자동차 도장실무

제1장 자동차 보수도장 일반
1. 도장 목적 15
2. 신차 도장(OEM 도장) 16
● 표면처리공정···················16
● 하도도장······················17
● 중도도장······················18
● 상도도장······················18
● 검사··························19
● 신차라인의 도장구성·············19
3. 자동차 보수도장 20
● 보수도장의 목적·················20
● 보수도장의 공정·················20
4. 최근 자동차 도장의 변천 22
5. 자동차보수도료의 조성 22
● 하도용 도료····················22
● 중도용 도료····················29
● 상도도료······················33
● 경화제························39
6. 도료의 건조 39
● 도료 건조의 기본 조건············40
● 건조의 종류····················40
● 건조시간······················43
● 건조 7단계·····················45
7. 도료 및 도막시험법 46
● 시험 방법에 관한 규격············46
● 시험 및 결과 판정시 주의사항······47
● 도료 시험법····················48
● 도막 시험법····················51
제2장 도장장비와 공구
1. 보수도장 설비 60
● 도장실(spray booth) ·············60
● 구비요건······················62
● 도장실의 조건··················66
● 유지관리······················69
2. 연마실(sanding room) 72
3. 공압설비(air piping) 73
● 공기압축기(air compressor) ·······74
● 공압 배관(air pipe) ··············78
● 압축 공기 중의 수분·············81
● 자동차 보수 도장시의 공기소모량····18
● 압축 공기 라인 설계 시 최소 직경···· 82
● 사용 호스와 길이에 따른 압력 저하··28
● 압축공기의 관내에서의 문제점······38
4. 기타 장비 및 공구 83
5. 공정별 사용 장비 및 공구 85
대표적인 공구
● 스프레이 건(spray gun) ··········86
● 샌더(sander) ··················109
● 흡진기·······················113
● 건조기(dryer) ·················114
공정별 공구
● 하도 공정·····················117
● 중도 공정·····················120
● 조색 공정·····················121
● 상도 공정·····················127
● 광택 공정·····················127
6. 기타 재료 130
● 마스킹(masking) 관련 재료······130
● 연마지(sand paper) ············137
● 송진포(tack cloth) ·············143
● 필터·························144
● 용기·························145
● 에어 블로 건(air blow gun) ······146
● 스프레이건 거치대··············147
● 걸레·························147
● 세척용 기구···················148
● 적외선 온도계·················148
제3장 조 색
1. 색의 기본원리 151
● 색을 지각하는 기본원리에 관한 일반 지식 ··················151
● 색의 분류 및 색의 3속성·········155
2. 색의 혼합 157
● 가산혼합·····················157
● 감산혼합·····················157
● 중간혼합·····················158
3. 색의 표시 158
● 관용색명, 일반색명··············158
● 먼셀의 표색계·················158
● CIE 색표계···················163
4. 색의 지각적인 효과 164
● 색의 대비·····················164
● 색의 동화, 잔상, 명시도와 주목성, 진출, 후퇴, 수축, 팽창 등 ··166
5. 색의 감정적인 효과 170
● 온도감, 중량감, 흥분과 침정, 색의 경연감 등 색의 수반감정에 관한 사항·····170
● 색의 연상과 상징에 관한사항······172
6. 색채 응용 173
● 색채의 조화와 배색에 관한 일반지식 173
● 조색방법에 관한 사항············176
제4장 자동차 보수도장 조색
1. 조색이란 177
● 색상차이의 원인················178
● 색상의 비교···················181
● 조색 방법·····················184
2. 솔리드 컬러 조색 186
● 조색의 목적···················187
● 조색공정·····················187
3. 2coat 메탈릭·?펄 컬러 조색 188
● 메탈릭 컬러(metalic color) ······188
4. 3coat 펄 도료의 조색 196
● 펄 컬러(pearl color) ···········196
● 펄(pearl) 조색법···············198
● 자동차 메이커별 차량 칼라 확인법·· 199
제5장 자동차도장공정[표준도장]
1. 자동차 보수 도장의 범위 205
● 전체 도장(all spray) ············205
● 패널 도장(panel spray) ·········206
● 부분 도장(blending spray) ·······207
● 터치업 도장(touch up spray) ·····207
2. 표준 도장 공정 208
● 탈지공정과 에어블로············208
● 하도공정·····················210
