1、 FORD LABORATORY TEST METHOD BI 103-02 Date Action Revisions 2001 03 13 Revised Editorial no technical change A. Cockman 1990 01 16 Printed copies are uncontrolled Page 1 of 8 Copyright 2001, Ford Global Technologies, Inc. PREPARATION OF PANELS FOR PAINT TEST Application This method describes the ap
2、proved methods of preparing paint panels for laboratory tests of the applied coatings. Apparatus Required Pressure Cup De Vilbiss Type KB*, or equivalent. Pressure Gun De Vilbiss Type JGA502 - 704 FX or 704FF*, or equivalent. Suction Feed Spray Guns and Cups May be used for routine laboratory tests
3、(except metallics) but, in case of dispute or where specified, a pressure cup shall be used. Suction Cup TGC-545 and Suction Gun JGA-502-30EX, or approved equivalent. *Source: Aerograph DeVilbiss Co. Ltd. The DeVilbiss Co. Ringwood Road 300 Phillips Ave. West Howe, Bournemouth, Hants P.O. Box 913 En
4、gland Toledo, OH 43692 Spray Booth With at least one meter minimum width for spraying panels automatically. The booth should be slightly pressurized so that dirt, dust, etc., will not enter. Air flow of 45 - 60 m/min. is required to pass over the spray rack. The air make-up shall be filtered by stan
5、dard equipment designed for that purpose. The booth shall be air conditioned so as to maintain a temperature of 24 +/- C and a relative humidity of 45 - 65 %. A spray booth with at least a one meter minimum width is also required for proper hand spraying of panels. The spray booth shall be located i
6、n a room of sufficient size as to allow the operator to be unhampered in his movements while spraying the panels. The booth should be slightly pressurized so that dirt, dust, etc., will not enter. Air make-up shouldbe filtered by standard equipment designed for that purpose. FORD LABORATORY TEST MET
7、HOD BI 103-02 Page 2 of 8 Copyright 2001, Ford Global Technologies, Inc. Automatic Spray Equipment Required for spraying exterior and interior metallic body enamels. The Spraymation automatic spray equipment is recommended, however, any approved automatic spray machine is acceptable if the results w
8、ill correlate with Model 310540 Spraymation. In case of dispute, Spraymation Model 310540, with a De Vilbiss No. AGB Series 541 Gun, Needle, and Tip-AV 15 E with No. 30 air cap shall be used. Source: Spraymation Inc. 25 Amity St. Little Falls, N.J. U.S.A. Paint Mixer Red Devil No. 30, or equivalent
9、Source: Elcometer Ltd. Edge Lane Droylsden, Manchester England Laboratory Forced Air Oven Capable of maintaining a constant temperature of 180 +/- 2 C. Thickness Gage - (Ref: FLTM BI 117-01) Permascope with a constant pressure probe, or equivalent. Sources: Fischer Instrumentation (GB) Ltd Fischer M
10、esstechnik Arnhem Industrial Estate 7034 Maichingen Arnhem Road Industriestrasse 21 Newbury, Berks England Germany Test Panels Steel body skin panels ground to surface finish of 1.4 +/- 0.3 micrometre. C.L.A., or as otherwise specified in the relevant specification. Optional Panel Sizes: 100 mm x 30
11、0 mm 150 mm x 300 mm 75 mm x 230 mm 100 mm x 200 mm FORD LABORATORY TEST METHOD BI 103-02 Page 3 of 8 Copyright 2001, Ford Global Technologies, Inc. For special tests the use of Ford Test Panels to the following may be specified: UMA18001 - Bare steel - 150 x 190 x 0.75 mm UMA18002 - Phosphated stee
12、l - 150 x 190 x 0.75 mm UMA18002 - Phosphated steel - 105 x 300 x 0.75 mm The number of panels prepared shall be determined by the applicable Engineering Materials Specification; however, no less than four of each color shall be prepared. Panels used for test in Group 1 shall be phosphate coated to
13、meet the requirements of WSK-M3P1-C. Clean untreated panels may be used for the tests in Group 2. These panels shall be dried at 140 C (metal temperature) for five minutes in a forced air oven prior to painting to remove absorbed moisture and allowed to return to 23 +/- 2 C prior to application of t
