1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Release/Revision93.07.01 EP00E10258822000 Released W HardtWP 3948-a Page 1 of 12 PAINT, NONMETALLIC SOLVENT BORNE FOR ESK-M32J127-ABASECOAT/CLEARCOAT SYSTEM, BAKING,EXTERIOR TOPCOAT1. SCOPEThe ma terial defined by
2、this specification is a nonmetallic basecoat of abas ecoat/clearcoat system required to provide the best exterior qualitynonme tallic finish. It consists of a physical drying basecoat with athermosetting acrylic clear topcoat (e.g. SK-M32J9553-A) , which are appliedwet on wet and concurrently stoved
3、. It shall be suitable for sprayapplication.2. APPLICATIONThis spe cification was released originally for material used as thebasecoat for a wet-on-wet final colour topcoat system on automotive bodiesand other exterior parts. It s hall be satisfactory for use over specifiedprimer s, primer surfacers
4、 or over baked enamel, as in repair or tu-toningoperations.3. REQUIREMENTS3.1 STATISTICAL PROCESSSupplie rs must conform to the requirements of Ford Quality SystemStand ard Q-101. A mutually acceptable Control Plan as describedtherein is required for material/source approval. Appropriatestatist ical
5、 tools must be used to analyze process/product data sothat variation in the final product is continuously reduced.3.2 COMPOSITION3.2.1 Infrared Spectrophotometry and/or Thermal AnalysisFord Motor Company, at its option, may conduct infraredand/o r thermal analysis of material/parts supplied to thiss
6、peci fication. The IR spectra and thermograms establishedfor initial approval sh all constitute the reference standardand s hall be kept on file at the designated materiallaborat ory. All samples shall produce IR spectra andtherm ograms that correspond to the reference standard whentested under the
7、same conditions.ENGINEERING MATERIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 2 of 12 3.2.2 UV Spectroscopic AnalysisA UV spectroscopic anal ysis is to be carried out on approvedinitial samples from the Ford Motor Company Quality Controlor Ford Test Laboratories. The results are to be retained.Resul
8、ts from UV spectroscopic analyses carried out forco ntrol purposes must correspond with the values obtainedfrom the initial sample.3.3 CONDITIONINGAll panels shall be aged for 72 h at 23 +/- 2 C or 16 h at 43 +/- 2C befo re testing for resistance properties unless otherwisespecified.In the event of
9、differences between test results, the results afterageing at room temperature shall govern.Al l tests according to this specification shall be performed in acontrolled atmosphere of 23 +/- 2 C and 50 - 65 % relative humidityif not otherwise specified.3.4 FLASH POINT(ASTM D 56)The flash point shall c
10、onform to the safety regu lations applicable tothe plant and/or country where the material shall be used.3.5 COMPOSITION3.5.1 ResinEssentially a synthetic resin system capable of meeting thisspecification requirements.3.5.2 PigmentationThe pigment shall have weather and light resista nt propertiesan
11、 d be balanced and blended so that the finished enamelmatch es the Master Appearance Sample (MAS) Panel inappear ance, colour and lustre, and shall give sufficientperformance to meet the requirements of this specification.3.5.3 SolventThe volatile portion shall contain sufficient ac tive solventsto
12、give satisfactory adhesion when the enamel is applied overa previously baked coat of the enamel.The properties of solvents in the volatile portion shall beso arran ged that the enamel will level out satisfactory onspray application. The volatility of the solvents is to beso chosen that the material
13、will give a dry film thickness of40 micrometre without sagging and with satisfactory freedomfrom roughness or dry spray.ENGINEERING MATERIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 3 of 12 3.5.4 Clear TopcoatBa secoat meeting this specification shall be totallycompatible with the Ford Engineering a
