1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 11 25 N-STATUS Replaced by WSS-M2P181-C J. Crist, FNA 2003 08 19 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.9, 4 deleted 1999 05 17 Activated T. Honey, J. Parker, G. Molnar, A. Weakley Printed copies are uncontrolled Copyright 2008, Ford
2、 Global Technologies, Inc. Page 1 of 7 PAINT PERFORMANCE, FLEXIBLE SUBSTRATES, EXTERIOR WSS-M2P181-A NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines the performance of a multi-layered paint or dry paint film system required for all exterior body parts where best appearance, high fl
3、exibility, high durability, and impact resistance are required. This system is specified for assembly plants and component suppliers, covering all processes including in-department and pre-delivery repairs. 2. APPLICATION This specification was released originally to define paint performance of exte
4、rior surfaces. It is specified for vehicle bumpers, claddings, bodyside moldings, and other parts visible after assembly. 3. REQUIREMENTS Terminating exterior edges visible after assembly shall conform to the full requirements of this specification. In-department and pre-delivery paint repairs shall
5、 meet the requirements of this specification. Parts must conform to the color requirements defined by the Ford Color Harmony Team. Note: For in process color check the preferred method is SAE J1545, three angle CMC. Material specification requirements are to be used for initial qualification of mate
6、rials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.3 SYSTEM COMPONENTS 3.3.1 Substrates Flexible polymers and flexible polymer blends, PU, PC, TEO etc. with a
7、flex modulus typically of less than 1250 MPa. 3.3.2 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. When necessary, in or
8、der to meet the requirements of this specification, surface enhancements, such as flaming or plasma treatment, that modify surface tension, surface resistivity or chemical reaction(s) that change the surface chemistry are required, they shall be specified on Engineering Documents. ENGINEERING MATERI
9、AL SPECIFICATIONWSS-M2P181-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 2 of 7 3.3.3 Coating Material 3.3.3.1 Primer and Color Coat When necessary in order to meet the requirements of this specification, an adhesion promoter and/or primer surfacer must be use
10、d as specified on Engineering Documents. 3.3.3.2 In-Department and Predelivery Repairs Repaired areas must meet the requirements of this specification. All repair materials and processes used should be approved by the affected Product Materials Activity. Maximum film thickness and/or number of repai
11、rs for repaired parts will be specified in the mutually agreed control plan and conform to para 3.4.4. All repairs must be in a complimentary color to the original finish by agreement with the receiving company. 3.3.4 Finished Parts Testing must be conducted on actual production parts containing a m
12、inimum of 25% regrind. Where part dimensions limit equipment access and testing, representative panels (minimum 25% regrind) 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
13、 respect to substrate, primer thickness, sanding, enamel thickness, and processing. Panels with the appropriate regrind content can be laboratory prepared (simulating production conditions) and used for long term weathering exposure, such as Florida and Arizona submissions. 3.4 FILM PROPERTIES 3.4.1
14、 Appearance (FLTM BI 109-01 & ASTM D 523) As released by Corporate Design: (Use as a guide) 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
15、: 60 Glossmeter 5 +/- 1 K: 60 Glossmeter 3 +/- 1 L: 60 Glossmeter 1.5 + 0.5/- 1 Color, gloss and surface finish shall match the Master Appearance Sample or the initial sample as approved by Design Center. See para 5.3 table for gloss correction for index of refraction. 3.4.2 Hardness Shall be suffic
16、iently cured after baking to withstand normal handling and shipping without damage. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 3 of 7 3.4.3 Film Thickness (ASTM B 487) Coating thickness must be sufficient to meet
17、 all requirements of this material specification. Refer to applicable materials specifications and/or process standards for film thickness values. 3.4.4 Film Thickness, max (ASTM B 487) The finished unit, part, or test specimen shall not exceed 230 micrometers total film thickness. There shall be no
18、 more than 2 in-department repairs. 3.4.5 Paint Adhesion (FLTM BI 106-01, Method D, knife blade) Less than 5% paint removal of any paint layer with no complete diamonds removed. Lightly sand paint film surface until dull, before checking adhesion. 3.5 RESISTANCE PROPERTIES 3.5.1 Water Resistance 240
19、 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 3.4.5 within 20 minutes after removal from water. 3.5.2 Hydrolysis Resistance 28 days (FLTM BI 106-03) Use 5 samples for each color tested. Test sample for
20、 adhesion at 14 day intervals per para 3.4.5. If an adhesion failure is detected, recheck sample in a different area to verify. 3.5.3 Fluid Spotting Resistance None (FLTM BI 113-01) Test Fluids: (Current production factory fill materials, Motorcraft products or equivalent) Liquid Soap Windshield Sol
