1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2013 05 10 Released E. Kapic, R. Starbowski FNA Controlled document at www.MATS Copyright 2013, Ford Global Technologies, LLC Page 1 of 5 PERFORMANCE, THIN FILM CONVERSION COATINGS, ZIRCONIUM WSS-M10P13-A 1. SCOPE This specification de
2、fines the performance requirements for the zirconium nano-scale thin film conversion coatings produced on assemblies made from steel and/or aluminum, which are subsequently painted. 2. APPLICATION This specification was released originally for the zirconium nano-scale thin film conversion coatings u
3、sed on iron, steel, zinc or zinc alloy coated steel, and aluminum substrates where maximum paint adhesion and corrosion performance are required. The coating process provides a clean, grease-free surface necessary for painting, and promotes paint adhesion and corrosion protection when the paint film
4、 is broken. 3. REQUIREMENTS The supplier shall contact the responsible Materials Engineer prior to initiating qualification testing. Typical quality documentation requirements are listed in section 4.1 of this document. All materials approved under this specification shall meet all engineering requi
5、rements when applied under assembly plant conditions. 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 MATERIAL ANALYSIS Ford Motor Company, at its option, may co
6、nduct analysis of materials, and representative parts/panels supplied to this specification. The analyses that may be conducted include, but are not limited to, material chemical analysis, coating analysis, and corrosion and mechanical resistance testing. The chemical material analyses established f
7、or the initial approval shall constitute reference standards, and all samples shall produce the results within specified ranges of the corresponding reference standards when tested under the same conditions. All the key material component ranges, and the key material manufacturing control limits mus
8、t pass standard Gauge Repeatability and Reproducibility requirements (AIAG, MSA 2010 - Measurement Systems Analysis Reference Manual). 3.3 MATERIAL COMPATIBILITY The supplier shall notify the responsible Materials Engineer if any incompatibility with other process related materials (e.g. sealers, ad
9、hesives, electrocoat, etc.) is anticipated. The supplier shall keep abreast of changes in technology of the process related materials which may affect the compatibility and performance of the pretreatment products. The supplier shall review the potential incompatibilities with the responsible Materi
10、als Engineer to agree on the appropriate material compatibility testing. The appropriate material compatibility testing shall be done to ensure the process will deliver required performance. ENGINEERING MATERIAL SPECIFICATION WSS-M10P13-A Copyright 2013, Ford Global Technologies, LLC Page 2 of 5 3.4
11、 PHYSICAL PROPERTIES Zirconium Coating Weight (XRF Analysis, other analytical method approved by the responsible Materials Engineer) Note: The zirconium coating weight ranges as defined below only apply to the described materials. Cold Rolled Steel 20 200 mg/m2 Electro Galvanized Steel 40 300 mg/m2
12、Hot Dip Galvanized Steel 40 300 mg/m2 Galvannealed Steel 40 300 mg/m2 Aluminum 10 150 mg/m2 Note: The supplier is responsible for setting up an appropriate analytical method for measuring the zirconium coating weight. The coating weight measurement method shall be reviewed with the responsible Mater
13、ials Engineer, and must pass standard Gauge Repeatability and Reproducibility requirements (AIAG, MSA 2010 - Measurement Systems Analysis Reference Manual). 3.5 PROCESS WINDOW DEFINITION The final testing requirements shall be defined by the responsible Materials Engineer. The supplier shall perform
14、 a Design of Experiments (DOE) (Response Surface Analysis is recommended) to determine the process window of the pretreatment process controls. At a minimum the DOE shall include the concentrations of the main bath components (such as Zirconium, Fluoride, coating deposition accelerators, etc.), pH,
15、process time and process temperature. Additional study variables may include any other pretreatment bath key components or parameters, and the substrate cleaning conditions (fresh vs. aged alkaline cleaner bath). Appropriate screening experiments should be run to determine what variables/parameters
16、and their levels should be tested. The results of the screening experiments should be reviewed with the responsible Materials Engineer in order to set up the final DOE. Response attributes to the DOE will be based on the materials tested, and will be chosen from tests listed within this specificatio
17、n. Minimal testing required: Coating Weight, Paint Adhesion (FLTM BI 106-01, Method B) before and after Water Immersion (FLTM BI 104-01), Stone Chip Resistance (SAE J400 and FLTM BI 157-06), Corrosion Resistance (L-467 and L-3190). The process window characteristics must be submitted with the initia
18、l approval package. 3.6 PREPARATION OF TEST PANELS Testing shall be conducted on standard test panels representing the current production substrates, and current mill oils and pre-lubricants. Test panels shall be prepared according to the exterior performance specification WSS-M2P180-D (latest). 3.6
19、.1 Test Substrates Cold Rolled Steel (CRS) Electro Galvanized Steel (EG) Hot Dip Galvanized Steel (HDG) Galvannealed Steel (GA) Aluminum 6111 Alloy (AA6111) Aluminum 6022 Alloy (AA6022) Other substrates may be requested as needed, and should be included in plant specific testing when appropriate. Th
20、is shall be specified by the responsible Materials Engineer. ENGINEERING MATERIAL SPECIFICATION WSS-M10P13-A Copyright 2013, Ford Global Technologies, LLC Page 3 of 5 3.6.2 Paint System Pretreated test panels shall be painted with a Ford approved fully layered paint system that includes electrocoat
21、primer, primer surfacer, and topcoat (basecoat + clearcoat). Unless otherwise specified by the responsible Materials Engineer, the panels shall be painted with a white topcoat system. Materials shall be applied, baked and aged according to individual material specifications. 3.6.3 Testing Sample Siz
22、e A minimum of three (3) test panels shall be prepared for each test variation, unless a different agreement is made between the responsible Materials Engineer and the supplier prior to testing. The same number of control panels shall be prepared with the pretreatment system currently approved and u
23、sed in Ford Motor Company assembly production. 3.7 RESISTANCE PROPERTIES 3.7.1 Paint Adhesion Grade 1 max (FLTM BI 106-01, Method B) 3.7.2 Water Resistance Grade 1 max (FLTM BI 104-01, 240 hr.) No blistering or loss of paint adhesion accepted. Paint adhesion shall be tested according to paragraph 3.
