1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Ver 3 2008 07 08 N-STATUS Replaced by WSS-M4G252-E2; Inserted 3.0; Deleted 3.12 & 4 M. Mehandru, FNA 1978 11 03 Revised Metricated & Retyped, CAH1-RD572066-158 1977 11 23 Released CAG1-CR-570932 Printed copies are uncontrolled Copyright 2008,
2、 Ford Global Technologies, LLC Page 1 of 5 SEALER, VINYL - SPRAYABLE - CHIP RESISTANT - HEAT CURING ESB-M4G215-A NONPAINTABLE NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a vinyl base, heat curing material which can be airless sprayed to 0.02 - 0.05 in (0.5 -
3、1.3 mm) film on phosphated CRS, phosphated galvanized, zinc rich primer coated steel sheet and electrocoated substrates, to provide a corrosion resistant film which will withstand stone chipping. 2. APPLICATION This specification was released originally for material used in underbody areas such as f
4、enders and wheel housings. Film thickness and bake temperatures are restricted as follows: Minimum Maximum 2.1 FILM THICKNESS 0.02 in (0.5 mm) 0.05 in (1.3 mm)* 2.2 BAKE SCHEDULE 8 min at 135 C 50 min at 165 C (Metal Temperature) *0.05 in (1.3 mm) maximum permissible in areas where spray patterns ov
5、erlap. Coating thickness in excess of 0.05 in (1.3 mm) will cause blistering and cracking of the coating in high temperature primer bake ovens. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements
6、For Production Materials (WSS-M99P1111-A). 3.1 COLOR Medium blue or as specified in the Welding Manual 3.2 SOLIDS, min 97% (ASTM D 2834, except heat for 3 h at 100 C in a mechanical convection oven) ENGINEERING MATERIAL SPECIFICATION ESB-M4G215-A Printed copies are uncontrolled Copyright 2008, Ford
7、Global Technologies, LLC Page 2 of 5 3.3 VISCOSITY (FLTM BV 103-1, 0.052 in (1.32 mm) orifice, 40 psi (276 kPa) air pressure). 3.3.1 As Received 15 - 40 s 3.3.2 Aged, max 80 s (72 h at 43 C) 3.4 WEIGHT PER VOLUME (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.2 lb/gal (0.02 kg
8、/L), based on the recorded weight of the original approved production sample. (See para 5.1). 3.5 SPRAYABILITY Shall be suitable for use in the airless spray equipment designated by the Process Engineering Department. (See para 5.2) 3.6 INVERTED BAKE No evidence of cracking, blistering, separation f
9、rom the metal or loss of material. Test Method: Apply a 1 x 8 x 0.05 in (25 x 200 x 1.3 mm) ribbon on an electrocoated 4 x 12 x 0.035 in (100 x 300 x 0.89 mm) CRS panel. Invert the panel and air dry for 30 min at 23 C. Heat the panel in the inverted position for 15 min in a mechanical convection ove
10、n maintained at 135 C. Repeat the above procedure except heat for 50 min at 165 C. 3.7 SAG, max 0.06 in (1.5 mm) Test Method: Apply a 1 x 8 x 0.05 in (25 x 200 x 1.3 mm) ribbon on an electrocoated 4 x 12 x 0.035 in (100 x 300 x 0.89 mm) CRS panel. Permit the panel to air dry for 30 min at 23 C in a
11、vertical attitude with the 8 in (200 mm) dimension of the ribbon vertical. Heat the panel for 15 min at 135 C in a mechanical convection oven. The panel is to be held in a vertical attitude with the 8 in (200 mm) dimension of the ribbon vertical. Allow the panel to cool to 23 C and measure the sag.
12、Repeat the above procedure except heat for 50 min at 165 C. 3.8 ABRASION, ADHESION, AND CORROSION RESISTANCE The coating shall protect body substrated from stone abrasion when subjected to10 pt (5500 cm3) of gravel per SAE J 400, and corrosion after exposure to 1000 h salt spray per ASTM B 117. Ther
13、e shall be 100% coating retention to all substrates after the abrasion test with no corrosion extending more than 0.12 in (3.0 mm) from scribed or abraded areas after salt spray exposure. ENGINEERING MATERIAL SPECIFICATION ESB-M4G215-A Printed copies are uncontrolled Copyright 2008, Ford Global Tech
14、nologies, LLC Page 3 of 5 Test Method: . Prepare panels as described in Table I . Scribe an “X“, with approximately 4 in (100 mm) legs, through to base metal on the top portion of all prepared panels. . Allow panels to set for 72 h at 23 C, then check coating adhesion before environmental exposure.
