1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes Rev 03 2012 03 26 N Status No usage, no replacement N. Benipal, NA 1990 10 23 NB00E10090373004 Revised PAK MP 1983 09 10 CDN1-AF-504579-1 Released CCL, MDM WP 3948-a Page 1 of 18 CREATED FROM THE PDF FILE ENAM
2、EL, ACRYLIC, HIGH SOLIDS, LOW VOC, ESB-M33J100-A EXTERIOR ENAMEL, ACRYLIC, HIGH SOLIDS, LOW VOC, ESB-M33J100-A2 EXTERIOR, REDUCED VISCOSITY NOT TO BE USED FOR NEW DESIGN 1. SCOPE The materials defined by these specifications are low volatile organic compound (VOC) modified thermosetting acrylic resi
3、ns which are pigmented to yield a colored, glossy, durable enamel suitable for exterior use. 2. APPLICATION These specifications are released for paints used as the final color coat on all exterior car body parts. They shall be satisfactory for use over specified primers, sealers or other enamels, a
4、s in repair or two-toning operations. ESB-M33J100-A The material defined by this specification is supplied at normal viscosity and solids level as shown in this document. ESB-M33J100-A2 The material defined by this specification is supplied with reduced viscosities such that they are ready for use i
5、n the assembly plants. The reduced viscosities and associated reduced solids levels shall be agreed upon by the supplier, the affected assembly plant, Body and Assembly Paint Operations and NAAO Production Purchasing prior to delivery of the materials to the respective assembly plant. The materials
6、shall meet all other requirements of the parent (“A“ level) specification. 3. REQUIREMENTS 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appro
7、priate statistical tools must be used to analyze process/product data so that variation in the final product is continuously reduced. ENGINEERING MATERIAL SPECIFICATION ESB-M33J100-A/A2 WP 3948-a Page 2 of 18 3.2 COMPATIBILITY There shall be compatibility between all topcoats, primers, sealers and a
8、dhesives utilized in the assembly plant. This will allow for normal production processing of these materials. Refer to the Sealer Application Manual for the description of specific sealers/adhesives. 3.3 COMPOSITION 3.3.1 Vehicle Non-Volatiles The modified thermosetting vehicle system shall be durab
9、le, and yield a smooth appearance with high gloss and good levelling. 3.3.2 Pigmentation Pigments shall be of exterior automotive quality, and have required durability and lightfastness. The pigment blend shall provide a satisfactory color match to the Ford master panel on file. 3.3.3 Ultraviolet Li
10、ght Absorber(s)/Stabilizer(s) All colors shall be supplied with a UV-light stabilizer package as necessary to promote long-term exterior durability and to prevent topcoat delamination from electrodeposition primer or spray primer-surfacer. 3.3.4 Volatile Components The proportions of solvents consti
11、tuting the volatile portion shall be selected such that the enamel will display satisfactory levelling upon spray application. The volatility of the solvents is to be so chosen that the specified film thicknesses can be obtained without the occurrence of paint sagging and with satisfactory freedom f
12、rom roughness or dry spray. The volatile portion shall contain sufficient active solvents to give satisfactory adhesion when the enamel is applied over a previously baked coat of the enamel. 3.3.4.1 Resistivity 0.05 to 4.00 megaohms Volatile solvents and other components affecting electrical conduct
13、ivity shall be adjusted such that the resistivity at application viscosity shall be within specified limits and result in optimal sprayability characteristics. ENGINEERING MATERIAL SPECIFICATION ESB-M33J100-A/A2 WP 3948-a Page 3 of 18 3.3.5 Volatile Organic Compound at Application Viscosity (VOC) Th