24、7.1 within 30 minutes after removal from water. 3.7.3 Humidity Resistance Grade 1 max (FLTM BI 104-02, Method A, 240 hr.) No blistering, or loss of paint adhesion accepted. Paint adhesion shall be tested according to paragraph 3.7.1 within 30 minutes after removal from cabinet. 3.7.4 Corrosion Resis
25、tance 3.7.4.1 Laboratory Accelerated Corrosion Test, 6 weeks exposure. (Test Method (formerly CETP) 00.00-L-467, evaluate according to FLTM BI 169-01) Corrosion creep across the scribe, maximum. Cold Rolled Steel 10 mm Electro Galvanized Steel 6 mm Hot Dip Galvanized Steel 6 mm Galvannealed Steel 6
26、mm 3.7.4.2 Laboratory Accelerated Corrosion Test, 6 weeks exposure. (Test Method (formerly CETP) 00.00-L-3190, evaluate according to FLTM BI 169-01) Corrosion creep across the scribe, maximum. Aluminum 4 mm ENGINEERING MATERIAL SPECIFICATION WSS-M10P13-A Copyright 2013, Ford Global Technologies, LLC
27、 Page 4 of 5 3.7.5 Chip Resistance 3.7.5.1 Grit Blast, Split Shot Rating 5 min (FLTM BI 157-06) 3.7.5.2 Stone Chip, Rating 5B or 97% min (SAE J400, 1.4 L, -20 2C and 23 2C) paint retention, no chips 3 mm Dia. Evaluate substrate-to-topcoat (S/T) point of failure only. During the chip testing make sur
28、e that test the panels have appropriate backing to prevent excessive panel bending. 3.7.6 Cylindrical Mandrel Test (ASTM D522, Method B, 25 mm (1 inch) mandrel, 1 sec bend time) No paint peeling is produced at the paint to substrate interface. Equal to, or better than the current process control pan
29、els. 3.7.7 Glass Bonding/Paint System Compatibility (Materials Engineering Procedure AVP-T118-001, Pretreatment Material Technology Change Section, consult with the responsible Materials Engineer for appropriate testing requirements) Equal to, or better than the current process control panels. 4. GE
30、NERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 Material(s) technical data sheet(s), Design Matrix, Design FMEA, and other material
31、 related processing information shall be made available for review prior to qualification testing. Process P-Diagram and plant specific Process FMEA shall be developed before the material can be introduced to a production facility. Under agreed-upon circumstances, certain previously submitted data m
32、ay be applied to subsequent data submissions. In this case, the qualification requirements will depend on the degree of changes made to the material. The final test requirements shall be agreed upon between the responsible Materials Engineer and the supplier prior to testing. 4.2 PANEL INFORMATION 4
33、.2.1 Cold Rolled Steel panels Use panels in accordance with WSS-M1A365-A12. Class 3 (Non Nickel-flash) CRS panels are laboratory quality mild CRS available from ACT Test Panel Technologies*. 4.2.2 Hot Dip Galvanized Steel panels Use panels in accordance with WSS-M1A365-A12, coated to WSS-M1P94-A: 70
34、G70G-GI, Class 1 Qualified coil stock is available from ACT Test Panel Technologies*. 4.2.3 Electro Galvanized Steel panels Use panels in accordance with WSS-M1A365-A12, coated to WSS-M1P94-A: 60G60G-EG, Class 1 Qualified coil stock is available from ACT Test Panel Technologies*. ENGINEERING MATERIA
35、L SPECIFICATION WSS-M10P13-A Copyright 2013, Ford Global Technologies, LLC Page 5 of 5 4.2.4 Galvannealed Steel panels Use panels in accordance with WSD-M1A333-A2, coated to WSS-M1P94-A: 45A45A-HD, Class 3 Qualified coil stock is available from ACT Test Panel Technologies*. 4.2.5 Aluminum panels Qualified alloys are available from ACT Test Panel Technologies*. *The panels can be ordered from: ACT Test Panel Technologies 273 Industrial Drive Hillsdale, MI 49242 (517) 439-1485
