1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1995 12 07 Activated J. FauntWP 3948-a Page 1 of 11 THERMALLY CURED SILICATE, ABRASION RESISTANT, WSS-M16J18-ATRANSPARENT PLASTIC PARTS1. SCOPEThe material defined by this specification is a clear UV stabilizedth
2、ermally curable coating.2. APPLICATIONThis specification was released originally to describe p roperties necessaryfor a clear protective coating for polycarbonate headlamp lens. Prior toapproval to this specification the coating will have to meet any additionalrequirements listed on the Engi neering
3、 Drawing deemed necessary to producequality parts, and sufficient pilot and production trials to confirm theacceptable manufacturing window defined by this specification.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers and part producers must conform to Quality SystemRequirements, QS
4、-9000. Material specification r equirements are to beused fo r initial qualification of materials. A Control Plan forong oing production verification is required. This plan must bereviewed and approved b y the relevant Ford Materials activity and/orFor d Supplier Technical Assistance (STA) prior to
5、production partssubmission. Appropriate statistical tools must be used to analyzepr ocess/product data and assure consistent processing of thematerials.Part producers using this material in their products, must use Fordapproved materials and must conform to a process control plan whichhas been appro
6、ved by STA and/or the relevant Materials Activity.3.2 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on ma terial conditioned ina control led atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under thesame conditio
7、ns unless otherwise specified.ENGINEERING MATERIAL SPECIFICATIONWSS-M16J18-AWP 3948-b Page 2 of 11 3.3 COMPOSITIONFord Motor Company, at its option, may conduct infrared spectroscopy(IR), emission spectroscopy (ES), pyrolitic gas chromotography (PGC),and thermogravimetric analysis (TGA) of material/
8、parts supplied tothis specification. The spectra established for initial approvalshall constitute the re ference standard and shall be kept on file atthe designated material laboratory. All samples shall produce spectrathat correspond to the reference standard when tested under the sameconditions as
9、 those specified on the master spectrum.3.3.1 CoatingTh e coating shall not contain any commercial substance(s)kno wn to attack polycarbonate. Consult the appropriatematerial supplier for published list of these materials.The supplier will furnish the range of humidities underwhich the coating can b
10、e applied and cured without anyevidence of blush.3.3.2 Specific Composition The supplier will furnish the specific composition of theformulation upon request.3.4 PHYSICAL PROPERTIES3.4.1 Viscosity, Package Initial production(ASTM D 2196, Brookfield LVT with UL Batch +/- 10%adaptor at 60 RPM)3.4.2 No
11、n-Volatile, min Initial production(FLTM BI 102-01) batch +/- 5 %3.4.3 Volume Non-Volatile at TBDapplication viscosity, min(EPA Method 24)3.5 PREPARATION OF TEST PANELS3.5.1 PanelsUnles s otherwise specified, 2.5 - 4.0 mm thick approvedinj ection molded headlamp lens grade clear polycarbonate,(excep
12、t for para 3.8.1), at least 75 mm long andrepre sentative of production material. The process used toclean the polycarbonate prior to painting shall be describedin detail.3.5.2 Primer If required, apply, flash, and cureto manufacturers instructions.ENGINEERING MATERIAL SPECIFICATIONWSS-M16J18-AWP 39
13、48-b Page 3 of 11 3.5.3 Clear TopcoatFor para 3.6 and para 3.7.1 - 3.7.6, apply the c oating at theconditions specified for Trial 29 in Table 1. F or para 3.7.7- 3.7.10, apply the coating a the conditions spe cified by theexperimental design in Table 1. For para 3.8.1 - 3.8.3, applythe coating at th
