1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 03 2012 02 16 NStatus No replacement named N. Benipal, NA 2005 08 29 Revised Inserted 3;0; Deleted 3.9 and 4 1983 02 05 Released C3N1-PR905424-2 Controlled document at www.MATS Copyright 2012, Ford Global Technologies, LLC Page 1 of 6 CHI
2、P RESISTANT COATING, ONE-COMPONENT URETHANE - ESB-M99J311-A PAINTABLE, HEAT CURING, NON-MASKING CHIP RESISTANT COATING - ONE-COMPONENT URETHANE - ESB-M99J311-A2 PAINTABLE, LOW HEAT CURING, NON-MASKING NOT FOR NEW DESIGN 1. SCOPE The materials defined by these specifications are heat curing one-compo
3、nent urethane coatings which can be sprayed to an 203-279 m film on cathodic electrocoated CRS and cathodic electrocoated galvanized steel. The material shall provide a paintable corrosion resistant film which will withstand stone chipping. 2. APPLICATION These specifications were released originall
4、y for one-component urethane coatings that provide stone chipping protection on a vehicles lower bodyside. This area of a vehicle receives severe stone chipping abuse. Since the material has good adhesion at extremely low film thicknesses, no masking operations are required during its application. 3
5、. REQUIREMENTS The material shall meet all requirements detailed in this section. Approved production material applied and tested under identical conditions shall be used as the control. In the event that both the sample under test and the control material fail any requirements, that test shall be r
6、epeated. These requirements apply to both laboratory-prepared and production batches of the coating. 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). 3.1 COMPOSITION
7、ESB-M99J311-A ESB-M99J311-A 3.1.1 Non-Volatile, +/- 1% 64 67 (FLTM BI 102-01) 3.1.2 Toxicity The material shall be non-toxic and shall not cause skin rash or irritation (dermatitis) to exposed handlers in normal production operations. Benzene and chlorinated hydrocarbon solvents are considered toxic
8、 and their use is strictly prohibited in compounding material to these specifications. ENGINEERING MATERIAL SPECIFICATION ESB-M99J311-A/A2 Copyright 2012, Ford Global Technologies, LLC Page 2 of 6 3.2 PHYSICAL PROPERTIES ESB-M99J311-A ESB-M99J311-A2 3.2.1 Weight Per Volume at 1.32 +/- 0.2 1.38 +/- 0
9、.2 23 +/- 2 C, kg/L 3.2.2 Viscosity, KU 85 - 95 90 - 100 (ASTM D 562) 3.2.3 Heat Stability 105 KU max 110 KU max (FLTM BI 102-03) Test Method: Make the following exceptions to FLTM BI 102-03: . Measure the viscosity per ASTM D 562. . Place in an oven at 49 C for 5 days. 3.3 PREPARATION OF TEST PANEL
10、S Materials submitted for initial approval shall be tested on both cold rolled steel and minimum spangle temper rolled quality galvanized steel (ESB-M1A62 type) panels for all requirements of this specification. 3.3.1 System Components . Substrates: Ford PTQ cold rolled steel and ESB-M1A62 galvanize
11、d steel. . Pre-treatment: ESB-M3P1 zinc phosphate. . Primer: ESB-M64J19 cathodic electrocoat primer, 12.7 - 17.8 m followed by the specified bake cycle. . Stone Chip Material: 203 - 280 m. Do not reduce the material. Within 3 min after the stone chip material application, make a wet-on-wet applicati
12、on of guidecoat. . Guidecoat: ESB-M6J119, 19.0 - 25.4 m; co-bake the stone chip material and the guidecoat as specified in para 3.3.2. . Topcoat: Prepare two sets of topcoated panels. Set I: ESB-M50J100 - Quality acrylic enamel, 38.1 - 50.8 m followed by the specified bake cycle. Set II: ESB-M32J120
13、-A1/A2 Polyester basecoat/clearcoat; dry film thicknesses - basecoat: 15 m, min and clearcoat: 38 - 44 m followed by the specified bake cycle. ENGINEERING MATERIAL SPECIFICATION ESB-M99J311-A/A2 Copyright 2012, Ford Global Technologies, LLC Page 3 of 6 3.3.2 Co-bake Cycle . Bake, min; 10 min at 149
14、+/- 2 C metal temperature (ESB-M99J311-A). 10 min at 135 +/- 2C metal temperature (ESB-M99J311-A2). . Bake, max; 30 min at 163 +/- 2 C metal temperature. 3.3.3 Panel Aging Age panels 72 h at room temperature or 16 h at 43 +/- 2 C oven temperature before initiating a test program. 3.4 APPEARANCE 3.4.
