1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Release No. Release/Revision Rev. 2 2008 11 06 N-STATUS No Replacement C. McComb, FNA 1991 04 18 NB00I10043054074 Released John Faunt WP 3948-a Page 1 of 4 METALLIZE PLASTIC PARTS, REFLECTORS ESB-M5P11-A NOT TO BE USED FOR N
2、EW DESIGN 1. SCOPE This specification defines the performance requirements and processing procedures for functional first surface coatings on the reflector parabola (third surface to exterior). The coatings on the thermoplastic or thermosetting plastic parts involve vapor deposition of metals and pr
3、otective coating(s) in a vacuum. 2. APPLICATION This specification was released originally for the coatings used on reflector parabolas of composite type aerodynamic headlamps. 3. 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acc
4、eptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to analyze process/product data so that variation in the final product is continuously reduced. 3.2 CONDITIONING AND TEST CONDITIONS All test values indicated herein are bas
5、ed on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.3 APPEARANCE 3.3.1 All parts shall be free from any objectionable blemishes on the reflectiv
6、e surface. A blemish is defined as the presence of any one or combination of the following: Orange peel, weld marks, crazing, etc., unless otherwise designated on the drawing or visual standards. 3.3.2 All parts shall be finished off smoothly; flash, gates, etc. removed. All visible surfaces shall b
7、e highly polished unless otherwise specified. 3.3.3 Photometry Engineering Test Procedure SM-22 Sample must meet requirements of para 5.1.1 and 5.1.2 of SM-22. ENGINEERING MATERIAL SPECIFICATION ESB-M5P11-A WP 3948-b Page 2 of 4 3.4 ADHESION 3.4.1 Adhesion to Plastic Grade 1 or better (FLTM BI 106-0
8、1, Method “B“) The coating system shall show satisfactory adhesion of all coats to one another. 3.5 INITIAL HARDNESS The finish shall be sufficiently cured at time of packing to withstand normal handling and shipping without marring. 3.6 RESISTANCE PROPERTIES 3.6.1 Resistance Requirements Parts test
9、ed as outlined in para 3.6.2 shall conform to the following: . The finished part shall not warp, craze, crack, check or sustain a dimensional change greater than the tolerances specified on the engineering drawing. . Bright metallic surfaces shall show no indications of oxidizing, peeling, blisterin
10、g, tarnishing or other discoloration. . Colored surfaces shall show no indications of checking, blistering, loss of adhesion, chalking and only slight fading. 3.6.2 Resistance Tests 3.6.2.1 Resistance to Cycling (FLTM BO 115-01) 3.6.2.2 Resistance to Heat 3 h at 110 +/- 2 C or as specified on the en
11、gineering drawing. 3.6.2.3 Resistance to Humidity 120 h at 98 +/- 2 % relative humidity and 38 +/- 1 C. 3.6.2.4 Resistance to Salt Spray, min 48 h (ASTM B 117) 3.6.2.5 Water Immersion, min 96 h (FLTM BI 104-01) ENGINEERING MATERIAL SPECIFICATION ESB-M5P11-A WP 3948-b Page 3 of 4 3.6.2.6 Weathering R
12、esistance . Florida Exposure (Miami area). . 12 months at 45 degrees facing south. . Test reflector as a finished assembly. Accelerated Weathering (One of the following methods) . EMMA Weathering in Arizona 335 MJ (SAE J1961) . Xenon Arc Weather-o-meter, min 400 h (SAE J1960) . Carbon Arc Weather-o-
13、meter, min 400 h (FLTM BO 101-01) Note: Florida exposure results shall take precedence over accelerated weathering results. 3.7 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted.
14、Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing,
15、Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or
16、Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1, unless a different suffix (e.g., A2 or A3) is specified on the engineering document for the application. ENGINEERING MATERIAL SPECIFICATION ESB-M5P11-A WP 3948
17、-b Page 4 of 4 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials E
18、ngineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this spe
19、cification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. In addition to meeting the requirements of this specification, the materials will be assessed for suitability for intended applications as part of the approval process. Upon approval, the material will be added to the Engineering Material Approved Source List.
