1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 03 2012 04 12 N Status No usage or replacement named N. Benipal, NA 2004 03 24 Revised Para 3.0 inserted, paras 3.26 and 4 deleted 1976 08 25 Released CPF22-792517 Controlled document at www.MATS Copyright 2012, Ford Global Technologies,
2、LLC Page 1 of 7 CORROSION PREVENTIVE COMPOUND - SPRAYABLE ESR-M7C54-A NOT TO BE USED FOR NEW DESIGN 1. SCOPE 1.1 This specification establishes the performance and product requirements of a sprayable corrosion preventive compound suitable for application in an automotive dealership or Vehicle Predel
3、ivery Service Center. 1.2 This specification is not intended to limit the compound to any specific material, but defines the performance required of the entire system. 2. APPLICATION This specification was released originally for a compound used to provide supplemental corrosion protection to the ve
4、hicle underbody, the inner surfaces of body sheet metal, and other portions of the vehicle which may be subject to severe corrosion. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Product
5、ion Materials (WSS-M99P1111-A). 3.1 The material shall meet all the requirements of this specification and must be in a ready-to-use form. 3.2 SPRAYABILITY The material must be capable of being applied with either “air“ of “airless“ spray equipment which is readily available to automotive dealers an
6、d Vehicle Predelivery Service Centers. It must be capable of being sprayed at material temperatures ranging between 4 C and 38 C without using abnormal spraying techniques or applying excessive pressure. The affected product engineering office shall judge whether the spray pattern is acceptable for
7、the intended application. In addition the material must be capable of being packaged in, and delivered from, an aerosol container without excessive plugging of the spray orifice, valve, or delivery tube. The spray pattern produced must be suitable for the intended application. The material must also
8、 be of such a consistency that it can be hand brushed onto small irregular surfaces. If desired, the requirements for aerosol packaging and hand brushing may be waived by the affected product engineering office. 3.3 The test compound, when applied to substrates such as elastomers, sliding mechanisms
9、, plastics, sound deadeners, sealers, other corrosion resistant coatings, nonferrous metals, etc. shall not have any detrimental effect on the substrate. 3.4 ODOR The material must not have an objectionable odor either during or after application. The odor shall be subjectively evaluated by both the
10、 affected product engineering office and by the Industrial Hygiene Section, Employee Health Services Department. ENGINEERING MATERIAL SPECIFICATION ESR-M7C54-A Copyright 2012, Ford Global Technologies, LLC Page 2 of 7 3.5 SAFETY The material must be reasonably safe to apply and to handle. It must me
11、et all federal, state and local regulations, and must be formulated to minimize employee health hazards due to toxic or otherwise injurious ingredients. 3.6 COLOR The material must be black and provide complete hiding of the substrate to which it is applied at 5 - 6 mils (0.13 - 0.15 mm) wet thickne
12、ss. However, this requirement may be waived by the affected product engineering office. 3.7 CONSISTENCY The material must be homogeneous and free from grit and foreign matter. In addition, the material must not contain ingredients which would cause unusual wear to the components of conventional pump
13、ing equipment or which could plug an orifice 0.015 in (0.38 mm) in diameter. 3.8 EFFECTS ON PAINT The material must not stain, soften, lift, or otherwise degrade production or service paint films. Test Method: Apply a 1 in (25 mm) circular spot of the test compound to appropriate size steel panels p
14、ainted with the materials listed below. Apply the test compound to both a light pastel and light colored metallic for each of the paints listed. Prepare painted panels for production materials using the most recent application techniques. Prepare painted panels for service material per label directi
15、ons (including compounding of AR60 lacquers). Age all panels 168 h at 23 +/- 2 C followed by 16 h at 43 +/- 3 C. . Production Enamel (ESB-M32J100-A, or latest equivalent coating) . Production Enamel (ESB-M50J100-A, or latest equivalent coating) . Production Enamel Repair (Catalyzed ESB-M32J100-A, or
16、 latest equivalent coating) . Production Enamel Repair (Catalyzed ESB-M50J100-A, or latest equivalent coating) . Service Air Dry Lacquer (ESR-M2P100-B, AR60 Series, or latest equivalent coating) . Service Air Dry Enamel (ESR-M2P100-B, AE60 Series, or latest equivalent coating) After 168 h at 23 +/-
17、2 C and 50 +/- 5% relative humidity, remove the test compound from the painted panels with Ford Silicone and Wax Remover or mineral spirits and observe for failures described above. 3.9 CREEP After a 7 day test period, the material shall show evidence of creep (movement of material) of at least 1/4
18、in (6.0 mm) at some point between the 2 test panels described below. At least 1/3 of the overlap area must be covered with a thin film of the material. ENGINEERING MATERIAL SPECIFICATION ESR-M7C54-A Copyright 2012, Ford Global Technologies, LLC Page 3 of 7 Test Method: Fasten the ends of 2 panels (s
19、ame size and type as specified in para. 3.10) together with a 1/2 in (13 mm) overlap by means of three 1/8 in (3.0 mm) steel blind rivets centered uniformly in the 1/2 in (13 mm) overlap area (max shear strength of rivets: 325 lb (1450 newtons). Mechanically expand the rivets by a pull stem. Apply t
20、he compound liberally to the top edge of the joint by means of a spatula. Hang the panels in a vertical position for 168 +/- 2 h at 23 +/- 2 C. Carefully separate the panels to avoid disturbing the compound between them. Examine for compliance with requirements noted above. 3.10 PREPARATION OF TEST
21、PANELS Test panels for para. 3.11, 3.12, 3.13, 3.14, 3.15, 3.16. 3.17, 3.18, 3.19 must be prepared as follows: Spray the test compound to a wet film thickness of 10 +/- 1 mils (0.25 +/- 0.025 mm) using an airless spray pump (such as AR0 Model #612-862) equipped with appropriate size orifice to produ
22、ce a “flat“ (in one plane) spray pattern. Test panels to be used unless otherwise specified, are clean 4 x 12 x 0.032 in (100 x 300 x 0.81 mm) cold rolled 1008/1015 low carbon sheet steel (Rockwell B hardness 60 - 65), such as Q-Panel No. R-412. Maintain the coating thickness applied to the panels b
23、y mounting the spray gun in an apparatus that will maintain a fixed distance from the test panel, yet permit side-to-side motion in a fixed plane (similar to ASTM D 823). During spraying, verify the film thickness actually applied every 10 panels using a wet film thickness gage such as a Nordson No.
24、 790010. Verify that the coating thickness applied is correct and that it is uniform across the face of the panel. Discard this panel after checking the film thickness. If the coating thickness is not within the range specified above, the previous 10 panels must be discarded and new panels sprayed.
25、All panels for eventual salt spray testing must be coated on both sides. However, clearly identify the back of the panel (drilled holes, plastic tag, etc.) to be sure that the front face of the panel is correctly exposed in the salt spray cabinet. Do not touch the face of the panels prior to or afte
26、r spraying. Handle by grasping at the edges only. Do not stack panels or allow them to touch. Air dry panels by hanging in a vertical position for 168 h at 23 +/- 2 C and 50 +/- 5% humidity. 3.11 DRY TIME Panels prepared per para. 3.10 must be dry to touch (no more than a slight tacky condition with
27、 no transfer of material to the fingertip upon application of firm pressure) within 24 h at 23 +/- 2 C and 50 +/- 5% relative humidity. 3.12 RESISTANCE TO BURNING Prepare panels per para. 3.10. After 4 h air drying at 23 +/- 2 C and 50 +/- 5% humidity, there shall be no rapid flame spread, no drippi
28、ng of flaming material, or excessive smoke when subjected to the ignition sources listed below. Any flame produced must be self-extinguishing within 30 s after removal of the ignition source. A) Arc weld 2 panels together (end to end). B) Cut panel across the short dimension with an acetylene torch.
29、 C) Cut panel across the short dimension with a abrasive cutting wheel. ENGINEERING MATERIAL SPECIFICATION ESR-M7C54-A Copyright 2012, Ford Global Technologies, LLC Page 4 of 7 3.13 COLD ADHESION (FLTM BV 101-01) No cracking, peeling or lifting of the test compound from the surface of the panel. Spr
30、ay panels per para. 3.10 over primed 12 x 12 in (300 x 300 mm) panels specified in FLTM BV 101-01. Conduct test at - 34 C. 3.14 LOW TEMPERATURE FLEXIBILITY No cracking, peeling or lifting of the compound from the surface of the panel. Test Method: Prepare panels per para. 3.10 and allow to air dry f
31、or 168 h at 23 +/- 2 C and 50 +/- 5% relative humidity. Condition the panels at -29 +/- 1 C for 120 +/- 5 min. While at that temperature, bend each test panel quickly 180 around a mandrel 3/16 inch (4.8 mm) in diameter which has also been cooled to -29 +/- 1 C. Wear plastic or rubber gloves when han
32、dling the panels. No more than 5 s shall elapse between the time the chamber is opened and the panel is bent. 3.15 RESISTANCE TO FLOW AT ELEVATED TEMPERATURES No movement of material toward the reference line. Prepare panels per para. 3.10 and allow to air dry for 168 h at 23 +/- 2 C. Remove a 1 in
33、(25 mm) strip of the coating along one of the long edges of the panel after cutting the film with a sharp instrument parallel to the edge of the panel and perpendicular to the surface of the panel. The cut edge must be straight, uniform, and continuous. Draw or scratch a straight line on the panel p
