First Best Smart Electro-Deposition 0

First ! Best ! Smart ! Electro-Deposition 0

First ! Best ! Smart ! Background Electrodeposition A term for a broad range of industrial processes which includes electrocoating, e -coating, cathodic electrodeposition, and Anode + electrophoretic coating, or lectrophoretic painting. A characteristic feature of this process is that colloidal particles suspended in a liquid medium migrate under the influence of an electric field (electrophoresis) and are deposited onto an electrode. All colloidal particles that can be used to form stable suspensions and that can carry a charge can be used in electrophoretic deposition. This includes materials such as polymers, pigments, dyes, ceramics and metals. The process is useful for applying materials to any electrically conductive surface. The materials which are being deposited are the major determining factor in the actual processing conditions and equipment which may be used. Cathode <Cathode Reactions> Electrolysis of water : H 2 2 H 2 O + 2 e- + 2 OH- Film deposition : O 2 H 2 -NR 2 H+ + OH- + H 2 O A<Anode Reaction> R+ Electrolysis of water : 2 H 2 O CH 3 COO- 4 H+ + O 2 + H+ + 4 e. CH 3 COOH 1

First ! Best ! Smart ! History Development of ED coating 1920 1939 Latex rubber electrodeposited on glove forms. 1959 First experiments on anodically electrodeposition paint by Dr. George E. F. Brewer at the Ford Motor Company. 1963 First anodic electrocoating production facility, Ford Motor Co. 1971 Introduction of cathodic electrocoating technology to the automotive and appliance industries. 1976 Introduction of high-film-build cathodic technology. 1939 -Electrodeposition of emulsions on the inside of steel food Containers. 2

First ! Best ! Smart ! History 1 st Gen. ED coating 2 nd Gen. Development 3 rd Gen. , Conventional 3 rd Gen. , High Functional Generation 3 rd, Conventional (Available) 2 nd (Not available) 1 st (Not available) 3 rd, High-functional (Available) Main Anionic, 1 pack Cationic, 1 pack 2 pack Low bake type Lead Free High TP / High functional Detail 1. Pb contains 2. Low film build 1. Pb contains 2. Yellowing / Non yellowing 3. High film build 1. Pb contains 2. Non yellowing 3. Medium film build 1. Pb Free 2. Non yellowing 3. Medium film build 1. 2. 3. 4. Products ED 1600 ED 1700 ED 1800 / ED 1900 ED 2000 ED 2100/ED 2600 ED 3000/ ED 7000 / ECO Application HMC 1, 2 HMC 3, 4, 5, Asan, DYKMC HMC BUS HMC 5, BHMC, ZAZ, JAC, Izh-Avto HMC 1~4 , 51, Asan, Jeonju, BHMC, DYKMC, HMI, PK(Iran), Jeonju S/Frame Chara -cter 1980 1985 1990 1995 2000 2005 High Throw power High Functional Weatherability Sn free available 2010 3

First ! Best ! Smart ! Organization KCC 1. Harmony with Du. Pont Europe & US ED technology 2. Optimization of domestic automotive technology (Formulation / Process technology development) 3. Application of KCC technology & trouble shooting Du. Pont (Europe) AQUA EC Technology 1984 ~ 2004 GLOBAL E-COAT SYSTEM Du. Pont (US) Electro. Shield, Cor. Max Technology 2004 ~ 2022 4

First ! Best ! Smart ! Organization ED Dept. in Ulsan 1. Quality improvement of Du. Pont-KCC product 2. Manufacturing technology development 3. Co-Work with Du. Pont 4. Quality improvement of automotive plant E-Coat Organization Central Research Institute 1. Establishment of KCC ED technology foundation 2. Development of high performance ED ( High throw power, weatherability) 3. Development of main binders and additives Global sales & technical service Dept. 1. Technical service to Automotive plants 2. Support of coating facilities & factor control 3. Support of sales & technical development 5

First ! Best ! Smart ! Customer list Bath number : 14, Bath Capacity : 2, 832 ton HMC Jeonju, Pilot 1, 2 HMC 1, 2 : Accent, Click, Santafe, Avante : Bus, Truck, Pilot models HMC Asan : Grandeur, Sonata Domestic In-Line HMC 3 : Avante HMC 51, 52 HMC 41, 42 : Genesis, Equus, Tusan : Genesis coupe, Starex, Porter 6

