1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2013 07 04 N-STATUS Replaced by WSS-M99P37-A A. Wedepohl,NA 2006 12 19 Revised Inserted 3.0; Deleted 3.1, 3.2, 3.3, 3.12, 3.13 Updated J. Faunt 1995 12 15 Activated J. Faunt Controlled document at www.MATS Copyright 2013, Ford Global Technolo
2、gies, LLC Page 1 of 6 DRY PAINT FILM LAMINATE, FINISHED PARTS, WSB-M99D61-A2 PLASTICS, EXTERIOR NOT FOR NEW DESIGN 1. SCOPE The material defined by this specification is a dry paint film laminate for use on thermoplastic exterior parts. 2. APPLICATION This specification was released originally for e
3、xterior mirror skull cap, a component in a mirror assembly. Production application of this material consists of injection molding behind a thermoformed laminate preform insert which has been configured to the finished part. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material
4、suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.4 CONSTRUCTION LAYER MAJOR COMPONENT Clearcoat Acrylic polymer/polyvinylidene difluoride Print/Design Optional gravure ink Basecoat Pigmented acrylic/polyvinylidene difluoride
5、 Size and Varies with thermoplastic substrate backing Backing Sheet Total thickness and variation will be in a control plan agreed to by the supplier and user. Approval for the construction is granted by material class, e.g. ABS, TPO, PC, etc. 3.5 FILM PROPERTIES 3.5.1 Appearance (FLTM BI 109-01 and
6、 BI 110-01) Color, gloss and surface finish shall match the Master Appearance Sample or the initial sample as approved by Design Center. See para 5.1 table for gloss correction for index of refraction. 3.5.2 Adhesion min, Figure 1 (FLTM BI 106-01) No more flaking than Fig 1 (less than 5%). ENGINEERI
7、NG MATERIAL SPECIFICATION WSB-M99D61-A2 Copyright 2013, Ford Global Technologies, LLC Page 2 of 6 3.5.3 Manual Separation The individual layers of material must not be separable from each other by mechanical means without cohesive break. 3.5.4 Visual Evaluation The finished parts shall show no evide
8、nce of blisters or delamination. 3.5.5 Heat Aging The finished part shall show no visible evidence of warpage, deformation, cracks, delamination or any other failure to an extent that would affect its use in the ultimate assembly. There shall be no local shrinkage where the part has been gated which
9、 would interfere with assembly to relating parts, or affect its appearance. The finished part shall show no change in appearance when compared to the original part. The adhesion of the film laminate to itself and to the substrate shall meet para 3.5.2 after heat aging. 3.5.5.1 Assembly Mount the ass
10、embly on a suitable fixture in car position in a mechanical convection oven maintained at 80 +/- 2 C for 7 d. Evaluate after conditioning at 23 +/- 2 C. 3.5.5.2 Component As under 3.5.5.1, except the component is unmounted. 3.6 PAINT REPAIR OVEN RESISTANCE Not required for shielded assemblies - see
11、process manual The finished part shall show no visible evidence of warpage, deformation, cracks, delamination or any other failure to an extent that would affect its use in the ultimate assembly. There shall be no local shrinkage where the part has been gated which would interfere with assembly to r
12、elating parts, or affect its appearance. The finished part shall show no change in appearance when compared to the original part. The adhesion of the film laminate to itself and to the substrate shall meet para 3.5.2 after heat aging. Mount the assembly on a suitable fixture in car position in a mec
13、hanical convection oven maintained at 120 +/- 2 C for 30 minutes. Evaluate after conditioning at 23 +/- 2 C. 3.7 RESISTANCE PROPERTIES 3.7.1 ENVIRONMENTAL CYCLING (FLTM BQ 104-07, Procedure 1 and Procedure 8) ENGINEERING MATERIAL SPECIFICATION WSB-M99D61-A2 Copyright 2013, Ford Global Technologies,
14、LLC Page 3 of 6 The finished part shall show no visible evidence of warpage, deformation, cracks, delamination or any other failure to an extent that would affect its use in the ultimate assembly. The finished part shall show no change in appearance when compared to the original part. The adhesion o
15、f the film laminate to itself and to the substrate shall meet para 3.5.2 after heat aging. 3.7.2 RESISTANCE TO COLD IMPACT (FLTM BO 151-01, para 3.7.2.1; ASTM D 3763, para 3.7.2.2) 3.7.2.1 Drop Ball - Method 2 No shattering or breaking (any fissure through the full thickness of the material). 3.7.2.
