1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 11 19 N-STATUS No replacement named J. Crist, Na 2005 05 26 Revised Inserted 3.0; Deleted 3.1, 3.9 & 4 1977 11 11 Released AH1-708 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 4 LAMINATE, VINYL -
2、 METAL - EXTERIOR GRADE ESB-M4D382-A NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a polyvinyl chloride film laminated to a metal substrate which is suitable for post forming exterior parts. 2. APPLICATION This specification was released originally for material
3、 used for the 1978 Mark V coach lamp bezel, with the vinyl film coordinated to match the vinyl roof. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A).
4、3.2 APPEARANCE (FLTM BI 109-01) The color, pattern, and finish shall match the approved Body and Electrical Product Engineering master sample, or shall be as specified on the engineering drawing. In addition, there shall be no evidence of vinyl tear, delamination or drawback, particularly in the cri
5、tical radius areas after forming. 3.3 DESIGN LIMITATIONS The vinyl metal laminate defined in this specification is intended for use in part designs employing bends with outside radii that are recommended to be not less than 0.120 in (3.05 mm). Bends of greater severity may cause failure of the vinyl
6、 along the bent edge. For each design, laminates subject to this specification shall be evaluated simulating the most severe proposed application condition. 3.4 METAL BACKING The metal originally released for this application is SAE 51434 type stainless steel. Other types of metals, such as aluminum
7、, may be employed provided they offer corrosion resistance and performance equivalent to the specified SAE 51434 steel. The type, quality and finish of the metal backing selected must be specified on the engineering drawing. 3.5 VINYL FILM (Test conducted on vinyl film only) ENGINEERING MATERIAL SPE
8、CIFICATIONESB-M4D382-APrinted copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 4 3.5.1 General This film shall have the necessary flexibility and elongation characteristics to allow it to be easily formed in the drawing operation without delamination, tearing, drawback
9、 (creepage), loss of embossing, color change or cracking. The original properties of the vinyl film shall not be adversely affected after lamination or forming. The vinyl film shall be ESB-M2F133-A exterior vinyl roof quality, and is generally used, for this specification, without fabric backing. 3.
10、5.2 Mildew (FLTM BN 012-03) After the test the samples shall show no less than 1 mm zone of inhibition and there shall be no evidence of pink staining. 3.5.3 Soiling, max 15% (FLTM BN 112-01) Cleanability, based on manual rubbing with Nainsook cloth and/or a soft bristle brush, using liquid detergen
11、t, shall be equal to the approved master sample. 3.5.4 H2S Staining No discoloration (FLTM AN 102-01) 3.6 THICKNESS AND DIMENSIONS The thickness of the vinyl film, metal substrate and total thickness of the laminate shall be specified on the engineering drawings along with other part dimensions. 3.7
12、 FLAT LAMINATE - PRIOR TO FORMING 3.7.1 Drawability The flat laminate shall bend 180 around a 1/8 in (3.2 mm) mandrel without damage to the vinyl film or delamination of the vinyl-metal bond. In addition, the decorative vinyl surface shall exhibit no hazing, blushing, crazing, cracking or clouding a
13、nd shall be equivalent to the originally evaluated and approved master sample (on file in the BEPE Textile Engineering Section). 3.7.2 Resistance to Elevated Temperature The vinyl film shall exhibit no flattening or loss of embossing, print or ink pattern loss (washout), vinyl creepage or drawback g
14、reater than that exhibited by the original, approved master sample on file in the BEPE Textile Engineering Section. Additionally, the vinyl film shall not stain, exhibit color tone change or change in hue in excess of rating 4-5 of the AATCC Gray Scale for evaluating change in color (10 step). Test
15、Method: Place a 4 x 4 in (100 x 100 mm) flat test specimen or a formed part of the vinyl-metal construction in a convection oven maintained at 121 +/- 3 C for a period of 30 min (vinyl surface up). For parts such as vinyl roof moldings, that are covered with heat protection pads during paint repair
16、oven exposure, place the specimen or part in a convection oven maintained at 88 +/- 3 C for a period of 30 min. Allow to cool to room temperature and visually examine and compare with the original exposed, approved master sample. ENGINEERING MATERIAL SPECIFICATIONESB-M4D382-APrinted copies are uncon
17、trolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 4 3.7.3 Scuff Resistance (FLTM BN 108-04, 500 cycles, 2 lb (0.91 kg), “A“ head) The vinyl surface shall show no evidence of breakthrough. 3.7.4 Abrasion Resistance (FLTM BN 108-02, 1000 cycles, 1000 g load) The vinyl coating shall show
18、no evidence of wearthrough and the entire vinyl film shall possess a uniform and compatible coating. 3.8 FORMED PART 3.8.1 Peel Adhesion (ASTM D 413, Machine Method, 1 in (25 mm) wide strip specimen) The adhesion between the vinyl film and the metal substrate, when conducted on flat surfaces as well
19、 as on highly contoured surfaces and edges, shall be as follows: Original (as received): Laminate must not separate without at least a 50% cohesive failure of the vinyl. 3.8.2 Dimensional Stability The formed part shall show no evidence of flattening or loss of embossing, print or ink pattern loss (
20、washout), loss of grain, blistering, shrinkage or expansion to the extent of causing unsightly wrinkles. The part shall exhibit no visible delamination, pullouts, creepage or cracking that will result in an objectionable appearance and/or exposure of the metal substrate. Test Method: Place other ass
21、embly in a mechanical convection oven maintained at 83 +/- 3 C for 7 days. Allow the specimens to cool to room temperature and examine. 3.8.3 Thermal Shock Resistance (FLTM BI 107-05) Direct the steam blast at the smallest radii of both concave and convex surfaces, formed edges and on the crosshatch
22、. The formed laminate shall show no evidence of degradation, loss of adhesion or delamination. 3.8.4 Impact, Gardner At Room Temperature 10 in lb (1.1 J) At -29 C 5 in lb (0.6 J) The vinyl film shall show no evidence of cracking, crazing, blushing or delamination. Test Method: The parts shall be imp
23、acted on the decorative surface, 1/4 in (6.4 mm) away from any formed edge, using a Gardner Model IG-1120 (or equivalent) tester with a 1/2 in (12.7 mm) diameter hemispherical impact head. The parts shall also be impacted on both convex and concave decorative surface areas. The low temperature test
24、shall be conducted after exposure for a 4 h minimum at -29 +/- 1 C and impacted within 20 s after removal from the low temperature chamber. 3.8.5 Weathering Resistance The vinyl coating shall not stain, craze, blush, haze, crack, exhibit color tone change or change in hue, in excess of rating 4-5 of
25、 the AATCC Gray Scale for evaluating change in color (10 step), when exposed as follows: ENGINEERING MATERIAL SPECIFICATIONESB-M4D382-APrinted copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 4 Fadeometer 1600 h (SAE J 1885) Weatherometer 1600 h (FLTM BO 101-01) Florid
26、a Exposure 160,000 langleys (45 South DWI) Arizona Exposure 160,000 langleys (45 South DWI) 3.8.6 Environmental Aging After exposure to the following cycle, the part shall exhibit no visible vinyl delamination, pullouts, creepage, shrinkage, cracking or scuffing on any surface that will affect the a
27、ppearance when installed. Cycle consists of the following sequence*: 2 h exposure in the steam autoclave, 88 - 93 C 1 h exposure at -29 C 1 h exposure at 88 C * Note: Prior to exposure, trace the original position of the outer edges of the vinyl on the metal flange end to provide a gage for subseque
28、nt movement or creepage of the decorative vinyl. 3.8.7 Resistance to Gasoline and Hydrocarbons After soaking separate samples in: Hydrocarbon fluid (2.1% toluene, 0.5% diisobutylene, 97.4% octane primary reference fuel) Any regular grade of commercially available non-leaded gasoline Leaded gasoline
29、The material surface shall not exhibit any color change, loss of gloss, dulling, tackiness or spotting. In addition, the vinyl-metal laminate shall exhibit no evidence of delamination, shrinkage or cracking. Test Method: Soak each 2 x 8 in (50 x 200 mm) sample in a beaker containing approximately 16
30、 fluid ounces (473 ml) of hydrocarbon fluid or gasoline for 1 h. Remove sample, dry at standard conditions for 3 h and observe. 3.8.8 Salt Spray Exposure (ASTM B 117, 240 h) The parts shall exhibit no evidence of color change, chalking, wrinkling, crazing, milkiness or loss of embossment greater tha
31、n that exhibited by the approved master sample on file in the BEPE Textile Engineering Section. In addition, the vinyl-metal laminate shall not delaminate, crack, corrode excessively or exhibit any other characteristics which would produce an objectionable appearance when the part is in the installed position.