First ! Best ! Smart ! Customer list Bath number : 16, Bath Capacity : 3, 297 ton BHMC 1, 2 Pars Khodro, Iran Khodro Diesel Izh-Avto, ZAZ DYKMC 1, 2 Overseas In-Line HMI, HMMR China JAC, GO(2 Lines) DFML, SMT HAOS 7

First ! Best ! Smart ! Customer list Bath number : 72, Bath Capacity : 1, 475 ton Domestic (Ulsan, Gyeongnam) Overseas(excluding China) 8 Lines, 143 tons Overseas(China) 11 Lines, 160 tons Domestic (Chungcheong, Gyeongin) 13 Lines, 213 tons 13 Lines, 392 tons Part Line Domestic (Daegu, Pohang) 14 Lines, 151 tons Domestic (Jeonju, Gwangju) 8 Lines, 417 tons 8

First ! Best ! Smart ! Sales Unit : million won 80, 000 67, 587 70, 315 67, 731 77, 770 Reason of sales increase 70, 000 60, 000 12, 890 28, 779 18, 653 • Increase paint amount for HMC 25, 424 50, 000 overseas plant • Extension to the new overseas 40, 000 30, 000 plants 54, 697 51, 663 48, 991 42, 307 20, 000 -. HMMR Export 수출 10, 000 내수 Domestic - 2007 2008 2009 -. Pars Khodro -. ZAZ -. Lots of Chinese plants 2010 • overall sales increase (15%↑ vs 2007) • overseas sales increase (123% vs 2007) 9

First ! Best ! Smart ! Promotion issues IRAN KHODRO NISSAN PROTON NOW, KCC ED is UNDER SUBMISSION AVTO VAZ GAZ 10

First ! Best ! Smart ! Commercialized Products ED 2100, ED 2600, ED 2800 ED 3000 Commercialized Products ED 3100, ED 3500, ED 3600, ED 3700 ECO 1000, ECO 1200, ECO 2000 ED 7000 -BLACK 11

First ! Best ! Smart ! ED 2100 Series Product History Feature ED 2100, ED 2600, ED 2800 1999 : HMC Asan plant (The first Pb free ED paint at domestic automotive plant) 2000 : Application to the all HMC plants 2010 : HMC 5 th plant, BHMC 1 st plant, ZAZ, Izh-Avto -. -. -. Pb Free, Medium Build Curing condition : 160℃ P/B : 0. 25 ~ 0. 35 Mixing Ratio 1 : 3. 4(P/B 0. 3) PTA 52%, PTB 40% 12

First ! Best ! Smart ! ED 3000 Series Product ED 3000 HT-GREY(M), ED 3000 HT-GREY(S) History 2005 : HMC 2 nd plant (The first Sn Free ED paint at domestic automotive plant) 2006 : Application to the all HMC plants 2010 : HMC 1, 2, 3, 41, 42, Asan, HAOS(Feed Over From PPG) Feature -. -. -. High Throwing Power Pb/Sn Free, Pb Free, Medium Build Curing condition : 160℃ P/B : 0. 20 ~ 0. 30, Mixing Ratio 1 : 4. 5(P/B 0. 25) PTA 52%, PTB 36% 13

First ! Best ! Smart ! ED 3000 Series Application history 1. 2005. 12. 5 Application to the HMC 2 nd plant 2. 2006. 3 1) Feed Over (~ 3 Turn over) 2) Tear Down Application result 1. T/power improvement 1) Hood /Otr. Inr. : 50% improve 2) Cowl Comp : 36% improve 3) S/Side : 44% improve 4) Wheel House Inr. Assy. : 81% improve Tear Down Wheel House Inner Assy’ S/Side Otr Inner 2. Appearance improvement 14

