BHAGIRATH COACH AND

METAL FABRICATORS
PVT. LTD.

TRANING PRESENTATION
BY:
NEERAJ DESHMUKH
B.TECH(MECH.)FINAL YEAR
ROLL NO: 3112623

COMPANY PROFILE:
BCMF was started in the year 1975.
ISO 9001:2000 certification
BCMF is the only cargo body supplier of EICHER.
Its deal with Truck Body, Coach Buses Body,

Luxury Passenger Buses Body, Container

Bodies, Ambulances Body, Mobile Laboratories
Body, Executive Coaches Body.

What is POWDER COATING ?

Powder coating is a dry finishing process, using fine particles

of paint, which are electrostatically charged and sprayed onto a

work piece.
Once the powder is applied, the part is cured, causing the
powder to adhere to the surface.
The main advantage of using the powder coating process is the
waste powder which is unused during the process can be
collected back by morden powder collecting methods , thus
helps to use this powder over and over again, which in turn
makes the Powder coating process highly economical.

PRINCIPLE:
Powder coating is based on Electrostatic

charging process.
In Electrostatic powder coating particles with
opposite charges attract each other.
When exiting the powder gun, the powder
particles are charged through the deposition of
air ions. The resulting ionized powder particles,
similar to the free ionized air particles, are
attracted to all earthed objects. In practice, the
earthed object is the work piece, thus the
powder remains bonded to it.

Characteristics of Powder Metal Powder

Particle Shape: The particle shape depends

largely on the method of powder manufacture. The

shape may be special nodular, irregular, angular,
and dendritic.
Particle Size: The particle size influences the
control of porosity, compressibility and amount of
shrinkage.
Flow Rate: It is the ability of powder to flow readily
and confirm to the mould cavity. It determines the
rate of production and economy.
Compressibility: It is defined as volume of initial
powder to the volume of compact part. It depends
on particle size, distribution and shape.

Apparent Density: It depends on particle size and

is defined as the ratio of volume to weight of

loosely fille.
Purity: Metal powders should be free from
impurities as the impurities reduces the life of dies
and effect sintering process.
Powder Constituents:
1. Resins are the key component of powder coatings.
2. Pigments are generally solid particulate materials
such as titanium dioxide or carbon black.
3. Extenders such as aluminum silicate are used to
provide opacity and act as filler.

PROCESS:
There are three steps in Powder coating

process.
(1) PRE TREATMENT PROCESS.
(2) POWDER COATING
(3) CURING

PRETREATMENT PROCESS:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Degreasing.
Water rinse.
Derusting.
Water rinse.
Activation.
Phosphating.
Water rinse.
Passivation.
Drying.

Sequence Process of (Pretreatment)

Powder Coat:

DEGREASING

WATER RINSE

DERUSTING

WATER RINSE

DESCALING

WATER RINSE

MATERIAL DRY

PASSIVATION

WATER RINSE

PHOSPHATING

ACTIVATION

Powder Coating by Spray gun:

The powder is applied with an

electrostatic spray gun to a part

that is at earth (or ground)
potential. Before the powder is
sent to the gun it is fluidized to
separate the individual grains of
powder and to improve the
electrostatic charge that can be
applied to the powder so that the
powder flows more easily to the
gun. Because the powder
particles are electro statically
charged, the powder wraps
around to the back of the part as
it passes by towards the air off
take system.

CURING:
When a thermosets powder is exposed to elevated

temperature, it begins to melt, flows out, and then

chemically reacts to form a higher molecular weight
polymer in a network-like structure. This curing process,
called cross linking. Normally the powders cure at 200C
(390F) in 10 minutes.
The equipments used for Powder Coating Are Powder
Coating Booths, Coating Equipments, and Baking Oven &
Material handling systems.
In which the work piece is going in to oven,
The temperature of the oven is 200*c.

ADVANTAGES:
No solvents are used.
Over-spray (up to 98%) can be reused.
More resistant to chipping, cracking, and

fading.
Corrosion and chemical resistant.
Coating does not run, drip, or sag.
Thick coatings are easily done.
Simple clean-up and maintenance.

DISADVANTAGE:
Thin coatings are difficult to produce
Storage and handling of the powder requires

special climate controls

Color matching is somewhat more difficult
Cure temperatures may be too high
Difficult to coat sharp corners

CARGO BODY OF
EICHER

PRODUCTION:
First of all take:
1. Raw material.
2. Base frame assembly.
3. Side assembly.
4. Grinding and Final rework.

1.Raw Material

2. Base frame assembly

3. Side assembly

4. Grinding & Final Work

PAINT SHOP
Paint application is one of the most demanding

aspects of automobile manufacturing. Not only does

the paint coating protect the body surface, it also
enhances visual appeal by sadding color and gloss
important selling points. The technology used must
meet high expectations of quality and cost.
Primary measures at the outset are unable to
prevent emissions, secondary measures are
necessary to reduce them. Statutory regulations
also require the careful use of valuable resources
such as water, power and paint raw materials.

PROCESS:
Degreasing :

Solvent degreasing is a process in which a cleaning agent is

applied directly to the surface by spraying, brushing, or wiping. This
process removes oil, grease, dirt, loose particles, and any other
contaminants that may exist on the surface of the material.
Phosphating :
Phosphate coatingsare used onsteelparts
forcorrosionresistance,lubricity, or as a foundation for subsequent
coatings or painting.
The main types of phosphate coatings aremanganese,ironand zinc.
Passivation:
Passivation, inphysical chemistryandengineering, refers to a
material becoming "passive," that is, being less affected by
environmental factors such as air and water. Passivation involves a
shielding outer-layer of base material, which can be applied as a
microcoating, or oxidation which occurs spontaneously in nature.

Dry oven:

After passing all pretreatment zones by

means of the conveyor system, residual humidity
is eliminated in the dry off oven to make sure the
adhesion of coming powder application.
Sealant:
Sealantis a substance used to block the
passage offluidsthrough the surface or joints or
openings in materials,a type ofmechanical seal.
Sealants are notadhesivesbut some have
adhesive qualities and are calledadhesivesealantsorstructural sealants.

Paint booth:

Primer is designed to adhere to surfaces

and to form a binding layer that is better prepared
to receive the paint.
Metal hydroxides/oxides do not provide a
solid surface for the paint to adhere to, and paint
will come off in large flakes. Using a primer will
provide extra insurance against such a scenario.
Baking oven:
Baking may also be called as stoving.
during baking in liquid form achieves formation of
continuous film. the extent of cross - linking during
the reaction depends upon the ingredients of paint.

READY FOR DISPATCH: