1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 11 25 N-STATUS Replaced by WSS-M2P180-C J. Crist, FNA 2003 08 19 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.3. 3.10, 4 deleted 1999 07 22 Activated G. Molnar P. Osman T. Weingartz D. Green Printed copies are uncontrolled Copyright 2008,
2、Ford Global Technologies, Inc. Page 1 of 7 PAINT PERFORMANCE, RIGID SUBSTRATES, EXTERIOR WSS-M2P180-A NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines the performance of a multi-layered paint system required for all exterior rigid body sheet metal and all exterior rigid body parts w
3、here best appearance and highest durability are required. This system is specified for assembly plants, component suppliers and refinish repair. 2. APPLICATION This specification was released originally to define paint performance of exterior surfaces and define the performance requirements for a co
4、mplete service refinish paint system. It is specified for vehicle bodies, hoods, fenders and other exterior parts visible after assembly. This specification is applicable to all surfaces outboard of the weather-strip. 3. REQUIREMENTS Terminating exterior edges visible after assembly shall conform to
5、 the full requirements of this specification. In-department, pre-delivery and refinish paint repairs shall meet the requirements of this specification. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Prod
6、uction Materials (WSS-M99P1111-A). 3.4 SYSTEM COMPONENTS 3.4.1 Substrates Auto body steel, aluminum, pre-coated or electroplated zinc or zinc alloy coated steel and zinc die casting or as specified on Engineering Documents. Rigid polymers and rigid polymer blends, SMC, ABS, etc. with a flex modulus
7、typically greater than 1250 MPa. 3.4.2 Substrate Condition The surface to be coated must be cleaned by an automated process to ensure the absence of oil or alkaline residues, fingerprints, corrosion, mold release agents, dirt, moisture, and other foreign materials. ENGINEERING MATERIAL SPECIFICATION
8、WSS-M2P180-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 2 of 7 3.4.3 Coating Material 3.4.3.1 Zinc Phosphate (Metallic Substrates) Zinc phosphate coating per WSK-M3P1-C for cold rolled steel, pre-coated, electroplated zinc or zinc alloy coated steel and zinc
9、die castings. Zinc phosphate coating per WSK-M3P1-C shall be used if steel and aluminum parts are processed concurrently. The aluminum tolerance of the process used shall not be exceeded and all requirements of both WSK-M3P1-C and this specification shall be met by both steel and aluminum parts. 3.4
10、.3.2 Cathodic Electrocoat (Metallic Substrates) Ford Engineering approved current production materials. 3.4.3.3 Primer and Color Coat (All Substrates) Ford Engineering approved current production materials should be used. When necessary in order to meet the requirements of this specification, an adh
11、esion promoter and/or primer surfacer must be used as specified on Engineering Documents. Powder must be applied over cathodic e-coat. 3.4.3.4 In-Department and Predelivery Repairs Repaired areas must meet the requirements of this specification. All repair materials and processes used should be appr
12、oved by the affected Product Materials Activity. Maximum film thickness and/or number of repairs for repaired parts will be specified in the mutually agreed control plan and conform to para 3.5.6. 3.4.4 Finished Parts Testing must be conducted on actual production parts. Where part dimensions limit
13、equipment access, representative panels run through the production processes may be substituted for production parts. These panels shall be processed together with parts and shall be representative of the parts with respect to substrate, phosphate coating, primer thickness, sanding, enamel thickness
14、, and processing. 3.5 FILM PROPERTIES 3.5.1 Color Tolerancing TBD (FLTM BI 109-01 Visual Assessment) (SAE J 1545, Three-Angle CMC) Shall match the Master Approved Sample color panel. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologi
15、es, Inc. Page 3 of 7 3.5.2 Gloss (FLTM BI 110-01) As released by Engineering: A: 20 Glossmeter, min 90 B: 60 Glossmeter 76 +/- 4 C: 60 Glossmeter 70 +/- 4 D: 60 Glossmeter 62 +/- 3 E: 60 Glossmeter 50 +/- 3 F: 60 Glossmeter 35 +/- 3 G: 60 Glossmeter 20 +/- 3 H: 60 Glossmeter 10 +/- 3 J: 60 Glossmete
16、r 5 +/- 1 K: 60 Glossmeter 3 +/- 1 L: 60 Glossmeter 1.5 + 0.5/- 1 3.5.3 Hardness Shall be sufficiently cured after baking to withstand normal handling and shipping without damage. Properly cured paint finish shall be hard enough to dry sand easily with 360 grit paper without gumminess or severe scra
17、tching. 3.5.4 Polishing A and B Gloss surfaces shall be capable of being sanded with 1200 grit or finer and polished. No noticeable change in gloss or appearance except for a min of polishing lines shall result. Deep polishing lines or swirl marks are not acceptable. 3.5.5 Film Thickness (FLTM BI 11
18、7-01, Metallic Substrates) (ASTM B 487, Non-Metallic Substrates) Coating thickness must be sufficient to meet all requirements of this material specification. Refer to applicable materials specifications and/process standards for film thickness values. 3.5.6 Film Thickness, max (FLTM BI 117-01) (AST
19、M B 487, Non-Metallic Substrates) The finished unit, part, or test specimen shall not exceed 350 micrometers total film thickness. There shall be no more than 3 in-department repairs. 3.6 RESISTANCE PROPERTIES 3.6.1 Paint Adhesion, max Grade 1 (FLTM BI 106-01, Method B) ENGINEERING MATERIAL SPECIFIC
20、ATIONWSS-M2P180-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 4 of 7 3.6.2 Water Resistance 240 h (FLTM BI 104-01)No blistering, dulling, softening, loss of adhesion, and/or any other film failure. Adhesion shall be tested according to para 3.5.1 within 15 - 2
21、0 minutes after removal from water. 3.6.3 Humidity Resistance 240 h (FLTM BI 104-02, Method A) No blistering, dulling, softening, and/or loss of adhesion. 3.6.4 Salt Spray Resistance 480 h (Nonprecoated Metallic Substrates) (ASTM B 117) No rust spots, blistering, chipping, peeling, gloss, or adhesio
22、n loss, or more than 3 mm rust creepage. Edges and flanges shall meet the same requirements as other visible surfaces. 3.6.5 Scab Corrosion Resistance, max 3 mm creep (Metallic Substrates) (FLTM BI 123-01) 3.6.5.1 Steel substrates 15 cycles 3.6.5.2 Zinc, Zinc alloy substrates 50 cycles 3.6.6 Fluid S
23、potting Resistance None (FLTM BI 113-01) Test Fluids: Deionized Water Liquid Soap Windshield Solution (current production factory fill) As received by the production facility (Neat) and at a 30% concentration in deionized water. Coolant Solution (current production factory fill) As received by the p
24、roduction facility (Neat) and at a 30% concentration in deionized water. Motor Oil (current production factory fill) Bug 0.5% phosphoric acid; hydrochloric acid of 0.4 N (c 0.2%); nitric acid of 0.1% and additionally a solution in water of 0.75% CaSO4adjusted to a pH of 4; deionized water and tap wa
25、ter, bee dropping mixture (47 g Formic Acid, 24 g Tannic Acid 10% in H2O, 24 g Honey, and 5 g Albumin 10% in H2O). Apply 0.05 mils of specified solutions along the entire length of 2 test panels. Place on gradient bar (38 - 82 C, calibrated for heat-up rate of 2 minutes or less for 0.10 mm steel sub
26、strate). Remove one panel after 15 minutes temperature, other after 30 minutes. Rinse any remaining solution with water. Examine panels for etching, discoloration, pitting, etc. Report etch-free temperature for test material and control. 3.6.8 Fuel Resistance (FLTM BO 101-05) Fuel Composition (FLTM
27、AZ 105-02) by volume: 1) CM15 2) CM15 (ME15) 3) Gasohl 4) Gasoline BS 7070 5) Diesel After 5 minute recovery time, no color change in excess of Gray Scale rating 4 - 5 (AATCC Evaluation Procedure 1/ISO 105-A02), dulling, surface distortion or permanent softening permitted. Adhesion shall meet the re
28、quirements of para 3.6.1. 3.6.9 Mar Resistance Shall be equal (FLTM BI 161-01) to or better A & B Gloss Materials than Current (FLTM BN 108-13, 1 mm Diameter Ball) Production C-J Gloss Materials Material ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-A Printed copies are uncontrolled Copyright 2008, F