15、Evaluate the adhesion by cutting a 1 in (25 mm) wide ribbon along the bottom edge of the panels. Grasp the ribbon and attempt to peel at 180. Acceptable adhesion requires a minimum 2.5 lb/in (440 N/m) peel strength or 90% minimum cohesive failure at film thicknesses greater than 0.02 in (0.51 mm). .
16、 Subject the bottom portion of the 0.02 in (0.51 mm) coated panels to 10 pt (5500 cm3) of gravel. Examine panels for coating retention loss. . Expose the abraded panels to 1000 h salt spray. . After salt spray exposure, allow the panels to dry at 23 C for 48 h and then reevaluate adhesion as describ
17、ed in the third paragraph above. Remove the coating from the lower half of the test panels and along the scribed area. Examine for evidence of corrosion and corrosion extension from the scribe. 3.9 ABRASIVES Shall not cause premature failure of the pumping equipment, the spray guns or the spray tips
18、 due to the presence of abrasive fillers, etc. Test Method: Dilute a 1 g sample of the material with 1 g of M14J167 special spirits and mix thoroughly. Rub a portion of the diluted material 100 times between 2 pieces of flat, clean plate glass. The appearance of scratches on the glass plate shall be
19、 considered a failure. 3.10 STORAGE STABILITY Shall be stored at ambient room temperature below 38 C, away from all sources of heat. Heat greatly accelerates aging. Under these storage conditions, the minimum shelf life of the material shall be 3 months. When this material is stored at temperatures
20、below 23 C, it shall be conditioned at room temperature prior to application. Adequate conditioning permits the material to obtain its maximum application properties. 3.11 QUALITY Shall be a smooth homogeneous mixture, free from foreign materials and properties detrimental to normal production opera
21、tions. ENGINEERING MATERIAL SPECIFICATION ESB-M4G215-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 5 5. GENERAL INFORMATION: The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 WEI
22、GHT PER VOLUME 12 - 14 lb/gal (1.44 - 1.68 kg/L) 5.2 MATERIAL AND EQUIPMENT The material as delivered shall require no additional filtering and must be capable of producing the following: . A 3 in (75 mm) flat spray pattern at a 12 in (300 mm) distance, nozzle to substrate, using a 0.021 in (0.53 mm
23、)/40 C airless nozzle. . A 4 in (100 mm) flat spray pattern at a 12 in (300 mm) distance, nozzle to substrate, using a 0.036 in (0.91 mm)/65 C airless nozzle. Both patterns are to be obtainable with material at 23 C temperature and 2900 psi (20 MPa) maximum pump pressure. 5.3 SUBSTRATES 5.3.1 Electr
24、ocoat Primer ESB-M64J18 or ESB-M64J19, freshly primed (1 h maximum after bake). 5.3.2 Phosphated Galvanized CRS Parker - minimum spangle, temper rolled, Bonderite 40. 5.3.3 Phosphated CRS Ford approved “Paint Test Quality“ (PTQ), Bonderite 40. 5.3.4 Steel Sheet, Zinc Rich Primer coated: ESB-M1A217 5
25、.4 OVERSPRAY In overspray areas, when only minimum bake schedules (8 min at 135 C) are attained film thicknesses of less than 0.02 in (0.05 mm) will exhibit poor adhesion. Individual suppliers shall determine and report the minimum film thickness at which adhesion is developed when baked at the abov
26、e schedule. 5.5 MECHANICAL CONVECTION OVEN Oven(s) used to cure the material shall be capable of obtaining 135 C metal temperature on body steel in 7 - 8 min and 165 C in 8 - 10 min. ENGINEERING MATERIAL SPECIFICATION ESB-M4G215-A Printed copies are uncontrolled Copyright 2008, Ford Global Technolog
27、ies, LLC Page 5 of 5 TABLE I PANEL PREPARATION Primer ESB-M6J119 Sealer/Primer Vinyl Applied over Vinyl Film Thickness Apply 0.0075 in (19 m Bake Schedule Substrates 0.02 in 0.5 in - 0 Wet Primer (Metal Temprature) (0.5 mm) (1.3 mm 0) On Wet Vinyl * 8 min, 135 C 50 min, 165 C Phosphated X X X X CRS X X X X Phosphated X X X X Galvanized X X X X ZINCROMETAL X X X X X X X X E-Coat X X X X X XX *See para 5.3 for Approved Substrate Listing *Air dry the vinyl coating for 15 min at 23 C prior to primer application.
