1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 05 21 Revised See Summary of Revisions for details Global Paint Team 2005 05 10 Revised Revised 2, 3.4.3, 3.5.13, 3.5.16 & 4.1 C. Lin 2004 05 27 Activated C. Lin Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LL
2、C Page 1 of 9 PAINT, TWO COMPONENT COLOR COAT FOR PLASTIC, INTERIOR SOFT TOUCH, STRAIGHT SHADE WSS-M15J15-A1 SOFT TOUCH, METALLIC WSS-M15J15-A2 1. SCOPE The material defined by these specifications is a pigmented two-component urethane paint system suitable for first surface application to interior
3、plastic parts. 2. APPLICATION These specifications were released originally as a decorative finish for interior parts, primarily airbag covers. All painted parts must meet WSS-M2P188-A1. All paint applicators must meet the Painted Part Approval Process (AVP-T113-0116). These paint systems are typica
4、l used for painting Airbags. Note: the use of primer/sealer is required for ABS substrates unless approved by Materials Engineering. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Product
5、ion Materials (WSS-M99P1111-A). 3.2 PHYSICAL PROPERTIES 3.2.1 Stability (6 months at 23 +/- 2 C) Shall not liver or jell upon standing and must be free from settling which is not dispersed by normal agitation. The viscosity of the material shall not increase or decrease more than 10 s. 3.3 PREPARATI
6、ON OF TEST PANELS 3.3.1 Testing Requirement/ Specimen Preparation Tests shall be performed on plaques of appropriate substrate. See Table 1 for testing requirements & sample size. Design Verification Testing (DV) is done on plaques by the paint supplier as defined in Table 1. Product/Process Validat
7、ion Testing (PV) is done on production painted parts as outlined in the painted part Performance Specification WSS-M2P188-A1. ENGINEERING MATERIAL SPECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 9 3.3.2 Substrate Polymers and poly
8、mer blends (i.e ABS, PC, PC/ABS). All test specimens shall be injection molded plaques or parts having a nominal thickness of 2.5 +/- 0.2 mm or as specified on the engineering document. 3.3.3 Plastic Preparation The surface to be painted shall be cleaned by an acceptable process, e.g. power wash, to
9、 remove mold releasing agents, fingerprints, oils, dirt and moisture. 3.3.4 Primer When necessary in order to meet the requirements of this specification, an adhesion primer, primer surfacer or sealer may be needed. Surface enhancements, such as flaming or plasma treatment that modify surface tensio
10、n, surface resistivity may also be required in order to meet the requirements. This must be noted in the initial submission package and recorded on the Ford Approved Source List (ASL). 3.3.5 Cure Supplier shall define Cure Window as described in Paragraph 3.6. This should be included in the submissi
11、on package and DFMEA. 3.3.6 Ageing Test panels or test specimens prepared for investigations according to this specification must be aged for at least 72 hours at 23 +/- 2 C or 16 hours at 45 +/- 1 C prior to testing 3.4 APPEARANCE 3.4.1 General Color, gloss, grain, tactile effect and surface finish
12、 shall match master Trim Sample and/or Master Appearance Sample as approved by Corporate Design The coating shall exhibit no craters, pinholes, solvent popping, seediness, abnormal roughness, or excessive flow. 3.4.2 Color (FLTM BI 109-01, Visual Assessment) (SAE J1545, MA58 Three-Angle CMC) Shall m
13、atch the Master Approved Sample. ENGINEERING MATERIAL SPECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 9 3.4.3 Gloss (FLTM BI 110-01, ASTM D 523) As released by Engineering: A: 20 Glossmeter, min 92 B: 60 Glossmeter 76 - 84 C: 60 G
14、lossmeter 66 - 74 D: 60 Glossmeter 58 - 66 E: 60 Glossmeter 47 - 53 F: 60 Glossmeter 33 - 38 G: 60 Glossmeter 17 - 23 H: 60 Glossmeter 7 - 13 J: 60 Glossmeter 4 - 6 K: 60 Glossmeter 2 - 4 L: 60 Glossmeter 0.5 - 2.0 N: 60oGlossmeter 1.8 - 2.4 The color, pattern and finish shall match the approved Des
15、ign Center master sample, or shall be as specified on the Engineering Document. Gloss can be affected by grain so the end gloss for the part will be determined & approved by visual evaluation by Design Quality. An accurate gloss reading needs to be performed on a flat smooth surface otherwise an acc
16、urate gloss reading cant be obtained. 3.5 FILM PROPERTIES All film properties are based on the proper preparation per para 3.3 with acceptable appearance, gloss reading, film thickness and after post cure per paragraph 3.3.6. 3.5.1 Film Thickness, range, micrometers 45 - 55 (ASTM B 487 or other mutu
17、ally agreed upon method) Note : These ranges are considered to be requirements unless otherwise supported by testing data agreed to by Materials Engineering. 3.5.2 Adhesion (FLTM BI 106-01, Method D) 3.5.2.1 Adhesion Less than 5% paint removal with no complete diamonds removed. Six lines in each dir
