1、ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 2 of 20 Date Action Changes 2015 10 09 Revised Separated B2 B3 from remainder of document G. Weber, NA 1996 07 22 Revised Revised para 3.8.5.2, 3.8.9, 3.9.5.6 E. Nunez 1996 06 07 Revised Upd a solution in water of 0.75 % by weight CaSO4 adjuste
2、d to a pH of 4; deionized water (DI) and tap water, Bee Dropping (Ford Method 24). Apply 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 mm steel substrate).Remove one panel after 15
3、minutes at temperature, other after 30 minutes. Rinse any remaining solution with water. Examine panels for etching, discoloration, pitting, etc. Report etch-free temperature for test material and control. The test enamel shall display resistance to chemical attack which is equal to or better than c
4、urrently available automotive 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 Preparation Prepare 3 panels according to para 3.4.1 through 3.4.4, applying paint at standard dry film
5、 thickness, utilizing the minimum, standard, and maximum enamel bakes of para 3.4.6 respectively. A total of 4 coats of enamel shall be applied to each panel and baked separately, using the required baking schedule. Scuff-sand between enamel coats using #400 grit sandpaper or equivalent. The film th
6、ickness of the combined cathodic electrocoat primer, primer surfaces and basecoat/clearcoat enamel shall be 380 +/- 5 micrometre. 3.8.5 Weathering Resistance 3.8.5.1 Florida Exposure 120 Mos. (SAE ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 12 of 20 J1976, Procedure A (To Failure) Miami
7、area, facing south standard rack at 5 deg from horizontal) Test the following systems: fully-fortified basecoat/ clearcoat systems - standard bake and catalyzed low bake repair; and unfortifed basecoat/clearcoat system - standard bake (neither basecoat nor clearcoat will contain UVAs or HALs). Prepa
8、re panels as per 3.4.5. Compare adhesion for fully formulated systems at low and standard film thicknesses Panels should be marked for SAE J1976, Procedure A testing on the back. A vertical 25 mm line is scribed at the lower left corner of panels prior to Florida exposure testing. (The scribe line i
9、s located 25 mm from the left edge of panel, and 10 mm from the bottom edge). Panels are exposed in 12 month intervals for a total of 120 months (i.e., 12 months, 24 months, 36 months). A total of 10 panels is required. Additional exposure panels shall be prepared and allowed to remain on test beyon
10、d the 10 year requirement until failure. Failure is defined as any degradation which will render the paint film unserviceable to the final customer. Note: The performance rating assigned to completed 60 Months Florida exposure panel takes precedence over a panel of the same material exposed for 2500
11、 h in accelerated weathering tests (Xenon Arc Weatherometer refer to para 3.8.6.2). Panels on exposure longer than 24 months shall be retrieved from exposure site and washed as per recommended washing procedure (FLTM BI 160-01, B, 1) every 24 months. Test for Adhesion on Completed Exposure Panels: C
12、lean 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, an “X“, to be located at the center of panel and 50 mm from the bottom, is scribed. The “X“ shall be 30 mm in height and 20 mm wide. Tape the
13、original scribe line and the “X“ scribe 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. After two years Florida exposure, the panels shall exhibit no more than 15 % loss of original 20 degree glo
14、ss (ref. para. 3.5.2) or more than 20 % loss of original DOI (ref. para. 3.5.4). Note: If the completed Florida exposure panels require more thorough cleaning to facilitate proper evaluation, the lower 1/3 of the panels may be polished with Ford Custom Silicone Gloss cleaner, part number B7AZ-19530-
15、AA, using a soft cloth. This procedure is performed only after the panels have been previously washed and subjected to water immersion and the “X“- scribe tape pull. ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 13 of 20 The panels shall show no more evidence of chalking, dulling, fading o
16、r other color change than the standard master sample on file. Also, the panels shall be free from cracking and microchecking when examined with the aid of a light source such as a Berkley Colortran Multi-1OA Lamp, Model 100-301 using a Sylvania 120V FBY bulb. Any evidence of such cracking or microch
17、ecking is considered to be a failure. 3.8.5.2 Accelerated Exposure 6000 h (Modified SAE J1960, (To Failure) Xenon Arc Weatherometer, using Type “S“ Borosilicate Inner and Outer filters, Radiant Exposure 0.55 W/m2) Clearcoat systems to be tested include: ESB-M33J3-A2 unfortified (without UVAs or HALs
18、), and ESB-M33J3-A2 fully-formulated (with UVAs & HALs). These will be prepared as per 5.3.2, 5.3.3, 5.3.5. Fully-formulated basecoat/clearcoat systems to be tested include: standard bake and catalyzed low-bake repair. Prepare panels as per 3.4.5. Compare adhesion for fully formulated systems at low
19、 and standard film thicknesses. Scribe vertical 25 mm line at lower left corner of panels and place in Apparatus at beginning of condensation cycle. Additional panels shall be prepared and tested to failure with failure being defined as any degradation rendering the film unserviceable to the final c
20、ustomer. Refer to para 5.3.1 for recommended testing schedule. Test for adhesion as per recommended procedure in Florida Exposure (3.8.6.1). After 2000 h in weatherometer, the panels should not exhibit more than 15 % loss of original gloss (ref para 3.5.2) or more than 20 % loss of original DOI (ref
21、 para 3.5.4). 3.8.6 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 of the chamber during the test cycle shall be conducted in accordance with the procedures
22、 and requirements outlined in the Standard. Upon completion of required test cycles, the panels shall show no evidence of cracking, peeling, fissures or the formation of any film defects, in excess of those observed on a control panel, which could cause paint failures on vehicles. The control panel
23、shall be approved current production enamel which shall be exposed simultaneously with the test material. ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 14 of 20 3.8.6.1 Test Cycle 24 h per cycle A test cycle consists of the following: (1) During the deep heating moist SO2 phase (SFW 2.0S),
24、 the panels in the test chamber are exposed to an atmosphere consisting of 100 % relative humidity at 40 +/- 3 C, in the presence of 2.0 liters of sulfur dioxide for 8 hours. (2) The chamber atmosphere is then evacuated, and the cabinet door opened to ambient room conditions of 24 +/- 2 C and relati
25、ve humidity below 75 %. Test panels remain in the opened cabinet for 16 hours. Next, the panels are removed from cabinet and inspected. If required, panels are returned to the cabinet to undergo further test cycles. 3.8.6.2 Preparation of Test Panels Prepare panels in accordance with paras 3.4.1 thr
26、ough 3.4.4, using standard film thicknesses and standard bake schedule. Upon removal from oven and cooling down to room temperature, the panels shall be rebaked per the standard enamel bake of para 3.4.6. There shall be no wiping or sanding between coats. The maximum test surface allowed by DIN 5001
27、8 in the test chamber is 0.5 sq m +/- 0.1 sq m. Panels shall be a minimum size of 100 mm x 150 mm in order to obtain consistent test results.When panels are cut, any exposed edges are to be protected with an air-dry corrosion resistant primer. 3.8.7 Resistance to Gasohol No color change, dulling, su
28、rface distortion or permanent softening is permitted. Panel Preparation - Two types of panels required. . Prepare panels as per para 3.4.1 thru 3.4.5. Apply enamel at standard dry thickness and bake one set at minimum enamel bake (3.4.6.1) and the other set at standard enamel bake (3.4.6.2). 3.8.7.1
29、 Procedure for Drip Test Run tests using Blends “A“ and “B“ separately The size of the test panels shall be 100 x 150 mm. A burette must be used to allow the Gasohol to drip at a rate which requires approximately 1 h for the 50 mL to be evacuated (equivalent to approximately one drop every three sec
30、onds). Note: The panel shall be placed paint side up at an angle of 60 degrees from the horizontal.The distance from the tip of the burette to the spot where the drop impinges on the panel is 300 mm. (The spot is centered 100 mm above the lower edge of the test panel).The test panel shall be placed
31、in a flat open dish to contain accumulated Gasohol. ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 15 of 20 Conduct testing in a well ventilated hood at ambient room temperature of 24 +/- 2 C, away from all sources of ignition. Gasohol Composition by Volume Blend A: ASTM Reference Fuel C 85
32、 % Methanol 15 % Blend B: ASTM Reference Fuel C 15 % Methanol 85 % Remove panels from test and allow them to recover for 1 h at ambient room conditions. Examine panels for color change, dulling, and surface distortion or permanent softening. 3.8.8 Sag Resistance (FLTM BI 22-1) Shall be equivalent to
33、 the control enamel. 3.8.9 Mar Resistance (FLTM BI 161-01) Prepare panels as per para 3.4.1 thru 3.4.4, use standard film thicknesses and bake at minimum, standard and maximum bake schedules. Percent loss in gloss shall not be greater than that exhibited by control. 3.8.10 Intercoat Adhesion (FLTM B
34、I 106-01, Part B) Chipping, flaking, or loss of adhesion shall not exceed Fig. 2 of Test Method (less than 5% loss). No delamination of any layer in the basecoat/clearcoat enamel system. Panel preparation - Three sets of panels required. 1. Prepare panels as per 3.4.1 through 3.4.4. Apply enamel at
35、standard dry film thickness and bake per maximum bake. Cool panels to room temperature.Avoid touching the panel test surface with hands. Do not wipe. Recoat panel with same enamel. Apply at standard film thickness and bake per minimum bake. 2. Prepare panels as per 3.4.1 through 3.4.3, bake spray pr
36、imer 60 minutes at 193 C ambient (53 minutes minimum at 193C metal temperature). Mask right half of panels vertically. Do not wipe. Apply basecoat at standard dry film thickness and flash for two minutes.Remove masking. Apply clearcoat to entire panel at standard dry film thickness, flash for two mi
37、nutes. Bake at minimum enamel bake schedule. 3. Note: All enamel will be applied at standard film thicknesses. Prepare 4 panels as per 3.4.1 through 3.4.4, bake 2 panels per standard bake schedule and remaining 2 per maximum bake schedule. ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 16 o
38、f 20 Cool panels to room temperature. Avoid touching the panel test surface with hands. Do not wipe. Recoat 1 panel each of the standard bake and maximum bake with current production quality white enamel and bake using standard bake. Recoat 1 panel each of standard and maximum bake panels with ename
39、ls previously used to prepare same. Bake panels using standard bake schedule. 3.8.11 Chipping Resistance (SAE J400) Equal to or better than control, not to exceed a 4B SAE rating and no rust spots shall be visible indicating chips to metal. Panel Preparation - The following sets of panels are requir
40、ed: . Prepare three types of panels as indicated in para 3.8.10. . Prepare panels as per 3.4.1 through 3.4.4, at the following film thicknesses and enamel bakes: . Low Film Thickness, Maximum Enamel Bake Schedule . Standard Film Thickness, Standard Enamel Bake Schedule. . High Film Thickness, Minimu
41、m Enamel Bake Schedule. . Prepare panels as per 3.4.5. . Prepare panels as per 3.4.1 through 3.4.4, apply enamel at standard dry film thickness and bake for 60 minutes (ambient) at maximum bake temperature. Prepare and test similarly prepared panels for all systems identified in para 5.1. After chip
42、ping, panels shall be subjected to 24 h Salt Spray per FLTM BI 103-01. 3.9 BASECOAT ESB-M33J3 -B2 ONLY FOR INTERIOR APPLICATIONS 3.9.1 Physical Properties 3.9.1.1 The physical properties of basecoat ESB-M33J3-B2 are determined by requirements of the basecoat/clearcoat enamel. Refer to para 3.3 for s
43、pecific requirements. 3.9.2 Preparation of Test Panels 3.9.2.1 Substrate Panels prepared per para 3.4.2 (electrocoat primed - no primer surfacer). 3.9.2.2 Enamel Apply basecoat ESB-M33J3-B2 at low film build (para 3.4.4) and flash as required and bake per para 3.4.6, minimum and standard bake schedu
44、les. ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 17 of 20 3.9.3 Appearance 3.9.3.1 Color (FLTM BI 109-01) The color of the basecoat is determined by the requirements of the basecoat/clearcoat enamel to match the Ford master panel. 3.9.3.2 Gloss, All Colors (FLTM BI 110-01 20 deg Glossmet
45、er) Gloss varies with each color due to pigmentation requirements. 3.9.3.3 Gloss, After Rebake (FLTM BI 110-01, 20 deg Glossmeter) No more than 4 units decrease in gloss is permitted when panel is rebaked per para 3.4.6. 3.9.3.4 General The basecoat shall bake out to a presentable, serviceable film
46、showing no craters, pinholing. seediness, abnormal roughness or excessive metallic mottling. It shall have reasonable tolerance for ordinary cleaning. 3.9.4 Film Properties 3.9.4.1 Film Thickness 25 - 39 micrometers (FLTM BI 117-01) 3.9.4.2 Adhesion No chipping or (FLTM BI 106-01) flaking 3.9.4.3 Ha
47、rdness (FLTM BI 112-02) Tukon 5.0 K.H.N. 3.9.5 Resistance Properties 3.9.5.1 Water and Soap Spotting No spotting is (FLTM BI 113-01) permitted 3.9.5.2 Acid Spotting No spotting or (FLTM BI 13-5) discoloration permitted ENGINEERING MATERIAL SPECIFICATION ESB-M33J3-B2/B3 Page 18 of 20 3.9.5.3 Resistan
48、ce to Xylene (FLTM BI 152-01) No dulling, softening or other undesirable effects are permitted. 3.9.5.4 Abrasion Resistance, min 700 cycles (FLTM BN 108-02, CS #10 wheels 500 g load) Failure is defined as wear through of the paint film, exposing primer. 3.9.5.5 Florida Exposure 12 months under (Miam
49、i area, under glass, glass facing south at 5 deg from the horizontal) No more than slight color change, fading or chalking is permitted.No greater loss of gloss is permitted then equivalent approval production colors.There shall be no evidence of cracking, checking, blistering or peeling at end of exposure period. 3.9.5.6 Accelerated Exposure 600 h (Modified SAE J1960, Xenon Arc Weatherometer, using type “S“ inner and outer filters, Radiant Exposure 0.55 W/m2) The complete test panel shall be subject to the same exposure performance requirements as described above for Florida panels. 3.9.5
