1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2015 10 26 Released E. Kapic, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 6 PERFORMANCE, CLEANER, BODY SHEET METAL WSS-M14P18-B1 1. SCOPE This specification defines the performance require
2、ments of cleaner materials used on the sheet metal and assemblies made from steel and aluminum, which are subsequently painted. 2. APPLICATION This specification was released originally for two-package liquid alkaline cleaners used in the zinc phosphate and thin-film pretreatment systems. The materi
3、als are used for cleaning iron, steel, zinc or zinc alloy coated steel, or aluminum parts where the maximum paint adhesion, chipping, and corrosion resistance is required. The cleaner provides clean, grease-free, surface for depositing pretreatment coating and subsequent painting. 3. REQUIREMENTS Th
4、e 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 requirements when applied under ass
5、embly plant conditions. 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 MATERIAL ANALYSIS Ford Motor Company, at its option, may conduct analysis of materials, supplied to this specification. The analyses may include, but are not limited to, mater
6、ial chemical analysis, subsequent pretreatment and paint coating analysis, and corrosion and mechanical resistance testing. If a chemical material analysis is established for initial approval, it shall constitute reference standards, and all samples shall produce the results within specified ranges
7、of the corresponding reference standards when tested under the same conditions. All the key material component ranges, and the key material manufacturing control limits must pass standard Gauge Repeatability and Reproducibility requirements (AIAG, MSA 2010 - Measurement Systems Analysis Reference Ma
8、nual). 3.3 MATERIAL COMPATIBILITY The supplier shall notify the responsible Materials Engineer if any incompatibility with other process related materials (e.g. sealers, adhesives, etc.) is anticipated. The supplier shall keep abreast of changes in technology of the process related materials which m
9、ay affect the compatibility and performance of the pretreatment products. The supplier shall review the potential incompatibilities with the responsible Materials Engineer to agree on the appropriate material compatibility testing. The appropriate material compatibility testing shall be done to ensu
10、re the process will deliver required performance. ENGINEERING MATERIAL SPECIFICATION WSS-M-14P18-B1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 6 3.4 PREPARATION OF TEST PANELS Testing shall be conducted on standard test panels representing the current production substrates, and current
11、mill oils and lubricants. 3.4.1 Test Substrates Cold Rolled Steel (CRS) Electro Galvanized Steel (EG) Hot Dip Galvanized Steel (HDG) Aluminum 6111 Alloy (AA6111) Aluminum 6022 Alloy (AA6022), or equivalent low copper aluminum alloy Other substrates may be requested as needed, and should be included
12、in regional or plant specific testing when appropriate. This shall be specified by the responsible Materials Engineer. 3.4.2 Testing Sample Size A minimum of three (3) test samples shall be prepared for each test variation, unless a different agreement is made between the responsible Materials Engin
13、eer and the supplier prior to testing. The same number of control panels shall be prepared with the cleaner materials currently approved and used in Ford Motor Company assembly production. 3.4.3 Test Panels Aging This section is applicable to liquid oils and lubricants, and all substrates listed in
14、section 3.4.1. The prepared panels are used for the Water-Break Free evaluation, Pretreatment Coating Quality evaluation, and Residual Surface Carbon analysis. Clean the test panels with a lint-free cloth soaked with acetone. Rinse the test panels with acetone to ensure the lubricant free surface. A
15、llow the panels to air-dry at room temperature (23 2 C). Immediately after drying, apply the lubricants using a #6 drawdown bar, or other suitable device to deposit a wet film approximately 0.014 mm thick or as specified by the Materials Engineer. Place the test panels horizontally in a 50C oven to
16、age for 168 hours. The panels should have sufficient spacing to allow air flow between the panels. 3.4.4 Preparation of Aluminum Panels with Hot Melt (“Dry”) Lubricants This section is applicable to hot melt (“dry”) lubricants, and aluminum substrates listed in section 3.4.1. The prepared panels are
17、 used for the Water-Break Free evaluation, Pretreatment Coating Quality evaluation, and Residual Surface Carbon analysis. Prepare two sets of aluminum panel for evaluation. 1. Aluminum panels with the lubricant coating weight per WSS-M9G24-A1. 2. Aluminum panels with the lubricant coating weight of
18、approximately 50% above the material specification. ENGINEERING MATERIAL SPECIFICATION WSS-M-14P18-B1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 6 3.5 PREPARATION OF CLEANER BATH The cleaner materials currently approved and used in Ford Motor Company assembly production shall be used to
19、 prepare the control cleaner baths. 3.5.1 Cleaner Bath Lubricant Aging The testing shall be conducted at four (4) levels of lubricant contamination. Zero contamination refers to the freshly built cleaner bath at its normal operational concentration and temperature. To age the cleaner bath, add the l
20、ubricants by weight to the tank to achieve 0.25%, 0.50%, and 1.00% lubricant contamination. If blending multiple lubricant products, report the exact concentrations of each test material in the cleaner aging mixture used to contaminate the cleaner baths. Exact cleaner bath concentrations and paramet
21、ers shall be reported, including concentration of alkaline package, concentration of surfactant package, pH, temperature, free and total alkalinities. 3.5.2 Cleaner Bath Metal Ion Aging The testing shall be conducted at two (2) levels of contamination. Zero contamination refers to the freshly built
22、cleaner bath at its normal operational concentration and temperature. To age the cleaner bath, add the 50 ppm of zinc (Zn) and 50 ppm of aluminum (Al). Zinc and aluminum are added as zinc nitrate and aluminum nitrate solutions. Make any necessary adjustments to Free Alkalinity and/or pH after the zi
23、nc nitrate and aluminum nitrate additions. Report the exact concentrations of each test material used to contaminate the cleaner baths. Exact cleaner bath concentrations and parameters shall be reported, including concentration of alkaline package, concentration of surfactant package, pH, temperatur
24、e, free and total alkalinities. 3.5.3 Cleaning Process 1. Spray clean 60 seconds at 50 2C 2. Immersion clean 120 seconds at 50 2C 3. Warm water rinse 30 seconds at 35 2C 3.6 RESISTANCE PROPERTIES 3.6.1 Water-Break Free 90% min Process three (3) aged panels of each substrate from sections 3.4.3 and 3
25、.4.4 through the 0.00%, 0.25%, 0.50% and 1.00% lubricant aged cleaner baths from section 3.5.1. The cleaning process conditions are given in section 3.5.3. Evaluate for percent of surface which holds water film for at least 10 seconds after the water rinse step. Definition of 100% water break-free i
26、s a surface that is completely covered with water. 3.6.2 Pretreatment Coating Quality After the Water-Break Free evaluation, continue processing the panels from section 3.6.1 through a full, applicable, pretreatment process. Consult with the responsible Materials Engineer on which pretreatment proce
27、sses should be used during the qualification. ENGINEERING MATERIAL SPECIFICATION WSS-M-14P18-B1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 6 1. Traditional zinc phosphate pretreatment process according to WSS-M3P1-D a. Coating weights b. Crystal size c. SEM images at 1000X magnification
28、 2. Two-Step zinc phosphate pretreatment process according to WSS-M3P38-A a. Coating weights b. Crystal size c. SEM images at 1000X magnification 3. Thin film pretreatment process according to WSS-10P13-A1 a. Coating weights 3.6.3 Residual Surface Carbon 15 mg/m2 max Clean three (3) aged panels of e
29、ach substrate from sections 3.4.3 and 3.4.4 through the fresh cleaner bath (0.00% contamination) at normal operational conditions. The cleaning process conditions are given in section 3.5.3. Use clean forced air to dry the panels immediately after cleaning. Place in a Coulometer and determine the re
30、sidual organic carbon using an oven temperature of 450 C. Note: Other comparable analytical techniques may be acceptable for determining the residual surface carbon. The supplier is responsible for setting up the alternative analytical method, and the method shall be reviewed with the responsible Ma
31、terials Engineer. The method must pass standard Gauge Repeatability and Reproducibility requirements (AIAG, MSA 2010 - Measurement Systems Analysis Reference Manual). 3.6.4 Cleaner Etch Rate Solvent clean, dry and weigh one 102 x 152 mm panel of each substrate given in section 3.4.1. Weigh the panel
32、s. Then process the panels according to section 3.5.3 with the cleaner solutions prepared according to sections 3.5.1 and 3.5.2. Use clean forced air to dry the panels immediately after cleaning. Re-weigh the panels and determine weight loss. Report the etch rate results along with the corresponding
33、 cleaner bath parameters, including concentration of alkaline package, concentration of surfactant package, pH, temperature, free and total alkalinities. 3.6.5 Foaming Evaluation Equal or Better than Control (Note: Better = Less Foam) Perform the following testing with 0.00%, 0.25 %, 0.50 % and 1.00
34、 % lubricant loaded cleaner solutions. Heat the cleaner solution to 50 2C. Transfer 100 ml of the cleaner solution to a 200 ml graduated cylinder. Put a stopper onto the cylinder and slowly invert twice. Vent after each inversion to release air pressure. Shake the cylinder vigorously using an up and
35、 down motion for 12 shakes (once up and once down equals one shake). Immediately place on level surface and measure foam volume from liquid/foam interface to top of foam. Repeat measurements at 30 and 60 seconds. 3.6.6 Emulsification For each test lubricant prepare cleaner solutions at four differen
36、t concentrations: 1. At 25% of normal concentration per the cleaner material technical data sheet (25% of alkaline package and 25% of surfactant package) ENGINEERING MATERIAL SPECIFICATION WSS-M-14P18-B1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 6 2. At 50% of normal concentration per
37、the cleaner material technical data sheet (50% of alkaline package and 50% of surfactant package) 3. At normal concentration per the cleaner material technical data sheet (100% of alkaline package and 100% of surfactant package) 4. At 200% of normal concentration per the cleaner material technical d
38、ata sheet (200% of alkaline package and 200% of surfactant package) An example of bath concentrations is given in the table below. Alkaline Package (% of Normal Concentration) Surfactant Package (% of Normal Concentration) Alkaline Package (g/L) Surfactant Package (g/L) 25 25 3.75 0.4 50 50 7.5 0.8
39、100 100 15 1.6 200 200 30 3.2 Heat the cleaner solution to 60 2C. Transfer 200 ml of the cleaner solution to a 250 ml graduated cylinder. Add 4 ml of test lubricant. Put a stopper onto the cylinder. Holding the cylinder vertically, agitate vigorously for 10 seconds. Carefully vent the cylinder to re
40、lease air pressure. Report the level (in milliliters) of lubricant/surfactant separation at 5 minutes, 60 minutes and 24 hours. Report the corresponding cleaner bath parameters, including concentration of alkaline package, concentration of surfactant package, pH, temperature, free and total alkalini
41、ties. 4. GENERAL INFORMATION This 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 ot
42、her material 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 subm
43、itted data may 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 I
44、NFORMATION 4.2.1 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
45、-M1P94-A: 70G70G-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*. ENGINEE
46、RING MATERIAL SPECIFICATION WSS-M-14P18-B1 Copyright 2015, Ford Global Technologies, LLC Page 6 of 6 4.2.4 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
47、-1485 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified an
48、d authorized representative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality
49、 control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.4 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials
