1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Release/Revision1990 06 01 EP00E01031536000 released C E Herriott concurred J SchultWP 3948-a Page 1 of 12 PAINT, MEDIUM SOLID POLYESTER, BAKING, WSK-M50J111-AEXTERIOR TOP COAT1. SCOPEThe ma terial defined by this
2、specification is a medium solid non-metallicbaking enamel to provide the best exterior quality. It shall be suitablefor electrostatic spray application.2. APPLICATIONThi s specification was released originally for material used as a finalcolour top coat on automotive b odies and other exterior parts
3、. It shall besatisfactory for use over specified primers, primer surf acers or over bakedenamel, as in repair or tu-toning operations.3. REQUIREMENTS3.1 STATISTICAL PROCESSSupplie rs must conform to the requirements of Ford Quality SystemStand ard Q-101. A mutually acceptable Control Plan as describ
4、edtherein is required for material/source approval. Appropriatestatist ical tools must be used to analyze process/product data sothat variation in the final product is continually reduced.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company in its option, may conduct in frared an
5、d/or thermalana lysis of materials/parts supplied to this specification. The IRspectra and thermograms established for initial approval shallconst itute the reference standard and shall be kept on file at thedesignated Material Laboratory. All samples sha ll produce IR spectraand thermograms that co
6、rrespond to the reference standard when testedunder the same conditions3.3 ULTRA VIOLET SPECTROGRAPHIC ANALYSIS(FLTM tbd)All approved materials shall contain with Initial Sample Report anUV- spectroscopic analysis. This shall be recorded and filed byQuality Control or relevant Testing Laboratories o
7、f the Ford MotorCompany.Subsequent material UV-spectroscopic analysis sh all correspond to thedata of the Initial Sample.ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 2 of 12 3.4 CONDITIONINGAll panels shall be aged for 72 h at 23 +/- 2 C or 16 h at 43 +/- 2 Cbefore testing for resi
8、stance properties unless otherwise specified.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.3.5 FLASH POINTThe flash point shall conform to the safety regu lations applicable tothe plant
9、and/or country where the material shall be used.3.6 COMPOSITION3.6.1 ResinEssentially hydroxyl polyester and melamine formaldehyderesin.3.6.2 PigmentThe pig ment shall be balanced and blended so that thefinis hed enamel matches the Master Appearance Sample (MAS)Panel in colour and luster and meets t
10、he require ments of thisspecification.3.6.3 SolventThe volatile portion shall contain sufficient ac tive solventsto 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
11、will level out satisfactory onspray application. The volatility of the solvent s is to be sochosen that the material will give a dry film th ickness of 40micrometre without sagging and with satisfactory freedom fromroughness or dry spray.3.6.4 Specific CompositionWhen i t is necessary to obtain spec
12、ific data regardingmaterial formulation, it is understood that the supplier willfurnish such data on request.3.6.5 Ultra Violet Light AbsorberIn case of critical colours (e.g. red) the enamel shallco ntain sufficient amounts of a UV-absorber package (e.g.Hydroxyphenylbenztriazol and steric hindrance
13、d amidequ encher) as decided by the vendor to provide long termdurability.ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 3 of 12 3.6.6 Special DataAll initial and batch submissions must indicate density andnon-v olatile content of the material as supplied on thesample report.3.7 PHYSI
14、CAL PROPERTIES3.7.1 Non-volatile Initial Sample +/-1.0 %(FLTM BI 102-01)Minimum solid content for various colour classes are shown intabular form, item 3.9.3.These solid limits apply to enamels adjusted to a viscosityof 25 s Ford Cup 4, at 25 C (FLTM BI 111-01).3.7.2 Density Initial Sample +/-(ASTM
15、D 1475) 0.02 g/mL3.7.3 Viscosity(FLTM BI 111-01, Ford Cup 4, 25 C)Package Viscosity Initial Sample +/-5 sPreferred value, min 30 s3.7.4 Shelf StabilityDuring a storage of 3 months at room temperature, thematerial as received shall not gel or liver upon standing andmu st be free from settling which c
16、annot be dispersed bynormal a gitation. The viscosity of the material shall notincr ease in excess of 10 s (FLTM BI 102-03, Ford Cup 4,25 C).3.7.5 Solvent Emissions, max 0.096 kg/L(ASTM D 3960)This r equirement is as determined by the United StatesEnvironmental Protection Agency Reference Method #24
