1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 01 2011 09 21 Revised / Activated B4 See Summary of Revisions for Details A. Weakley, Eu/ J.Crist, NA 2007 07 31 Activated J. Robincheck Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 1 of 12 PAINT, ONE
2、 COMPONENT BASECOAT/CLEARCOAT WSS-M16J9-B2 OVER RIGID SUSTRATES, EXTERIOR PAINT, TWO COMPONENT BASECOAT/CLEARCOAT WSS-M16J9-B3 OVER RIGID SUSTRATES, EXTERIOR PAINT, ONE COMPONENT BASECOAT/TWO COMPONENT CLEARCOAT WSS-M16J9-B4 OVER RIGID SUSTRATES, EXTERIOR 1. SCOPE The materials defined by these spec
3、ifications are paints, which consist of a basecoat and clear topcoat applied by a baked process. These materials are monobaked. Paint systems may be processed wet-on-wet application and monobaked, or paint may be baked between wetcoats. This specification also includes unique colors that require Tri
4、 or 4 coat systems. Tricoat colors consist of a pigmented groundcoat followed by a non-hiding midcoat over which is applied a clear or tinted clear. Four coat systems consist of a Basecoat, Clearcoat baked then the application of an effect basecoat with a clear or tinted clear. 2. APPLICATION These
5、specifications were released originally for paints used as the final topcoat on exterior trim components made of rigid substrates, such as spoilers, appliqus, mirror housings, handles, roof racks, running boards. It shall be satisfactory for use over specified primers or over previously baked enamel
6、, as in paint repair or tutone operations. 2.1 LIMITATIONS Bake temperature should not exceed softening temperature of substrate material as agreed upon by Ford Materials Engineering. 2.1.1 One Component, Basecoat/Clearcoat, Exterior Paint Systems for Rigid Substrates already approved to WSS-M33J7 d
7、o not need to retest for Technology approval to WSS-M16J9-B2/B3/B4. 3. REQUIREMENTS Testing to be used for initial qualification of materials and shall be made on the basis of comparison with approved production material, chosen by the approving materials engineer. 3.1 STANDARD REQUIREMENTS FOR PROD
8、UCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 COMPOSITION Both the basecoat and clearcoat contain UV absorbers. The supplier will furnish the specific composition and concentration of the absor
9、bers upon request. ENGINEERING MATERIAL SPECIFICATION WSS-M16J9-B2/B3/B4 Copyright 2011, Ford Global Technologies, LLC Page 2 of 12 3.2.1 Resin Shall be either a polyester, acrylic, modified urethane polymer or a polyurethane. Minor amounts of modifiers and/or plasticizers are allowed. 3.2.2 Pigment
10、s Pigments are exterior automotive grade selected to match the Ford Motor Company master and meet the durability requirements. 3.2.3 Solvents The volatility of solvents will be such that there shall be no paint sagging, roughness or dry spray at specified film thicknesses. Solvents shall be HAPS com
11、pliant if it is required by local government regulations 3.3 PHYSICAL PROPERTIES LIQUID STATE The following evaluation must be conducted on both the basecoat and clearcoat application viscosity. Throughout the application viscosity range, material shall be in compliance with local emission regulatio
12、ns. Property variation acceptability as identified below, shall be based on the recorded values of the originally approved production sample as approved by Ford Materials Engineering. This data will be used in developing control plan requirements. 3.3.1 Non-Volatile Content, range Initial sample +/-
13、 4% (ASTM D 1353) 3.3.2 Volatile Organic Compound, range Initial sample +/- 1% (ASTM D 3960) 3.3.3 Weight per Volume, range Initial sample +/- 0.03 g/ml (ASTM D 1475) 3.3.4 Volume Solids, range Initial sample +/- 2.0% (ASTM D 2697) 3.3.5 Viscosity Report (ASTM D 1200) 3.3.6 Stability No more than 30
14、% (ASTM D 1849) viscosity increase permitted. 3.3.6.1 Shelf Stability, 90 days 3.3.6.2 Accelerated Stability, 60 C, 16 h 3.3.7 Resistivity 0.005 to 2.00 megohms (ASTM D 5682) Volatile solvents and other components affecting electrical conductivity shall be adjusted such that the resistivity at appli
