1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 11 18 N-STATUS No replacement named C. McComb, NA2008 10 29 Revised See Summary of Revisions for details C. McComb 2006 11 10 Activated C. McComb Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 7 CO
2、ATING PERFORMANCE, DECORATIVE FINISH, BRIGHT METAL WSS-M2P191-A2 PARTS, EXTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines the coating performance requirements for partially of fully coated exterior parts made from chromium plated die castings, chromium plated steel or plasti
3、c, chromium flashed stainless steel, anodized aluminum and stainless steel. 2. APPLICATION This specification was released to define coating performance of partially coated exterior bright metal visible parts. A DOE is necessary to determine the optimum time of the completion of the plating process
4、and the application of the coating, per paragraph 3.6. Ink is not recommended by Materials Engineering unless used over a black chrome process. The equipment listed in FLTM BI 107-05 is critical for accurate Thermal Shock test results, per paragraph 3.4.12 Testing to be conducted at Design Verificat
5、ion (DV) or Process Validation (PV) per table 1 unless otherwise agreed to by Materials Engineering. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. Material Specification requirements are to be used for initial qualification of materials. A
6、ll parts must also meet the appropriate DVP & R and Subsystem Design Specification requirements. 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. 3.1 STANDARD REQUIREMENTS FOR PRO
7、DUCTION 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 Test Specimen Preparation Tests shall be performed on actual components processed through the production process. Where th
8、is is not possible, plaques can be used. These shall be the same substrate processed in the same manner as production components. When plaques are used as a substitute for actual components, this must be clearly noted at Part Submission Warrant (PSW) and/or the Laboratory Test Report. ENGINEERING MA
9、TERIAL SPECIFICATIONWSS-M2P191-A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 7 3.2.2 Bright Metal Surface To ensure proper coating adhesion the surface to be coated must be absent of oil or alkaline residues, fingerprints, corrosion, mold release agents,
10、dirt, moisture, and other foreign materials. 3.2.3 Color Coating over Bright Metal Finish The coating must meet the requirements of this specification. Clear coat may be necessary to meet the requirements. If required, it will need Materials Engineering approval and must be noted in Construction Det
11、ail 3.2.5 3.2.4 Aging Test panels or test specimens prepared for investigations according to this specification must be aged for at least 72 hours at 23 +/- 2 C or 16 hours at 45 +/- 1 C prior to testing. When plaques are used as a substitute for actual components, this must be clearly reported on t
12、he (PSW) and/or the laboratory test report. 3.2.5 Construction Details The following information shall be reported to Materials Engineering: 1) Type of coating(s) 2) Thickness of coating(s) 3) Type of Bright Finish 4) Type of Substrate 3.3 APPEARANCE 3.3.1 Color As determined (FLTM BI 109-01 Visual
13、Assessment) by Color Harmony (SAE J1545, Three-Angle CMC) team Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. 3.3.2 Gloss (FLTM BI 110-01, ASTM D 523) A: 20 Glossmeter, min 92 B: 60 Glossmeter 76 - 84 C: 60 Glossmeter 66 - 74 D: 60 Glossmeter 5
14、8 - 66 E: 60 Glossmeter 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 The color, pattern and finish shall match the approved Design Center master sample or shall be as specified on the Engineerin
15、g Drawing. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P191-A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 7 3.3.3 Film Thickness, range (FLTM BI 117-01) The film thickness of all test specimens shall be reported on the PSW and Laboratory Test Report. The film
16、 thickness shall follow the manufacturers recommendation. 3.4 RESISTANCE PROPERTIES 3.4.1 Initial Adhesion, max Grade 1 (FLTM BI 106-01, Method B) 3.4.2 Water Resistance 240 h (FLTM BI 104-01) No blistering, dulling, softening, loss of adhesion, and/or any other film failure. Adhesion shall be teste
17、d according to para 3.4.1 within 20 minutes after removal from water. 3.4.3 Humidity Resistance 240 h (FLTM BI 104-02, Method A) No blistering, dulling, softening, and/or loss of adhesion. Adhesion shall meet the requirements of para 3.4.1. 3.4.4 Corrosion Resistance, max 60 cycles (Metallic Substra
18、tes) (FLTM BI 123-03 except scribe as in FLTM BI 123-01, ASTM D 610) No obvious corrosion from visible cut edges. 3 mm maximum creepage from scribed lines No more face corrosion than grade 6, ASTM D 610. 3.4.5 Fluid Spotting Resistance, min Rating 4-5 (FLTM BI 168-01, Method A and B, AATCC Evaluatio
19、n Procedure 1/ISO 105-A02) Test Fluids: (Body and Exterior Trim use) No color dulling, surface distortion or permanent softening permitted. After exposure Adhesion testing performance must be met per Para. 3.4.1. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P191-A2 Printed copies are uncontrolled Copyrig