18、ection should make up the grid. The overall dimensions should be at least 25 mm wide by 50 mm long from the widest and longest points unless restricted by part size. 3.5.3 Water Resistance, min. Grade 0 (FLTM BI 104-01, 96 h,) No blistering, softening, dulling, or loss of adhesion per para 3.5.2 wit
19、hin 30 minutes of removal from water. ENGINEERING MATERIAL SPECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 9 3.5.4 Abrasion Resistance, min 1000 cycles (SAE J948, Taber method, 500 g load, CS-10 wheels) Abrasion resistance shall b
20、e determined on test panels with smooth surface. Measure and report the samples paint film thickness and run a min of 1000 cycles for every 25 micrometers of paint thickness on the panel. Paint must be sprayed on panels of contrasting color (ex. Black paint on gray substrate) to prevent dry hiding i
21、ssues. The paint film shall show no abrasion through to the substrate. 3.5.5 Resistance to Cleaning Agents, max Rating 4 discoloration (FLTM BN 107-01, 10 cycles, AATCC Evaluation Procedure 2) Test Procedure: Saturate the white cotton cloth with the cleaners listed. Evaluation according to the AATCC
22、 Scale. Cleaners (see also para 4.1) 1) Deionized water 2) Window cleaner with ammonia 3) All purpose cleaner 4) Dry (no cleaners or water) 3.5.6 Long Term Heat Exposure, min. Rating 4 (7 d at 100 +/- 2 C, ISO 105-A02/ AATCC Eval. Proc. 1) Appearance Evaluation: No evidence of cracks, no blistering,
23、 no change in appearance or other failure when compared with original unaged sample. Panels or parts exposed per para 3.5.6 shall be immersed in water for 24 h per FLTM BI 104-01 and then tested for adhesion per para 3.5.2. 3.5.7 Short Term Heat, Humidity and Cold Cycle, min. Rating 4 (ISO 105-A02/A
24、ATCC Eval. Proc. 1) 5 h at -40 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H. 5 h at -40 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C One hour ramp time between each
25、 step. Appearance Evaluation: No evidence of cracks, no blistering, no change in appearance or other failure when compared with original unaged test sample. Panels or parts exposed per para 3.5.7 shall be immersed in water for 24 h per FLTM BI 104-01 and then tested for adhesion per para 3.5.2. ENGI
26、NEERING MATERIAL SPECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 9 3.5.8 Fogging (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number, min 70 Formation of clear film, droplets or crystals i
27、s cause for rejection. 3.5.9 Resistance To Fade 3.5.9.1 Accelerated Xenon Weathering, min Rating 4 (FLTM BO 116-01 at 2406.4kJ/m2 Gloss Change 30% or SAE J2412* at 1240kJ/m2, L.a.b. delta 1.9 ISO 105 A-02/AATCC Evaluation Procedure 1) *note the FLTM is the preferred method note method used on data s
28、ubmission form. Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only Duplicate panels are required, one for appearance evaluation and one for water immersion. After the color and gloss measurements, one of the weathered panels shall be subjected to the water immersion test for 24 h per FLTM BI 1
29、04-01 and must meet requirements of para 3.5.2. 3.5.9.2 Florida Weathering Under Glass 1 year submission (FLTM BI 160-01, ISO 105 A-02/AATCC required for new Evaluation Procedure 1) technology only (paint or substrate) 12 months Rating 4, min Gloss change 30% L.a.b. delta E 1.9 Test parts shall be e
30、xposed under glass in the Miami, Florida area, black box, under glass at a 5 angle facing South. After the color and gloss measurements, one of the weathered panels shall be subjected to the water immersion test for 24h per FLTM BI 104-01 and meet the requirements of para 3.5.2. Note: All new airbag
31、 cover technology (paint and/or substrate) must meet 12 months Florida Weathering per sec. 3.5.9.2. The parts tested shall be completely free from evidence of cracking, checking, blistering, and peeling 3.5.10 Migration Staining, min Rating 5 (FLTM BN 103-01, ISO 105-A02/AATCC Evaluation Procedure 2
32、) No evidence of exudation, adhesion (tackiness), separation, color transfer, or flattening of embossing when placed face to face with itself. ENGINEERING MATERIAL SPECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 9 3.5.11 High Perf
33、ormance Paint Adhesion* * note method used on data submission form Test Method: Expose the samples at 80 +/- 2 C and 80 +/- 5% Relative Humidity for 96 hours then follow all steps of FLTM BI 107-05 and FLTM 160-04. FLTM BI 107-05 Adhesion, min Rating 19 No loss of gloss or any other surface deterior
