1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2004 02 12 Activated M. Ward Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 1 of 5 CORROSION PROTECTIVE COATING, ZINC RICH INORGANIC BASECOAT, WSS-M21P42-A1 LUBRICATED ALUMINUM RICH ORGANIC TOPCOAT, SILVER C
2、ORROSION PROTECTIVE COATING, ZINC RICH INORGANIC BASECOAT, WSS-M21P42-A2 LUBRICATED ORGANIC TOPCOAT, BLACK CORROSION PROTECTIVE COATING, ZINC RICH INORGANIC BASECOAT, WSS-M21P42-A3 LUBRICATED INORGANIC TOPCOAT, CLEAR 1. SCOPE The materials defined by these specifications are corrosion protective coa
3、tings over steel. They consist of a high zinc and aluminum flake micro layer forming basecoat, with an organic, cross linked, micro layer forming topcoat with an integral lubricant in silver and black for A1 and A2. The A3 topcoat is an aqueous, inorganic sealing system that provides increased heat
4、resistance; these coating systems all provide enhanced corrosion protection, color and/or consistent torque-tension control. They are free of chromium, nickel, lead and cadmium. 2. APPLICATION These specifications were released originally for materials used for corrosion protective coatings over ste
5、el. Since the process does not induce hydrogen embrittlement, these coatings are suitable for high hardness parts. The cure temperature for the zinc-rich basecoat is 220 C to 240 C and 200 C to 220 C for the topcoat. These coatings shall not be specified if this temperature adversely affects the com
6、ponent being coated. These coatings provide good bi-metallic corrosion resistance when in contact with aluminum. They should not be applied to parts in contact with uncoated copper, magnesium or stainless steel surfaces. 2.1 SERVICE TEMPERATURE The maximum recommended continuous service temperature
7、resistance is 260 C. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 LICENSEE APPLICATOR QUALITY REQUIREMENTS Applicators must follow coating man
8、ufacturer procedures and recommendations for chemical usage, equipment and processing. ENGINEERING MATERIAL SPECIFICATIONWSS-M21P42-A1/A2/A3 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 2 of 5 3.2 MATERIAL PERFORMANCE 3.2.1 Raw Material Storage Stability The mat
9、erial must be capable of being stored at 23 +/- 2 C for 60 days without detrimental effect to the performance of the coated parts. 3.2.2 Cleaning Prior to coating, the parts shall be free of oil, scale, and similar foreign materials. The cleaning process shall have no detrimental effect on the subst
10、rate, including freedom from embrittlement. The primary cleaning process will include fine grain zinc phosphate with a coating weight of 3 - 4 g/m. Alternative cleaning techniques may be required for some materials/parts such as parts made of powdered metal, austempered spring clips, and some intern
11、ally threaded fasteners. Each exception must be recorded in the applicators control plan and approved by the coating manufacturer. 3.2.3 Curing The basecoat is typically cured at a metal temperature of 220 C to 240 C and the topcoat at 200 C to 220 C. The coating shall not be used on materials that
12、are adversely affected by these metal temperatures. Parts must be sufficiently cured at the time of packing to withstand normal handling and shipping without marring. 3.2.4 Finished Condition Parts must be dry to touch such that, when held with a Watmans No.41 filter paper, or equivalent, and applyi
13、ng hand pressure for 5 to 10 seconds, there shall be no visible staining of the filter paper when viewed without using supplementary magnification. For referee purposes this test shall be carried out using a force of 10N. 3.2.5 Appearance The coating shall be uniform in color and free from discontin
14、uities when viewed without magnification. 3.2.6 Storage Life Parts supplied shall still meet the specific requirements of this specification 6 months after receipt by Ford when stored at 5 to 28 C with no direct heat or sunlight. 3.3 ADHESION The cured coating shall withstand normal handling, storag
15、e and installation without flaking or peeling or other loss of adhesion. Parts heated to 120 C for 60 minutes shall not exhibit blistering, peeling, flaking or coating which can be removed by a filament type tape, such as 3M No. 898-2. The testing of coating quality by salt spray and/or determinatio
16、n of coating thickness will be performed on parts passing the adhesion test. ENGINEERING MATERIAL SPECIFICATIONWSS-M21P42-A1/A2/A3 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 3 of 5 3.4 RESISTANCE PROPERTIES 3.4.1 Corrosion Resistance (SAE/USCAR-1, ASTM B 117,