20、ht 2010, Ford Global Technologies, LLC Page 4 of 7 3.4.6 Acid Resistance Equal or better than (FLTM BI 113-01 except at 60 and current production 80 C for 30 minutes) material The following solutions shall be tested on candidate materials: Sulfuric acid (H2SO4) adjusted to pH of 2 Phosphoric acid (H
21、3PO4), 0.5% 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 specified solutions 2 test panels. Place one each in preheated ovens at 60 and 80 C, respectively. Remove after 30 minutes. Rinse any remaining solution with water. Examine
22、 panels for etching, discoloration, pitting, etc. Report etch-free temperature for test material and control. 3.4.8 Scratch Resistance A & B Gloss Materials Fracture Load 8.0mN Nano Scratch Test (DVM-0058-PA) Deformation 3 mm dia. Panels will be rated versus the current production system following t
23、he same layering scenarios and must be equal to or better than current production materials. 3.4.10 Environmental Cycling, Total of 15 cycles Rating 4-5 (FLTM BQ 104-07, Procedure 1 or 10, 25% Gloss Loss AATCC Evaluation Procedure 1/ISO 105-A02) No evidence of cracks, no blistering, no change in app
24、earance or other failure when compared with original material approval. After exposure Adhesion testing performance must be met per Para. 3.4.1. 3.4.11 High Performance Adhesion, Euro only Resistance Against High Pressure Cleaner 2 mm2max (FLTM BO 160-04, Method B) Prior to testing, the painted surf
25、ace shall be X-scribed through to the substrate (30 angle). The test must be performed on the X-scribe. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P191-A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 7 3.4.12 Thermal Shock No loss of adhesion (FLTM BI 107-05)
26、to the substrate or between film layers permitted 3.4.13 Heat Resistance, min Rating 4-5 (7days at 80 +/-2 C, AATCC Evaluation Procedure 1/ 25% Gloss Loss ISO 105-A02) Return to room temperature before evaluation. After exposure Adhesion testing performance must be met per Para. 3.4.1. 3.5 WEATHERII
27、NG RESISTANCE Note: The panels shall be completely free from evidence of cracking, checking, rusting, blistering, and peeling. The coating shall be free from mildew and show a minimum of dirt retention after Florida exposure. 3.5.1 Natural, Exposure Time, New Colors (SAE J1976, Procedure A), wash pa
28、nels per FLTM-BI 160-01-B 1 year submission 2 year rated report 3.5.1.1 Color Change, min Rating 4 (AATCC Evaluation Procedure 1/ISO 105-A02) 3.5.1.2 Gloss Change, max 25% (FLTM BI 110-01) 3.5.1.3 “X“ scribe tape pull adhesion, min retention 90% (DVO 7097) Clean exposure panels will be placed in dei
29、onized 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 scribed. The “X“ shall be 30 mm in height and 20 mm wide. Tape the “X“ with 3M 898-2 tape and check for pee
30、ling and delamination between any layers. There shall be no blistering or delamination of any of the coating layers. 3.5.2 Accelerated Weathering Resistance Xenon Weatherometer (SAE J1960, 0.55 W/m2Irradiance, Borosilicate inner and outer filters, 3000 hrs. 3.5.3 Color Change, min Rating 4 (AATCC Ev
31、aluation Procedure 1/ISO 105-A02) 3.5.4 Gloss Change, max 25% (FLTM BI 110-01) 3.5.5 “X“ scribe tape pull adhesion, min retention 90% (DVO 7097) ENGINEERING MATERIAL SPECIFICATIONWSS-M2P191-A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 7 3.6 PROCESS WINDO
32、W DEFINITION The supplier shall perform a Design Of Experiments (DOE) utilizing response surface analysis to determine the Process Window of the system. The four variables to be included in the design are bake time, bake temperature, film thickness, and min/max time between bright finish application
33、 and application of coating. 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 to the DOE should be base
34、d on the materials tested and should include, but not be limited to: Film Thickness (para 3.3.3) Initial Adhesion (para 3.4.1) Water Resistance (para 3.4.2) High performance adhesion (para 3.4.10). 3.7 HARDNESS Shall be sufficiently cured after baking to withstand normal handling and shipping withou
35、t damage. Properly cured paint finish shall be hard enough to dry sand easily with 360 grit paper without gumminess or severe scratching. 4.0 SUMMARY OF REVISIONS Revisions 2008 10 29 o Paragraph 3.3.2 A Gloss updated o Paragraph 3.4.5 Updated to new Fluid Spotting Method o Paragraphs 3.4.6, 3.4.8 &
36、 3.4.10 Reworded for clarity o Paragraph 3.4.7 Removed replaced by new 3.4.5 o Paragraph 3.4.13 added ENGINEERING MATERIAL SPECIFICATIONWSS-M2P191-A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 7 of 7 TABLE 1 Sample size per color New Coating Technology New Col
37、or Existing Technology To be done at DV testing To be done at PV testing 3.4.1 Adhesion 3 X X X X 3.4.2 Water Resist 3 X X X X 3.4.3 Humidity Resist 1 X X X 3.4.4 Corrosion 1 X X 3.4.5 Fluid Spot 1 X X 3.4.6 Acid Resist 1 X X 3.4.7 Fuel Resist 1 X X 3.4.8 Mar/Scratch 3 X X X 3.4.9 Split Shot, 1 X X X 3.4.9 Gravel, 1.4 L, 1 X X X X 3.4.10 Environ. Cycling 1 X X X 3.4.11 High Perf. Adhesion 3 X X 3.5.1 XW 3000 h 1 X X X 3.5.2 Florida exposure 2 X X X X = required
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