● 중도공정·····················243
3. 상도공정 256
● 도장부위별 도장방법············256
● 2Coat 도장공정················271
● 3Coat 도장공정················282
● 수용성 도료 도장방법············286
제6장 자동차도장공정[부분도장]
1. 도장 범위 292
● 차체의 중앙에 상처 발생·········292
● 패널 모서리 부분의 상처 발생·····293
● 후드의 부분도장················294
2. 부분도장 공정 295
제7장 자동차도장공정[마스킹작업]
● 마스킹 테이프 붙이는 방법·······314
● 마스킹 제거하는 방법············314
● 마스킹 작업요령················315
● 마스킹 테이프 넓이에 따른 작업부위 316
● 마스킹 작업···················317
제8장 자동차도장공정[기타 재질도
1. 플라스틱 도장 324
● 목 적························324
● 플라스틱 소재의 종류············325
● 플라스틱 도장 공정·············325
● 플라스틱 사출 성형 불량현상······327
2. 알루미늄 재질 도장 328
● 탈지·························328
● 연마·························328
● 워시프라이머 적용··············329
제9장 자동차도장공정[광택]
1. 광택(gloss)의 정의 330
2. 광택작업 공정 332
● 세차(car washing) ·············332
● 도장상태의 확인················332
● 작업준비·····················333
● 작업 용품·····················335
● 도장면의 결함제거··············337
● 콤파운딩(compounding) 작업·····339
● 폴리싱(polishing) 작업··········340
3. 광택 작업시 주의 사항 341
제10장 자동차도장공정[UV도료]
1. UV 도료란 344
● UV경화도료의 조성·············344
● 광개시제(photoinitiator) ·········345
● 도료의 반응과정················346
● UV도료의 장단점···············346
● UV도료 취급 시 주의사항········348
● UV도료 및 장비················349
제11장 자동차도장공정[유리막코팅]
1. 유리막 코팅이란 350
2. 유리막 코팅의 특징 350
3. 자동차 도장면에 대한 오염방지 코팅 351
4. 유리막 코팅의 작업방법 351
제12장 자동차도장공정[덴트]
1. 덴트의 정의 356
2. 덴트 복원기술의 이해 357
3. 덴트 복원용 공구 358
4. 덴트 공정 360
제13장 특수도장
1. 특수 도료 362
● 크롬 도장(chromium painting) ··· 362
● 캔디 도장(candy painting) ·······366
● 미라크롬·····················366
● 온도 감응형 도료···············367
● 야광도료 및 형광도료············367
● 무늬 형성 도료················368
● 마블링(marbling) ··············368
● 기타·························371
2. 커스텀 도장(custom painting) 372
● 이미지 도장···················372
● 고스트 프레임 도장·············383
제14장 안 전
1. 안전기준 및 재해 386
● 안전기준·····················386
● 재해·························388
● 화재·························389
● 안전 색채·····················390
● 유기용제·····················390
● 도장 작업시 발생하는 손상·······394
● 휘발성 유기화합물[VOC] ·········394
2. 안전보건표지 399
3. 도장 작업시 사용되는 안전보호구
종류 399
● 방진복·······················399
● 마스크·······················400
제15장 도장 결함
1. 도장작업 전 도장 결함 402
● 침전(setting) ··················402
● 겔화(gelling, livering) ··········403
● 피막(skinning) ················403
2. 도장작업 중 도장결함 404
● 연마 자국(sander scratch) ·······404
● 퍼티 자국(putty mark) ··········405
● 퍼티 기공·····················406
● 메탈릭 얼룩(blemish) ···········407
● 먼지 고착(seeding) ·············407
● 크레타링(cratering) ·············409
● 오렌지 필(orange peel) ·········410
● 흘림(sagging) ·················411
● 백화(blushing) ················412
● 번짐(bleeding) ················412
3. 도장 작업 후 작업 불량 413
● 부풀음(blister) ················413
● 리프팅(lifting) ·················414
● 핀홀(pin hole) ················415
● 박리현상(peeling) ··············416
● 광택저하(fading) ···············417
● 균열(checking) ················417
● 물자국 현상(water spoting) ······418
● 크래킹(cracking) ···············419
● 변색(discoloration) ·············420
● 녹(rusting) ···················420
● 화학적 오염···················421