15、cation viscosity shall be within specified limits. ENGINEERING MATERIAL SPECIFICATION WSS-M16J9-B2/B3/B4 Copyright 2011, Ford Global Technologies, LLC Page 3 of 12 3.4 PREPARATION OF TEST PANELS 3.4.1 Substrates Auto body steel, aluminum, pre-coated or electroplated zinc or zinc alloy coated steel a
16、nd zinc die casting or as specified on Engineering Document. Rigid polymer and rigid polymer blends, SMC, ABS, PPO, etc. 3.4.2 Substrate Condition The surface to be coated must be cleaned to ensure the absence of oil or alkaline residues, fingerprints, corrosion, mold release agents, dirt, moisture,
17、 and other foreign materials. Surface energy/resistivity or chemical reaction(s) enhancements (flaming, corona discharge or plasma) and/or addition of conductive materials, necessary to meet the requirements of this specification, shall be approved by Materials Engineering and noted on the ASL 3.4.3
18、 Electrocoat For metallic substrates requiring e-coat, apply 17- 24 m and bake 10 minutes at 182 C metal temperature or as otherwise recommended. Record e-coat and oven type used. 3.4.4 Primer Apply 17 - 24 m DFT (Dry Film Thickness) of the primer or as otherwise recommended, as specified for the su
19、bstrate. 3.4.5 Basecoat/Clearcoat Apply basecoat to required dry film thickness by spray under conditions appropriate for basecoats, and flash as required. Apply clearcoat to required dry film thickness. Bake using appropriate bake schedule. Record paint and oven type used. (As developed by para 3.5
20、). 3.4.6 Design Verification/Initial Qualification Test Requirements as listed in Table 1 3.4.7 Aging After application of the top coat, all panels shall be aged at least 72 h at 23 +/- 2 C, 50 +/- 5% relative humidity or 16 hours at 45 +/- 1 C before testing. 3.4.8 Cure Process Window Must be devel
21、oped per paragraph 3.5. ENGINEERING MATERIAL SPECIFICATION WSS-M16J9-B2/B3/B4 Copyright 2011, Ford Global Technologies, LLC Page 4 of 12 3.5 PROCESS WINDOW DEFINITION - NEW RESIN TECHNOLOGIES ONLY The supplier shall perform a DOE utilizing response surface analysis to determine the Process Window of
22、 the system. The three variables to be included in the design are Bake Time, Bake Temperature, and Film Thickness. An initial screening experiment should be run to determine what level will generate a window which includes testing to failure. This screening experiment should be reviewed with the Mat
23、erials Engineer to set up the final DOE. Response attributes to the DOE should be based on the materials tested and should include, but not be limited to: Film Thickness (Para 3.6.3, 3.6.4) Ultraviolet Light Transmittance (Para 3.6.5) Adhesion (Para 3.7.1) Water Immersion (Para 3.7.2) Chipping (Para
24、 3.7.8) Environmental Cycling (Para 3.7.9) High Performance Adhesion (Para 3.7.10) Report minimum, maximum, and target values for time, temperature, and film thickness. 3.6 FILM PROPERTIES 3.6.1 Color (FLTM BI 109-01, SAE J1545 Three Angle CMC) Shall match the Master Approved Sample color panel or t
25、he initial sample as approved by Design Center. 3.6.2 Gloss (FLTM BI 110-01, ASTM D 523) Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. 3.6.2.1 Gloss After Rebake 4 unit decrease max Rebake panel at target bake conditions per Para 3.5. 3.6.3 Fi
26、lm Thickness (FLTM BI 117-01, Metallic Substrates, PELT or equivalent, ASTM B 487, Non-Metallic Substrates, PELT or equivalent) Targeted Film Thickness: These ranges are considered to be requirements unless otherwise supported by testing data agreed to by Materials Engineering. E-coat 17-24 m Primer
27、/Surfacer 1724 m Basecoat/Clearcoat 15-30 m /38-50 m Values other than the above Target values shall be defined from process window (Para 3.5). These must be approved by Materials Engineer will be specified on the control plan. 3.6.4 Film Thickness Not to exceed (FLTM BI 117-01, Metallic Substrates,
28、 PELT or equivalent, 350 micrometers with ASTM B 487, Non-Metallic Substrates, PELT or equivalent) 2 Repairs ENGINEERING MATERIAL SPECIFICATION WSS-M16J9-B2/B3/B4 Copyright 2011, Ford Global Technologies, LLC Page 5 of 12 3.6.5 Ultraviolet Light Transmittance For each color, report the minimum film
29、build of basecoat and of clearcoat over epoxy-free spray primer required to meet a maximum light transmission of no more than 0.1% at 360 nm and 0.5% at 400 nm. Fortified (with UV package) clearcoat can be used for this evaluation. The equipment used for this measurement is an integrating sphere spe
30、ctrophotometer or equivalent. These values shall be used to help determine minimum film thickness for the process window in section 3.5. 3.6.6 General The paint shall bake out to a presentable serviceable film showing no craters, pinholes, seediness, abnormal roughness or excessive metallic mottling
31、. It shall have a reasonable tolerance for ordinary cleaning, and exhibit no dulling or color change when washed with commercially available cleaners. 3.7 RESISTANCE PROPERTIES 3.7.1 Paint Adhesion, Grade 2 max (FLTM BI 106-01, Method B) Lightly hand sand paint film surface (10 double rubs, moderate
32、 pressure) with P600 paper until dull, before scribe operation and checking adhesion. 3.7.2 Water Immersion No blistering, dulling, (FLTM BI 104-01, 240 h) softening, loss of adhesion, and/or any other film failure Adhesion shall be tested according to Para 3.7.1 within 20 minutes after removal from
33、 water. 3.7.3 Condensing Humidity Resistance Rating 4-5 min (FLTM BI 104-02, Method A, 240 h) 8.0mN (DVM-0058-PA, Nano Scratch Test) Deformation 3 mm Dia first run plus three in-line repairs Rating 3B or 93% paint retention no chips 3 mm Dia ENGINEERING MATERIAL SPECIFICATION WSS-M16J9-B2/B3/B4 Copy
34、right 2011, Ford Global Technologies, LLC Page 7 of 12 Chipping is identified as intercoat adhesion loss between any adjoining layers revealing dis-similar colors, scuffing is acceptable. Chipping metrics may be obtained by image analysis software if available. 3.7.9 Environmental Cycling, 15 cycles
35、 Rating 4-5 min (FLTM BQ 104-07, Procedure 10, 25% Gloss Loss evaluate after 20 h at 23 +/-2 C) No evidence of cracks, no blistering, no change in appearance or other failure when compared with an original part. After exposure, adhesion testing performance must be met per Para 3.7.1. 3.7.10 High Per
36、formance Adhesion Thermal Shock Rating 19 max (FLTM BI 107-05) Alternate Method Resistance Against High Pressure Cleaner 2 mm2 max (FLTM BO 160-04, Method B AATCC Evaluation procedure 1: Rating 4 max Gloss Change per ASTM D 523 25% loss max Color Change per FLTM BI 109-01 E 2.0 max After 5 years Flo
37、rida exposure or 5000 h accelerated weathering: AATCC Evaluation procedure 1: Rating 3 max Gloss Change per ASTM D 523 50% loss max Color Change per FLTM BI 109-01 E 5.0 max ENGINEERING MATERIAL SPECIFICATION WSS-M16J9-B2/B3/B4 Copyright 2011, Ford Global Technologies, LLC Page 9 of 12 3.8.3.2 Adhes
38、ion After Water Immersion 90% adhesion (FLTM BI 104-01, 24 h) retention There shall be no blistering or delamination between any layers of the total paint system. To be evaluated on all exposure intervals. 3.8.4 Basecoat/Clearcoat Durability Index (DVM 5869 - New Resin Technology Only) (TBC/1250) +
39、(X/2000) greater to or equal to 8 X = TICC if TICC is less than 1.2(TCC) otherwise X = TCC. Method to Determine: TBC Stability of UVA free basecoat/clearcoat interface Report TBC (Stability of UVA free basecoat/clearcoat interface) Defined as the time for clearcoat delamination failure for each colo
40、r. If the color has not failed by 5000 h, TBC = 5000 TICC Time to zero UVA absorbance using isolated clearcoat film. (FLTM AI 103-02, Method A) Prepare quartz slides with clearcoat only. Adjust clearcoat thickness to obtain a starting absorbance (340 nm region) of 2 2.5 after nominal clearcoat bake.
41、 Measure clearcoat thickness in micrometers. Calculate absorbance per micrometer. Correct for absorbance using 100% theoretical mixing of basecoat and clearcoat UVA. Evaluate clearcoat UVA absorbance using a UV-VIS spectrophotometer. Observe the UV spectrum from 450 250 nm. Determine maximum 340 nm
42、region absorbance on initial (baseline) sample and after 1000, 3000 and 5000 h exposure to Xenon Arc weatherometer (SAE J2527, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant exposure. Plot absorbance as a function of exposure time to determine absorbance loss rate (ab
43、sorbance loss per hour). Calculate TICC (time to zero UVA absorbance using isolated clearcoat film) followed by the equation: 1(absorbance/micrometer)(clearcoat film thickness)/(absorbance loss rate) = hours to clearcoat absorbance equals zero. TCC Time to zero UVA absorbance using full paint system
44、. (FLTM AI 103-02, Method B) Remove clearcoat from the sample (avoid basecoat layer) with a razor or equivalent scraping device or by in-plane microtomy. Using either solvent extraction from the scraping method or direct measurement with a UV microscope and summing the layers, and evaluate clearcoat
45、 UVA absorbance using a UV-VIS spectrophotometer. Observe the UV spectrum from 450 250 nm. Determine absorbance on initial (baseline) sample and after 1000, 3000 and 5000 h exposure to Xenon Arc weatherometer (SAE J2527, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant
46、exposure). Plot absorbance as a function of exposure time to determine UVA loss rate (absorbance loss per hour). Extrapolate UVA loss rate plot to zero absorbance. Determine the exposure hours at zero clearcoat UVA absorbance. Report as TCC. ENGINEERING MATERIAL SPECIFICATION WSS-M16J9-B2/B3/B4 Copy
47、right 2011, Ford Global Technologies, LLC Page 10 of 12 3.8.5 Clearcoat Photo Oxidation 2.5 max change in (DVM 5867 - New Resin Technology only) (-OH,-NH / CH) ratio Method: Photochemical stability is determined by a comparison of the chemical state change of the topcoat surface before and after exp
48、osure to 5000 h Xenon Arc weatherometer (SAE J2527, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant exposure). Evaluate the topcoat photo oxidation stability using Fourier Transform Infrared Photo-Acoustic Spectroscopy (FTIR-PAS). Obtain spectra of the surface layer of
49、 topcoat, approximately the top 7 micrometers, experimentally defined as the photo-acoustic sampling depth by modulation at 3 kHz at 3000 wavenumbers in a rapid scan FTIR-PAS experiment or 3 kHz phase modulation in a step scan FTIR-PAS Intensity spectrum, should be a polymer filled with carbon black to at least 50% for a rapid-scan experiment and to at least 65% for a step-scan experiment. Compression set rubber works best. Resolution- laser sampling at eve
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