21、ution Neat and at a 30% concentration in deionized water. Coolant Solution Neat and at a 30% concentration in deionized water. Motor Oil Bug & Tar Remover No color change in excess of Gray Scale rating 4 - 5 (AATCC Evaluation Procedure 1/ISO 105-A02), dulling, surface distortion or permanent softeni
22、ng permitted. Adhesion shall meet the requirements of para 3.4.5. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 4 of 7 3.5.4 Resistance to Acid Spotting (FLTM BI 113-02) No color change in excess of Gray Scale ratin
23、g 4 - 5 (AATCC Evaluation Procedure 1/ISO 105-A02), dulling, surface distortion or permanent softening permitted. Adhesion shall meet the requirements of para 3.4.5. 3.5.5 Fuel Resistance (FLTM BO 101-05) Fuel Composition (FLTM AZ 105-02) by Volume: 1) CM15 2) CM15(ME15) After 5 min recovery time, n
24、o 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 requirements of para 3.4.5. 3.5.6 Mar/Scratch Resistance A & B Gloss Materials 85% Gloss Retention (FLTM BI 161-01) A
25、- J Gloss Materials Rating 1 at 2N (FLTM BN 108-13, 1 mm Dia. Ball) Scratch Mark 3.5.7 Stone Chip Resistance (FLTM BI 157-06), max Rating 4 (SAE J400, 10 Pints Gravel), max 3 mm Maximum single chip size SUBSTRATE FLEXURAL MODULUS ASTM D 790 METHOD 1 350 MPa No Chips 350 - 550 MPa 7B (0.6%) 550 - 790
26、 MPa 4B (5.0%) 790 - 1000 MPa 3B (7.0%) above 1000 MPa 2B (10.0%) Topcoat systems to be tested will include: One first run panel, and one first run plus one in-line repair panel. These two systems will conform to the above specified ratings. Also test one first run plus two in-line repairs. Panels w
27、ill be rated versus the current production system following the same layering scenarios and must be equal to or better than current production materials. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 5 of 7 3.5.8 Co
28、ld Checking Resistance 15 Cycles (FLTM BI 107-02) Evaluation after 2 hours conditioning at 23 +/- 2 C. No evidence of cracks, no blistering, no change in appearance or other failure when compared with an original unaged part. Adhesion shall meet the requirements of para 3.4.5. 3.5.9 Resistance Again
29、st High Pressure Cleaner (FLTM BO 160-04, Method B) Prior to testing the painted surface shall be X-scribed through to the substrate (30 deg angle). The test must be performed on the X-scribed. No loss of adhesion from paint to substrate or between paint films permitted. 3.5.10 Shock Test Test metho
30、d: A part or a section of it shall be stored for 16 h at - 40 +/- 2 C and then immediately immersed into water of 70 +/- 2 C for 5 minutes. Examination shall be done after reconditioning to room temperature. No distortion, no cracks or any other failures. Adhesion shall meet requirements of para 3.4
31、.5. 3.5.11 Heat Resistance (7 days at 80 +/- 2 C) Return to room temperature before evaluation. No color change in excess of Gray Scale rating 4 - 5 (AATCC Evaluation Procedure 1/ISO 105-A02), gloss loss or loss of adhesion per para 3.4.5. 3.6 FLEXIBILITY REQUIREMENTS 3.6.1 Flexibility at 23 +/- 2 C
32、 No cracking when bent over appropriate mandrel SUBSTRATE FLEXURAL MODULUS ASTM D 790 METHOD 1 MANDREL DIAMETER 350 MPa 13 mm 350 - 550 MPa 25 mm 550 - 790 MPa 50 mm 790 - 1000 MPa 100 mm above 1000 MPa No requirement 3.6.2 Cold Impact, max Rating 0 (FLTM BO 151-02, -35 +/- 2 C) ENGINEERING MATERIAL
33、 SPECIFICATIONWSS-M2P181-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 6 of 7 3.7 WEATHER RESISTANCE Note: Accelerated Weathering is only to be considered if, for Engineering concurred special reasons, no Florida results are available. Under such circumstances
34、 comparative testing only is allowed against materials 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
35、free from evidence of cracking, checking, rusting, 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 spec
36、ified AATCC rating (AATCC Gray Scale Evaluation Procedure 1/ISO 105-A02). 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 pan
37、els are removed from water bath and thoroughly 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
38、 no blistering or delamination of any of the coating layers. 3.7.1 Natural, AATCC Rating 4 (SAE J 1976, Procedure A) Exposure Time 1 & 2 yr submission 3.7.2 Accelerated, AATCC, min Rating 4 (SAE J1960, 0.55 W/m2 Irradiance) Exposure Time 3000 h required, Borosilicate Inner and Outer Filters 3.8 PROC
39、ESS 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 design are Bake Time, Bake Temperature, and Film Thickness. An initial screening experiment should be run to determine w
40、hat 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 to the DOE should be based on the materials tested and should be chosen from the following tests: adhesion (para 3
41、.4.5), hydrolysis resistance (para 3.5.2), mar/scratch resistance (para 3.5.6), stone chipping (para 3.5.7), and accelerated weathering (para 3.7.2). ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 7 of 7 5. GENERAL I
42、NFORMATION 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 55 45 Light Metallics 50 40 Light (white) Straight Shades 55 45 Med/Dark Straight Shades COB 60 50
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