1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Ver. 2 2008 10 15 N-STATUS Replaced by WSS-M2P181-C G. Weber, FNA 2005 04 05 Activated R. HarrisPrinted copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 1 of 8 PAINT PERFORMANCE, FLEXIBLE SUBSTRATES, EXTERIOR WSS-M2P1
2、81-B 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 flexibility, high durability, and impact resistance are required. This system is specified for ass
3、embly 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 exterior surfaces. It is specified for vehicle bumpers, claddings, bodyside moldings, and other part
4、s 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 meet the requirements of this specification. Parts must conform to the color requirements defin
5、ed 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 materials. Effective 2007 model year and beyond, all paint applicators must meet the Exterior Parts
6、Painter Approval Process (AVP-T113-015). Applicable to North America only. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPONENTS 3.2.1 Substrates Fle
7、xible polymers and flexible polymer blends, PU, PC, TEO etc. with a flex modulus (ASTM D 790, Method 1) typically of less than 1250 MPa. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-B Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 8 3.2.2 Substrate Condition
8、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 order to meet the requirements of this specification, surface enhancements
9、, 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. 3.2.3 Paint System Requirements 3.2.3.1 Primer and Color Coat When necessary in order to m
10、eet the requirements of this specification, an adhesion promoter and/or primer surfacer must be used as specified on Engineering Documents. 3.2.3.2 Repairs, In-Department and Pre-delivery Repaired areas must meet the requirements of this specification. All repair materials and processes used should
11、be approved 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 3.3.5. All repairs must be with the identical color to the original finish. 3.2.4 Finished Parts Testin
12、g must be conducted on actual production parts containing a minimum 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 toge
13、ther with parts and shall be representative of the parts with 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
14、as Florida and Arizona submissions. 3.3 FILM PROPERTIES 3.3.1 Color As determined by (FLTM BI 109-01 Visual Assessment) Color Harmony team (SAE J1545, Three-Angle CMC) Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. ENGINEERING MATERIAL SPECIFIC
15、ATIONWSS-M2P181-B Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 8 3.3.2 Gloss (FLTM BI 110-01) As released by Corporate Design: (Use as a guide) A: 20 Glossmeter, min 92 B: 60 Glossmeter 76 - 84 C: 60 Glossmeter 66 - 74 D: 60 Glossmeter 58 - 66 E: 60 Glossme
16、ter 47 - 53 F: 60 Glossmeter 33 - 38 G: 60 Glossmeter 17 - 23 H: 60 Glossmeter 7 - 13 J: 60 Glossmeter 4 - 6 K: 60 Glossmeter 2 - 4 L: 60 Glossmeter 0.5 - 2 3.3.3 Hardness Shall be sufficiently cured after baking to withstand normal handling and shipping without damage. 3.3.4 Film Thickness, min (AS
17、TM B 487, PELT or equivalent) Coating thickness must be sufficient to meet all requirements of this material specification. Refer to applicable materials specifications and will be specified on the mutually agreed upon control plan. 3.3.5 Film Thickness, max (ASTM B 487, PELT or equivalent) The fini
18、shed unit, part, or test specimen shall not exceed 230 micrometers total film thickness. There shall be no more than 2 in-department repairs. 3.4 RESISTANCE PROPERTIES 3.4.1 Paint Adhesion (FLTM BI 106-01, Method D, knife blade) Less than 5% paint removal of any paint layer with no complete diamonds
19、 removed. Lightly sand paint film surface until dull, before checking adhesion. 3.4.2 Water Resistance 240 h (FLTM BI 104-01)No blistering, dulling, softening, loss of adhesion greater than 5% and/or any other film failure. Adhesion shall be tested according to para 3.4.1 within 20 minutes after rem
20、oval from water. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-B Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 8 3.4.3 Hydrolysis Resistance 28 days (FLTM BI 106-03) Use 5 samples for each color tested. Test sample for adhesion at 14 day intervals per para 3.