14、e conditions specified by the experimentaldesign in Table 2. A Zeiss MCS Diode Array Spectrometer isrecommended to measure coating thickness. A surfaceprofilometer or a mutua lly agreed upon method can be used inlieu of the Zeiss instrument.3.6 APPEARANCE3.6.1 Color, max Clear, Yellowness(ASTM D 192
15、5) Index, YI 1.003.6.2 Gloss 60 deg(FLTM BI 110-01)Not m ore than a 10 % decrease in gloss relative to theuncoated plastic.3.6.3 Clarity Sample three(ASTM D 1003) locationsHaze ma y not increase by more than 0.5 % average from theuncoated plastic.Luminous transmittance may not decrease by more than
16、0.5 %average from the uncoated plastic.3.6.4 GeneralThe coating shall bake out to a presentable, ser viceable filmshowing no craters, pinholes, seediness, abnormal roughnessor excessive metallic mottling.3.7 FILM PROPERTIESUse the experimental design given in Table 1 for para 3.7.7 through3.7.10, an
17、d Table 2 for para 3.8.1 through 3.8.3. The process windowdefin ed by acceptable results for para 3.7.7 through 3.7.10 willconstitute the Initial Acceptable Process Window.Me asure film builds at the same panel location(s) that theperformance measurements are taken.3.7.1 Abrasion Resistance, max All
18、 five panels:(FLTM BN 108-02, Taber Abrader, 7 % increase inCS-10 wheel, 500 g load, 300 cycles, haze5 panels)ENGINEERING MATERIAL SPECIFICATIONWSS-M16J18-AWP 3948-b Page 4 of 11 3.7.2 Adhesion Fig. 4b or better(ASTM D 3359, Method B, 5 panels)Use 3M # 898 tape.3.7.3 Thermal Shock Resistance(FLTM BI
19、 107-05)The coating shall exhibit no blistering.Direct the steam blast along the entire length o f each arm ofthe “X“ in a continuous motion for the 30 sec test period.3.7.4 Resistance to Water and Soap Spotting(FLTM BI 113-01)Discoloration, max None3.7.5 Resistance to Acid Spotting(FLTM BI 113-02)D
20、iscoloration, max NoneGloss, no more than a 10 % loss from value before exposure.See para 3.6.23.7.6 Chemical Resistance48 h at 23 +/- 2 CTest Fluids:1. Moto r Oil 5W30 type SF (API), Ford Service Part NumberX0-5W-30-QSP.2. Tar Remover (petroleum base), Ford Service Part NumberB7A-19520-A3. Windshie
21、ld Washer Fluid, Methanol Base, ESB-M8B15-B,dilute 1:1 with distilled water for test.4. Antifreeze, Ford Service Part Number E2FZ-19549-AA,dilute 1:1 with distilled water for test.5. Reference Fuel D ASTM D 471.Test Procedure: Wipe t he entire coated surface of the panelwith a 150 mm square soft cot
22、ton cloth (folded into a 75 mmsquare) that has been immersed in a container containing 60mL of one of the chemicals listed in this test method. Holdthe cloth by one corner allowing the excess liqu id drip. Whenthe cloth has stopped dripping, wipe a test pane l as follows:One back and forth wipe in t
23、he horizontal direction for thebottom, middle and upper surface. Store the pane l for 48 h inan env ironment maintained at 23 +/- 2 C and a relativehu midity of 50 +/- 10 %. Repeat this procedure for theremain ing chemicals. After 48 h clean each panel with aclean soft cloth. Inspect the panel witho
24、ut magn ification forrating.ENGINEERING MATERIAL SPECIFICATIONWSS-M16J18-AWP 3948-b Page 5 of 11 Test Acceptance Criteria: The panel surface shal l not exhibitany surface deterioration, coating delamination, substrate orcoating cracking or color pick up.3.7.7 Water Immersion Resistance, min 240 h(FL
25、TM BI 104-01)Test Met hod: Paint and test three panels per trial number.Imme rse panels for 240 h in distilled or deionized watermaintained at 60 +/- 1 C. Remove panels from the water, anddry the scribed area with a paper towel, cloth or airpressure. Scribe panel s within 5 minute of removal from th
26、ewater, a nd immediately perform an adhesion test per ASTM D3359, Method B, with 13 cm2 of 3M 898-2 tape. After the tapepull, abrade the surfac e with # 0000 steel wool to highlightthe areas of loss of adhesion.The following conditions shall be a basis for rejection.1. 3B, 2B, 1B, or 0B performance
27、as described in ASTM D3359.2. Evidence of loss of adhesion of the coating.3.7.7.1 Haze After Water Immersion, max 5 % increase from(ASTM D 1003) coated plasticTest Method: Paint an d test three panels per trialnumber. Remove panel s from the water, and dry thescribed with a paper towel, cloth or air
28、 pressure.Measure haze within 5 minutes of removal from thewa ter immersion bath at three equally spacedinterval s on the center of the long axis of thepanel. Report all three readings and the averageof the three readings. The average increase o f thethr ee readings must be less than 5 %. Note anyvi
29、sible haze formation in addition to the hazereadings. The following is an additional basi s forrejection:1. No vis ible increase in haze may be noted atpanel locations in excess of 6.5 mm from thepanel periphery.Ford may, at its discretion, require that actualparts meet this requirement at Ford spec
30、ifiedproduction process conditions.ENGINEERING MATERIAL SPECIFICATIONWSS-M16J18-AWP 3948-b Page 6 of 11 3.7.8 Initial ultraviolet light absorbance on quartz.(FLTM AI 103-02, Method A)Use Method A with the following modifications:The quart z slide may be a 1 in. x 3 in. x 1 mm microscopeslide.Step 2.
31、 App ly and process coating with conventionalequipment.Step 3. DeleteStep 4. DeleteStep 5. Note the wavelength and absorbance of the maximumabsorba nce. If the absorbance is 3.0, use aneutral density filter of value #2.0 in thereference side of the spectrophotometer. Provi de toFord the absorption s
32、pectra and the neutral de nsityspectrum, if applicable.3.7.9 Initial ultraviolet light absorbance on plastic panel(s).(FLTM AI 103-02, Method B)Use Method B with the following changes:Only initial ultraviole t light absorbance is to be measured.No panels should be prepared for either Florida orweath
33、erometer exposure.Step 2. DeleteStep 15. Provide to Ford the a bsorption spectra, the weightof the sampled film, and the abs/conc.3.7.10 Thermal CyclingPa nels shall be subjected to 15 consecutive repetitions ofthe following cycle:16 hours humidity at 37 +/- 2 C and 95 % minimum relativehumidity.3 h
34、ours at - 30 +/- 2 C.1 hour recovery at 25 +/- 2 C at 50 % relative humidity.3 hours at 110 +/- 2 C.1 hour recovery at 25 +/- 2 C at 50 % relative humidity.The following conditions shall be basis for rejection:1. Any evidence of blistering or dulling 2. Evidence of loss of adhesion.ENGINEERING MATER
35、IAL SPECIFICATIONWSS-M16J18-AWP 3948-b Page 7 of 11 3.8 WEATHERING REQUIREMENTSCoat and process plastic panels per Table 2. Expose the panels asfollows:3.8.1 Ultraviolet light absorber loss rate.Coat and process clear polycarbonate, GE Plastic s Lexan Resin41, color 111, 0.0625 i nch thick panels pe
36、r Table 2. Measurein itial ultraviolet absorbance spectrum from 450 nm to 250nm. Perform accelerated weathering per SAE J1960 with thefo llowing modification: Use type S borosilicate inner andouter filters, 0.55 W/m2 irradiance intensity. Measure andrecord ultraviolet absorbance spectra at the sam e
37、 spot on thete st plaque at the following exposure intervals; 250, 500,750, 1000, 1500, and 2000. Record and report the absorbancespectra, and the ultrav iolet light absorber loss rate at thewavelength of the absorber maximum as a function of exposure.On an identical set of panels, perform and repor