17、 but isonly applicable to materials used in the USA.3.7.6 Volume Solids Not less than(FLTM BI 154-02) Initial Sample3.8 PREPARATION OF TEST PANELS(FLTM BI 103-02, Method B, b)3.8.1 SubstrateFo rd Engineering Approved Standard Steel Test Panels zincphosphated and prepared in accordance with Ford Manu
18、facturingStandard U-MA18004/U-MA18005.ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 4 of 12 3.8.2 Cathodic ElectrocoatFord Engineering approved current production materials.Apply the above primer to a minimum dry film thickness of 25micro metre and bake as defined in relevant materia
19、lspecification.3.8.3 Primer SurfacerFord Engineering approved current production material.Apply the above primer to a minimum dry film thickness of 30micrometre, and bake as defined in relevant materialspecification.Pane ls for salt spray resistance (FLTM BI 103-01), waterresistance (FLTM BI 104-01)
20、, chip resistance (FLTM 107-01),and weathering resistance shall be prepared acco rding to FLTMBI 103-02, method B.Do not sand the primer surface.3.8.4 EnamelApply enamel under test (reduced with WSK-M14J23 9-A Xylene tospray viscosity as specified by vendor) to an en amel dry filmthickness of 40 - 5
21、0 micrometre.Bake according to item 3.8.53.8.5 Baking Cycles3.8.5.1 Standard Bake Bake 10 minutes at 130 C metaltemperature.3.9.1 Colour3.9.2.1 Gloss3.9.2.2 Gloss after re-bake3.10.4 Hardness3.11 Resistance properties includingAdhesion and Bleeding3.12 Weathering3.13.1 Repair colour match. 3.8.5.2 R
22、ebake Standard Bake and thenBake 10 minutes at 140 C metal temperature.3.9.1 Colour3.9.2.2 Gloss after rebake3.13.2.3 Intercoat adhesion.ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 5 of 12 3.8.5.3 In Plant Repair En amels containing acid catalyst(i tem 3.13). Bake 10 minutes at100
23、C metal temperature.3.9 APPEARANCE3.9.1 Colour(FLTM BI 109-01)Colour shall match the approved Master Appearance Sample(MAS ) Panel after all baking cycles described in section3.8.53.9.2 Gloss(FLTM BI 110-01, 20 deg glossmeter)3.9.2.1 Standard BakeMinimum gloss requirements by colour class areshow n
24、in item 3.9.3 for panels baked at standardbake conditions.3.9.2.2 Rebake GlossA decrease of not more than 4 units gloss ispermitted when panel is rebaked per item 3.8.5.23.9.3 Table of Solids and Gloss.Class Colour % Solids, min Gloss units ,min1 Black 42 882 All dark solid 45 75colours3 All colours
25、 with 48 75mainly organic pigmentation4 All colours with 53 75mainly inorganic pigments except white colours5 White and 57 80Off WhiteENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 6 of 12 3.9.4 LevellingThe surface of the material under test shall be equal to orbetter than current ap
26、p roved production material for smooth-ness when applied and baked under identical conditions.3.9.5 HoldoutThere shall be no evidence of dulling or change of imageclarity when enamel colour coat is applied over sanded andunsanded primer surfacer, and no difference in gloss of thecolour coat between
27、san ded and unsanded primer. There shallbe no prominence of sand scratches. Tests shall be made atboth maximum and minimum bake cycles.3.9.6 Distinctness of Image tbd(FLTM BI 110-03)3.10 FILM PROPERTIES3.10.1 General AppearanceThe enamel shall bake o ut to a presentable, serviceable filmshowing no c
28、raters, pinholes or abnormal roughness.It shall have a reasonable tolerance for ordinary cleaningand show excellent polishing characteristics.3.10.2 Wet on Wet CompatibilityThe mate rial must be compatible for wet on wet applicationwith current production primer surfacer.3.10.3 Film Thickness Enamel
29、 only 40 - 50 micrometre(FLTM BI 117-01)Co ating must be sufficient to meet all performancerequirements of this specification.3.10.4 Final Hardness3.10.4.1 Penetration, full system, age 72 h at 23 +/- 2 CTukon, min 6.0 KHN(FLTM BI 112-02)3.10.4.2 SurfacePencil, min H(FLTM BI 151-01)ENGINEERING MATER
30、IAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 7 of 12 3.10.5 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 are notacce
31、ptable.Ha rdness and polishing characteristics shall be such thatair-borne dirt dried in the film and dry spray a reas or othersurface defects can be removed by sanding and polishing.Aft er sanding with 600 grit paper lubricated with mineralspirit a nd then wheel polished with a medium grit compound
32、there shall be no noticeable change in appearanc e between thepolished and unpolished area.3.10.6 Hiding Power, Dry, max 40 micrometre(FLTM BI 158-01)Complete visual hiding3.11 RESISTANCE PROPERTIES3.11.1 Paint Adhesion(FLTM BI 106-01, Methods A & B)Method A No chippingMethod B Grade 0No chipping3.1