15、1 Color Gray 3.4.2 Leveling The chip coating film shall level with a minimum of orange peel. The surface of the material under test shall be equal to or better than the approved master sample for smoothness when applied and cured under identical conditions. 3.5 FILM PROPERTIES 3.5.1 Sagging and Solv
16、ent Popping No sagging or solvent popping is allowable at 2 - 280 m dry film thickness. 3.5.2 Dry Sanding Characteristics The chip coating plus ESB-M6J119-B spray primer shall dry sand (using a new sheet of 280 grit stearate filled paper for each panel) smoothly without clogging the paper and with a
17、 minimum of sand scratches. The material shall be equivalent in all respects to current approved production coating applied and tested under identical conditions. 3.5.3 Paintability No significant color shift, difference in orientation of metallic flakes (metallic paints) or other objectionable appe
18、arance defects in the topcoat over the chip coating. 3.6 RESISTANCE PROPERTIES 3.6.1 Adhesion (FLTM BI 103-01 and FLTM BI 106-01, Part B) Test Requirements: FLTM BI 103-01: Less than 3 mm creepback from the scribe. FLTM BI 106-01 Part B: No loss of topcoat or primer adhesion. ENGINEERING MATERIAL SP
19、ECIFICATION ESB-M99J311-A/A2 Copyright 2012, Ford Global Technologies, LLC Page 4 of 6 Test Method: . Prepare panels per para 3.3 with the following exception: Apply the chip coating as a film wedge, ranging from 2 - 203 m. . Scribe the entire length of the panels and salt spray test for 1000 h. . W
20、ithin 30 min after salt spray testing, tape test the scribed area and test the coatings adhesion per FLTM BI 106-01, Part B. 3.6.2 Chip Resistance at Room Temperature Followed by Salt Spray (SAE J400 and FLTM BI 103-01) After tape adhesion, there shall be an SAE chip rating of 7A max, less than 3 mm
21、 creepback from the scribe, and no face blistering. Test Method: . Strike the test specimen with 4.7 L of gravel per SAE J400 JUN 80. . Scribe an “X“ to the substrate on the lower 76 mm of the test specimen. . Expose to salt spray for 1000 h per FLTM BI 103-01. . Within 30 min after the completion o
22、f salt spray testing, apply ESF-M3G48 tape, with firm thumb pressure, to the entire surface of the part. Remove the tape by pulling one end at a 90 angle with moderate speed. 3.6.3 Chip Resistance at -30 C Followed by Salt Spray (SAE J400 and FLTM BI 103-01) After tape adhesion, there shall be a chi
23、p rating of 7B max, less than 3 mm creepback from the scribe, and no blistering. Test Method: Same as described in para 3.6.2 except for the following change: Prior to gravelometer testing, condition the panels for 4 h min at -30 C. Gravelometer test the panels immediately after removal from the -30
24、 C environment. 3.6.4 Condensing Humidity, min 240 h (FLTM BI 104-02, Procedure A) No blistering or loss of gloss. ENGINEERING MATERIAL SPECIFICATION ESB-M99J311-A/A2 Copyright 2012, Ford Global Technologies, LLC Page 5 of 6 3.6.5 Accelerated Weathering Resistance Panels shall show no more than a mi
25、nimum degree of fading, chalking or dulling. No increase of brittleness or loss of adhesion is permitted and panels shall be completely free from evidence of cracking, checking, blistering, or peeling when exposed to the following cycle for 500 h: . 4 h at 60 C with ultraviolet light exposure. . 4 h
26、 at 50C condensing water exposure. See para 5.1 for recommended weathering machines. 3.6.6 Florida Exposure Panels shall be prepared as in para 3.3 and 3.6.1, scribed with an “X“ to bare metal and exposed in the Miami, Florida area at 5 facing south for 12 months. There shall be no blistering, peeli
27、ng or visible rusting along the scribe marks more than 3 mm total width. 3.6.7 Storage Stability The chip coating 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 mater
28、ial shall be 3 months. When this material is stored at temperatures below 23 C, it shall be conditioned at room temperature prior to application. Adequate conditioning permits the material to obtain its maximum application properties. 3.7 PRODUCTION VALIDATION TEST Phase I The supplier shall test a
29、production-size batch per para 3.1, 3.2, 3.4, 3.5 and 3.6 of the material specification. Prepare test panels per para 3.3. All test results, with the exception of the results from para 3.6.5, 3.6.6 and 3.6.7 shall be approved by B&CE personnel and the supplier before a plant trial will be scheduled.
30、 Phase II If the material passes the Phase I requirements, then Phase II can be implemented. Material from a production-size batch must perform adequately during an assembly plant trial. B&A Paint Operations and B&CE Materials and Corrosion Protection Engineering personnel will determine if the mate
31、rial passes the trial. ENGINEERING MATERIAL SPECIFICATION ESB-M99J311-A/A2 Copyright 2012, Ford Global Technologies, LLC Page 6 of 6 3.8 IN-PROCESS TESTS Statistical 3.8.1 Test Specification Minimum Test Acceptance Para No. Sample Size Criteria Non-Volatile 3.1.1 2 samples per batch All must pass Wg
32、t. per Volume 3.2.1 2 samples per batch All must pass Viscosity 3.2.2 2 samples per batch All must pass Sagging and 3.5.1 2 samples per batch All must pass Solvent Popping Gravelometer SAE J 400 2 samples per batch All must pass Initial Adhesion FLTM BI 2 samples per batch All must pass 106-01, “B“
33、3.8.2 Reaction Plan The material shall pass all the required tests before the batch is shipped to the Ford Motor Company. If a batch does not pass all requirements, chemical additives may be introduced to the batch prior to total quality control retesting. If the batch cannot be modified to meet all
34、 specified requirements, it cannot be shipped to the Ford Motor company. A batch shall not exceed 11,355 L. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. 5.1 RECOMMENDED ACCELERATED WEATHERING EQUIPMENT Equipment for para 3.6.5 is listed below: . Q-Panel Company QUV . Atlas Corporation UVCON
