1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 07 31 Revised Updated and renumbered 1999 03 04 Revised Completely Revised and Updated, -B Inactivated K. Thurgood FAO 1991 05 20 NB00I10031967001 Released N. Chamberlain NAAO K. Thurgood EAO Printed co
2、pies are uncontrolled Page 1 of 9 Copyright 2002, Ford Global Technologies, Inc. STEEL, SHEET, ZINC OR ZINC ALLOY, CONDUCTIVE WSB-M1A311-B2 DUPLEX LAYER COATED 1. SCOPE The materials defined by this specification are two side zinc or zinc/ alloy coated mild steel sheet produced by the electrolytic o
3、r hot dip deposition process, which has been coated with a conductive chromate/ zinc dust corrosion inhibitor complex, and then overlaid (roller coated) with a conductive organic coating (on one side or both sides) to produce a Duplex coating. 2. APPLICATION This specification was released originall
4、y for material used for automobile body parts requiring good perforation (inside-out) corrosion resistance. CAUTION: Performance of the adhesive and sealer on the finished assembly may be dependent on adhesive and sealer compatibility with this material. It is, therefore, imperative that all enginee
5、ring drawings be reviewed by Materials Engineering prior to release. 3. REQUIREMENTS 3.1 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 BASE MATERIAL 3.2.1 Unless o
6、therwise specified on the Engineering Drawing, the requirements of WSD-M1A333-A2 shall apply. ENGINEERING MATERIAL SPECIFICATION WSB-M1A311-B2 Page 2 of 9 Copyright 2002, Ford Global Technologies, Inc. 3.3 COATING: ZINC BASED METALLIC 3.3.1 Coating Mass (ASTM A 90) Coating Mass Coating Mass Per Side
7、, g/m2 Designation Single Spot, minimum/max* Hot Dipped Electrolytic - - 60 60/90 60/80 70 70/100 70/90 98 100/130 100/130 *ASTM A 90 should be suitably modified to allow coating mass determinations on individual sides. 3.3.2 Coating Composition (Electrolytic) Unless an alloy coating is chosen, the
8、primary deposit shall be zinc. Electrolytic zinc/nickel shall contain 10.5 - 13.5 % nickel. Electrolytic zinc/iron shall contain 12 - 18 % iron. The frequency of testing and the analytical method shall form part of the control plan. 3.3.3 Coating Composition (Hot Dipped) Unless an alloy coating is c
9、hosen, the primary deposit shall be zinc. The frequency of testing and the analytical method shall form part of the control plan (see also para 4.2). 3.3.4 Coating Bend Test (ASTM A 924M/ASTM A 591) Coated steel shall conform to the coating Bend Test requirements of ASTM A 924M for hot dipped and AS
10、TM A 591 for electrolytic coated products. 3.3.5 Coating Wraparound and Edge Condition For one side coated products, traces of coating are allowed on the uncoated side of the sheet from the edges to 15 mm from the coil edges. No coating is allowed on the remainder of the uncoated side. The amount of
11、 coating on the strip edge shall be no greater than the max stipulated in para 3.3.1 and of sufficient adhesion to prevent flaking during the manufacturing process. ENGINEERING MATERIAL SPECIFICATION WSB-M1A311-B2 Page 3 of 9 Copyright 2002, Ford Global Technologies, Inc. 3.4 PRETREATMENT A conducti
12、ve inorganic/zinc dust corrosion inhibitor complex, shall be used to give a satisfactory bond between the zinc or zinc alloy coating and the conductive organic coating. 3.4.1 Conductive Inorganic/Zinc Complex 460 +/- 80 Coating Weight, as Cr, Measured by mg/m2 X-ray Fluorescence (ASTM B 568) 3.5 CON
13、DUCTIVE ORGANIC COATING This shall comprise of an epoxide binder (epoxy resin) modified with metallic particles (zinc and/or other conductive pigment). The control plan referred to in para 3.1 shall address coating composition and consistency of electrical conductivity. 3.5.1 Zinc-Rich Primer Coatin
14、g Thickness Cut a sample with a minimum coated surface area of 4500 mm2. Remove the oil and air dry according to para 3.11. Weigh to the nearest 1 mg. Remove all zinc-rich primer by repeated wiping with tissue soaked with 2-butanone solvent. Air dry and re-weigh. The thickness is calculated based on
15、 the zinc-rich primer density of 3.75 Mg/m3, according to the following equation: Weight Loss (mg) 1000 Thickness (micrometers) = - X - Surface Area (mm2) 3.75 The thickness shall be 9.0 microns (+ 2.5/- 1.5). 3.6 COATED SURFACE FINISH The material shall have a workmanlike appearance and shall not h
16、ave defects of a nature or degree for the grade and quality ordered that will be detrimental to the fabrication of the finished part. 3.7 COATED SURFACE PAINTABILITY Material supplied to this specification must have prior approval for paintability by the responsible Materials Engineering activity. T
17、his approval shall be based on samples prepared to the local process and resistance requirements appropriate to the country of vehicle manufacture. Where the material or component is delivered to Ford in the fully painted condition, this para is not applicable and the performance defined by the draw
