1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW15777 Vehicle Exterior and Add-On Parts Paint Appearance Requirements Copyright 2011 General Motors Company All Rights Reserved August 2011 Originating Department: North American Engineering Standards Page 1 of 26 1 Scope 1.1 Material Descri
2、ption. This standard describes the surface appearance and quality requirements for painted vehicle exterior, add-on parts and primed parts. The requirements are described in terms of appearance attributes and surface blemishes for each zone within a part. The purpose of these requirements is to ensu
3、re that the level of final finish on GM vehicles meets or exceeds the level expected by our customers. This standard applies to primed and/or finished parts produced by suppliers and those top-coated in GM assembly plants and includes requirements for paint suppliers. 1.2 Symbols. Not applicable. 1.
4、3 Typical Applications. Painted car bodies, exterior parts painted by or supplied to GM and primed exterior parts supplied to GM. 1.4 Remarks. Implementation of this standard is targeted to apply to all new GM vehicle programs with Initial Design Release (IDR) dates after 6/1/2011. Current programs
5、will still be required to meet the requirements of the February 2009 version of GMW15777 and/or SOR documents referenced at the time suppliers were awarded contracts. Individual vehicle program teams may move to implement this updated specification on current programs, but will consult with Assembly
6、 Plant, Supplier Quality, Suppliers, Purchasing and others as required to assess cost and other ramifications. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM E1499 VDA 16 DIN 6175-2 VDA 280 SAE J361 2.2 GM
7、Standards/Specifications. GM4389M GMW3032 GMW14797 GMW16382 GMW2 GMW3059 GMW15192 GMW15850 GMW3005 GMW3399 GMW15420 2.3 Additional References. Bill of Materials (BOM) charts by color - plant-specific Factor tolerances documented on the color data sheet which is available through GM Supply Power Glob
8、al Exterior Harmony Review Report GM Color Standards and Primer Standards available from the regional engineering center or Thierry Corporation (www.thierry-) GTR34920 Enclosures and Decks Technical Specification Ishihara Test for Colorblindness Statements of Requirements (SOR) TMC003 Material Safet
9、y Data Sheet guidance documents (available at ) Vehicle Technical Specification (VTS) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW157
10、77 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 2 of 26 3 Requirements 3.1 Physical Requirements. Exterior body parts are divided into different appearance zones to set the quality of each zone separately (see Table A1). 3.1.1 Part Zones. Detailed zone definitions of ea
11、ch part are common with Global Customer Audit (GCA 2010) definitions. A definition summary is included in Table A1 and Figure A1 in Appendix A. Any concerns related to part zone definitions will be resolved with direction from GM Manufacturing Quality. 3.1.2 Completed Vehicle or Painted Part Inspect
12、ion. For vehicle and part audits, all painted parts shall be inspected in approximate vehicle position and at approximate distance of 600 mm from the observer, or at other distances as specified in VDA 16 or SAE J361. 3.1.3 Manufacturing Facility Quality Inspection Stations for Paint Appearance Defe
13、ct Identification. Manufacturing facility paint quality inspection stations shall be designed to support consistent identification of appearance defects. Assembly facility inspection station construction and lighting requirements for paint defect identification are detailed in GTR34920. It is recomm
14、ended that supplier facility inspection areas be designed with similar characteristics to provide a consistent environment for identification of Appendix A, Table A2 specified defects prior to shipping supplied parts to GM facilities. 3.1.4 Light Booth Evaluation for Component and Panel Color Match.
15、 For component and panel color evaluation, a controlled lighting environment will be utilized and must conform to VDA 16 and VDA 280 specifications or SAE J361 specifications. 3.1.5 Outdoor Inspection for Vehicle Color Match. Outdoor visual comparison to the GM-approved color standard is the method
16、to be used for approval of exterior color match of vehicle bodies and add-on parts. Equipment measurement techniques and standardized work defined in section 4 and Appendix C of this specification shall be utilized to support the visual evaluation and for process control between visual evaluation ev
17、ents. For visual evaluation of paint surface finish, quality and overall vehicle harmony, it is required that completed vehicles be reviewed outdoors in natural daylight (both sunny and cloudy). Color harmony events should be scheduled between 10:00 AM and 2:00 PM, in conditions as defined in SAE J3
18、61, 7.1. Conditions for the evaluation must be documented. 3.1.6 Steady State Color Harmony Assessments at Assembly Plants. Exterior vehicle color harmony assessments in steady state production are targeted to be performed once per month. The assembly plant Quality Engineering Manager (QEM) is respo
19、nsible for scheduling and conducting harmony assessments. Suppliers are not generally required to support these reviews, but may be contacted by the QEM, or designate, to support specific concerns. The plant QEM, or designate, works in conjunction with Design Appearance Quality (DAQ) representatives
20、 to define corrective actions. 3.1.7 Qualification for Visual Evaluation for Color Match. Evaluators of color match must have proven capability as determined by methods including the Farnsworth-Munsell 100 Hue Test (refer to ASTM E1499 and SAE J361, Section 9 Color). The minimum Farnsworth-Munsell s
21、core requirement is 16 or less (Superior Discrimination). Evaluators of color match must also have proven capability as determined by the Ishihara Test for Colorblindness. 3.2 Inspection Devices. The following inspection devices are approved for use in measuring the specified appearance attributes.
22、Devices that are not Gage Repeatability and Reproducibility (R and R) approved should be avoided where practical. Alternates devices, not specified here, may be acceptable for use, but must be approved by GM Supplier Quality and Global Paint and Polymers Manufacturing Engineering (GPPC) in writing p
23、rior to contract award. All measurement equipment will be maintained per manufacturers recommendation. Paint and part suppliers will be responsible to incorporate and maintain certification to standard (minimum once per year) of approved measurement systems within their manufacturing process. 3.2.1
24、Paint Film Thickness. The following equipment is approved for measuring film thickness. Elcometer 355 and 456 (all models) Automation USA QuaNIX 7500 (ferrous/non-ferrous probe with external cable) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for Resa
25、leNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15777 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 3 of 26 BYK-Gardner Byko Test Model MPOR Imaginant (formerly JSR Ultrasonics) PELT Gage (multi-layers) Oxford
26、Instruments 233 m (replaces CGX-A2) Fischer MP30e (replaces Fischer Deltascope MP3C; not formally validated) Selected equipment must be properly calibrated to support accurate measurement on the vehicle or component substrate and paint layering system. See specifications for minimum paint layering s
27、ystem film thicknesses for plastic parts as detailed in GMW14797. All body color polymeric parts must meet the requirements of this specification. See specifications for minimum paint layering system film thicknesses for metallic substrates in GMW3005 and MATSPC. Painted bodies and metallic add-on p
28、arts must meet the requirements of these specifications and one of the following: Assembly Plant plant-specific Bill of Materials (BOM) charts by color. Add-On Part Suppliers - Approved Color Source available from each paint supplier. 3.2.2 Orange Peel Measurement. Preferred method is Wavescan Dual
29、meter measurement for all points. See Table A2 for minimum default Orange Peel values. In order of preference, the following methods for orange peel evaluation are approved. BYK-Gardner Wavescan Dual Models AW-4840 (primer and topcoat, part radius 0.5 m) BYK-Gardner Micro-wave-scan AW-4824 (part rad
30、ius 0.30 m) Orange Peel Visual Plaques 3.2.2.1 Equipment is available from BYK-Gardner at 9104 Guilford Road, Columbia, MD 21046, Phone (800) 343-7721, or at . Technical specifications for equipment, including footprint and scan length are available at this same website. 3.2.2.2 For parts that canno
31、t be measured by the BYK-Gardner Wavescan Dual or Micro-wave-scan meters due to size or shape, visual Orange Peel standards may be used. They can be obtained from ACT Laboratories, Hillsdale, MI 49242, (517) 439-1485. Only purchase GM Orange Peel Standards. 3.2.2.3 For primed parts that are subseque
32、ntly painted at a GM plant, and where the parts have a greater than 50 unit gloss when read using a 20 degree meter, use of the BYK-Gardner Wavescan Dual or Micro-wave-scan is recommended. 3.2.2.4 For primed parts that are subsequently painted at a GM plant, and where the parts have less than 50 uni
33、t gloss when read using a 20 degree meter, use of Orange Peel Visual Plaques is recommended. For full Production Part Approval Process (PPAP) approval, individual specified checkpoints (using an average of 3 readings) must meet the minimum applicable Premium or Non-Premium performance level specifie
34、d in Appendix A2. Readings within the continuous improvement range can be considered “Saleable” if an action plan with timely resolution is approved by Supplier Quality and the program team. Additional specific orange peel values may be detailed in the Statements of Requirements (SOR), Vehicle Techn
35、ical Specification (VTS) documents or Math Files for components and may include requirements for R value as well as Wb, Wc, and Wd. For GM Paint shops that are not capable to this specification, and do not have vehicle cross-shipping requirements, an alternate orange peel specification may be releas
36、ed with the SOR documents for supplied exterior painted parts. This alternate specification for orange peel will require GPPC leadership and program team approval and will also apply to exterior parts painted by GM. 3.2.2.5 Standard measuring lengths of 5, 10, and 20 cm are available on the measurin
37、g devices. The length used to determine orange peel values may be specified in the math data files or should be agreed to by the supplier, supplier quality, and Global Customer Audit (GCA); however, the GPPC Annual Appearance Survey standard roll length is 10 cm for all checkpoints. 3.2.3 Color. 3.2
38、.3.1 Visual Standards. GM Color Standards and Primer Standards can be obtained from the regional engineering center or Thierry Corporation (www.thierry-). See requirements for color match (Of-Color) in Appendix A, Table A2. 3.2.3.2 Spectrophotometry Equipment. The following multi-angle instruments a
39、re approved for color measurement. BYK Mac CM-6362 (Gage R and R Approved for part radius 0.5 m) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STAND
40、ARDS GMW15777 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 4 of 26 Recommended specifications for instrumental color match of painted bodies, exterior parts painted by or supplied to GM and primed exterior parts supplied to GM are shown in Table A2. The primary referenc
41、e for color difference calculation is the GM Master Certified Standard (MCS) for each color as defined in GMW16382. Also see Appendix C: Best Practice Recommendations for Data Collection. 3.2.4 Gloss. BYK-Gardner Micro-Tri Gloss Meter Elcometer 406 Mini Novo-Gloss (60 degree single angle and 20/60 d
42、egree dual angle) 3.2.4.1 Start with the 20 degree meter setting. If the gloss is equal to or greater than 60 gloss with the 20 degree meter setting, continue to use the 20 degree meter setting. If less than 60 gloss, change to the 60 degree meter setting for measurements. 3.2.4.2 Recommended gloss
43、levels for high-gloss exterior painted surfaces and primed parts are shown in Table A2. For this appearance attribute, initial performance levels will be established. On-going process control for Gloss is not required, except in the event that minimum performance levels are not met. 3.2.5 Distinctne
44、ss of Image (DOI). BYK Gardner Wavescan Dual Models AW-4840 BYK Gardner Micro-wave-scan AW-4824 ATI Industries DOI Meter (Not Gage R and R Approved) See Table A2 for minimum default values for DOI. For this appearance attribute, initial performance levels will be established. On-going process contro
45、l for DOI is not required, except in the event that minimum performance levels are not met. 3.2.6 Mottle Effect in Metallic Paint Finishes. Measurement shall be made after application of all elements of the topcoat layering system. Painted surface finish must meet minimum specifications by cloud siz
46、e as detailed in Table A2. The following instruments are approved for surface finish measurement. BYK-Gardner Cloudrunner (Gage R and R Test Pending). Specifications for maximum allowable mottle in Table A2. Suppliers are not required to purchase this tool, but must support problem solving to resolv
47、e identified issues. 3.2.7 Substrate Surface Finish. Surface finish of substrates to be top-coated must not impact painted appearance performance of vehicle body or add-on parts to minimum (Table A2) or product-specific appearance specifications (SOR, VTS, Math File). In the event that final appeara
48、nce of painted bodies or add-on parts is negatively impacted by substrate surface finish, GM reserves the right to demand substrate and/or processing changes as required to meet specifications for painted part appearance as listed in Table A2, SOR documents and/or VTS documents. GM Supplier Quality,
49、 working with GPPC, will arrange for measurement of substrates for any identified concerns per specifications referenced herein. Measurements will be made prior to application of any elements of the paint layering system. Reference GMW15192, GMW15420, GMW2, GMW3032, GMW3399 and GMW15850 for additional clarification of steel, aluminum and polymer substrate quality requirements. 3.3 Additional Re
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