1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 07 31 Activated J. Robincheck Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 11 PAINT, ONE COMPONENT BASECOAT/CLEARCOAT WSS-M16J9-B2 OVER RIGID SUSTRATES, EXTERIOR PAINT, TWO COMPONENT BASECOAT/CLE
2、ARCOAT WSS-M16J9-B3 OVER RIGID SUSTRATES, EXTERIOR 1. SCOPE The materials defined by these specifications are paints, which consist of a basecoat and clear topcoat applied by a baked process. These materials are monobaked. Unique tricoat colors are also included in this specification. Tricoat colors
3、 consist of a pigmented groundcoat followed by a non-hiding midcoat over which is applied a clear or tinted clear. Paint systems may be processed wet-on-wet application and monobaked, or paint may be baked between wetcoats. 2. APPLICATION These specifications were released originally for paints used
4、 as the final topcoat on exterior trim components made of rigid substrates, such as spoilers, appliqus, mirror housings, handles, roof racks, running boards. It shall be satisfactory for use over specified primers or over previously baked enamel, as in paint repair or tutone operations. 2.1 LIMITATI
5、ONS Bake temperature should not exceed softening temperature of substrate material as agreed upon by Ford Materials Engineering. 2.1.1 One Component, Basecoat/Clearcoat, Exterior Paint Systems for Rigid Substrates already approved to WSS-M33J7 do not need to retest to WSS-M33J11-B1. 3. REQUIREMENTS
6、Testing to be used for initial qualification of materials and shall be made on the basis of comparison with approved production material, chosen by the approving materials engineer. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys
7、Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 COMPOSITION Both the basecoat and clearcoat contain UV absorbers. The supplier will furnish the specific composition and concentration of the absorbers upon request. 3.2.1 Resin Shall be either a polyester, acrylic, modified uretha
8、ne polymer or a polyurethane. Minor amounts of modifiers and/or plasticizers are allowed. ENGINEERING MATERIAL SPECIFICATIONWSS-M16J9-B2/B3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 11 3.2.2 Pigments Pigments are exterior automotive grade selected to mat
9、ch the Ford Motor Company master and meet the durability requirements. 3.2.3 Solvents The volatility of solvents will be such that there shall be no paint sagging, roughness or dry spray at specified film thicknesses. Solvents shall be HAPS compliant if it is required by local government regulations
10、 3.3 PHYSICAL PROPERTIES LIQUID STATE The following evaluation must be conducted on both the basecoat and clearcoat application viscosity. Throughout the application viscosity range, material shall be in compliance with local emission regulations. Property variation acceptability as identified below
11、, shall be based on the recorded values of the originally approved production sample as approved by Ford Materials Engineering. This data will be used in developing control plan requirements. 3.3.1 Non-Volatile Content, range Initial sample +/- 4% (ASTM D 1353) 3.3.2 Volatile Organic Compound, range
12、 Initial sample +/- 1% (ASTM D 3960) 3.3.3 Weight per Volume, range Initial sample +/- 0.03 g/ml (ASTM D 1475) 3.3.4 Volume Solids, range Initial sample +/- 2.0% (ASTM D 2697) 3.3.5 Viscosity Report (ASTM D 1200) 3.3.6 Stability No more than 30% (ASTM D 1849) viscosity increase permitted. 3.3.6.1 Sh
13、elf Stability, 90 days 3.3.6.2 Accelerated Stability, 60 C, 16 h 3.3.7 Resistivity 0.005 to 2.00 megohms (ASTM D 5682) Volatile solvents and other components affecting electrical conductivity shall be adjusted such that the resistivity at application viscosity shall be within specified limits. ENGIN
14、EERING MATERIAL SPECIFICATIONWSS-M16J9-B2/B3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 11 3.4 PREPARATION OF TEST PANELS 3.4.1 Substrates Auto body steel, aluminum, pre-coated or electroplated zinc or zinc alloy coated steel and zinc die casting or as sp
15、ecified on Engineering Document. Rigid polymer and rigid polymer blends, SMC, ABS, PPO, etc. with a flex modulus (ASTM D 790, Method 1) typically greater than 1750 MPa. 3.4.2 Substrate Condition The surface to be coated must be cleaned to ensure the absence of oil or alkaline residues, fingerprints,
16、 corrosion, mold release agents, dirt, moisture, and other foreign materials. Surface energy/resistivity or chemical reaction(s) enhancements (flaming, corona discharge or plasma) and/or addition of conductive materials, necessary to meet the requirements of this specification, shall be specified on
17、 Engineering Documents 3.4.3 Electrocoat For metallic substrates requiring e-coat, apply 20 - 23 m and bake 10 minutes at 182 C metal temperature or as otherwise recommended. Record e-coat and oven type used. 3.4.4 Primer Apply 17 - 24 m DFT (Dry Film Thickness) of the primer or as otherwise recomme