17、ASTM D 610, WX100) Fasteners shall be tested and evaluated in accordance with SAE/USCAR-1, and shall pass the number of hours specified in Table 1 and the General Requirements of WX100. Parts other than fasteners shall be tested in accordance with ASTM B 117. Parts shall show no single ferrous corro
18、sion spot larger than 1.5 mm in diameter, and shall not exhibit ferrous corrosion overall exceeding 0.1%, per ASTM D 610, grade 8, after the number of test hours specified in Table 1. 3.4.2 Corrosion Resistance Fasteners shall be tested in accordance to N.S.S. and APGE requirements specified in Tabl
19、e 1. 3.4.3 Water Resistance (FLTM BI 104-01) Shall not blister or show any signs of red rust when subjected to immersion in water for 240 hours. 3.4.4 Gasoline Resistance Shall not blister or show any signs of softening or dulling when subjected to immersion in current factory fill gasoline for 24 h
20、ours at 23 +/- 2 C. 3.4.5 Hot Oil Resistance Shall not blister or show any signs of softening or dulling when subjected to immersion in engine oil (SAE 10W30 per WSE-M2C903-A2 or equivalent) for 24 hours at 66 +/- 3 C. 3.4.6 Ethylene Glycol Resistance Shall not blister or show any signs of softening
21、 or dulling when subjected to immersion in a 50% solution of water and long life coolant concentrate (WSE-M97B44-B or equivalent) for 24 hours at 23 +/- 2 C. 3.4.7 Brake Fluid Resistance Shall not blister or show any signs of softening or dulling when subjected to immersion in currently approved bra
22、ke fluid for 24 hours at 23 +/- 2 C. 3.4.8 Power Steering/Transmission Fluid Shall not blister or show any signs of softening or dulling when subjected to immersion in current factory fill power steering and transmission fluid for 24 hours at 66 +/- 3 C. ENGINEERING MATERIAL SPECIFICATIONWSS-M21P42-
23、A1/A2/A3 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 4 of 5 3.5 COATING THICKNESS AND COATING WEIGHT (MASS) (ASTM B 568/ISO 3497, ASTM B 499/ISO 2178) The coating thickness and minimum coating weight are given in Table 1. The coating thickness should be measure
24、d on flat surfaces using a magnetic induction thickness instrument (ASTM B 499/ISO 2178) or by calibrated X-ray fluorescence spectroscopy (ASTM B 568/ ISO 3497), and should be based on an average of at least ten measurements. Alternatively, the thickness of the basecoat can be determined using a wei
25、gh-coat-weigh method. Details of this method are available from the coating manufacturer. 3.6 THREAD ACCEPTANCE REQUIREMENTS (WA900, WE900, WX100) For thread acceptance requirements see Ford Worldwide Fastener Standards WA900, WE900 and WX100. 3.7 TORQUE-TENSION (WZ 101) The coating shall meet the r
26、equired torque and friction coefficient specified in Table 1. ENGINEERING MATERIAL SPECIFICATIONWSS-M21P42-A1/A2/A3 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 5 of 5 TABLE 1 GUIDANCE TO PROPERTIES OF WSS-M21P42-A1/A2/A3 COATING SYSTEMS Specification Color # Co
27、ats (a) Min. Thickness m Min. Ct. Wt. g/m2WZ 101 Torque Nm (b) WZ 101 Friction Coefficient N.S.S. Hrs. Ferrous CorrosionN.S.S. Hrs. Zinc Oxidation APGE Cycles Examples of Part Applications WSS-M21P42-A1 Silver 1 + 1 7 Min. Basecoat 8 10 Typical 5 Min Topcoat 5 8 Typical 28 Min. Basecoat 7.5 Min. Top
28、coat Mean: 46 - 52 3 Sigma: 40 - 58 Mean: 0.14 0.01 3 Sigma: 0.14 0.03 840 240 60 Parts for exterior use requiring lubrication, external threaded Hex Flange fasteners M5 and larger, stampings, brackets, clips, clamps and door strikers WSS-M21P42-A2 Black 1 + 2 7 Min. Basecoat 8 10 Typical 5 Min Topc
29、oat 5 8 Typical 28 Min. Basecoat 17.5 Min. Topcoat Mean: 46 - 52 3 Sigma: 40 - 58 Mean: 0.14 0.01 3 Sigma: 0.14 0.03 840 120 40 Parts for exterior use requiring lubrication and a black appearance, external threaded Hex Flange fasteners M5 and larger, stampings, brackets, clips, clamps and door strik
30、ers WSS-M21P42-A3 Silver 2 + 1 7 Min. Basecoat 8 10 Typical 2 Min Topcoat 2 4 Typical 28 Min. Basecoat 4 Min. Topcoat Mean: 46 - 52 3 Sigma: 40 - 58 Mean: 0.14 0.01 3 Sigma: 0.14 0.03 840 240 60 Parts for exterior use requiring lubrication, external threaded Hex Flange fasteners with captive washers M5 and larger, stampings, brackets, clips, clamps and door strikers NOTE: (a) NUMBER OF COATS ARE FOR DIP-SPIN APPLIED COATINGS AND MAY BE DIFFERENT DUE TO PROCESS. (b) BASED ON WZ101 TEST PROGRAM B.