14、pproved clearcoat SK-M32J9 553-A or approved equivalent materials applied on it.Afte r baking to the required conditions the basecoat/clearcoat system shall present an exterior topcoat finish ofthe highest quality.3.5.5 Specific CompositionWhen i t is necessary to obtain specific data regardingmater
15、ial formulation, it is understood that the supplier willfurnish such data on request.3.5.6 Ultraviolet Light AbsorberIn case of critical colours (e.g. red), the enamel maycont ain sufficient amounts of suitable ultraviolet lightabsorber packages. These will be selected by th e supplier toprovide lon
16、g term durability.3.5.7 Special DataAll in itial and batch submissions must indicate density,non volatile content, and volume solids of the material assupplied on the sample report.3.6 PHYSICAL PROPERTIES3.6.1 Nonvolatile residue Initial sample report +/- 1.0 %(FLTM BI 102-1)Minimum solid content 23
17、 %unless otherwise releasedThese solid limits apply to basecoats adjusted t o a viscosityof 20 s Ford Cup 4, at 25 C (FLTM BI 111-01).Solvent may be specifie d by vendor but shall be Ford ProductEngineering Approved prior to use.3.6.2 Density(FLTM BI 154-02)In accordance with initial sample report +
18、/- 0.05 g/ccm.3.6.3 Viscosity(FLTM BI 111-01, Ford Cup 4, 25 C)Package Viscosity Initial Sample +/- 5 sENGINEERING MATERIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 4 of 12 3.6.4 Shelf Stability(FLTM BI 102-03, Ford Cup 3, 25 C)During a storage of 3 months at room temperature, thematerial as receive
19、d shall not gel or liver upon standing andmu st be free from settling which cannot be dispersed bynormal a gitation. The viscosity of the material shall notincrease in excess of 25 s.3.6.5 Volume Solids +/- 1.0 %(FLTM BI 154-02)3.6.6 Opacity of Dry Film(FLTM BI 158-01)Complete coverage of undercoat/
20、substrate at a dry filmthickness of maximum 30 micrometres.Higher values than 30 micrometre will be accepted with red/orange or other colours, which for environmental andto xicological reasons cannot be improved in hiding power,provid ed that such colours are already identified duringFirst Sight Fea
21、sibility evaluation and ok line trial resultshave been produced under usual process conditions.3.7 PREPARATION OF TEST PANELS(FLTM BI 103-02, Method B, b)3.7.1 SubstrateFord Engineering Approved Standard Steel Test Panels coatedwith Ford Engineering approved zinc phosphate an d prepared inacc ordanc
22、e with Ford Manufacturing Standard UMA 18004/UMA18005 or equivalent.3.7.2 Cathodic ElectrocoatFord Engineering approved current production materials.Apply the above primer to a minimum dry film thickness of 23micro metre and bake as defined in relevant materialspecification.3.7.3 Primer SurfacerFord
23、 Engineering approved current production material.Apply the above primer to a minimum dry film thickness of 30- 35 m icrometre, and bake as defined in relevant materialspecification.Do not sand the primer surface.ENGINEERING MATERIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 5 of 12 3.7.4 BasecoatApp
24、l y basecoat under test (reduced to spray viscosity assp ecified by vendor) to a dry film thickness of 15 - 30micrometre.3.7.5 Acrylic ClearcoatApply approved clearcoa t against specification SK-M32J9553-A(reduced to spray visco sity as specified by vendor) to a dryfilm thickness of 35 - 45 micromet
25、re.Minimum total dry film thickness 50 micrometre3.7.6 Flashoff Time3.0 minute between basecoat and clearcoat application.3.7.7 Baking CyclesBasecoat and clearcoat baked simultaneously3.7.7.1 Standard Bake Bake 10 minutes at 130C metal temperature 3.8.1 Colour3.8.2.1 Gloss3.8.2.2 Gloss after rebake3
26、.9.4 Hardness3.10 Resistance properties includingAdhesion3.11 Weathering3.12.1 Repair colour match3.7.7.2 RebakeStandard bake and then bake 10 minutes at 150 Cmetal temperature.3.7.7.4 Adhesion to intermediate coats2 pack repair painting (low bake)3.8.1 Colour3.8.2.2 Gloss after rebake3.12.2.3 Inter
27、coat adhesion3.7.7.3 In Plant RepairEnamels containing acid catalyst (item 3.12)Bake 10 minutes at 100 C metal temperature.ENGINEERING MATERIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 6 of 12 3.8 APPEARANCE3.8.1 Colour(FLTM BI 109-01)Colour of clearcoat film shall remain water white after allbaking
28、 cycles described in item 3.7.7.Col our of basecoat and clearcoat shall match the relevantapproved Master Appearance Sample (MAS) Panel.3.8.2 Gloss(FLTM BI 110-01, 20 deg glossmeter)3.8.2.1 Standard Bake, min 85 %3.8.2.2 Rebake GlossA decrease of not more than 4 units gloss ispermitted when panel is
29、 rebaked per para 3.7.7.2.3.8.3 LevellingThe surface of the material under test shall be equal to orbe tter than current approved production material forsmoothness when applied and baked under identica l conditions.3.8.4 HoldoutThere shall be no evidence of dulling or change of imageclarity when ena
30、mel colour coat is applied over sanded andunsanded primer surfacer, and no difference in gloss of thecolour coat between san ded and unsanded primer. There shallbe no prominence of sand scratches. Tests shall be made atboth maximum and minimum bake cycles.3.8.5 Heat ResistanceA decrease in gloss of
31、maximum 4 units is permitted when thepaint film is stoved ad ditionally according to para 3.7.7.2.3.9 FILM PROPERTIES3.9.1 General AppearanceThe enamel shall bake o ut to a presentable, serviceable filmshowing no craters, pinholes or abnormal roughness.It shall not shown excessive mottling in the ba
32、secoat.It shall have a reasonable tolerance for ordinary cleaningand s how excellent polishing characteristics when wheelpolished with wide range of various compounds and cleaners.ENGINEERING MATERIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 7 of 12 3.9.2 Wet-on-Wet CompatibilityThe m aterial must b
33、e compatible for wet-on-wet applicationwith current production primer surfacer and clearcoat.3.9.3 Film Thickness(FLTM BI 117-01)Basecoat plus clearcoat, min 50 micrometreCo ating must be sufficient to meet all performancerequirements of this specification.3.9.4 Final Hardness3.9.4.1 Penetration, fu
34、ll system,age 72 h at 23 +/- 2 CTukon, min 7.5 KHN(FLTM BI 112-02)3.9.4 PolishingTh e enamel surface shall be capable of being sanded andpolished, or polished only. No noticeable chang e in gloss orapp earance, except for a minimum of polishing lines shallresul t. Deep polishing lines or swirl marks
35、 are notacceptable.Ha rdness and polishing characteristics shall be such thatair-borne dirt dried in the film and dry spray areas orother surface defects can be removed by sanding andpolishing.Af ter sanding with 1000 grit paper lubricated with mineralspirit a nd then wheel polished with a medium gr
36、it compoundthere shall be no noticeable change in appearanc e between thepolished and unpolished area.3.10 RESISTANCE PROPERTIES3.10.1 Paint Adhesion(FLTM BI 106-01, Methods A & B)Method A No chippingMethod B Grade 0No chippingThere shall be no flaking of clearcoat from the basecoat.ENGINEERING MATE
37、RIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 8 of 12 3.10.2 Water Resistance 240 h(FLTM BI 104-01)No blistering, softenin g, dulling, colour change and/or lossof adhesion.Adhesion shall be tested according to para 3.10.1 Method B.3.10.3 Water and Soap Spot Resistance(FLTM BI 113-01)3.10.3.1 Water S
38、potting,max discolouration None3.10.3.2 Soap Spotting,max discolouration None3.10.4 Acid Spot Resistance,max discolouration None(FLTM BI 113-02)3.10.5 Xylene Wipe ResistanceNo dulling, softening o r other undesirable effects after theena mel, which has been aged 72 h, is rubbed 10 times in acircular
39、 motion with a wad of cheesecloth wetted with Xyleneand allowed a 30 minute recovery period.3.10.6 Stone Chip Resistance,(FLTM EU BI 57-2) Rating 1 maximum(FLTM BI 157-04) Rating 3 maximum3.10.7 Cold Check Resistance, 10 cycles No cracking(FLTM BI 107-02) or dulling3.11 WEATHERING3.11.1 Florida expo
40、sure, 12 months Rating 4(FLTM BI 160-01, 5 deg south,direct weathering inland)Prior to examination the exposed samples must be cleaned withapproved soap solution.Aft er exposure in accordance with para 3.11.1 and 3.11.2,washed but unpolished exposure samples shall show a minimumdegree of dulling, ch
41、ange of colour and distinct ness of imagewith both standard and catalyzed repair paint when comparedto an unexposed retained master.Both original and repair shall alter in colour, tone andgloss t o the same degree in the same direction. Only thesl ightest colour change is permitted. These samples sh
42、allshow no colour change, or iridescence in excess of specifiedAATCC rating (AATCC Grey Scale for Evaluating Change inColour, 10 step).ENGINEERING MATERIAL SPECIFICATIONESK-M32J127-AWP 3948-b Page 9 of 12 Gloss after exposure shall be minimum 70 units (20 degglossmeter FLTM BI 110-01).The film shall
43、 be free from dirt and mildew. Un soiled panelsshall be preferred to those soiled by exposure.No chalking is permitted.The panels shall be completely free from evidence ofcracking, checking, rusting, blistering, and peeling.One sma ll area of the exposed panel shall be slightlypolished with a curren
44、t polish followed by a 24 h waterimmers ion test of the complete panel according to FLTM BI104-01 . The panel is then again compared to the unexposedpanel. Only a slight colour change is permitted on thepolished as well as on the unpolished area of the panel.3.11.2 After Weathering Adhesion(FLTM BI
45、106-01, Method C)No loss of adhesion of clear coat or total paint systempermitted.3.11.3 After Weathering Water ResistanceAf ter Florida exposure and/or accelerated weathering, testspecimens shall be test ed according to FLTM BI 104-01 for 24hours. Adhesion shall be tested according to para 3.11.1.3
46、.11.4 New Vendors and Resin FormulationsSubmi ssions of the above shall required weather resistanceover an extended period up to 5 years. Prior use withoutProduct Engineering approval is not permitted.Sufficient panels shall be initially sent to Flo rida to allowinterim evaluation afte r each 12 mon
47、ths during this exposureperiod.Lon g term Florida exposure panels prior to exposure shallhave 1/3 of the surface polished with a surface grindingcompound. Using cotton wool the surface shall be rubbed 10times under medium pres sure in a straight longitudinal line.Wipe excess compound away using clea
48、n towel.Grinding compound as recommended by Materials Engineering.3.11.5 ReflectanceMeasure and record reflectance of Florida test panels as agraph prior to and afte r each year of exposure up to 5 yearsusing spectrophotometer or other suitable equipment.ENGINEERING MATERIAL SPECIFICATIONESK-M32J127
49、-AWP 3948-b Page 10 of 12 Recommended equipment i s Zeiss Spectrophotometer Type DMR 21and/or equivalent with reflectance attachment.3.11.6 Weather Exposure Control PanelsFor all exterior weather exposure tests to thissp ecification, control panels shall be produced as below.These shall be exposed for both 12 and 24 months wherere levant, alongside those panels tested under para 3.11.1under the same test conditions.Panels are prepared as previously but coated wit h a base coatof un tinted clean silver (e.g. XSC-1056 or MaterialEngin eering Approved equivalent) with the sa