14、e percent volatile is determined per ASTM D 2369 except that the oven exposure time shall be 60 minutes at 110 C instead of 20 minutes. The kg/L is determined per ASTM D 1475. Color: VOC (max) (kg/L) Light metallic colors 0.52 Medium metallic colors 0.52 Dark metallic colors 0.49 Black 0.46 All dark
15、 solid colors 0.49 (less than 20 % TiO2) Reds, maroons, oranges 0.47 (less than 20 % TiO2) Medium dark colors 0.44 (20 - 80 % TiO2) Medium colors 0.44 (80 - 95 % TiO2) Light colors 0.44 (95 % or more TiO2) White 0.43 3.3.6 Specific Composition The supplier shall furnish such data upon request. 3.4 P
16、HYSICAL PROPERTIES 3.4.1 Viscosity (Package) (FLTM BI 111-01) Viscosity of material shall match value shown on Initial Sample Report within range of +/- 5 s on #4 Ford Cup. NOTE: At application viscosity, the enamels shall be in compliance with VOC requirements. ENGINEERING MATERIAL SPECIFICATION ES
17、B-M33J100-A/A2 WP 3948-a Page 4 of 18 3.4.2 Viscosity Stability 3.4.2.1 Shelf Stability (Test is conducted at package viscosity.) After standing for 90 days at a room temperature of 26 +/- 1 C, material must be free of settling which cannot be dispersed by normal agitation. A viscosity increase of m
18、ore than 15 s on a #4 Ford Cup is not permitted. 3.4.2.2 Accelerated Shelf Stability (FLTM BI 102-03, Test is conducted at package viscosity.) The material must be free of settling which cannot be dispersed by normal agitation after standing for 16 hrs at 60 +/- 2 C. A viscosity increase of more tha
19、n 15 s on #4 Ford Cup is not permitted. 3.5 PREPARATION OF TEST PANELS 3.5.1 Substrate Cold rolled, unpolished 100 mm x 300 mm x 0.71 mm steel panels with a Class “1“ finish are required. They shall be coated using the current production phosphate process. 3.5.2 Electrocoat Primer 3.5.2.1 Medium-Bui
20、ld Cathodic Electrocoat Primer Panels shall be coated with current production Medium-Build Cathodic Electrocoat Primer to achieve a dry film thickness 20 - 23 micrometre. The bake schedule is 10 minutes at 182 C metal temperature. 3.5.2.2 High-Build Cathodic Electrocoat Primer Panels shall be coated
21、 with current production High-Build Cathodic Electrocoat Primer to achieve a dry film thickness of 30 - 33 micrometre. The bake schedule is 10 minutes at 182 C metal temperature. When an evaluation is conducted over this electrocoat primer, panels shall be prepared either with or without spray prime
22、r in accordance with assembly plant practice. ENGINEERING MATERIAL SPECIFICATION ESB-M33J100-A/A2 WP 3948-a Page 5 of 18 3.5.3 Spray Primer Using electrocoat-primed panels, apply current production primer-surfacer by spray to a dry film thickness of 18 25 micrometre. The color and gloss of the spray
23、 primer shall be consistent with spray primer currently used in production with the respective topcoat(s). Bake primer 30 min at 163 C ambient (minimum 20 minutes at 163 C metal temperature) for adhesion tests (para 3.7.4) and 20 minutes at 149 C ambient (minimum 10 minutes at 149 C metal temperatur
24、e) for all other tests. 3.5.4 Enamel Apply enamel to a dry film thickness of 45 - 55 micrometre by spray. Flash for two (2) minutes. Bake per standard bake of para 3.5.6.2 (17 minutes at 130 C ambient with a minimum of 10 minutes at 130 C metal temperature). 3.5.5 Catalyzed Repair Prepare panels per
25、 para 3.5.1 through 3.5.4. Catalyze enamel according to manufacturers recommendations. Mask right half of panels vertically and apply catalyzed enamel to a dry film thickness of 45 - 55 micrometre. There shall be no sanding or wiping of the panels prior to the application of catalyzed enamel. Remove