34、arallel to the cut edge of the film and 1/8 in (3.0 mm) away from it. Suspend the panel vertically, with the exposed area downward, for 2 h in a gravity convection oven maintained at 175 +/- 3 C. Remove the panels from the oven and allow to cool to 23 +/- 2 C. Observe the position of the cut edge of
35、 the coating relative to the reference line drawn or scratched on the panel. 3.16 SALT SPRAY RESISTANCE (ASTM B 117, 5% salt solution) Surface rust on front face of panel must be less than the following levels: Exposure Surface Area Time, h With Rust, max 1000 2.0%* 1500 8.0% 2000 12% Prepare panels
36、 per para. 3.10 and scribe through test coating to bare metal to form an “X“ the full length of the panel. Tests must be run in triplicate. After exposure, strip coating from panels by soaking in mineral spirits for 24 h, then gently brushing coating off with a soft bristled paint brush. After remov
37、al of test compound, evaluate front face of panel per ASTM D 1654 Method A, Schedule No. 2 using the 1/4 in (6.0 mm) grid to determine the percentage of the surface area with rust. Average the results of the triplicate test. Disregard any rust within 1/4 in (6.0 mm) of all edges. If the panels were
38、supported in a rack, disregard the area scraped by the rack and 1/4 in (6.0 mm) beyond the scraped area. *The 1000 h exposure panel shall have no undercutting by rust greater than 1/16 in (2.0 mm) on either side of the scribe mark. No rust spots greater than 1/4 inch (6.0 mm) in diameter are allowed
39、, nor is an overall etching of fine dots. ENGINEERING MATERIAL SPECIFICATION ESR-M7C54-A Copyright 2012, Ford Global Technologies, LLC Page 5 of 7 3.17 SALT SPRAY RESISTANCE AFTER HEAT AGING (ASTM B 117, 5% salt solution) Surface rust on front face of panels must be less than 2% after heat aging pan
40、els for 336 +/- 2 h at 70 +/- 1 C followed by 500 h salt spray exposure. Tests must be run in triplicate. After exposure, strip coating from panels by soaking in mineral spirits for 24 h, then gently brushing coating off with a soft bristled paint brush. After removal of test compound, evaluate fron
41、t face per ASTM D 1654 Method A, Schedule No. 2 using the 1/4 in (6.0 mm) grid to determine the percentage of the surface area with rust. Average the results of the triplicate test. No rust spots greater than 1/4 inch (6.0 mm) in diameter are allowed, nor is an overall etching of fine dots. Disregar
42、d any rust within 1/4 in (6.0 mm) of all edges. If the panels were supported in a rack, disregard the area scraped by the rack and 1/4 in (6.0 mm) beyond the scraped area. 3.18 SALT SPRAY AFTER DETERGENT EXPOSURE (ASTM B 117, 5% salt solution) Surface rust on front face of panels must be less than 2
43、% after exposure to 30 commercial (do-it-yourself type) car wash cycles* followed by 500 h salt spray exposure. Tests must be run in triplicate. After exposure, strip coating from panels by soaking in mineral spirits for 24 h, then gently brushing coating off with a soft bristled paint brush. After
44、removal of test compound, evaluate front face of panel per ASTM D 1654 Method A, Schedule No. 2 using the 1/4 in (6.0 mm) grid to determine the percentage of the surface area with rust. *10 cycles of wash and rinse consisting of 2-1/2 min wash and 2-1/2 min rinse applied at a car wash booth using a
45、hand directed wash wand with tip of wand held 4 - 6 in (100 - 150 mm) from surface of panel. Water temperature must be 60 +/- 3 C min. Repeat for additional 10 cycles at 48 h and a final 10 cycles at 96 h. Average the results of the triplicate test. No rust spots greater than 1/4 inch (6.0 mm) in di
46、ameter are allowed, nor is an overall etching of fine dots. Disregard any rust within 1/4 in (6.0 mm) of all edges. If the panels were supported in a rack, disregard the area scraped by the rack and 1/4 in (6.0 mm) beyond the scraped area. 3.19 ABRASION RESISTANCE The material must be resistant to c
47、hipping caused by the impingement of gravel. No more than 15% removal of material at 23 +/- 2 C nor 30% removal of material at 0 +/- 1 C is allowed from panels prepared according to para. 3.10 and subjected to one cycle of SAE J400 gravelometer (omit the pull with masking tape). Examine the 4 x 4 in
48、 (100 x 100 mm) square area that exhibits the worst degree of chipping and determine the percentage of material removed from this area. Run the test in triplicate and average the results. 3.20 WATER DISPLACEMENT The material must be capable of displacing small amounts of moisture which may be presen
49、t on the surface to be sprayed. The presence of the moisture must not have any detrimental effect on the performance of the material. 3.21 CLEAN-UP The test compound must be readily removable from painted surfaces, bright trim, interior trim, glass, vinyl roofs, tires, etc. using commercially available cleaners without damaging the substrate. ENGINEERING MATERIAL SPECIFICATION ESR-M7C54-A Copyright 2012, Ford Global Technologies, LLC Page 6 of 7 3.22 CHEMICAL AND PHYSICAL PROPERTIES Specific chemical and physical