18、ing is mandatory (see also para 4.7). ENGINEERING MATERIAL SPECIFICATION WSB-M1A311-B2 Page 4 of 9 Copyright 2002, Ford Global Technologies, Inc. 3.8 FORMABILITY The quality level of steel supplied to fabricate a specific component shall be negotiated between the manufacturing activity and the steel
19、 supplier. Acceptance of subsequent orders by the steel supplier for a given component at the agreed upon quality level implies that all steel supplied will be of a comparable quality level and will form that part satisfactorily as defined by the manufacturing activity. Ford Motor Company may, at it
20、s option and in agreement with the steel supplier, compile a list of property requirements such as mechanical properties, forming characteristics and surface texture, for each specific part. This list will be mandatory extension of these specifications. The current responsible area within Ford Europ
21、e is Advanced Vehicle Technology (AVT); Materials Engineering at least 10 mm from each edge. Adhesion measurements should be done on clean, oil-free samples. Oil can be removed by washing with VM 1 micrometer (+ 0.5 micrometer) band width; 12.5 mm minimum effective traverse length; flat skid type is
22、 defined thus: . Class 1 (also known as “B“ (EN 10130) or full finish (FF): Ra 1.0 - 1.7 (2.5 mm cut-off) Peak density 45 ppcm (Peak Valley Pairs per centimeter) minimum (at 2.5 mm cut-off). . Class 2 (also known as “A“ (EN 10130) or general purpose (GP): Ra 1.0 - 2.4 (2.5 mm cut-off) Peak Density n
23、ot defined. . Class 3 Ra and Peak Density not defined. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 INITIAL SUPPLIER APPROVAL For initial approval, the supplier must furnish the following inform
24、ation for each coating designation/coating line combination. . A plan detailing how each requirement of para 3 will be controlled on a continuing production basis. . Test results from a typical production sample for the requirements outlined in para 3. . Zinc or Zinc alloy coating mass histogram inc
25、luding mean and standard deviation values. Data shall consist of a minimum of 500 mass measurements randomly taken from each side of a minimum of 20 coils while the process is operating in statistical control. . Test results from typical production samples for paintability requirements outlined in p
26、ara 3.7. . Conductive Organic Coating thickness histogram including mean and standard deviation values. Data shall consist of a minimum of 500 thickness measurements randomly taken from each side of a minimum of 20 coils while the process is operating in statistical control. ENGINEERING MATERIAL SPE
27、CIFICATION WSB-M1A311-B2 Page 8 of 9 Copyright 2002, Ford Global Technologies, Inc. . Typical coating chemical analysis. For products coated by Hot Dipping, coating composition is to be determined by analysis of samples taken from the molten bath. For Electrodeposited coatings, composition shall be
28、as deposited. . Results of testing specified in the FORD ADHESIVE AND SEALANT COMPATIBILITY PROCEDURE. Upon approval, the material will be added to the Engineering Material Approved Source List. 4.2 COATING COMPOSITION (Hot Dipped) Hot dipped zinc and hot dipped zinc/iron usually contain aluminum to
29、 aid adhesion of the coating to the base steel. The proportion of aluminum in the coating varies with coating thickness but rarely exceeds 1 %. Additionally, hot dipped zinc/iron usually contains 8 - 12 % iron. 4.3 COATING THICKNESS If it is desired to estimate the thickness of the coating from the
30、coating mass, the following factors (per side) shall be used: . Zinc (Hot Dipped or Electrolytic) 7.14 g/m2 = 1 micron . Zinc/Nickel (Electrolytic) 7.35 g/m2 = 1 micron . Zinc/Iron (Electrolytic) 7.25 g/m2 = 1 micron . Zinc/Iron (Hot Dipped) 7.21 g/m2 = 1 micron 4.4 REFERENCE DOCUMENTS QS-9000 WSD-M
31、1A333-A2 ASTM A 90 FLTM BA 113-01 ESB-M2P130-A ASTM A 591 WSS-M99P9999-A1 ESB-M2P129-B ASTM A 924M ASTM B 117 ASTM B 568 4.5 DESIGNATION EXAMPLE . 60GU60GC-EL (Means 60 g/m2 minimum electrolytic zinc on both sides and a conductive organic layer on one side, in this case the exposed side.) ENGINEERIN
32、G MATERIAL SPECIFICATION WSB-M1A311-B2 Page 9 of 9 Copyright 2002, Ford Global Technologies, Inc. 4.6 THICKNESS TOLERANCE (CAUTION) If and when choosing a minimum gage from ES-YC15-1N260-AA, if the previous choice of gage was nominal, it is important to avoid generating an inadvertent increase in th
33、e ACTUAL thickness of the component, and consideration should be given to specifying the next lowest minimum gage e.g. (Ford Europe example) for an existing 0.80 mm nominal gage, the nearest equivalent minimum gage in ES-YC15-1N260-AA is 0.75 mm. 4.7 PAINTABILITY Material supplied to North America shall meet the following requirements: . Material intended for Class 1 surface applications shall meet the requirements of ESB-M2P130-A. . Material intended for Class 2 and 3 surface applications shall meet the requirements of ESB-M2P129-B.
