1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 03 05 Revised Para 3.6.1 modified; Para 3.7.3.2 added T. Honey 2008 10 08 Revised Changed text in red to black and removed strikethrough text. T. Honey 2008 03 12 Activated T. Honey, J. Tardiff Printed copies are uncontrolled Copyright 20
2、09, Ford Global Technologies, LLC Page 1 of 8 SPRAYABLE BED LINER, TWO COMPONENT, POLYOL WSS-M99P40-A SPRAYABLE BEDLINER, TWO COMPONENT, ISOCYANATE WSS-M99P40-A2 1. SCOPE This specification defines the material and performance of a spray applied polyol based elastomeric film (WSS-M99P40-A1) and an i
3、socyanate hardener (WSS-M99P40-A2) for use on exterior pickup box inner tubs where a low gloss texture appearance, high flexibility, high durability, and impact resistance are required. This system is specified for assembly plants and component suppliers, covering all processes including in-departme
4、nt and pre-delivery repairs. 2. APPLICATION This specification was released originally to define the performance of sprayable bed liner materials applied to painted surfaces. It is specified for vehicle pickup box inner tubs, running boards, inner floor panels, and other parts visible after assembly
5、. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. Bed liner material applied at the assembly plant shall conform to the full requirements of this specification. In-department and pre-delivery paint repairs shall meet the requirements of this
6、 specification. 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 RHEOLOGY Suppliers must submit flow characterization data to Ford Motor Company for flow modeling
7、 and process window determination. For a specified temperature range, the requested properties include, but are not limited to, viscosity, yield stress, apparent activation energy for viscosity and apparent activation energy for yield stress. This data constitutes the reference standard and shall be
8、 kept on file at the designated material laboratory. 3.3 COMPOSITION 3.3.1 Vehicle Thermosetting, two-component polyurea elastomer system that provides excellent exterior durability, mechanical properties and chemical resistance. 3.3.2 Ultraviolet Light Absorber and Stabilizer Material shall contain
9、 absorber and/or hindered amine in sufficient amount to provide good long-term durability. ENGINEERING MATERIAL SPECIFICATIONWSS-M99P40-A/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 8 3.4 PHYSICAL PROPERTIES LIQUID STATE 3.4.1 Weight per Volume (ASTM D
10、816) Elastomer Resin Component A1 1.00 +/- 0.10 kg/L Catalyst Component A2 1.10 +/- 0.05 kg/L 3.4.2 Viscosity, typical range (Brookfield Viscosity ASTM D1824 #4 Spindle, 20 RPM, 30 sec) Elastomer Resin Component A1 1100 - 1700 cps Catalyst Component A2 20 32 Stokes (Bubble Time Method ASTM D1545) 18
11、50 - 2950 cps 3.4.3 Storage Stability, max 10% Change The supplier shall provide a viscosity profile versus time from initial through 90 days storage at 23 +/-2 C and 32 +/-2 C. Measurements shall be taken at weekly intervals. Curves shall be made available to Materials Engineering prior to addition
12、 on the Approved Source List. 3.4.4 Volatile Organic Compound (EPA Reference Method 24) Elastomer Resin Component A1 0.4 kg/L max. Catalyst Component A2 0.1 kg/L max. Mixed Product As Applied 0.05 kg/L max. 3.5 MANUFACTURING PROPERTIES 3.5.1 Material Consistency Shall be a smooth homogenous mixture,
13、 free from entrapped air, foreign materials and any propertied detrimental to normal production operation. 3.5.2 Color Each component is distinctly different in color. The mixed material shall meet manufacturing process control requirements. Final approval of material color for production shipments
14、shall be made by the affected manufacturing activity and identified on the supplier control plan. ENGINEERING MATERIAL SPECIFICATIONWSS-M99P40-A/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 8 3.6 ENGINEERING REQUIREMENTS (FREE FILM) 3.6.1 Compression Set
15、 (ASTM D 395, Method A (90 IRHD), Type I cylindrical disk test samples, 1.5 mm applied to steel panel and stacked 8 tall to achieve total material thickness of 12.5 +/- 0.5 mm, Diameter 29.0 +/- 0.5 mm, Compressive force: 1780 N (400 lbf), Report compression set as a percentage of the original thick
16、ness. 3.6.1.1 Compression Set, % Deflection 70 hrs at 23 C 6.0 +/- 1.0% 70 hrs at 50 C 30.0 +/- 1.0% 70 hrs at 65 C 35.0 +/- 1.0% 70 hrs at 85 C 42.0 +/- 1.0% Samples are to be conditioned for 24 hrs at 23 +/- 2 C and 50 +/- 5% RH. 3.6.2 Cured Flammability (ISO 3795/FMVSS 302) Burn Rate, max 100 mm/
17、minute The specimen size required for material approval is 355 x 100 x 2.0 +/- 0.1 mm with a smooth surface. 3.6.3 Hardness, Durometer A 95 +/- 5 (ISO 868/ASTM D 2240) 3.6.4 Tensile Strength, min 14 MPa (ISO 37/ASTM D 412, Die C, 500 mm/min test speed) 3.6.4.1 Elongation at Break, min 120% 3.6.5 Tea
18、r Strength, min 60 kN/m (ISO 34, Method B, procedure a/ ASTM D 624, Die C, 500 mm/min test speed) 3.6.6 Water Absorption, max 1.0% by wt. (ISO 62/ASTM D 570) 3.6.7 Brittleness Point, max -40 C (ISO 812, Type B specimen/ ASTM D 2137, Method A) 3.6.8 Heat Aged (ISO 188/ASTM D 573, 150 +/- 50 air chang
19、es/h, 1000 h at 100 +/- 2 C) Hardness Change, max 5% Tensile Strength Change, max 10% Elongation Change, max 10% ENGINEERING MATERIAL SPECIFICATIONWSS-M99P40-A/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 8 3.6.9 Density 1.03 +/- 0.05 g/cm3(ISO 1183, Met
20、hod A/ ASTM D 792, Method A1) 3.7 RESISTANCE PROPERTIES (APPLIED TO SUBSTRATE) Test panels are to be prepared with the intended facility application equipment over the intended substrate, pretreatment and paint layering system following the applicable Ford Motor Company material specifications. Appl
21、y a smooth application of bed liner material to 75 x 200 mm panels at the target horizontal film thickness. 3.7.1 Film Thickness (FLTM BI 117-01, Metallic Substrates, PELT or equivalent) (ASTM B 487, Non-Metallic Substrates, PELT or equivalent) Horizontal Basecoat Applications 1.3 + 0.2 mm (50 + 10
22、mils) Vertical Basecoat Applications 0.8 + 0.2 mm (30 + 10 mils) Textured Dust Coat Application Typically 0.3 mm (15 mils) 3.7.2 Sag Resistance No sag at 2.5 mm (100 mils) Test Method: Apply a wedge of material, ranging from 0 to 4 mm in thickness, to a panel prepared per para 3.7. Position the pane
23、ls horizontally for 1h at 23 +/- C. Determine the application thickness of observed sag along the wedge. 3.7.3 Adhesion Characteristics 3.7.3.1 Peel Strength Adhesion, min 3.6 N/mm (20 pli) (50 mm/min test speed) Test Method: Prepare two panels per para 3.7. Ambient cure at room temperature for 24 h
24、ours. Make 2 parallel cuts 25 mm apart along the 200 mm length of the panel through to the base substrate with a sharp knife. Insert the tip of the knife and peel back a tab approximately 38 mm long. Using an Instron Extensometer with a 90 constant angle test fixture or equivalent, measure and docum
25、ent the maximum peel strength generated. (It is recommended that a piece of masking tape or aluminum foil be placed over approximately 30 mm of one end of the test panels prior to application of the bed liner material.) 3.7.3.2 Pull-Off Strength Adhesion, min 4.2 MPa (600 psi) (ISO 4624/ASTM D 4541,
26、 Elcometer 110 Pneumatic Adhesion Tester or Equivalent) ENGINEERING MATERIAL SPECIFICATIONWSS-M99P40-A/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 8 3.7.4 Heat Resistance Test 240 hrs No evidence of blistering, cracking, charring, embrittlement or other
27、 deleterious effects after exposure in a mechanical convection oven at 120 +/- 3 C. Peel strength adhesion shall be tested according to para. 3.7.3 3.7.5 Water Resistance 240 hrs (FLTM BI 104-01) No blistering, dulling, softening and/or any other film failure. Peel strength adhesion shall be tested
28、according to para. 3.7.3 3.7.6 Humidity Resistance 240 hrs (FLTM BI 104-02, Method A) No blistering, dulling, softening, and/or any other film failure. Peel strength adhesion shall be tested according to para. 3.7.3 3.7.7 Corrosion Resistance 60 cycles (Metallic Substrates) (FLTM BI 123-03 except sc
29、ribe as in FLTM BI 123-01, ASTM D 610 Scribe must be 1 mm thick in order to expose substrate) 3 mm maximum scribe creepage No more face corrosion than grade 6, ASTM D 610. 3.7.8 Fluid Spotting Resistance (FLTM BI 113-01) Test Fluids: (Current production factory fill materials, Motorcraft products or
