1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1996 07 22 Revised Revised para 3.8.5.2, 3.8.9, 3.9.5.6 E. Nunez1996 06 07 Revised Upd a solution in water of 0.75 % by weight CaSO4adjusted to a pH of 4; deionized water (DI) and tap water,Bee Dropping (Ford Met
2、hod 24).ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 13 of 25Apply 0.05 mL of specified solutions along entire length of two test panels. Place on gradient bar (38 C - 82 C,calibrated for heat-up rate of 2 minutes or less for 0.09 mmsteel substrate).
3、 Remove one panel after 15 minutes attemperature, other after 30 minutes. Rinse any remainingsolution with water. Examine panels for etching,discoloration, pitting, etc. Report etch-free temperaturefor test material and control.The test enamel shall display resistance to chemical attackwhich is equa
4、l to or better than currently availableautomotive coatings technology.3.8.4 Cold Checking Resistance 15 cycles(FLTM BI 107-02, Cold Cycling Procedure only)No cracking or noticeable dulling permitted.3.8.4.1 Panel PreparationPrepare 3 panels according to para 3.4.1 through 3.4.4,applying paint at sta
5、ndard dry film thickness,utilizing the minimum, standard, and maximum enamelbakes of para 3.4.6 respectively. A total of 4 coatsof enamel shall be applied to each panel and bakedseparately, using the required baking schedule.Scuff-sand between enamel coats using #400 gritsandpaper or equivalent. The
6、 film thickness of thecombined cathodic electrocoat primer, primer surfacesand basecoat/clearcoat enamel shall be 380 +/- 5micrometre.3.8.5 Weathering Resistance3.8.5.1 Florida Exposure 120 Mos.(SAE J1976, Procedure A (To Failure)Miami area, facing south standard rackat 5 deg from horizontal)Test th
7、e following systems: fully-fortified basecoat/clearcoat systems - standard bake and catalyzed lowbake repair; and unfortifed basecoat/clearcoat system -standard bake (neither basecoat nor clearcoat willcontain UVAs or HALs). Prepare panels as per 3.4.5. Compare adhesion forfully formulated systems a
8、t low and standard filmthicknesses.ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 14 of 25Panels should be marked for SAE J1976, Procedure Atesting on the back. A vertical 25 mm line is scribedat the lower left corner of panels prior to Floridaexposure
9、 testing. (The scribe line is located 25 mmfrom the left edge of panel, and 10 mm from the bottomedge). Panels are exposed in 12 month intervals for atotal of 120 months (i.e., 12 months, 24 months, 36months). A total of 10 panels is required.Additional exposure panels shall be prepared andallowed t
10、o remain on test beyond the 10 yearrequirement until failure. Failure is defined as anydegradation which will render the paint filmunserviceable to the final customer.Note: The performance rating assigned to completed 60Months Florida exposure panel takes precedence over apanel of the same material
11、exposed for 2500 h inaccelerated weathering tests (Xenon Arc Weatherometerrefer to para 3.8.6.2).Panels on exposure longer than 24 months shall beretrieved from exposure site and washed as perrecommended washing procedure (FLTM BI 160-01, B, 1)every 24 months.Test for Adhesion on Completed Exposure
12、Panels: Clean exposure panels will be placed in a deionizedwater bath for 16 h per FLTM BI 104-01. After panelsare removed from water bath and thoroughly blown dry,an “X“, to be located at the center of panel and 50 mmfrom the bottom, is scribed. The “X“ shall be 30 mm inheight and 20 mm wide. Tape
13、the original scribe lineand the “X“ scribe with 3M 898-2 tape and check forpeeling and delamination between any layers. Thereshall be no blistering or delamination of any of thecoating layers.After two years Florida exposure, the panels shallexhibit no more than 15 % loss of original 20 degreegloss
14、(ref. para. 3.5.2) or more than 20 % loss oforiginal DOI (ref. para. 3.5.4).Note: If the completed Florida exposure panels requiremore thorough cleaning to facilitate proper evaluation,the lower 1/3 of the panels may be polished with FordCustom Silicone Gloss cleaner, part numberB7AZ-19530-AA, using
15、 a soft cloth. This procedure isperformed only after the panels have been previouslywashed and subjected to water immersion and the “X“-scribe tape pull.ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 15 of 25The panels shall show no more evidence of ch
16、alking,dulling, fading or other color change than the standardmaster sample on file. Also, the panels shall be freefrom cracking and microchecking when examined with theaid of a light source such as a Berkley ColortranMulti-1OA Lamp, Model 100-301 using a Sylvania 120V FBYbulb. Any evidence of such
17、cracking or microcheckingis considered to be a failure.3.8.5.2 Accelerated Exposure 6000 h(Modified SAE J1960, (To Failure)Xenon Arc Weatherometer,using Type “S“ BorosilicateInner and Outer filters,Radiant Exposure 0.55 W/m2)Clearcoat systems to be tested include: ESB-M33J3-A2 unfortified (without U
18、VAs or HALs), and ESB-M33J3-A2fully-formulated (with UVAs & HALs). These will beprepared as per 5.3.2, 5.3.3, 5.3.5.Fully-formulated basecoat/clearcoat systems to betested include: standard bake and catalyzed low-bakerepair. Prepare panels as per 3.4.5. Compareadhesion for fully formulated systems a
19、t low andstandard film thicknesses. Scribe vertical 25 mm line at lower left corner ofpanels and place in Apparatus at beginning ofcondensation cycle.Additional panels shall be prepared and tested tofailure with failure being defined as anydegradation rendering the film unserviceable to thefinal cus
20、tomer. Refer to para 5.3.1 for recommendedtesting schedule.Test for adhesion as per recommended procedure inFlorida Exposure (3.8.6.1). After 2000 h in weatherometer, the panels should notexhibit more than 15 % loss of original gloss (refpara 3.5.2) or more than 20 % loss of original DOI(ref para 3.