38、 t the resultsof the adhesion test (ASTM D 3359, Method B, 13 cm2 of 3M898-2 tape) at each exp osure interval. In addition, performand report the results of the following measurements at eachexposure interval: haze (ASTM D 1003), and yellowing (ASTM D1925), and visual assessment of any microcracking
39、.Co at five polycarbonate panels, of the same polycarbonatetype as lens products, with the hardcoat minus any uv-absorber s, and process under the conditions of Trial 13 inTable 2. Measure initial yellow index (ASTM D 1925), haze(AST M D 003), and perform an adhesion test per ASTM D 359,Method B, wi
40、th 13 cm2 of 3M 898-2 tape. After t he tape pull,abrade the surface with # 000 steel wool to highlight theareas of loss of adhesion. Perform accelerated w eathering perSAE J1960 with the following modifications: type Sboros ilicate inner and outer filters, and 0.55 W/m2irradiance intensity. Measure
41、and record yellow index, haze,and adhesion a the foll owing intervals: 250, 500, 750, 1000,150 0, and 2000 hours, and at intervals of 500 hoursthe reafter until the coating or the coating interface haslost integrity, yellow index is in excess of 15, or haze isin excess of 20 %.Use an uncoated GE Pla
42、stics Lexan Resin 141, col or 111, panelas control; measure initial and exposed ultravioletabso rbance spectra from 450 nm to 250 nm at 250, 500, 750,1000, 1500, and 2000 hours.The uv-absorber depletion rate, the initial coatingabsor bance, and the results from the controls will helppredict the coat
43、ing useful lifetime. Predicted usefullifetime will be used to provide conditional app roval pendingthe results of para 3.8.2, and subsequently, par a 3.8.1. Theresults from para 3.8.2 will take precedence over predicteduseful lifetime.ENGINEERING MATERIAL SPECIFICATIONWSS-M16J18-AWP 3948-b Page 8 of
44、 11 3.8.2 Florida Exposure 12, 24, 36, 48, 60, and 84 months(SAE J 576) at 45 deg direct facingsouth 60 month exposure must meetacceptance criteria defined in para3.8.3.3.8.3 Accelerated Weathering Xenon Arc Apparatus 1000, 2000, 4000,(SAE J1960 with the following 6000, 7200, andmodification: Use ty
45、pe S borosilicate 10,000 hoursinner and outer filters, 0.55 W/m2irradiance intensity)Condition for acceptance: 7200 hours xenon arc exposure.EMMA (NTW) Weathering in Arizona 250, 500, 750,(SAE J 1961, Cycle 1) 1000, 1250, and1500 MJCondition for acceptance: 1250 MJ EMMA (NTW) exposure.Test acceptanc
46、e criteria: The panel surface when viewedwithout magnification shall not exhibit coating delamination,cr acking, checking, or blistering. In addition, the colorexpressed as units of t he Yellowness Index (YI) specified inASTM D 1925 (see paragraph 3.6.1). shall not exceed a valueof + 8.00 at the end
47、 of the exposure period. The panel shallpass adhesion according to ASTM D 3359, Method B, 13 cm2 of3M 898-2 tape, figure 4b or better. The panel shall exhibitless than 7 % increase in Haze per ASTM D 1003. Yellownessindex and haze measurements shall be taken at threeident ically spaced locations alo
48、ng the long axis of thepanel. Report the individual measurements and th e average foreach panel.3.9 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to making any change in
49、the properties, composition,constr uction, color, processing or labeling of the materialorig inally approved under this specification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the Supplier shall notify Purchasing, Toxicology andthe affected Materials Engineering activity of the proposed changesand obtain written approval of the Materials Engineering activity.Test da ta, test samples and a new code identification are tosubmitted with the request.ENGINEERING MATERIAL SPECIFICATIONWSS-M16J18-AWP 3948-b Page 9 of
