitive components. Corona discharge is ideal for non-conductive materials, while oxygen plasma cleaner removes organic contaminants.
Applications of Plasma Treatment in the Automotive Industry
Plasma treatment in the automotive industry is ideal for surface cleaning, coating, and activation of components such as body panels, batteries, or headlights.
Surface Cleaning and Contaminant Removal
Surface cleaning in the automotive industry helps remove contaminants such as dust, coolants, oils, grease, and fingerprints. The contaminants are by-products of machining or workers handling. They interfere with the adhesion of paints and coatings.
Thorough removal of contaminants ensures superior adhesion of coatings such as sealants and other protective films. The clean surface allows the coatings to bond uniformly, preventing problems such as bubbling or peeling. Hence reducing the risk of defects.
A clean surface makes the surface look appealing and improves the performance of the vehicle part. It protects a vehicle’s exterior body parts exposed to harsh environments.
Surface Activation for Improved Adhesion
Surface activation alters the surface properties of plastic, rubber, and metal components. Performing surface activation on various automotive components with different materials enables the formation of stronger bonds.
There are two types of surface activation forms, corona discharge and plasma etching. The etching forms some deep ridges in metallic surfaces. Corona discharge is for non-metallic surfaces such as plastics and foils.
Apart from forming stronger bonds, surface activation helps to reduce defects such as uneven coating, blistering, and peeling. The automotive parts and components become more durable with an attractive finish.
Surface activation helps to prevent corrosion due to the strong coatings on the components. The coatings enable the components to withstand exposure to harsh conditions. It is the ideal solution for components that face exposure to harsh conditions.
Improve the Surface Tension
Manufacturers create micro-textures on automotive parts or components to improve their surface tension. The paints and the coatings will adhere uniformly, resulting in high-quality finishes.
Plasma treatment processes use ionized gas (plasma) to create minute ridges, increasing a components’ adhesion quality. An improved surface tension also enhances a component’s resistance to corrosion, offering better protection against environmental conditions.
Improved surface tension increases a component’s resistance to wear and tear. Automotive parts are subject to constant movement. Strong coatings ensure that the parts resist mechanical stress and friction.
Specific Products in the Automotive Industry and Plasma Treatment Applications
Automotive parts such as body panels, engine components, and headlights benefit from plasma treatment processes.
Engine Components (Cylinders, Pistons, Valves)
Plasma treatment processes help to remove contaminants from engine components while creating a protective surface layer. The layer enables the components to resist high temperatures, friction, and wear.
Using plasma treatment processes on engine components such as pistons, valves, and cylinders improves their performance and durability. The treatments are ideal for high-performance engines that operate under extreme conditions.
Body Panels and Chassis
The ideal plasma treatment processes for body panels and chassis are surface activation and etching. Plasma activation ensures the coatings bond effectively, while etching ensures a smoother and uniform finish.
Plasma treatment ensures that the body panels and the chassis have a durable and corrosion-resistant coating. The components also benefit from a high-quality finish.
Interior Components (Dashboard, Seats, Trim)
Plasma treatment processes improve the bonding of adhesives and coatings on a vehicle’s interior components, such as dashboards, trims, and seats. The vehicle’s interior remains attractive while boosting its durability.
A stronger coating makes the interior component surfaces more resistant to fading or peeling.
Headlights and Taillights
Plasma cleaning of automotive headlights and taillights removes contaminants resulting in clearer plastic lenses. Cleaner headlights and taillights help to maintain maximum visibility and provide clarity, ensuring safety for road users.
Once the surfaces are cleaner, further treatment, such as bonding and coating, becomes possible. Plasma coating provides a layer that will protect the headlights and taillights from moisture and UV degradation.
Rubber Seals and Gaskets
Plasma treatment improves the adhesion of coatings and adhesives of rubber seals and gadgets. It enhances the component’s resistance to extreme temperatures and other environmental factors.
The rubber seals and gadgets last longer and can withstand leaks and failures. The result is durability and optimal performance in automotive applications.
Battery Components
The surface activation process in plasma treatment enhances electrical performance and safety by coating battery components. It improves the quality of coatings adding a protective layer.
The battery component becomes more efficient, reducing internal resistance and extending the lifespan of electric vehicles.
Wheels and Rims
Manufacturers perform plasma treatment to clean and coat an automotive’s wheels and rims efficiently. Cleaning removes contaminants and surface impurities. Plasma treatment also makes it possible to provide a strong coating that enhances resistance to unfavorable road conditions.
A suitable coating protects the rims from corrosion, wear and damage impact. Cleaner wheels are more durable and attractive.
Exhaust Systems
Plasma treatments help in coating exhaust systems to enhance their resistance to corrosive gases. Surface cleaning removes contaminants and prepares the surface for further treatment.
The process ensures that the exhaust systems function efficiently.
Benefits of Plasma Treatment in the Automotive Industry
Plasma treatment helps in cleaning contaminants and removing impurities such as oil and
grease. These impurities interfere with bonding and coating. Hence, using plasma treatment for automotive parts helps to improve the adhesion of coats and paints.
High-quality coatings and paintings ensure the automotive components are less likely to peel, chip, or crack under stress. Exterior body parts more likely to be affected by harsh conditions benefit from plasma treatments. Plasma-treated surfaces are more durable and highly resistant to wear and tear.
Plasma treatment processes do not require chemicals, unlike traditional industrial cleaning processes. It is an eco-friendly process that reduces waste and poisonous by-products, resulting in a cleaner manufacturing process.
You can use plasma treatment processes on a variety of materials. Automotive parts and components are made from different materials. Not many cleaning and surface modification processes are suitable for most materials.
Choosing the Right Plasma Treatment Machine for Automotive Applications
Looking for the right plasma treatment machine for automotive applications? There are a few factors you can consider to make the process easier.
Automotive parts and components come in different material types. Each plasma treatment machine is only suitable for a specific material type.
You’ll also have to consider the plasma treatment process you want to apply. However, it is essential to consider that large automotive parts will require open-air treatment processes. Hence, an atmospheric plasma machine is ideal. A low-pressure plasma machine is a better option for smaller automotive parts and components.
When you have a high-volume production process, you’ll need a machine that can easily fit into the existing assembly line. The ideal machine should offer fast cycle times and allow continuous processing. However, for smaller parts and components, a batch plasma system would be a better option.
Future Trends in Plasma Treatment for the Automotive Industry
The demand for electric vehicles (EVs) is pushing manufacturers to become more innovative with surface cleaning and treatment processes. Electric vehicles require unique components and parts with suitable surface preparation. Plasma treatment helps the EV components to have better bonding properties and a stronger coating.
Most automotive manufacturers are choosing to use lightweight materials so as to reduce a vehicle’s weight. However, lightweight materials require specific treatment processes. Plasma treatment ensures that it is possible to clean and alter the surfaces of these lightweight materials.
There is a need for more precise surface treatments for the more modern Autonomous Vehicles (AV). Most of the vehicles have complex components such as lights and sensors. Plasma treatment processes enhance the performance of protective coating on these components.
Consumers are also becoming sensitive to sustainability. Plasma treatments do not use chemicals and are still evolving to support greener manufacturing processes. New plasma machines will also help manufacturers lower their carbon footprint.
Conclusion
Plasma treatment processes have significantly contributed to the automotive industry by enhancing surface cleaning and modification. The various plasma processes, such as activation, cleaning, and etching, help to improve durability and bonding.
Please contact Fari Plasma for cutting-edge plasma treatment solutions.