16、2 Instrumented Impact 70% Retention Direct Use part section or plaques representative of the actual part with respect to materials thicknesses and molding conditions. Determine impact strength at 23 +/- 2 C and at -30 +/- 2 C. Record load and deformation at first crack max load and rate for brittle
17、or ductile failure. 3.7.3 SHOCK TEST The decorated component shall show no breaks, cracks or other failure. The adhesion of the individual surface coating shall meet the requirements of para 3.5.2. Maintain the finished part or section at -40 +/- 2 C for 16 h. Then, immediately immerse the part into
18、 a 70 +/- 2 C water bath for 5 minutes. Evaluate after conditioning test sample to 23 +/- 2 C. 3.8 RESISTANCE TO WEATHERING SAE J1545 (Florida exposure applicable to parts using materials without previous weathering approval.) After exposure the parts/decorated component shall meet the CIE values fo
19、r lightness (DL), chroma (DC), hue (DH) and sum (DE) listed in the table. In addition, there shall be no cracking or crazing of the coating. 3.8.1 24 months Florida Rating (FLTM BI 160-01, 5 south, direct (see page 4) weathering inland) New materials; Surrogate parts acceptable. ENGINEERING MATERIAL
20、 SPECIFICATION WSB-M99D61-A2 Copyright 2013, Ford Global Technologies, LLC Page 4 of 6 3.8.2 Xenon Arc Weatherometer Rating (SAE J 1960, 2500 kJ/m2) (see below) BORDERLINE UNACCEPTABLE DL 2.9 3.4 3.4 DC 1.5 2.0 2.0 DH 1.0 1.5 1.5 DE 2.9 3.4 3.4 Values represent approximately Rating 3 on AATCC Gray S
21、cale. 3.9 THERMAL SHOCK RESISTANCE (FLTM BI 107-01) The decorated component shall show no delamination of the surface coating 1 mm from the scribe or blistering away from the scribe lines. 3.10 RESISTANCE TO CHIPPING 3.10.1 Stone Shot, max Figure 2B (SAE J 400, 10 cycles) 3.10.2 Stone Chipping, max
22、Rating 1 or as (FLTM BI 157-02, Method B, except defined on water immersion shall be omitted) Engineering drawing 3.11 CHEMICAL RESISTANCE 3.11.1 Resistance to Waxing and Dewaxing Compounds (FLTM BO 155-01) The part shall not craze, crack or change in gloss more than +/- 5 units from the value obtai
23、ned in para 3.5.1. 3.11.2 Resistance to Water, Soap and Underbody Coating Spotting (FLTM BI 113-01, add Underbody Coating ESR-M7C54-A, to solutions required) Discoloration, max 4 - 5 AATCC ENGINEERING MATERIAL SPECIFICATION WSB-M99D61-A2 Copyright 2013, Ford Global Technologies, LLC Page 5 of 6 3.11
24、.3 Resistance to Chemical Solutions No spotting or discoloration after exposure to the following chemicals and conditions: Apply 1 - 3 mL of each chemical to the Film Laminate for the time and temperature indicated. RT = 23 +/- 2 C 1 h at RT 4 h at RT 24 h at RT Brake Fluid - - ESA-M6C25-A - 10% H2S
25、O4 - by weight - - 2% Albumin in DI Water - - Honey - - 0.75% CaSO4 - - Transmission Fluid ESR-M2C163-A2 - - Motor Oil ESE-M2C176-A - - Grease WSB-M1C233-A 5% NaOH - - by weight 3.11.4 Windshield Washer Fluid Resistance GOAL - No visible spot - AATCC rating 5. Acceptable: Dark stain 4 - 5 rating on
26、AATCC 5 point scale. Not Acceptable: Any white stain or a dark stain with an AATCC rating of 4 or lower. APPARATUS REQUIRED . Three 250 mL glass or polyethylene beakers - any reliable supplier. . Disposable eyedroppers or syringes - any reliable supplier. . Heavy duty scissors or shears (capable of