30、 equivalent) Liquid Soap Windshield Solution (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
31、, surface distortion or permanent softening permitted. ENGINEERING MATERIAL SPECIFICATIONWSS-M99P40-A/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 8 3.7.9 Fuel Resistance (FLTM BO 101-05) Fuel Composition (FLTM AZ 105-02, ASTM D 471/ISO 1817) by Volume:
32、1) Reference Fuel F = (diesel fuel, Grade #2, 100%) 2) Reference Fuel I = CM15 3) Reference Fuel K = CM85 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. 3.7.1
33、0 Xylene Resistance No softening or dulling permitted Using a circular motion, rub the surface of the coating 10 times with a wetted cheesecloth. 3.7.11 Mar Resistance Rating 1 at 7N (FLTM BN 108-13, 1 mm Diameter Ball, scratch mark Smooth Surface) 3.7.12 Abrasion Resistance, max 0.5 g removal (FLTM
34、 BN 108-02/ASTM D 1044, Smooth and Textured Surface, 5000 Cycles, 500g, CS10F) 3.7.13 Scuffing Resistance, max 0.5 g removal (FLTM BN 108-04/ASTM D 1044, Smooth and Textured Surface, 5000 Cycles, 500g, Scuff Head A) 3.7.14 Stone Chip Resistance, -29 C No cut through to (FLTM BI 157-06 & SAE J400, 4.
35、7 L Gravel substrate allowed Test both smooth and textured samples) Peel strength adhesion shall be tested according to para. 3.7.3 3.7.15 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
36、 appearance or other failure when compared with an original unaged part. Peel strength adhesion shall be tested according to para. 3.7.3 ENGINEERING MATERIAL SPECIFICATIONWSS-M99P40-A/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7 of 8 3.7.16 High Performance
37、 Adhesion 3.7.16.1 Resistance Against High Pressure Cleaner No Removal (FLTM BO 160-04, Method B) Prior to testing the painted surface shall be X-scribed through to the substrate (1 mm thick, 30 angle). The test must be performed on the X-scribe. 3.7.16.2 Thermal Shock (alternate method) No Removal
38、(FLTM BI 107-05) 3.7.17 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 materials of known Florida stability with an identica
39、l 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, blistering, and peeling. The film shall be free
40、 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 blown dry, peel strength adhesion shall be tested
41、 according to para. 3.7.2. 3.7.17.1 Natural, Exposure Time 3 yr required, (SAE J1976, Procedure A) 2.0 delta E, max New Color 1 yr required, (Known pigments and resins) 1.0 delta E, max 3.7.17.1.1 Gloss Retention, min 90% (ASTM D 523, 60 Meter) 3.7.17.2 Accelerated Weathering 3600 h required, (SAE J
42、1960, 0.55 W/m2Irradiance, 2.0 delta E, max Borosilicate inner and outer filters) New Color 3000 h required, (Known pigments and resins) 1.0 delta E, max 3.7.17.2.1 Gloss Retention, min 90% (ASTM D 523, 60oMeter) ENGINEERING MATERIAL SPECIFICATIONWSS-M99P40-A/A2 Printed copies are uncontrolled Copyr
43、ight 2009, Ford Global Technologies, LLC Page 8 of 8 3.8 PROCESS WINDOW DEFINITION The supplier shall perform Application and Adhesion DOEs to determine the Process Window of the system. The application variables to be included in the design are Thickness, Reapplication Time and Booth Temp/Humidity.
44、 The Adhesion variables to be included in the design are Topcoat Cure, Topcoat Repair, and Bed Liner Mix Ratio. 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 Materi
45、als 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: Initial Peel Strength Adhesion (para 3.7.2), Heat Resistance (para 3.7.3), Humidity Resistance (para 3.7.5) and Accelerated Weathering (para 3.7
46、.19.2). 4. GENERAL INFORMATION The information below is provided for clarification and assistance in meeting the requirements of these specifications. 4.1 RELATED MATERIALS 4.1.1 Parts / cleaner solvent Acetone 4.1.2 Automated gun tip cleaner box solvent Dibasic Esters (DBE) 4.1.3 Level I, small spot repair material Polyol Elastomer RBDL 1724F Catalyst Hardener CAT 133 4.1.4 Level II, large panel repair material Polyol Elastomer BDL 1724F Catalyst Hardener CAT 133 Or Polyol Elastomer Rhino SOLARMAX Catalyst Hardener CAT 133
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