26、 masking, flash-off the panels, and bake per para 3.5.6.4 (20 minutes at 99 C ambient temperature with a minimum of 10 minutes at 99 C metal temperature). 3.5.6 Enamel Baking Schedules 3.5.6.1 The minimum enamel bake is 17 minutes above 124 C ambient. A minimum of 10 minutes at 124 C metal temperatu
27、re is required. 3.5.6.2 The standard enamel bake is 17 minutes at 130 C ambient. A minimum of 10 minutes at 130 C metal temperature is required. 3.5.6.3 The maximum enamel bake is 30 minutes at 143 C ambient. A minimum of 20 minutes at 143 C metal temperature is required. 3.5.6.4 The catalyzed ename
28、l repair bake is 20 minutes at 99 C ambient. A minimum of 10 minutes at 99 C metal temperature is required. ENGINEERING MATERIAL SPECIFICATION ESB-M33J100-A/A2 WP 3948-a Page 6 of 18 3.6 APPEARANCE 3.6.1 Color (FLTM BI 109-01) The enamel shall match the Ford Motor Company master panel. Panels are pr
29、epared per paras 3.5.1 through 3.5.4. 3.6.2 Gloss (FLTM BI 110-01, 20 deg Glossmeter) Minimum gloss requirements, by color class, are shown in para 3.6.4. Panels are prepared per paras 3.5.1 through 3.5.4. 3.6.3 Distinctness of Image (FLTM BI 10-3) The values shall be as shown in para 3.6.4 when mea
30、sured on a flat test panel with a Hunter Lab D47-6 Dori-Gon, Distinctness of Image Meter (or equivalent). Panels are prepared per paras 3.5.1 through 3.5.4. 3.6.4 Gloss and Distinctness of Image Gloss DI Minimum Minimum Color Light metallic colors 72 42 Medium metallic colors 76 50 Dark metallic col
31、ors 76 60 Black 88 90 All dark solid colors 80 85 (less than 20 % TiO2) Reds, maroons, oranges 78 75 (less than 20 % TiO2) Medium dark colors 80 85 (20 - 80 % TiO2) Medium colors 80 85 (80 - 95 % TiO2) Light colors 80 80 (95 % or more TiO2) White 76 80 ENGINEERING MATERIAL SPECIFICATION ESB-M33J100-
32、A/A2 WP 3948-a Page 7 of 18 3.6.5 Gloss After Rebake (FLTM BI 110-01, 20 deg Glossmeter) Using a 20 deg Gardner Glossmeter, no more than 4 units decrease in gloss is permitted when panel is rebaked per para 3.5.6.3 (maximum enamel bake). 3.6.6 General The enamel shall bake out to a presentable, serv
33、iceable film showing no craters, pinholes, seediness, abnormal roughness or excessive metallic mottling. It shall have a reasonable tolerance for ordinary cleaning, and exhibit excellent polishing characteristics when wheel polished with a wide range of various compounds and cleaners. 3.7 FILM PROPE
34、RTIES 3.7.1 Enamel Film Thickness 45 - 55 micrometre (FLTM BI 117-01) Prepare panels per paras 3.5.1 through 3.5.4. 3.7.2 Hardness, min 7.5 KHN (FLTM BI 112-02) Prepare panels per paras 3.5.1 through 3.5.4. Hardness and polishing characteristics shall be such that airborne dirt dried in the film, dr
35、y spray areas, or other surface defects can be removed by sanding and polishing. After sanding with #600 grit paper lubricated with mineral spirits, then wheel polished with a medium grit compound, there shall be no noticeable change in the sheen between the polished and unpolished areas. 3.7.3 Hidi
36、ng Power, Dry 45 micrometre max, -lt. metallic and (FLTM BI 1-5) solid red colors 38 micrometre max, -all other enls Bake panels per para 3.5.6.2 (standard enamel bake). The enamels are required to provide complete visual hiding over a black and gray straight-line hiding chart. Exception colors whic
37、h require greater film thicknesses to achieve hiding are acceptable only if the affected assembly plant(s) can accomodate the additional paint thickness requirement. ENGINEERING MATERIAL SPECIFICATION ESB-M33J100-A/A2 WP 3948-a Page 8 of 18 3.7.3.1 Black and Gray Straight-Line Hiding Chart The hidin
