Effect of Clearcoat Thickness on Surface Roughness

By Chris Tighe, Jennifer Giroux , Paul Henshaw

The paint finish of a vehicle plays a major role in how customers perceive a vehicle’s quality. For most, the ideal look is mirror-like: highly glossy and perfectly smooth. Most vehicle manufacturers apply five coating layers; each layer in the coating process has a unique function. Beginning at the surface of the vehicle body, the zinc-coated steel is treated with phosphate.

The pur­pose of the phosphate layer is to clean and chemically treat the vehicle body. The zinc phosphate coating promotes adhesion of electrocoat primer, the second layer, to the steel and enhances corrosion pro­tection. The electrocoat layer, or e-coat layer, also aids in corrosion resistance of the steel body. The third layer, the full body anti-chip primer, is employed to improve resistance to chipping.

Above this layer lies the base coat layer, which is added for color and provides protection from second layer, to the steel and enhances corrosion pro­tection. The electrocoat layer, or e-coat layer, also aids in corrosion resistance of the steel body. The third layer, the full body anti-chip primer, is employed to improve resistance to chipping. Above this layer lies the base coat layer, which is added for color and provides protection from UV light.

Finally, the top layer, clearcoat, is applied to the vehicle to enhance durabil­ity and shine. light. Finally, the top layer, clearcoat, is applied to the vehicle to enhance durabil­ity and shine.