First ! Best ! Smart ! ED 3100, 3500, 3600, 3700 ED 3100, ED 3500, ED 3600, ED 3700 Product History Feature ED 3100 ED 3500 ED 3600 ED 3700 -. -. -. : : BHMC 2 nd plant HMI 2 nd plant DYKMC 1 st, 2 nd plant Pars Khodro, Iran Khodro Diesel -> Renault-Nissan CKD line High Throw Power E-coat Optimization to the overseas automotive plant facility condition Pb Free, Pb/Sn Free(ED 3700), Medium Build Curing condition : 160℃ or 165℃ P/B : 0. 25, 0. 3 15

First ! Best ! Smart ! ECO 1000 Series Product History Feature ECO 1000, ECO 1200, ECO 2000 2007 2008 2009 2010 -. -. -. : : HMC 51 st plant HMC BUS plant (Jeonju) HMC TRUCK plant (Jeonju) HMMR (Russia) KCC Technology of ED paint High Throwing Power Pb Free, Medium Build Curing condition : 160℃ P/B : 0. 25 16

First ! Best ! Smart ! ED 7000 -BLACK Product ED 7000 -BLACK History 2006 : HMC Side Frame line (for truck) High Weatherability (UV Durable) Feature -. -. -. Pb Free, Medium Build Type Curing condition : 173℃ P/B : 0. 15 ~ 0. 25 Mixing Ratio 1 : 4. 4(P/B 0. 2) PTA 44%, PTB 33% 17

First ! Best ! Smart ! Technical Researches • Compatibility for Zr. O 2 pretreatment * Ultra high T/Power → Consumption reduction ≒ 20% (Otr/inr=16/11㎛) * Low bake off, Low film density ① Improvement of Throw Power , Mapping, Film build ② Improvement of corrosion resistance Major Researches * Pigment Zero → Dirt Zero, Cost reduction ① ASH = 1~2% ② Film density = 1. 2 * One component system 18

First ! Best ! Smart ! Ultra High Throw Power E-Coat Target • Reduction of paint consumption through the Ultra High throw power property (Outer/Inner = 16/11㎛) • Low bake off, Low film density • Establishment of Throw Power Vs GA Gas pinhole Balance Approach • Good Appearance • Corrosion resistance at low film (below 16㎛) Plan • Line simulation(2011), Mass production and application(2012) 19

First ! Best ! Smart ! Ultra High Throw Power E-Coat Current E-coat Ultra high throw reduce exterior film build Ultra high Throw E-coat Overall usage reduction (15~20%) film substrate 20

First ! Best ! Smart ! E-coat for Zirconium pretreatment 1. feature • Shorten line length (No use of surface conditioner) • Reduction of sludge • Free of heavy metals • Operates at ambient temperature Difficulty of controlling appearance and DFT 2. Weaker Throw Power Phospate PT Zirconium PT Exterior 20 um 19 um Interior Approach 3. Mapping Problem 11. 5 um X • Improvement of Throw Power & Appearance • Control of film build 21

First ! Best ! Smart ! Pigment Free E-Coat • Extremely low Pigment Target • One component system * ASH = 1~2% * Film density = 1. 2 • Bath Circulation reduce Approach l Study and development with Du. Pont • Eliminates setting and Advantage flocculation concerns • Reduces operating cost • Increases UF flux rate • Ultra-low VOC 22

First ! Best ! Smart ! Practical technical supporting 1 2 3 1, 570배율 GA도금층 624배율 Submersible data acquisition unit Checking of rectifier condition & real coating voltage during coating at the ED bath SEM + Electron Probe Micro Analyzer Magnifying & analyzing defect area of ED film Focused Ion Beam +SEM + EPMA Magnifying & analyzing defect area of ED film 23

First ! Best ! Smart ! Practical technical supporting 4 5 Data pack for Oven Temperature checking Test Report for heavy metal analysis Oven condition check & Real MPT check during the oven drying process Offer the test report of heavy metals, PBBs, PBDEs of KCC paint 6 Test of bacteria, yeast, fungi in the ED process Finds and removes a factor Trouble shooting 24

First ! Best ! Smart ! Practical technical supporting 7 8 9 Cyclic Corrosion Test (approved by GM) QUV, IR, ICP, GC, EPMA, NMR, EDS, SEM. . Lots of analysis instrument are available Cyclic Corrosion Test (approved by GM) CCT for GM ECC for Renault And so on. . Salt Spray Test Official institution approved by KOLAS Lots of analysis Instrument is available for customers 25