Abstract: A robotic lifting and orienting system for an overspray-free paint system includes: a base coupled to wheels; and an automated carrier coupled to the base. The automated carrier includes: a fixture assembly configured to hold an object to be painted; one or more manipulators configured to move the fixture assembly relative to a paint robot; a propulsion system connected to the wheels and configured to move the robotic lifting and orienting system; and a control module configured to control the one or more manipulators and the propulsion system to control positioning and orienting of the object relative to at least one of the paint robot and an overspray-free paint applicator of the paint robot.

Abstract: A heating system includes a conveying system configured to transport a plurality of vehicle body-in-whites (BIWs) sequentially through an oven room to cure paint applied in a paint room. A preheating system includes one or more robot arms. A heat source is connected to the one or more robot arms. A controller is configured to control the one or more robot arms based on a position of one of the vehicle BIWs on the conveying system and to position the heat source near or in direct contact with one or more inner components of the one of the vehicle BIWs to heat the one or more inner components prior to the one of the vehicle BIWs entering the oven room.

Abstract: A paint bell cup for directing a spray of paint onto a surface includes a cup body having an outer surface, an inner conical surface having a circumferential edge, and a stem extending from the outer surface. The stem includes a passage that delivers paint toward the inner conical surface. The cup body includes one or more spray control features that extend along the inner conical surface toward the circumferential edge. The one or more spray control features promote a selected uniform droplet size of the paint traveling from the stem toward the circumferential edge.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: An adhesive composition includes an epoxy component and an additive component reactive with the epoxy component. The additive component includes an imidazole present in an amount of less than or equal to 10 parts by weight based on 100 parts by weight of the adhesive composition, and an amine present in an amount of less than or equal to 5 parts by weight based on 100 parts by weight of the adhesive composition. The epoxy component and the additive component are present in the adhesive composition in a ratio of from 1:1 to 15:1. A method of forming a component includes curing the adhesive composition at a temperature of less than or equal to 150° C. for less than or equal to 30 minutes to thereby join the first substrate and the second substrate.

Abstract: A method of forming a layer on a first component according to various aspects of the present disclosure includes melting a portion of a first metallic composition of the first component. The melting includes directing a laser beam toward a first surface of the first component. The method further includes depositing a second metallic composition on the first surface by directing a precursor including the second metallic composition toward an intersection of the first surface and the laser beam. The second metallic composition is galvanically more noble than the first metallic composition. The method further includes forming the layer on the first component by solidifying the first metallic composition and the second metallic composition. The first component is configured to be joined to a second component by engaging a plurality of micro-anchors defined on the layer with a polymer of the second component.

Abstract: A method monitoring a corrosion of a device includes conveying an electrical current through a monitoring component. The monitoring component includes a replaceable consumable electrode embedded in an electrolyte and disposed onboard and in electrical communication with the device. The electrode is configured to degrade before the device corrodes. The monitoring component includes a sensor disposed in electrical communication with the replaceable consumable electrode and the device. The sensor is configured for detecting a degradation of the electrode. After conveying, the method includes sending a first signal from the sensor to a storage medium. After sending the first signal, the method includes sending a second signal from the storage medium to a communication device to thereby monitor the corrosion. A monitoring system and a method of monitoring a corrosion of a plurality of joints of the device are also described.

Abstract: The present disclosure provides a metal-polymeric composite joint including a first component and a second component. The first component includes a metal. The first component has a first surface including a plurality of micro-anchors. The second component includes a composite material including a polymer and a reinforcing fiber. The second component has a second surface that at least partially engages the first surface of the first component. A portion of the polymer of the second component occupies at least a portion of the micro-anchors of the first component to fix the second component to the first component. In one aspect, the metal-polymeric composite joint further includes a passivation layer disposed between the first surface of the first component and the second surface of the second component.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: A workpiece carrier includes a base frame, a fixture base, a plurality of locators, and a drive source. The fixture base is secured to the base frame. Each of the plurality of locators is secured at a first end to the fixture base and at a second end to a workpiece. The drive source is in communication with the fixture base for rotationally driving the fixture base with respect to the base frame.