34、ation. Alternate Method FLTM BO 160-04 Adhesion, min No Adhesion Loss No loss of gloss or any other surface deterioration. 3.5.12 Resistance to Water and Soap Rating 4 Spotting, max discoloration (FLTM BI 113-01, ISO 105-A02/AATCC Evaluation Procedure 1) No film softening allowed for any solution. 3
35、.5.13 Resistance to Window Cleaner Spotting Rating 4 Apply 0.25 ml of glass cleaner per section 4.1 on test sample using a non-reactive O-ring. Expose the sample at the room temperature for 1 h. Evaluate per ISO 105-A02/AATCC Evaluation Procedure 1. 3.5.15 Resistance to Marring (SAE J365, 10 cycles)
36、 A and B gloss surfaces (see sec. 3.4.3) Shall be capable of being sanded with 1200 grit or finer and polished. No noticeable change in gloss or appearance except for a minimum of polishing lines shall result. C L gloss surfaces (see sec. 3.4.3) No evidence of discoloration, mar can be removed with
37、four rubs of the thumb across the mar. 3.5.16 Resistance to Scuffing, min 1000 cycles (SAE J365) Measure and report the paint film thickness of the panel and run a min of 1000 cycles for every 25 micrometer of paint thickness on the panel. No evidence of lifting, peeling, or excessive scuffing. No p
38、ermanent parallel deformation to the surface. Paint must be sprayed on panels of contrasting color (ex. Black paint on gray substrate) to prevent dry hiding issues. ENGINEERING MATERIAL SPECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7
39、 of 9 3.5.17 Soiling and Cleanability (FLTM BN 112-08, ISO 105-A02/AATCC Evaluation Procedure 1, grease and coffee soiling agents only) Cleanability Rating 3 3.5.18 Resistance to Suntan Lotion Rating 3 and Insect Repellent, max No loss of adhesion (FLTM BI 113-08, 23 C & 74 C) 3.5.19 Perspiration Re
40、sistance (FLTM BI 113-06, ISO 105-A02/AATCC Evaluation Procedure 1) Acid Perspiration Solution Rating 4 Alkaline Perspiration Solution Rating 4 Sodium Chloride Solution Rating 4 3.5.20 Flexibility Airbag Covers only. 3.5.20.1 Room Temperature (23 +/- 2 C) Test Method: Cut 13 x 100 mm sample from pla
41、que. Grasp sample firmly at each end, place over mandrel painted side up, and bend around mandrel 180 min. Use 25 mm mandrel. 3.5.20.2 Cold Temperature Test Method: Cut 13 x 100 mm sample from plaque. Place sample, mandrel and gloves into a freezer at - 30 + 0/- 2 C for 4 h min. Open freezer, put on
42、 gloves and grasp sample firmly at each end, place over mandrel painted side up, and bend around mandrel 180 min. Use 25 mm mandrel. No cracking of painted surface is allowed when bent over 25 mm mandrel. 3.5.21 Odor, max Rating 3 (FLTM BO 131-03 or SAE J1351) 3.5.22 Humidity Resistance (85 C and 90
43、% R.H for 96hr) No blistering, softening, or loss of adhesion per 3.5.2. 3.5.23 Scratch Resistance, max (FLTM BO 162-01, visual inspection of paint surface, 1mm scratch pins) Scratch, 2N Rating 1 Marring, 2N Rating 2 ENGINEERING MATERIAL SPECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled
44、Copyright 2009, Ford Global Technologies, LLC Page 8 of 9 3.6 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments (Response Surface Analysis is recommended) to determine the process window of the material. The three variables/parameters to be included in the design are bake
45、temperature, bake time, and film thickness. An initial screening experiment should be run to determine what levels should be tested for the variables/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DOE. Responses for the DOE shall include, but
46、 are not limited to, the following: Film Thickness, para 3.5.1 Gloss, para 3.4.3 Initial Adhesion, para 3.5.2 Water Resistance, para 3.5.3 Naptha or Xylene Crocking (2K only), FLTM BN 107-01, 10 cycles Odor para 3.5.21 4. GENERAL INFORMATION The information given below is provided for clarification
47、and assistance in meeting the requirements of these specifications. 4.1 CLEANING AGENTS (See para 3.5.5) 1) Window cleaner ZC-23* 2) All Purpose Cleaner ZC-11-A* * or Ford Motor Company recommended equivalents 5. SUMMARY OF REVISIONS 2009 05 21 Revisions o 3.3.1 Added DV & PV definitions for paint o
48、 Updated/Added 3.3.1 3.3.6 o 3.5.9 Added FLTM BO 116-01 and updated o 3.5.11 Changed Name and added Alternative method BO 160-04 o 3.5.18 Removed DVM replaced by FLTM BI 113-08 o 3.5.19 Changed method to align with WSS-M2P188-A o Added 3.5.21, 3.5.22, & 3.5.23 o Added Table 1 ENGINEERING MATERIAL SP
49、ECIFICATIONWSS-M15J15-A1/A2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 9 of 9 Table 1 Approval Test Requirements for Design Validation Sample size/color New paint technology New Substrate New color approved paint technology (MCDCC signoff) 3.4 Appearance 1 X X X 3.5.1 Film Thickness 1 X X X 3.5.2 Adhesion 3 X X X 3.5.3 Water Resistance 3 X X X 3.5.4 Abrasion Resistance 3 X X 3.5.5 Resistance to Cleaning Agents 3 X 3.5.6 Long Term Heat Exposure 1 X X X