18、nded, as specified for the substrate. 3.4.5 Basecoat/Clearcoat Apply basecoat to required dry film thickness by spray under conditions appropriate for basecoats, and flash as required. Apply clearcoat to required dry film thickness. Bake using appropriate bake schedule. Record paint and oven type us
19、ed. (As developed by para 3.5). 3.4.6 Design Verification/Initial Qualification Test Requirements as listed in Table 1 3.4.7 Aging After application of the top coat, all panels shall be aged at least 72 h at 23 +/- 2 C, 50 +/- 5% relative humidity or 16 hours at 45 +/- 1 C before testing. ENGINEERIN
20、G MATERIAL SPECIFICATIONWSS-M16J9-B2/B3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 11 3.5 PROCESS WINDOW DEFINITION - NEW RESIN TECHNOLOGIES ONLY The supplier shall perform a DOE utilizing response surface analysis to determine the Process Window of the s
21、ystem. The three variables to be included in the design are Bake Time, Bake Temperature, and Film Thickness. An initial screening experiment should be run to determine what level will generate a window which includes testing to failure. This screening experiment should be reviewed with the Materials
22、 Engineer to set up the final DOE. Response attributes to the DOE should be based on the materials tested and should include, but not be limited to: Film Thickness (Para 3.6.3, 3.6.4) Ultraviolet Light Transmittance (Para 3.6.5) Adhesion (Para 3.7.1) Water Immersion (Para 3.7.2) Chipping (Para 3.7.8
23、) Environmental Cycling (Para 3.7.9) High Performance Adhesion (Para 3.7.10) Report minimum, maximum, and target values for time, temperature, and film thickness. 3.6 FILM PROPERTIES 3.6.1 Color (FLTM BI 109-01, SAE J1545 Three Angle CMC) Shall match the Master Approved Sample color panel or the ini
24、tial sample as approved by Design Center. 3.6.2 Gloss (FLTM BI 110-01, ASTM D 523) Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. 3.6.2.1 Gloss After Rebake, max 4 unit decrease Rebake panel at target bake conditions per Para 3.5. 3.6.3 Film Th
25、ickness, min Report (FLTM BI 117-01, Metallic Substrates, PELT or equivalent, ASTM B 487, Non-Metallic Substrates, PELT or equivalent) Target values shall be defined from process window (Para 3.5) and must be sufficient to meet all requirements of this Specification. Will be specified on the mutuall
26、y agreed upon control plan. 3.6.4 Film Thickness, max Report, not to exceed (FLTM BI 117-01, Metallic Substrates, PELT or equivalent, 350 micrometers ASTM B 487, Non-Metallic Substrates, PELT or equivalent) There shall be no more than 3 in-department repairs. ENGINEERING MATERIAL SPECIFICATIONWSS-M1
27、6J9-B2/B3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 11 3.6.5 Ultraviolet Light Transmittance For each color, report the minimum film build of basecoat and of clearcoat over epoxy-free spray primer required to meet a maximum light transmission of no more
28、than 0.1% at 360 nm and 0.5% at 400 nm. Fortified (with UV package) clearcoat can be used for this evaluation. The equipment used for this measurement is an integrating sphere spectrophotometer or equivalent. These values shall be used to help determine minimum film thickness for the process window
29、in section 3.5. 3.6.6 General The paint shall bake out to a presentable serviceable film showing no craters, pinholes, seediness, abnormal roughness or excessive metallic mottling. It shall have a reasonable tolerance for ordinary cleaning, and exhibit no dulling or color change when washed with com
30、mercially available cleaners. 3.7 RESISTANCE PROPERTIES 3.7.1 Paint Adhesion, max Grade 2 (FLTM BI 106-01, Method B, carbide tip scribe only) Lightly hand sand paint film surface (10 double rubs, moderate pressure) with P600 paper until dull, before scribe operation and checking adhesion. 3.7.2 Wate
31、r Immersion No blistering, dulling, (FLTM BI 104-01, 240 h) softening, loss of adhesion, and/or any other film failure Adhesion shall be tested according to Para 3.7.1 within 20 minutes after removal from water. 3.7.3 Condensing Humidity Resistance No blistering, dulling, (FLTM BI 104-02, Method A,
32、240 h) softening, loss of adhesion, and/or any other film failure After exposure, adhesion testing performance must be met per Para 3.7.1. 3.7.4 Fluid Spotting Resistance, min Rating 4-5 (FLTM BI 168-01, Method A and B, AATCC Evaluation Procedure 1/ISO 105-A02) Test Fluids: (Body and Exterior Trim u
33、se) No color dulling, surface distortion or permanent softening permitted. After exposure, adhesion testing performance must be met per Para 3.7.1. ENGINEERING MATERIAL SPECIFICATIONWSS-M16J9-B2/B3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 6 of 11 3.7.5 Acid