Abstract: A method for laser welding of non-transmissive composite materials includes: forming an energy channel having an end opening and extending through a first part made of a first material; and welding a second part made of a second material to the first part via laser heating of the materials of the first and second parts proximate to the end opening of the energy channel such that the materials of the first and second parts fuse to form a weld nugget, attaching the first part to the second part.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: A workpiece carrier includes a base frame, a fixture base, a plurality of locators, and a drive source. The fixture base is secured to the base frame. Each of the plurality of locators is secured at a first end to the fixture base and at a second end to a workpiece. The drive source is in communication with the fixture base for rotationally driving the fixture base with respect to the base frame.

Abstract: A method of forming a cured film on an aluminum substrate includes depositing a film formed from a sol-gel coating composition onto the aluminum substrate without disposing a conversion coating composition onto the aluminum substrate. The method also includes, after depositing, curing the film. A coating system includes an aluminum substrate having a surface and a cured film disposed on and in contact with the surface. The cured film is formed from a sol-gel coating composition. The coating system is free from a layer formed from a conversion coating composition.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: The present technology discloses methods for joining a first workpiece and a second workpiece through an interlocking weld, and products formed thereby. The first workpiece has a first surface and a second surface opposite the first surface, and the second workpiece has a first surface, a groove formed in the first surface, and a second surface opposite the first surface. The system is formed by applying energy to the system, at least partially melting material of the first workpiece, and causing the material to flow into the groove, and allowing or causing the material to cool, forming an interlocked-weld joint connecting the workpieces.

Abstract: A measurement system receives design values specifying measurement points of a first design and values corresponding to measurement points of a first part manufactured according to the first design using a first process. The system calculates a reference point of the first part and translates the received values based on a difference between reference points of the first part the first design. The system includes a rotation module that applies a rotational transformation with a first angle to the translated values. The system includes an error minimization module that determines a first value for the first angle that minimizes deviations between the transformed values and the specified design values. The system includes an error determination module that computes deviations between the transformed values and the specified design values. The system includes an analysis module that calculates a process metric of the first process based on the computed deviations.

Abstract: A system and method of characterizing a color variation of a surface includes a device having a light source and a plurality of sensors positioned at respective viewing angles. An algorithm is stored on and executable by a controller to cause the controller to direct a beam of light at the measurement location with the light source and measure the light leaving the measurement location with the sensors at a plurality of azimuth angles to obtain respective measured color values. The controller is configured to define a color vector function F(?, ?) to represent the color variation of the surface. The controller is configured to determine the color vector function F(?, ?) based at least partially on the respective measured color values. The system allows for a representation of color space of a surface at any azimuth and viewing angle.

Abstract: A system and method of characterizing a color variation of a surface includes a device having a light source and a plurality of sensors positioned at respective viewing angles. An algorithm is stored on and executable by a controller to cause the controller to direct a beam of light at the measurement location with the light source and measure the light leaving the measurement location with the sensors at a plurality of azimuth angles to obtain respective measured color values. The controller is configured to define a color vector function F(?, ?) to represent the color variation of the surface. The controller is configured to determine the color vector function F(?, ?) based at least partially on the respective measured color values. The system allows for a representation of color space of a surface at any azimuth and viewing angle.

Abstract: A method can be used to coat a vehicle body. The method includes: (a) providing a metallic substrate; (b) applying a foundation coat over the metallic substrate; (c) applying a basecoat over the foundation coat; (d) applying a clearcoat over the basecoat; and (e) heating the metallic substrate, the foundation coat, the basecoat, and the clearcoat simultaneously in order to cure the foundation coat, the basecoat, and the clearcoat. The foundation coat is inherently UV stable and is configured to protect the vehicle body against corrosion, and bonds the metallic substrate to the basecoat and the clearcoat. A vehicle body includes a metallic substrate, a foundation coat bonded to the metallic substrate, a basecoat disposed over the foundation coat, and a clearcoat disposed over the basecoat.