14、he paint film. Group 1 Salt Spray Test FLTM BI 103-01 Water Immersion Test FLTM BI 104-01 Conical Mandrel Test FLTM BI 105-01 Adhesion Test FLTM BI 106-01 Chip Resistance Test FLTM BI 107-01 Cold Checking Test FLTM BI 107-02 Impact Test FLTM BI 108-01 Florida Exposure Group 2 Contrast Ratio FLTM BI
15、101-02 Dry Hiding Power FLTM BI 101-03 Dry Hiding Power (Straight Line Chart) FLTM BI 158-01 Intercoat Adhesion FLTM BI 106-02 Color Matching FLTM BI 109-01 Measurement of Gloss FLTM BI 110-01 Tukon Hardness of Paint FLTM BI 112-02 Water and Soap Resistance FLTM BI 113-01 Acid Resistance FLTM BI 113
16、-02 Perspiration Staining Resistance FLTM BI 113-03 Bleeding of Paint FLTM BI 114-01 Repair Color Match FLTM BI 115-01 Repair Color Match with Catalyst FLTM BI 115-02 Sward Hardness FLTM BI 112-01 FORD LABORATORY TEST METHOD BI 103-02 Page 4 of 8 Copyright 2001, Ford Global Technologies, Inc. Prepar
17、ation of Panels for Test The following methods describe the proper application of various primers, primer surfacers and enamels. Mixing The can of test material must be mixed for 10 minutes. After mixing, the paint is stirred with a spatula, allowing the tip to contact the bottom of the can. Mixing
18、is adequate if no evidence of settling is indicated when the spatula is withdrawn and examined. Spraying Viscosity The paint must be reduced to the proper spraying viscosity with the appropriate thinner as designated by the applicable Engineering Materials Specification. Measurement of viscosity is
19、conducted in accordance with FLTM BI 111-01. Spraying Panels When using the suction gun to spray panels, the distance between panels and gun must be 150 - 200 mm with the following line pressures: All metallic colors 450 kN/m2 All solid colors 450 kN/m2 Air dry service enamels 410 kN/m2 The followin
20、g conditions have been found suitable when using a suction gun: 1. Paint volume flow 350 +/- 50 ml/minute (with xylol). 2. Fluid tip AV601EX. 3. Needle JGA 402 D-EX. 4. Air pressure equivalent to 410 kN/m2 When using a pressure gun the fluid flow should be 450 - 565 mL/minute whether the material is
21、 reduced for hot or cold spray. Cup or tank pressures should be sufficient to deliver the correct fluid flow. The distance from the panel to the spray gun should be 300 - 350 mm. When using the automatic spray gun, the line pressure should be 450 kN/m2 and the fluid flow 390 - 420 mL/minute with Xyl
22、ol. The traverse gun speed should be 34 traverses/minute with one minute flash time between coats. The distance from the gun tip to the panel should be 250 mm for metallics and 300 mm for solids and reflow metallics. FORD LABORATORY TEST METHOD BI 103-02 Page 5 of 8 Copyright 2001, Ford Global Techn
23、ologies, Inc. Electrocoat Application Electrocoating of panels shall be prepared in accordance with FLTM BI 120-01. Primer Application Primer is sprayed in two coats, each coat consisting of two passes with one (1) minute flash off time between coats. Water Sanding (Wet Sanding) Water sanding of pan
24、els is performed with No. 400 waterproof paper. The operation is performed in one direction only. After water sanding prime coated panels are rinsed with deionized or distilled water and wiped with chamois leather. Then each test panel will be wiped in sanding direction with a lint-free rag wetted w
25、ith Naphtha U-MC004-8004-01 and subsequently dried for five minutes at 140 C. Enamel Metallic and solid colors require three coats with one minute flashoff time between coats for even dispersion and highest gloss. All three coats should be medium wet and uniform. This should give a uniform wet coati
26、ng free from sags and heavy edges. Ageing of Panels All panels for tests in Group 1 shall be aged for 16 hours at 45 +/- 2 C or for 72 hours at 23 +/- 2 C, unless otherwise stated in the Engineering Materials Specification, before testing. Air drying materials must only be conditioned at 23 +/- 2 C.
27、 This ageing time is in addition to the drying and baking times indicated in the Engineering Materials Specification. Panels for tests in Group 2 need not be aged unless specified. Conditioning and Test Conditions All test values indicated herein are based on material conditioned in a controlled atm
28、osphere 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. FORD LABORATORY TEST METHOD BI 103-02 Page 6 of 8 Copyright 2001, Ford Global Technologies, Inc. Test Methods The test methods shown are spe
29、cific for use with exterior synthetic body enamels. For other materials, refer to the applicable Engineering Materials Specification. Note: If any of the panels prepared according to Method B and C are required for water immersion resistance tests as described in FLTM BI 104-01, they shall be comple
30、tely sanded through to bare metal on one spot (nominally 25 mm in diameter) before applying the color coat. Panels for salt spray and water immersion tests shall have the back and edges additionally protected. Method “A“ - Flash Primer and Enamel Reduce flash primer to the viscosity required by the
31、applicable Engineering Materials Specification with the appropriate thinner and spray to required film thickness. Allow to flash off for one minute. Spray color coat of enamel to the required film thickness. Allow to flash off for three minutes. Bake enamel as outlined in the Engineering Materials S
32、pecification. Method “B“ - Primer, Primer Surfacer and Enamel Prepare panels according to one of the 3-coat paint systems as prescribed below. Select the paint system applicable for the respective enamel in production. 1. Spray Primer, Primer Surfacer, Enamel Apply primer, reduced to spraying viscos
33、ity, to the required dry film thickness. Bake according to the Engineering Materials Specification. Wet sand, unless otherwise specified by the Engineering Materials Specification, as described under “Preparation of Test Panels“. Spray primer surfacer reduced to application viscosity, to the require
34、d dry film thickness, and bake according to the Engineering Materials Specification after the specified flash off time. After cooling, if not otherwise specified in the Engineering Materials Specification, wet sand to the required dry film thickness as described under “Preparation of Test Panels“. S
35、pray the specified number of enamel coats to the required film thickness, flash off for three minutes and bake according to the Engineering Materials Specification. 2. Electrocoat Primer, Primer Surfacer, Enamel Apply electrocoat primer in accordance with FLTM BI 120-01 and bake according to the Eng
36、ineering Materials Specification. Apply primer surfacer reduced to spraying viscosity, to the required dry film thickness and bake according to the Engineering Materials Specification, wet sand to the required dry film thickness as described under “Preparation of Test Panels“. Spray the specified nu
37、mber of enamel coats to the required film thickness, flash off for three minutes and bake according to the Engineering Materials Specification. FORD LABORATORY TEST METHOD BI 103-02 Page 7 of 8 Copyright 2001, Ford Global Technologies, Inc. 3. Dip Primer, Primer Surfacer, Enamel Prepare test panels
38、according to Method “D“. Bake dip primer of flash off as per the Engineering Materials Specification. Apply primer surfacer, reduced to spraying viscosity, to the required dry film thickness and bake or air dry at room temperature according to the Engineering Materials Specification after the specif
39、ied flash off time. After cooling, if not otherwise specified in the Engineering Materials Specification, wet sand to the required dry film thickness as described under “Preparation of Test Panels“. Spray the specified number of enamel coats to the required film thickness, flash off the three minute
40、s and bake according to the Engineering Materials Specification. Method “C“ - Spray Primer, Enamel Apply primer, reduced to spraying viscosity, to the required dry film thickness. Bake according to the Engineering Materials Specification. After cooling, if not otherwise specified by the Engineering
41、Materials Specification, wet sand to the required dry film thickness, as described under “Preparation of Test Panels“. Spray the specified number of enamel coats to the required film thickness, flash off for three minutes and bake according to the Engineering Materials Specification. Method “D“ - Si
42、ngle Coat Dip Application (Primer or Enamel) Reduce material to the dipping viscosity as required in the Engineering Materials Specification. Fill dip tank (see sketch below) and insert the panel. If not otherwise required by the Engineering Materials Specification, and if the material tends to foam
43、 and aerate, remove test panel from the dip tank at a speed to enable foam or air bubbles to remain on the panel. Allow the test panel to hang as specified by the Engineering Materials Specification and bake or air dry at room temperature according to the Engineering Materials Specification. FORD LA
44、BORATORY TEST METHOD BI 103-02 Page 8 of 8 Copyright 2001, Ford Global Technologies, Inc. Method “E“ - Single Spray Coat of Primer or Enamel Over Bare Steel Spray material, reduced to application viscosity, to the required dry film thickness and bake or air dry at room temperature according to the E
45、ngineering Materials Specification. If more than one pass is required, allow one minute flash off between each pass. Method “F“ - Application of Air Dry or Low Bake Materials Directly on to Clean Metal Substrates, i.e. Brass, Terne Plate, Steel. 1. Cut a small hole near the top edge of oxide free pa
46、nels and finish all edges. 2. Remove All Surface Oil - Brush wipe both sides with White Spirits S-M14J132-A. Drain panels vertically. Repeat cleaning using fresh solvent until the washings are colorless. 3. Removal of Insoluble Fats - The panels are totally immersed and brush wiped both sides in thi
47、nner, S-M14J19-A. Mild steel and brass normally require one washing, however terne plate usually requires several washings. The acceptance level is the total absence of: a. Dull patches on mild steel or brass. b. Thumb-blacking on terne plate. 4. Final Cleaning - Totally immerse panels in an approve
48、d chlorocarbon cleaning solvent and drain vertically in a well ventilated location. A sharply demarcated straight evaporation line descending the panel indicates satisfactory cleaning. Any residual surface contamination causes line breakage, in this case all the above cleaning stages must be repeate
49、d. 5. Spraying of Panels - Cleaned and polished steel panels and the test panels prepared as above are placed adjacent to one another, sprayed and air dried or low baked together (according to the Engineering Materials Specification). The polished panels enable film thickness to be determined accurately. Chemicals, materials, parts, and equipment referenced in this document must be used and handled properly. Each party is responsible for determining proper use and handling in its facilities.
