1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2000 11 29 Revised Updated A. Cockman 1989 12 18 Released NB00I10046814 Printed copies are uncontrolled Page 1 of 6 Copyright 2000, Ford Global Technologies, Inc. METALLIZE, PLASTIC PARTS, FIRST SURFACE, ESB
2、-M5P9-A INTERIOR 1. SCOPE This specification defines the performance requirements for decorative first surface coatings on interior thermoplastic or thermosetting plastic parts involving sputter or vapor deposition of metals in a vacuum. The term “first surface“ means the surface first meeting the e
3、ye when the part is installed in position. 2. APPLICATION This specification was released originally for a finish used on plastic parts, either clear or opaque, where a bright metallic appearance is desired. See para 5 for definitions of procedures and materials found to produce acceptable metallize
4、d coatings. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to the Companys Quality System Requirements. 3.2 CONDITIONING AND TEST CONDITIONS All test values
5、indicated herein are based 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 Shall be uniform in density, texture and finish, free o
6、f visible porosity, warpage, heat scorch, checks, cracks, chipped edges and uneven surfaces. Shall also be free of other contamination. ENGINEERING MATERIAL SPECIFICATION ESB-M5P9-A Page 2 of 6 Copyright 2000, Ford Global Technologies, Inc. 3.3.1 Color (FLTM Bl 9-1) The metallized surface shall matc
7、h the Ford master panel on file. 3.3.2 Gloss (FLTM B1 110-1, 60 Glossmeter) Shall match the Ford master panel with +/- 3 units 3.3.3 Opacity The metallized areas shall be opaque on clear plastic parts which are backlighted or edge-lighted. Metal film thickness on all parts shall be sufficient to giv
8、e the finished surface a bright lustrous metallic appearance. If a colored pigmented base coat is desired for improved opacity or to match standard for luster or lighting, the part print shall so specify. 3.4 INITIAL HARDNESS The finish shall be sufficiently cured at time of packing to withstand nor
9、mal handling and shipping without marring. 3.5 FILM PROPERTIES 3.5.1 Adhesion (FLTM B1 106-1, Method B) Grade 1 3.6 RESISTANCE REQUIREMENTS 3.6.1 Hot and Cold Cycle Test Two cycles consecutively Test Method: The following sequential temperature exposures constitute one cycle: 6 h at -40 +/- 2 C 2 h
10、at 24 +/- 2 C 6 h at 91 +/- 2 C 2 h at 24 +/- 2 C 6 h at 109 +/- 2 C Acceptance: All test parts must complete two cycles without cracks, splits, bulges, sinks, visual distortion, paint blistering, peeling or discoloration. ENGINEERING MATERIAL SPECIFICATION ESB-M5P9-A Page 3 of 6 Copyright 2000, For
11、d Global Technologies, Inc. 3.6.2 Resistance to Abrasion 500 cycles (FLTM BN 7-1, dry cloth; two thicknesses; substitute a metallized part for the textile material). Acceptance: The cloth must not wear through the metallizing so as to expose the base substrate on test panel. 3.6.3 Resistance to Clea
12、ning Solutions Test Method: (FLTM BN 7-1, 15 cycles, min. Substitute a metallized part for the textile material. Saturate white cotton cloth with the cleaners listed). Acceptance: No more color transfer than Rating 4 on the AATCC Color Transference Scale when tested with the following cleaners: Wind
13、ex spray with ammonia COAZ-19526-A Triple - clean All Purpose Cleaner C9AZ-19C507-A Glass Cleaner 3.6.4 Interior Exposure Cycle (FLTM BO 15-1) 3 cycles 3.6.5 Resistance to Water and Soap Spotting (FLTM BI 113-1) Discoloration, max 0.3 N.B.S. 3.7 WEATHERING REQUIREMENTS Parts representative of produc
14、tion shall be exposed as follows: 3.7.1 Florida Exposure (Miami Area): 12 months at 45 under glass facing south 3.7.2 Accelerated Weathering: (one of the following) Carbon Arc Weather O meter, min 400 h (FLTM BO 1-1) Xenon Arc Weather O meter, min 400 h (SAE J 1885) ENGINEERING MATERIAL SPECIFICATIO
15、N ESB-M5P9-A Page 4 of 6 Copyright 2000, Ford Global Technologies, Inc. Test Acceptance Criteria: The metallized and non-metallized surfaces shall not exhibit coating delamination, cracking, checking, blister, fade or chalk by the end of the exposure period. The Florida exposure panel takes preceden
16、ce over a panel of the same material exposed in either accelerated weathering test. 3.8 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the mater
17、ial originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify the affected Purchasing, and Materials Engineering activities (with reasons) of the proposed changes. Upon notification of the
18、Company, further instructions will be provided. Note: Suppliers should be prepared to provide test data and samples demonstrating compliance to this specification, if requested. Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. Th
19、e restrictions are identified in Restricted Substance Management Standard WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification for direct supply to the Company must have prior approval. Certain materials subcontracted by part suppliers may also require prior approval. Th
20、ese include materials critical to the Companys business for regulatory, safety, environmental or compatibility requirements or contractual agreements. Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Materials Engineering activity
21、. Upon request, the Supplier shall submit 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 specification. 5. GENERAL INFORMATION The information given below is
22、provided for clarification and assistance in meeting the requirements of this specification. ENGINEERING MATERIAL SPECIFICATION ESB-M5P9-A Page 5 of 6 Copyright 2000, Ford Global Technologies, Inc. The following procedure and materials have been found to produce a metallized coating which will meet
23、requirements of this specification. Parts should be metallized as soon after molding as is practical. The surface shall be free from dirt, lint, mold release agents, fingerprints and any other contaminants. 5.1 STRESS RELIEVE Thermoplastic parts with intricate patterns of varying wall thicknesses ma
24、y be susceptible to crazing or cracking from residual stress. Parts shall be tested as described below before a coating is applied to determine the necessity for stress relieving. If parts show cracking, crazing, or checking, they must be stress relieved according to a cycle agreed upon by the suppl
25、ier and the responsible Product Engineering Office. 5.1.1 Test for Residual Stress Expose five (5) parts to three (3) complete cycles as listed in FLTM BO 15-1. Examine the parts for cracking, crazing, or checking. If none is evident, stress relieving is not required. 5.2 BASE COAT Apply (spray, flo
26、w or dip) the base coat material to the clean dry surface of the part requiring metallization. Cure per suppliers recommendation. 5.3 METALLIZE Apply a coating of metal, to the area specified, by sputter or evaporation in a vacuum. The method of application will be determined by color, luster, opaci
27、ty, and film thickness specified. 5.4 TOP COAT Apply sufficient top coat to meet specification and appearance requirements. Cure top coat per supplier recommendation. 5.5 CONTROL PLAN The Control Plan required in para 3.1 shall include the following data from the paint supplier: The nominal values a
28、re established from the initial approved production batch for each color. Recommended tolerances for subsequent batches are listed below. ENGINEERING MATERIAL SPECIFICATION ESB-M5P9-A Page 6 of 6 Copyright 2000, Ford Global Technologies, Inc. PAINT Weight per Gallon, Kg/L +/- 0.03 Weight Solids, % +
29、/- 3 Viscosity at 25 C +/- 5 Wet Hiding (crypt), if pigmented +/- 4 The painter shall chart the following application attributes: Application Viscosity Pot Pressure or Paint Flow Rate Atomizing Air Pressure Mix Ratio (isocyanate component should be controlled to 0.95 - 1,05), if applicable. Cure Cycle - Oven Temperatures and Cure Time
