1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 07 31 Revised Updated and renumbered 1998 09 21 Revised Revised para 3.2 J. Lott 1991 11 15 NL00 E19133242 Released S. Renko C. McKenney K. Thurgood Printed copies are uncontrolled Page 1 of 5 Copyright
2、 2002, Ford Global Technologies, Inc. STEEL, SHEET, ZINC/NICKEL, ALUMINUM RICH WSL-M1A325-A1 ORGANIC COATING 1. SCOPE The material defined by this specification is a mild steel sheet coated on both sides with an electrolytic zinc/nickel alloy, a pretreatment, and a roll coated aluminum rich organic
3、coating to produce a duplex system. 2. APPLICATION This specification was released originally for material used for fuel tanks requiring both additional corrosion protection and resistance to methanol fuel blends. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers
4、and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 BASE MATERIAL The base material shall conform to WSD-M1A333-A2 or -A3, coated to WSS-M1P94-A: 30N30N-EL. 3.3 PRETREATMENT A complex oxide conversion coating shall be used to increase
5、the adhesion and durability of the aluminum rich organic coating by providing a clean, grease free, corrosion inhibiting bond between the base material and finish. Coating weights should be measured on samples prior to roll coating and should be tested using either an atomic absorption or inductive
6、coupled plasma testing apparatus. 3.3.1 Cobalt Coating Weight, mg/m2 3.2 - 16.1 3.3.2 Chromium Coating Weight, mg/m2 8.6 - 16.1 ENGINEERING MATERIAL SPECIFICATION WSL-M1A325-A1 Page 2 of 5 Copyright 2002, Ford Global Technologies, Inc. 3.4 ALUMINUM RICH ORGANIC COATING The coating shall comprise of
7、an epoxy resin binder modified with aluminum metallic particles. The control plan referred to in para 3.1 shall address coating composition. 3.4.1 System Process The coating shall be applied using a roller process. All surfaces of material to be coated must be free from oil, grease, rust, and any ot
8、her foreign material. 3.4.2 Final Hardness (ASTM D 3363) Remove any additional coatings, such as dry metal forming lubricants, prior to hardness testing. Pencil, min 8H 3.4.3 Coating Thickness, micrometres 7.5 - 0.0 + 3.8 Any suitable method may be used to measure coating thickness. In case of dispu
9、te, the umpire method shall be metallographic technique. 3.4.4 Dry Film Composition 32.5 - 36.5 % (Weight percent - metallic aluminum content) 3.4.5 Appearance The coating shall be baked to a uniform film, showing no flow lines, pinholes, craters, or abnormal roughness. 3.4.6 Adhesion and Flexibilit
10、y Using the equipment and method described in FLTM BI 109-04, form a cup to a depth of 7.6 mm. Wash the coated surface with warm water and allow to air dry. Using firm and even pressure, apply tape across the dome area. Remove the tape within 90 seconds, pulling it with a smooth rapid motion at a 90
11、 degree angle to the surface. The tape sample shall have a rating of 8 or better when compared to the attached ball indent adhesion test rating sheet. 3.4.7 Adhesion Grade 1 or (FLTM BI 106-01) better ENGINEERING MATERIAL SPECIFICATION WSL-M1A325-A1 Page 3 of 5 Copyright 2002, Ford Global Technologi
12、es, Inc. 3.4.8 Salt Spray Resistance 2000 h (ASTM B 117) For initial sample approval only. The sample shall have a rating of 9 or better per ASTM D 1654, procedures A and B. 3.4.9 Proving Ground Corrosion Test (P3-87A or P3-76A) For initial approval only. Fuel tanks manufactured from this material m
13、ust withstand 100 cycles minimum without perforation. 3.4.10 Fuel Resistance No softening or peeling. (FLTM BZ 105-03) Some allowable rust Initial source approval required static soak testing of resistance seam welded samples at 60 C for a six month period. The paint film shall not soften, peel, or
14、show any signs of defect when soaked in any fuel/methanol blend, diesel, aggressive, or auto-oxidized fuel. Testing procedures, test fuels, and allowable rust based on original testing will be specified by the Materials Engineering activity. 3.5 WELDABILITY The coated steel shall be capable of being
15、 welded by the intended production process (seam welded, spot welded, etc.). The affected plant manufacturing engineering office must approve the weldability of this material by means of a manufacturing trial, using the equipment and manufacturing methods which are proposed for production. 3.6 FORMA
16、BILITY The quality level of coated steel supplied to fabricate a specific component is to be negotiated between the manufacturing activity and the coated steel supplier. Acceptance of subsequent orders by the coated steel supplier for a given component at the agreed upon quality level implies that a
17、ll coated steel supplied will form that part satisfactorily as defined by the manufacturing activity. 3.7 MATERIAL IDENTIFICATION 3.7.1 Zinc/Nickel Coating Designation The zinc/nickel coating designation shall be as specified in para 3.2. 3.7.2 Coil Identification Unless an alternate method is agree
18、d upon by the steel supplier and the manufacturing activity, the coated product shall be identified with the following information stenciled within 250 mm of the coil edge and repeated at .5 meter ENGINEERING MATERIAL SPECIFICATION WSL-M1A325-A1 Page 4 of 5 Copyright 2002, Ford Global Technologies,
19、Inc. intervals. Steel Company Name and Location Coaters Name (if different than above) Date Coated Ford Specification and Organic Coating Manufacturer 4 GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1
20、 ADDITIONAL COATING Additional coatings, such as dry metal forming lubricants may be required. These materials will be agreed upon between the manufacturing activity and the coated steel supplier. 4.2 INITIAL SUPPLIER APPROVAL For initial approval, the supplier must furnish the following information
21、. 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/nickel coating mass histogram including mean and standard deviations values. Data shall consist of a mini
22、mum of 500 thickness measurements randomly taken from each side of a minimum of 20 coils while the process is operating in statistical control. Conductive organic coating thickness histogram including mean and standard deviation values. Data shall consist of a minimum of 500 thickness measurements r
23、andomly taken from each side of a minimum of 20 coils while the process is operating in statistical control For initial approval only, zinc/nickel chemical analysis will be made and reported “as deposited“. Upon approval, the material will be added to the Engineering Material Approved Source List. ENGINEERING MATERIAL SPECIFICATION WSL-M1A325-A1 Page 5 of 5 Copyright 2002, Ford Global Technologies, Inc. BALL INDENT ADHESION TEST RATING SHEET