33、1.2 Chip Resistance Rating 1, max(FLTM BI 107-01) area loss 0.01 %3.11.3 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 item 3.11.1 Method B.3.11.4 Salt Spray Resistance, min 480 h(FLTM BI 103-01)No
34、 rust spots, blistering, chipping, peeling, gloss loss,adhesi on loss or rust creepage more than 3 mm from scribedline.Adhesion shall be tested according to item 3.11.1 Method B.ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 8 of 12 3.11.5 Water and Soap Spot Resistance(FLTM BI 113-01
35、)3.11.5.1 Water Spotting,max discolouration AATCC Rating 4-53.11.5.2 Soap Spotting,max discolouration AATCC Rating 4-53.11.6 Acid Spot Resistance(FLTM BI 113-05)max discolouration None3.11.7 Xylene Wipe ResistanceNo dulling, softening or other undesireable effe cts after theena mel, which has been a
36、ged 72 h, is rubbed 10 times in acircular motion with a wad of cheesecloth wetted with Xyleneand allowed a 30 minute recovery period.3.11.8 Stone Chip Resistance, max Rating 3(FLTM BI 157-04)3.11.9 Cold Check Resistance, 10 cycles No cracking(FLTM BI 107-02) or dulling3.11.10 Bleeding Resistance No
37、bleeding(FLTM BI 114-01) permitted3.12 WEATHERING3.12.1 Florida Exposure, 12 months AATCC Rating 4(FLTM BI 160-01)5 deg south, directweathering inland3.12.2 Accelerated, min AATCC Rating 4(SAE J1960)Radiant Exposure tbd GJ/m2Accele rated Weathering is only to be considered if forEngineering concurre
38、d s pecial reasons no Florida results areavailable. Under such circumstances comparative testing onlyis allowed against mate rials of known Florida stability withidentical chemical type of resin.In case of differences in the test results of Floridaex posure and the accelerated weathering the results
39、 of theFlorida exposure shall prevail.ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 9 of 12 Prior to examination the exposed samples must be cleaned withapproved soap solution.After exposure in accordance with 3.12.1 and 3.12.2, washedbut unpolished exposure samples shall show a mini
40、mum degreeof dulling, change of colour and distinctness of image withboth standard and catal yzed repair paint when compared to anunexposed retained master.Both bulk and repair shall alter in colour, tone and gloss tothe sa me degree in the same direction. Only the slightestcolo ur change is permitt
41、ed. These samples shall show nocolour change, or irridescence in excess of specified AATCCrating (AATCC Grey Scal e for Evaluating Change in Colour, 10step).Gloss after exposure shall be minimum 60 units (60 degglossmeter. FLTM BI 110-01).The film shall be free from dirt and mildew. Un soiled panels
42、shall 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 current polish followed by a 24 h waterimmers ion tes
43、t 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.3.12.3 After Weathering Water ResistanceAf ter Florida exposure and/or accelerated weath
44、ering, testspecimens shall be test ed according to FLTM BI 104-01 for 24hours. Adhesion shall be tested according to item 3.11.1.3.12.4 New Vendors and Resin FormulationsSu bmissions of the above shall require weather resistanceover an extended period up to 5 years. Prior use withoutProduct Engineer
45、ing approval is not permitted.Sufficient panels shall be initially sent to Flo rida to allowinterim evaluation afte r each 12 months during this exposureperiod.ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 10 of 12 Lon g term Florida exposure panels prior to exposure shallhave 1/3 of
46、 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 clean towel.Grinding compound as recommended by Materials Engineering.3.12.5 ReflectanceMeasure and reco
47、rd 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.Recommended equipment i s Zeiss Spectrophotometer Type DMR 21with reflectance attachment.3.13 REPAIR REQUIREMENTS.3.13.1 Repair Colour Match Sati
48、sfactory(FLTM BI 115-01) colour match3.13.2 Acid Catalyst Repair(FLTM BI 115-02)Amount of acid catalyst WSK-M99J366-A to be added toWSK-M50J111-A as specified by supplier.The cat alyzed enamel repair system shall meet all thefollowing requirements.3.13.2.1 Colour Satisfactory(FLTM BI 115-01) colour
49、match3.13.2.2 Gloss No gloss loss(FLTM BI 110-01, 20 deg glossmeter)3.13.2.3 Intercoat Adhesion No chipping(FLTM BI 106-02)3.13.2.4 HardnessPenetration on full repair systemTukon, min 6.0 KHN(FLTM BI 112-02)ENGINEERING MATERIAL SPECIFICATIONWSK-M50J111-AWP 3948-b Page 11 of 12 3.13.2.5 Chip ResistanceTest panels with a repair coat on unsanded top coat(standa rd bake) as well as test panels with arepair coat of catalysed top coat (100 C) onunsanded top coat (standard bake) must fulfilrequirements of item 3.11.8Only chipping of top coat shall be evaluated.3.13.2.6 Weather Resistance see ite