34、Resistance Equal or better than (FLTM BI 113-01 except at 60 and current production 80 C for 30 minutes) material The following solutions shall be tested on candidate materials: Sulfuric acid (H2SO4) adjusted to pH of 2 Phosphoric acid (H3PO4), 0.5% Bee dropping mixture (47 g Formic Acid, 24 g Tanni
35、c Acid 10% in H2O, 24 g Honey, and 5 g Albumin 10% in H2O). Apply specified solutions 2 test panels. Place one each in preheated ovens at 60 and 80 C, respectively. Remove after 30 minutes. Rinse any remaining solution with water. Examine panels for etching, discoloration, pitting, etc. Report etch-
36、free temperature for test material and control. 3.7.6 Mar Resistance A AATCC Evaluation procedure 1: Rating 4 max Gloss Change per ASTM D 523 25% loss max Color Change per FLTM BI 109-01 E 2.0 max After 5 years Florida exposure or 5000 h accelerated weathering: AATCC Evaluation procedure 1: Rating 3
37、 max Gloss Change per ASTM D 523 50% loss max Color Change per FLTM BI 109-01 E 5.0 max 3.8.3.2 Adhesion After Water Immersion 90% adhesion (FLTM BI 104-01, 24 h) retention There shall be no blistering or delamination between any layers of the total paint system. To be evaluated on all exposure inte
38、rvals. 3.8.4 Basecoat/Clearcoat Durability Index (DVM 5869 - New Resin Technology Only) (TBC/1250) + (X/2000) greater to or equal to 8 X = TICC if TICC is less than 1.2(TCC) otherwise X = TCC. Method to Determine: TBC Stability of UVA free basecoat/clearcoat interface Report TBC (Stability of UVA fr
39、ee basecoat/clearcoat interface) Defined as the time for clearcoat delamination failure for each color. If the color has not failed by 5000 h, TBC = 5000 ENGINEERING MATERIAL SPECIFICATIONWSS-M16J9-B2/B3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 9 of 11 TICC
40、Time to zero UVA absorbance using isolated clearcoat film. (FLTM AI 103-02, Method A) Prepare quartz slides with clearcoat only. Adjust clearcoat thickness to obtain a starting absorbance (340 nm region) of 2 2.5 after nominal clearcoat bake. Measure clearcoat thickness in micrometers. Calculate abs
41、orbance per micrometer. Correct for absorbance using 100% theoretical mixing of basecoat and clearcoat UVA. Evaluate clearcoat UVA absorbance using a UV-VIS spectrophotometer. Observe the UV spectrum from 450 250 nm. Determine maximum 340 nm region absorbance on initial (baseline) sample and after 1
42、000, 3000 and 5000 h exposure to Xenon Arc weatherometer (SAE J2527, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure. Plot absorbance as a function of exposure time to determine absorbance loss rate (absorbance loss per hour). Calculate TICC (time to zero UVA a
43、bsorbance using isolated clearcoat film) followed by the equation: 1(absorbance/micrometer)(clearcoat film thickness)/(absorbance loss rate) = hours to clearcoat absorbance equals zero. TCC Time to zero UVA absorbance using full paint system. (FLTM AI 103-02, Method B) Remove clearcoat from the samp
44、le (avoid basecoat layer) with a razor or equivalent scraping device or by in-plane microtomy. Using either solvent extraction from the scraping method or direct measurement with a UV microscope and summing the layers, and evaluate clearcoat UVA absorbance using a UV-VIS spectrophotometer. Observe t
45、he UV spectrum from 450 250 nm. Determine absorbance on initial (baseline) sample and after 1000, 3000 and 5000 h exposure to Xenon Arc weatherometer (SAE J2527, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure). Plot absorbance as a function of exposure time to
46、 determine UVA loss rate (absorbance loss per hour). Extrapolate UVA loss rate plot to zero absorbance. Determine the exposure hours at zero clearcoat UVA absorbance. Report as TCC. 3.8.5 Clearcoat Photo Oxidation 2.5 max change in (DVM 5867 - New Resin Technology only) (-OH,-NH / CH) ratio Method:
47、Photochemical stability is determined by a comparison of the chemical state change of the topcoat surface before and after exposure to 5000 h Xenon Arc weatherometer (SAE J2527, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure). Evaluate the topcoat photo oxidat
48、ion stability using Fourier Transform Infrared Photo-Acoustic Spectroscopy (FTIR-PAS). Obtain spectra of the surface layer of topcoat, approximately the top 7 micrometers, experimentally defined as the photo-acoustic sampling depth by modulation at 3 kHz at 3000 wavenumbers in a rapid scan FTIR-PAS
49、experiment or 3 kHz phase modulation in a step scan FTIR-PAS Intensity spectrum, should be a polymer filled with carbon black to at least 50% for a rapid-scan experiment and to at least 65% for a step-scan experiment. Compression set rubber works best. Resolution- laser sampling at every second laser crossing, 4000 data points, 8K transform, triangle apodization, phase corrected. Noise (definition) root mean square (rms) noise in 3600 2500 wavelength region based on two carbon black filled polymer