21、5.4).ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 16 of 253.8.6 Cracking Resistance 3 cycles(ISO 3231/DIN 50018 - SFW 2.0S)Testing is conducted in an environmental test chamber(Kesternich-type apparatus) as defined by ISO 3231/DIN 50018.The operation
22、 of the chamber during the test cycle shall beconducted in accordance with the procedures and requirementsoutlined in the Standard.Upon completion of required test cycles, the panels shallshow no evidence of cracking, peeling, fissures or theformation of any film defects, in excess of those observed
23、 ona control panel, which could cause paint failures onvehicles. The control panel shall be approved currentproduction enamel which shall be exposed simultaneously withthe test material.3.8.6.1 Test Cycle 24 h per cycleA test cycle consists of the following:(1) During the deep heating moist SO2 phas
24、e(SFW 2.0S), the panels in the test chamber areexposed to an atmosphere consisting of 100 %relative humidity at 40 +/- 3 C, in the presence of2.0 liters of sulfur dioxide for 8 hours.(2) The chamber atmosphere is then evacuated, andthe cabinet door opened to ambient room conditionsof 24 +/- 2 C and
25、relative humidity below 75 %. Test panels remain in the opened cabinet for 16hours. Next, the panels are removed from cabinetand inspected. If required, panels are returned tothe cabinet to undergo further test cycles.3.8.6.2 Preparation of Test PanelsPrepare panels in accordance with paras 3.4.1thr
26、ough 3.4.4, using standard film thicknesses andstandard bake schedule. Upon removal from oven andcooling down to room temperature, the panels shallbe rebaked per the standard enamel bake of para3.4.6. There shall be no wiping or sanding betweencoats.The maximum test surface allowed by DIN 50018 in t
27、hetest chamber is 0.5 sq m +/- 0.1 sq m. Panels shallbe a minimum size of 100 mm x 150 mm in order toobtain consistent test results. When panels arecut, any exposed edges are to be protected with anair-dry corrosion resistant primer.ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ES
28、B-M33J3-C1/C5WP 3948-b Page 17 of 253.8.7 Resistance to GasoholNo color change, dulling, surface distortion or permanentsoftening is permitted.Panel Preparation - Two types of panels required. . Prepare panels as per para 3.4.1 thru 3.4.5. Apply enamelat standard dry thickness and bake one set at mi
29、nimumenamel bake (3.4.6.1) and the other set at standard enamelbake (3.4.6.2).3.8.7.1 Procedure for Drip Test Run tests using Blends“A“ and “B“ separatelyThe size of the test panels shall be 100 x 150 mm. A burette must be used to allow the Gasohol to dripat a rate which requires approximately 1 h f
30、or the50 mL to be evacuated (equivalent to approximatelyone drop every three seconds).Note: The panel shall be placed paint side up at anangle of 60 degrees from the horizontal. The distance from the tip of the burette to the spotwhere the drop impinges on the panel is 300 mm.(The spot is centered 1
31、00 mm above the lower edgeof the test panel). The test panel shall be placedin a flat open dish to contain accumulated Gasohol.Conduct testing in a well ventilated hood atambient room temperature of 24 +/- 2 C, away fromall sources of ignition.Gasohol Composition by VolumeBlend A: ASTM Reference Fue
32、l C 85 %Methanol 15 %Blend B: ASTM Reference Fuel C 15 %Methanol 85 %Remove panels from test and allow them to recoverfor 1 h at ambient room conditions. Examine panelsfor color change, dulling, and surface distortionor permanent softening.3.8.8 Sag Resistance(FLTM BI 22-1)Shall be equivalent to the
33、 control enamel.ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 18 of 253.8.9 Mar Resistance(FLTM BI 161-01)Prepare panels as per para 3.4.1 thru 3.4.4, use standardfilm thicknesses and bake at minimum, standard and maximumbake schedules.Percent loss in
34、 gloss shall not be greater than thatexhibited by control.3.8.10 Intercoat Adhesion(FLTM BI 106-01, Part B) Chipping, flaking, or loss ofadhesion shall not exceed Fig. 2of Test Method (less than 5%loss). No delamination of anylayer in the basecoat/clearcoatenamel system.Panel preparation - Three set
35、s of panels required.1. Prepare panels as per 3.4.1 through 3.4.4. Apply enamelat standard dry film thickness and bake per maximum bake. Cool panels to room temperature. Avoid touching the paneltest surface with hands. Do not wipe. Recoat panel withsame enamel. Apply at standard film thickness and b
