1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev 02 2012 06 26 N Status No replacement or usage N. Benipal, NA 2005 07 29 Revised Inserted 3.0; Deleted 3.1, 3.7 and 4 1990 07 03 Released NB00 I 10082738 GAM, MP Controlled document at www.MATS Copyright 2012, Ford Global Technologies, LLC
2、 Page 1 of 6 TOPCOAT, CLEAR, ABRASION RESISTANT, UV CURABLE ESB-M80J2-A TRANSPARENT PLASTIC PARTS NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a clear UV stabilized multi-functional monomeric resin solution. 2. APPLICATION This specification was released origi
3、nally to describe the typical properties necessary for a clear protective coating for a polycarbonate headlamp lens. Prior to approval to this specification, the coating must meet additional processing, environmental, and assembly performance requirements listed on Engineering Drawings. Refer to par
4、a 5 for a partial list of the titles of the known documents and specifications. 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). 3.2 COMPOSITION 3.2.1
5、 Vehicle A multi-functional monomeric resin with a UV absorber blended in an appropriate manner to meet all the requirements of this specification. Minor amounts of modifiers and/or plasticizers are allowed. 3.2.2 Specific Composition The supplier will furnish the specific composition of the formula
6、tion upon request. 3.3 PHYSICAL PROPERTIES 3.3.1 Viscosity, Package 25 - 60 mPa.s (ASTM D 2196, Brookfield RVT #2 (centipoise) at 20 RPM) ENGINEERING MATERIAL SPECIFICATIONESB-M80J2-ACopyright 2012, Ford Global Technologies, LLC Page 2 of 6 3.3.2 Non-Volatile, min 96% This procedure is a modificatio
7、n of FLTM BI 102-01 and ASTM D 2369-86. Since the coating contains reactive monomers and oligomers that will evaporate during the forced air drying, a cure cycle must be incorporated before drying. Equipment Required Laboratory balance Desiccator with desiccant 10 mL disposable syringe Cotton gloves
8、 Laboratory UV Curing Unit Aluminum Foil Dish - (3) dishes per sample Forced Draft Oven, Type IIA or Type IIB as specified in ASTM E 145 Procedure Determine weight of an aluminum foil dish. Record weight as (W1). Mix the sample until homogeneous. If air bubbles are observed stir by hand until the ai
9、r is removed. For coatings believed to have a non-volatile content 60%: Use the syringe to transfer 0.30 +/- 0.10 g of the coating into a tared aluminum foil dish. Record weight as (S). Place the sample immediately into a UV curing unit capable of 300 watts/in output. Cure the sample for 45 seconds
10、at full power. For lower non-volatile coatings: Use the syringe to transfer 0.50 +/- 0.10 g of the coating into a tared aluminum foil dish. Record weight as (S). Flash sample for at least 5 minutes then place the sample into a UV curing unit capable of 300 watts/in output. Cure the sample for 45 sec
11、onds at full power. Remove the sample from the UV Curing cabinet then, place the sample into an forced air oven set at 175 C for five (5) minutes to volatilize residual photoinitiators. Air should be present to inhibit thermal polymerization of residual reactive dilutent. Remove the sample from the
12、oven, place into a dessicator. When cool, weigh the sample and record as (W2). Calculate weight solids (NV%): W2 - W1 NC % = - X 100 S ENGINEERING MATERIAL SPECIFICATIONESB-M80J2-ACopyright 2012, Ford Global Technologies, LLC Page 3 of 6 3.3.3 Volume Non-Volatile, at Application Viscosity, min 90% (
13、EPA Method No. 24) Volatile Organic Compounds, max 0.1 kg/L Allowable Content at Application Viscosity (ASTM D 2369, Procedure B) 3.3.4 Density 1.15 +/- 0.03 kg/L (ASTM D 1475) 3.4 PREPARATION OF TEST PANELS Prepare according to the following procedure: 3.4.1 Panels Unless otherwise specified, therm
14、oplastic or thermosetting plastic materials, 2.5 - 4.0 mm thick of any convenient size, representative of production material. The panels shall be cleaned by an acceptable commercial process to remove mold release agents, fingerprints, oils, dirt, moisture and any other surface contamination prior t
15、o coating. 3.4.2 Clear Topcoat Apply sufficient clearcoat to achieve 20 - 30 micrometers dry film thickness. Cure clear topcoat per manufacturers recommendation. Film Thickness: Beta backscatter . TC-200 Beta Scope or equivalent . Probe . Radioactive Isotope - Thalium 204, energy 0.75 Mev - mounted
16、in platen . Standards - Use the material that is representative of production material at the following coating thicknesses: 0 film, 15 micrometers, 38 micrometers, and saturation Procedure Calibrate the beta backscatter instrument using the standards, store calibration value(s). Take at least ten (
17、10) readings on different areas of the test panel to determine the film thickness and uniformity of coverage. Record all readings. 3.5 APPEARANCE 3.5.1 Color, max Clear, Yellowness (ASTM D 1925) Index, YI 3.00 ENGINEERING MATERIAL SPECIFICATIONESB-M80J2-ACopyright 2012, Ford Global Technologies, LLC