27、cutting thin wall nylon and rubber tubing). . A supply of cold running water. SUPPLIES . Nylon fluid tube - Cut into one inch sections use 10/test . EPDM Rubber fluid tube - Cut into one inch sections use 10/test. . Windshield Washer Concentrate ESB-M8B15-B containing methanol PROCEDURE METHOD 1: Wa
28、sher fluid concentrate 1. Place part on level surface. 2. Pour 25 - 50 mL of Windshield Washer Concentrate ESB-M8B15-B containing methanol into a beaker. Apply 3 mL of the washer fluid to three level areas approximately 3 cm apart where the fluid will form a bead. Allow the fluid to evaporate to alm
29、ost dryness (the outline of the bead still visible. Apply 3 mL of the fluid to two of the areas. Allow fluid to evaporate as before. Repeat procedure to one spot. Rinse under cold water for 15 s after last spot has just reached dryness. Blow dry. Examine for stains record results. ENGINEERING MATERI
30、AL SPECIFICATION WSB-M99D61-A2 Copyright 2013, Ford Global Technologies, LLC Page 6 of 6 METHOD 2: Washer fluid concentrate with nylon tubing extracts. 1. Place 10 one inch sections of nylon tubing into a beaker, cover with 100 mL of Windshield Washer Concentrate ESB-M8B15-B containing methanol. Cov
31、er beaker and wait 24 h. 2. Place part on level surface. 3. Apply 3 mL of the washer fluid to three level areas approximately 3 cm apart where the fluid will form a bead. Allow the fluid to evaporate to almost dryness (The outline of the bead still visible. Apply 3 mL of the fluid to two of the area
32、s. Allow fluid to evaporate as before. Repeat procedure to one spot. Rinse under cold water for 15 s after last spot has just reached dryness. Blow dry. Examine for stains record results. METHOD 3: Washer fluid concentrate with rubber tubing extracts 1. Place 10 one inch sections of rubber tubing in
33、to a beaker, cover with 100 mL of Windshield Washer Concentrate ESB-M8B15-B containing methanol. Cover beaker and wait 24 h. 2. Place part on level surface. 3. Apply 3 mL of the washer fluid to three level areas approximately 3 cm apart where the fluid will form a bead. Allow the fluid to evaporate
34、to almost dryness (the outline of the bead still visible. Apply 3 mL of the fluid to two of the areas. Allow fluid to evaporate as before. Repeat procedure to one spot. Rinse under cold water for 15 s after last spot has just reached dryness. Blow dry. Examine for stains record results. 3.11.5 Resis
35、tance to Cleaners and Removers Tar and Road Oil Remover ESR-M5B106-A Bright Metal Cleaner ESR-M5B194-B The part shall show no cracks, color tone changes or other surface failures. Use products per directions on respective containers. Rinse with tap water (30 - 40 C) and rub dry with soft cloth. Exam
36、ine surface for changes. 3.11.6 Fuel Resistance (FLTM BO 101-05) The part shall show no cracks, blisters or other surface deformations. The film laminate shall meet the adhesion requirements of para 3.5.2. Test Fuels: . Fuel C (ASTM D 471 and ISO 1817) . Diesel Fuel (ISO 1817, Fuel F) . Unleaded Gasoline 87 octane rating - ISW only 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 CHART GLOSS VS INDEX OF REFRACTION