36、ake perminimum bake.2. Prepare panels as per 3.4.1 through 3.4.3, bake sprayprimer 60 minutes at 193 C ambient (53 minutes minimum at193C metal temperature). Mask right half of panelsvertically. Do not wipe. Apply basecoat at standard dryfilm thickness and flash for two minutes. Remove masking. Appl
37、y clearcoat to entire panel at standard dry filmthickness, flash for two minutes. Bake at minimum enamelbake schedule. 3. Note: All enamel will be applied at standard filmthicknesses.Prepare 4 panels as per 3.4.1 through 3.4.4, bake 2 panelsper standard bake schedule and remaining 2 per maximum bake
38、schedule. Cool panels to room temperature. Avoid touchingthe panel test surface with hands. Do not wipe. Recoat 1panel each of the standard bake and maximum bake with currentproduction quality white enamel and bake using standard bake. Recoat 1 panel each of standard and maximum bake panels withenam
39、els previously used to prepare same. Bake panels usingstandard bake schedule. ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 19 of 253.8.11 Chipping Resistance(SAE J400) Equal to or better than control, not to exceed a 4B SAErating and no rust spots sh
40、all be visible indicating chips tometal.Panel Preparation - The following sets of panels arerequired:. Prepare three types of panels as indicated in para 3.8.10. Prepare panels as per 3.4.1 through 3.4.4, at thefollowing film thicknesses and enamel bakes: . Low Film Thickness, Maximum Enamel Bake Sc
41、hedule. Standard Film Thickness, Standard Enamel Bake Schedule. High Film Thickness, Minimum Enamel Bake Schedule. Prepare panels as per 3.4.5. Prepare panels as per 3.4.1 through 3.4.4, apply enamel atstandard dry film thickness and bake for 60 minutes(ambient) at maximum bake temperature.Prepare a
42、nd test similarly prepared panels for all systemsidentified in para 5.1.After chipping, panels shall be subjected to 24 h Salt Sprayper FLTM BI 103-01.3.9 BASECOAT ESB-M33J3-A1 and -B2ONLY FOR INTERIOR APPLICATIONS3.9.1 Physical Properties3.9.1.1 The physical properties of basecoat ESB-M33J3-A1,-A4
43、and -B2 are determined by requirements of thebasecoat/clearcoat enamel. Refer to para 3.3 forspecific requirements.3.9.2 Preparation of Test Panels3.9.2.1 SubstratePanels prepared per para 3.4.2 (electrocoat primed- no primer surfacer).3.9.2.2 EnamelApply basecoat ESB-M33J3-A1, -A4 and -B2 at lowfil
44、m build (para 3.4.4) and flash as required andbake per para 3.4.6, minimum and standard bakeschedules.ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 20 of 253.9.3 Appearance3.9.3.1 Color(FLTM BI 109-01)The color of the basecoat is determined by therequ
45、irements of the basecoat/clearcoat enamel tomatch the Ford master panel.3.9.3.2 Gloss, All Colors(FLTM BI 110-01 20 deg Glossmeter)Gloss varies with each color due to pigmentationrequirements.3.9.3.3 Gloss, After Rebake(FLTM BI 110-01, 20 deg Glossmeter)No more than 4 units decrease in gloss ispermi
46、tted when panel is rebaked per para 3.4.6.3.9.3.4 GeneralThe basecoat shall bake out to a presentable,serviceable film showing no craters, pinholing.seediness, abnormal roughness or excessive metallicmottling. It shall have reasonable tolerance forordinary cleaning.3.9.4 Film Properties3.9.4.1 Film
47、Thickness 25 - 39 micrometers(FLTM BI 117-01)3.9.4.2 Adhesion No chipping or(FLTM BI 106-01) flaking3.9.4.3 Hardness(FLTM BI 112-02)Tukon 5.0 K.H.N.3.9.5 Resistance Properties3.9.5.1 Water and Soap Spotting No spotting is(FLTM BI 113-01) permitted3.9.5.2 Acid Spotting No spotting or (FLTM BI 13-5) d
48、iscoloration permittedENGINEERING MATERIAL SPECIFICATION ESB-M33J3-A1/A5ESB-M33J3-B1/B5ESB-M33J3-C1/C5WP 3948-b Page 21 of 253.9.5.3 Resistance to Xylene(FLTM BI 152-01)No dulling, softening or other undesirable effectsare permitted.3.9.5.4 Abrasion Resistance, min 700 cycles(FLTM BN 108-02, CS #10
49、wheels500 g load)Failure is defined as wear through of the paintfilm, exposing primer.3.9.5.5 Florida Exposure 12 months under(Miami area, under glass, glassfacing south at 5 deg from the horizontal)No more than slight color change, fading or chalking ispermitted. No greater loss of gloss is permitted thenequivalent approval production colors. There shall beno evidence of cracking, checking, blistering orpeeling at en