21、4.1. If an adhesion failure is detected, recheck sample in a different area to verify. 3.4.4 Fluid Spotting Resistance (FLTM BI 113-01) Test Fluids: (Current production factory fill materials, Motorcraft products or equivalent) Liquid Soap Windshield Solution Neat and at a 30% concentration in deion
22、ized 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 softening permitted. Adhesion shall meet the requirem
23、ents of para 3.4.1. 3.4.5 Resistance to Acid Spotting (FLTM BI 113-02) 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 requirements of para 3.4.1. 3.4.6 Fuel Resista
24、nce (FLTM BO 101-05) Fuel Composition (FLTM AZ 105-02, ASTM D 471/ISO 1817) by Volume: 1) Reference Fuel F = (diesel fuel, Grade #2, 100%) 2) Reference Fuel I = CM15 3) Reference Fuel K = CM85 After 5 min recovery time, no color change in excess of Gray Scale rating 4 - 5 (AATCC Evaluation Procedure
25、 1/ISO 105-A02), dulling, surface distortion or permanent softening permitted. Adhesion shall meet the requirements of para 3.4.1. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-B Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 5 of 8 3.4.7 Mar/Scratch Resistance A &
26、 B Gloss Materials 70% Gloss retention (FLTM BI 161-01) A J Gloss Materials, on substrates below 1250 Mpa flexural modulus Friction Induced Wear (DVM-0056-PA) N.A. production only 23 +/- 2 C Test Conditions No gouge area or finish adhesion loss 69 +/- 2 C Test Conditions 5 cm2gouge area maximum C -
27、J Gloss Materials Rating 1 at 2N (FLTM BN 108-13, 1 mm Dia. Ball) scratch mark 3.4.8 Chip Resistance, max 3.4.8.1 Grit Blast, Split Shot Rating 4 (FLTM BI 157-06) 3.4.8.2 Stone Chip (SAE J400, 4.7 L Gravel), max 3 mm Maximum single chip size SUBSTRATE FLEXURAL MODULUS ASTM D 790 METHOD 1 350 MPa No
28、Chips 350 - 550 MPa 7B (0.6%) 550 - 790 MPa 4B (5.0%) 790 - 1000 MPa 3B (7.0%) above 1000 MPa 2B (10.0%) Chipping is identified as intercoat adhesion loss between any adjoining layers revealing dis-similar colors, scuffing is acceptable. Topcoat systems to be tested will include: - first run panel -
29、 first run plus one in-line repair - first run plus two in-line repairs Panels will 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-B Printed copies are
30、uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 6 of 8 3.4.9 Cold 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 p
31、art. Adhesion shall meet the requirements of para 3.4.1. 3.4.10 High Performance Adhesion 3.4.10.1 Resistance Against High Pressure Cleaner No Removal, N.A. (FLTM BO 160-04, Method B) 2 mm2max, Europe Prior to testing the painted surface shall be X-scribed through to the substrate (30 angle). The te
32、st must be performed on the X-scribe. 3.4.10.2 Thermal Shock (alternate method) No loss of adhesion (FLTM BI 107-05) to the substrate or between film layers permitted. 3.4.11 Heat Resistance (7 days at 80 +/- 2 C) Return to room temperature before evaluation. No color change in excess of Gray Scale
33、rating 4 - 5 (AATCC Evaluation Procedure 1/ISO 105-A02), gloss loss or loss of adhesion per para 3.3.1. 3.5 FLEXIBILITY REQUIREMENTS 3.5.1 Flexibility at 23 +/- 2 C No cracking when bent over appropriate mandrel SUBSTRATE FLEXURAL MODULUS ASTM D 790 METHOD 1 MANDREL DIAMETER 350 MPa 13 mm 350 - 550
34、MPa 25 mm 550 - 790 MPa 50 mm 790 - 1000 MPa 100 mm above 1000 MPa No requirement 3.5.1 Cold Impact, max Rating 0 (FLTM BO 151-02, -35 +/- 2 C) ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-B Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 7 of 8 3.6 WEATHER RESISTA
35、NCE 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 materials of known Florida stability with an identical chemical type of resin. In case of di
36、fferences 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, blistering, and peeling. Both original and repair shall alter in color, tone and gloss
37、 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 Gray Scale Evaluation Procedure 1/ISO 105-A02). The film shall be free from mildew and show a minimum of dirt r
38、etention. Wash panels from exposure per FLTM BI 160-01, B, 1. Clean exposure panels will be placed in a deionized water bath for 24 h per FLTM BI 104-01. After panels 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
39、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 coating layers. 3.6.1 Natural, Exposure Time 1 & 2 yr submission (SAE J1976, Procedure A) 3.
40、6.1.1 Color Change, min Rating 4 (AATCC Evaluation Procedure 1/ ISO 105-A02) 3.6.1.2 Gloss Change, max 25% (FLTM BI 110-01) 3.6.1.3 “X“ scribe tape pull adhesion, min retention 90% 3.6.2 Accelerated Weathering, New Colors 3000 h required (SAE J1960, 0.55 W/m2Irradiance, Borosilicate inner and outer
41、filters, 3.6.2.1 Color Change, min Rating 4 (AATCC Evaluation Procedure 1/ ISO 105-A02) 3.6.2.2 Gloss Change, max 25% (FLTM BI 110-01) 3.6.2.3 “X“ scribe tape pull adhesion, min retention 90% ENGINEERING MATERIAL SPECIFICATIONWSS-M2P181-B Printed copies are uncontrolled Copyright 2008, Ford Global T
42、echnologies, LLC Page 8 of 8 3.7 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 design are Bake Time, Bake Temperature, and Film Thickness. An initial screening ex
43、periment 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 to the DOE should be based on the materials tested and should be chosen from
44、the following tests: adhesion (para 3.4.1), water resistance (para 3.4.2), stone chipping (para 3.4.8), and high performance adhesion (para 3.4.10). 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1
45、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 BC/CC 60 50 4.2 WAVESCAN TARGET VALUES, max (BYK-Gardner or equivalent) du 15 Structures 0.1 mm wavelength Wa 15 Structures from 0.1 0.3 mm wavelength Wb 30 Structures from 0.3 1 mm wavelength Wc 20 Structures from 1 3 mm wavelength Wd 20 Structures from 3 10 mm wavelength We 20 Structures from 10 30 mm wavelength
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