38、g chart shall measure 50 mm by 280 mm, consisting of a black stripe of 25 mm by 280 mm and a gray stripe of 25 mm by 280 mm in a side-by-side configuration. 3.7.3.2 CIE L*a*b* Hiding Chart Values Black: L* 25.74 +/- 0.80 a* -0.11 +/- 0.50 b* 0.58 +/- 0.60 Gray: L* 60.44 +/- 0.93 a* -1.32 +/- 0.06 b*
39、 11.98 +/- 0.30 These values were obtained using the 10 deg Standard Observer and Illuminant D65. 3.7.3.3 Gloss of Black and Gray Stripes (FLTM BI 110-01, 20 deg glossmeter) Black Stripe 30 +/- 5 Gray Stripe 30 +/- 5 3.7.4 Adhesion 3.7.4.1 Scratch Test (FLTM BI 106-01, Method A) No chipping or loss
40、of adhesion is permitted. 3.7.4.2 Scribe Test (FLTM BI 106-01, Method B) The occurrence of flaking, chipping or peeling shall not exceed that of Classification Grade 2. Two types of panels are required. ENGINEERING MATERIAL SPECIFICATION ESB-M33J100-A/A2 WP 3948-a Page 9 of 18 Enamel Over E-coat: Pr
41、epare panels according to paras 3.5.1 through 3.5.2.2 (spray primer not used) with the exception that the Electrocoat primer bake shall be 30 minutes at 200 C metal temperature. The topcoat is then applied over E-coat and baked at the minimum enamel bake (para 3.5.6.1) of 8 minutes above 119 C, incl
42、uding 3 minutes at (or) above 130 C, metal temperature. Enamel Over Spray Primer: Prepare panels per paras 3.5.1 through 3.5.3 with the exception that the spray primer bake shall be 30 minutes at 200 C metal. The topcoat is then applied over the spray primer and baked at the minimum enamel bake (par
43、a 3.5.1.1) of 17 minutes at 124 C ambient with a minimum of 10 min at 124 C metal temperature. 3.7.5 Ultraviolet Light Transmittance Apparatus: Hewlett-Packard 8452 Diode Array UV-Visible Spectrophotometer (or equivalent) Software: HP89530A MS DOS (used with IBM AT or IBM XT (or equivalent) Allowabl
44、e UV radiation transmittance limits are: . less than 0.10 % transmittance from 300 to 350 nm . less than 0.40 % transmittance from 351 to 375 nm . less than 1.00 % transmittance from 376 to 400 nm Test film thickness is 30 micrometre maximum. PROCEDURE Enamel is sprayed on glass panels to yield a dr
45、y film thickness of 30 micrometre after baking at the maximum bake of 20 minutes at 143 C glass temperature per para 3.5.6.3. It is recommended that a film wedge from 25 micrometre to 35 micrometre be sprayed to insure that the required film thickness is obtained. ENGINEERING MATERIAL SPECIFICATION
46、ESB-M33J100-A/A2 WP 3948-a Page 10 of 18 Allowing a short time after removal from oven, while the glass panels are still warm, carefully scrape the coating off, yielding a single, continuous, intact film. The thickness of the dry film is measured to find an area 25 mm by 12 mm that is exactly 30 mic
47、rometre in thickness. The film is placed in the solid sample holder such that the 30 micrometre thick area can be measured by the spectrophotometer. Turn on the UV spectrophotometer power. Start up the HP 89530A MS-DOS control/data acquisition software, ending at the “Top Level“ menu. The lamp will
48、turn on automatically at this point. Option selection is made by striking function keys. Enter the operator name (F9), then select General Scanning mode (F1). General Scanning Mode menu appropriate control parameters are: mode : % transmission scan range : 300 to 400 nanometers Y-axis range : 0 to 0
49、.5 or Auto (display purpose only) scan duration : 1.0 seconds Next, select “blank scan“ to establish a background, without any materials in the light detection path. Block the light path at the sample holder and run a scan to verify the normal background transmission level. Readings should be less than 0.01 per cent transmission. Place your film in the sample holder and select scan. A graph will be displayed on the monitor screen. Select
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