29、ord Global Technologies, Inc. Page 6 of 7 3.6.10 Stone Chip Resistance, max (FLTM BI 157-06) Rating 4 (SAE J400) 3 Pints Gravel, 3 coat areas Rating 4b 10 Pints Gravel, Anti-Chip areas Rating 7b Topcoat systems to be tested will include: one first run panel, and one first run plus one in-line repair
30、 panel. These two systems will conform to the above specified ratings. Additional systems for testing will include, one first run plus two in-line repairs, and one first run plus three in-line repairs. Panels will be rated versus the current production system following the same layering scenarios an
31、d must be equal to or better than current production materials. 3.6.11 Weather Resistance Note: Accelerated Weathering is only to be considered if, for Engineering concurred special reasons, no Florida results are available. Under such circumstances comparative testing only is allowed against materi
32、als of known Florida stability with an identical chemical type of resin. In case of differences in the test results of Florida exposure and the accelerated weathering the results of the Florida exposure shall prevail. The panels shall be completely free from evidence of cracking, checking, rusting,
33、blistering, and peeling. Both original and repair shall alter in color, tone and gloss to the same degree in the same direction. Only the slightest color change is permitted. These samples shall show no color change, or iridescence in excess of specified AATCC rating (AATCC Grey Scale for Evaluating
34、 Change in Color, 10 step). The film shall be free from mildew and show a minimum of dirt retention. Wash panels from exposure per FLTM BI 160-01, B, 1. Clean exposure panels will be placed in a deionized water bath for 16 h per FLTM BI 104-01. After panels are removed from water bath and thoroughly
35、 blown dry, an “X“, to be located at the center of the panel and 50 mm from the bottom, is scribed. The “X“ shall be 30 mm in height and 20 mm wide. Tape the “X“ with 3M 898-2 tape and check for peeling and delamination between any layers. There shall be no blistering or delamination of any of the c
36、oating layers. 3.6.11.1 Natural AATCC Rating 4 (SAE J1976, Procedure A) New Color 1 year required, 2 year submission New Resin Technology 1 & 2 year required, 5 year submission ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, In
37、c. Page 7 of 7 3.6.11.2 Accelerated, min AATCC Rating 4 (SAE J1960) Exposure Time 3000 h 3.7 ENVIRONMENTAL CYCLING 3 Cycles (FLTM BQ 104-07, Procedure 5) Evaluation after 20 h conditioning at 23 +/- 2 C. No evidence of cracks, no blistering, no change in appearance or other failure when compared wit
38、h an original unaged part. Adhesion shall meet the requirements of para 3.5.1. 3.8 RESISTANCE AGAINST HIGH PRESSURE CLEANER No Paint Removal (Polymeric Substrates) (FLTM BO 160-04, Method B) Prior to testing the painted surface shall be X-scribed through to the substrate (30 angle). The test must be
39、 performed on the X-scribed. No loss of adhesion from paint to substrate or between paint films permitted. 3.9 PROCESS WINDOW DEFINITION The supplier shall perform a DOE utilizing response surface analysis to determine the Process Window of the system. The three variables to be included in the desig
40、n 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 Materials Engineer to set up the final DOE. Response attributes
41、 to the DOE should be based on the materials tested and should be chosen from the following tests: adhesion (para 3.6.1), humidity resistance (para 3.6.3), acid/alkali resistance (para 3.6.7), mar (para 3.6.9), stone chipping (para 3.6.10), and accelerated weathering (para 3.6.11.2). 5. GENERAL INFO
42、RMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 QMS TARGET VALUES, MIN Material Horizontal Vertical Dark Metallics 65 55 Light Metallics 60 50 Light Solids COB 65 55 Dark Solids COB 67 57 Light Solids 60 50 Dark Solids 65 55
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