18、 Page 4 of 6 3.5.2 Gloss (FLTM BI 110-01, 60 Glossmeter) Not more than a 10% decrease in gloss relative to the uncoated plastic. 3.5.3 Clarity (ASTM D 1003) . Haze may not increase by more than 0.5% from the uncoated plastic. . Luminous transmittance may not decrease by more than 0.5% from the uncoa
19、ted clear plastic 3.5.4 General The coating when cured shall be a presentable serviceable film showing no craters, pinholes, seediness or abnormal roughness. 3.6 FILM PROPERTIES 3.6.1 Film Hardness Shall be sufficiently hard at time of packing to withstand normal handling. 3.6.2 Adhesion (FLTM BI 10
20、6-01) No more than 1% loss of adhesion. 3.6.3 Abrasion Resistance, max 7% increase in haze (FLTM BN 108-02, Taber Abrader, CS-10 wheel, 500 g load, 300 cycles) 3.6.4 Water Resistance, min 240 h (FLTM BI 104-01) Test Method: Immerse the panels for 240 h in distilled or deionized water maintained at 3
21、2 +/- 1 C. Remove parts from the water and immediately scribe an “X“ through the coating to the substrate. Dry the scribed area with a paper towel, cloth or air pressure and immediately apply, with firm thumb pressure, a min of 13 cm2of 3M 898-2 tape. Remove the tape by pulling one end at 90 angle a
22、t a moderate speed. The following conditions shall be basis for rejection: . Removal of paint beyond 1.6 mm from the scribe line. . Any evidence of blistering or dulling of the coating on the test panel. . Evidence of loss of adhesion of the coating. ENGINEERING MATERIAL SPECIFICATIONESB-M80J2-ACopy
23、right 2012, Ford Global Technologies, LLC Page 5 of 6 3.6.5 Thermal Shock Resistance (FLTM BI 107-05) The enamel shall exhibit no blister or loss of adhesion when subjected to the following cycle. . 4 h water immersion . 4 h minimum exposure at -29 C. . Direct steam blast along the scribed “X“. Hold
24、 the steam wand 50 - 75 mm from the panel at an angle of 45 from the plane of the “X“. 3.6.6 Resistance to Water and Soap Spotting (FLTM BI 113-01) Discoloration, max None 3.6.7 Resistance to Acid Spotting (FLTM BI 113-02, except use of colorimeter is omitted) The coating shall exhibit no more dulli
25、ng or color change than the approved master sample on file in the Exterior Materials Section at Body Engineering. 3.6.8 Chemical Resistance 48 h at 23 +/- 4 C Test Fluids: . Motor oil - 10W40 type “SF“ (API), Ford Service Part Number E4AZ-19579-A . Tar remover (petroleum base), Ford Service Part Num
26、ber B7A-19520-A. . Windshield washer fluid, (methanol/detergent base with ethanolamine), Ford Service Part Number C9AZ-19550-AA. Dilute concentrate 1:1 with distilled water for test. . Antifreeze, Ford Service Part Number E2FZ-19549-AA. Dilute antifreeze 1:1 with distilled water for test. . Referenc
27、e Fuel D ASTM D 471 Test Procedure: Wipe the entire coated surface of the panel with a 150 mm square soft cotton cloth (folded into a 75 mm square) hat that has been immersed in a container containing 60 mL of one of the chemicals listed in this test method. Each chemical is applied to a separate pa
28、nel. The amount of chemical on the cloth is controlled by beginning the wipe only after the cloth has stopped dripping. One back and forth wipe shall be performed in the horizontal directions, for the bottom, middle and finally the upper surface. Store the panel for 48 h in an environmental chamber
29、at 23 +/- 4 C and RH of 30 +/- 10%. Clean the panel with a soft clean cloth. Inspect the panel without magnification. Test Acceptance Criteria: The panel surface shall not exhibit any surface deterioration, coating delamination, fracture or color pick up. ENGINEERING MATERIAL SPECIFICATIONESB-M80J2-
30、ACopyright 2012, Ford Global Technologies, LLC Page 6 of 6 3.6.9 Weathering Resistance Panels prepared in according with para 3.4 shall be exposed as follows: . Florida Exposure (Miami Area) 36 months at 45 facing south . Accelerated Weathering 2000 h (FLTM BO 101-01 or SAE J1960) Test Acceptance Cr
31、iteria: The panel surface when viewed without magnification shall not exhibit coating delamination, cracking, checking or blistering. In addition, the color expressed as units of the Yellowness Index (YI) specified in ASTM D 1925 (see para 3.6.1), shall not exceed a value of + 8.00 at the end of the
32、 exposure period. Note: Florida exposure results shall take precedence over weatherometer results. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 FLASH POINT 92 C min (ASTM D 92) 5.2 APPLICABLE SP
33、ECIFICATIONS . Motor Vehicle Safety Act - Public Law 89-563 . Federal Motor Vehicle Safety Standard 571.108 (FMVSS-108 as amended 05/17/84) . Federal Register Volume 48, No. 107 d, 06/02/83 . Ford Motor Company Product Engineering - Engineering Test Procedure SM-22 - ES-E4LB-13005-AA Specification - Headlamp Assembly - ESB-M4D100-A3 Polycarbonate - Optical Grade - Uncoated
