1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2005 04 05 Activated R. Harris Printed copies are uncontrolled Copyright 2005, Ford Global Technologies, LLC Page 1 of 8 PAINT PERFORMANCE, RIGID SUBSTRATES, EXTERIOR WSS-M2P180-B 1. SCOPE This specification defines the performance of a multi-
2、layered paint system required for all exterior rigid body sheet metal and all exterior rigid body parts where best appearance and highest durability are required. This system is specified for assembly plants, component suppliers and refinish repair. 2. APPLICATION This specification was released ori
3、ginally to define paint performance of exterior surfaces and define the performance requirements for a complete service refinish paint system. It is specified for vehicle bodies, hoods, fenders and other exterior parts visible after assembly. This specification is applicable to all surfaces outboard
4、 of the weather-strip. 3. REQUIREMENTS Terminating exterior edges visible after assembly shall conform to the full requirements of this specification. In-department, pre-delivery and refinish paint repairs shall meet the requirements of this specification. Effective for 2007 model year and beyond, a
5、ll paint applicators must meet the Exterior Parts Painter Approval Process (AVP-T113-015). Applicable to North America only. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1
6、111-A). 3.2 SYSTEM COMPONENTS 3.2.1 Substrates Auto body steel, aluminum, pre-coated or electroplated zinc or zinc alloy coated steel and zinc die casting or as specified on Engineering Documents. Rigid polymers and rigid polymer blends, SMC, ABS, etc. with a flex modulus (ASTM D 790, Method 1) typi
7、cally greater than 1250 MPa. 3.2.2 Substrate Condition The surface to be coated must be cleaned by an automated process to ensure the absence of oil or alkaline residues, fingerprints, corrosion, mold release agents, dirt, moisture, and other foreign materials. ENGINEERING MATERIAL SPECIFICATIONWSS-
8、M2P180-B Printed copies are uncontrolled Copyright 2005, Ford Global Technologies, LLC Page 2 of 8 3.2.3 Paint System Requirements Substrate Pre-treat Prime Topcoat Cold rolled steel Precoated steel Electroplate zinc Zn alloy coated steel Aluminum Zinc Phosphate WSS-M3P1-D Cathodic Electrocoat/ Prim
9、er, Surfacer WSS-M64J39-A/ ESB-M6J141-A Or current production Basecoat/ Clearcoat WSS-M33J3-D1 Or current production Thermoset Polymers SMC, BMC, DMC, etc. Current production, as applicable Primer, Surfacer ESB-M6J141-A Or current production Basecoat/ Clearcoat WSS-M33J3-D1 Or current production The
10、rmoplastic Polymers ABS, PC/ABS PA, PA/PPE, etc. N/A Primer, Surfacer If necessary ESB-M6J106-C Or current production Basecoat/ Clearcoat ESA-M16J9-A1 Or current production Zinc phosphate coating per WSS-M3P1-D shall be used if steel and aluminum parts are processed concurrently and the aluminum tol
11、erance of the process used shall not be exceeded. When necessary in order to meet the requirements of this specification, an adhesion promoter and/or primer surfacer must be used as specified on Engineering Documents. Primer must be applied over cathodic e-coat. 3.2.4 Repairs, In-Department and Pre-
12、delivery Repaired areas must meet the requirements of this specification. All repair materials and processes used should be approved by the affected Product Materials Activity. Maximum film thickness and/or number of repairs for repaired parts will be specified in the mutually agreed control plan an
13、d conform to para 3.3.6. 3.2.5 Finished Parts Testing must be conducted on actual production parts. Where part dimensions limit equipment access, representative panels run through the production processes may be substituted for production parts. These panels shall be processed together with parts an
14、d shall be representative of the parts with respect to substrate, phosphate coating, primer thickness, sanding, enamel thickness, and processing. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-B Printed copies are uncontrolled Copyright 2005, Ford Global Technologies, LLC Page 3 of 8 3.3 FILM PROPERTI
15、ES 3.3.1 Color As determined by (FLTM BI 109-01 Visual Assessment) Color Harmony team (SAE J1545, Three-Angle CMC) Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. 3.3.2 Gloss (FLTM BI 110-01) As released by Corporate Design: (Use as a guide) A:
16、20 Glossmeter, min 92 B: 60 Glossmeter 76 - 84 C: 60 Glossmeter 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 3.3.3 Hardness Shall be sufficien
17、tly cured after baking to withstand normal handling and shipping without damage. Properly cured paint finish shall be hard enough to dry sand easily with 360 grit paper without gumminess or severe scratching. 3.3.4 Polishing A and B Gloss surfaces shall be capable of being sanded with 1200 grit or f
18、iner and polished. No noticeable change in gloss or appearance except for a min of polishing lines shall result. Deep polishing lines or swirl marks are not acceptable. 3.3.5 Film Thickness, min (FLTM BI 117-01, Metallic Substrates, PELT or equivalent) (ASTM B 487, Non-Metallic Substrates, PELT or e
19、quivalent) Coating thickness must be sufficient to meet all requirements of this material specification. Refer to applicable materials specifications and will be specified on the mutually agreed upon control plan. 3.3.6 Film Thickness, max (FLTM BI 117-01, Metallic Substrates, PELT or equivalent) (A
20、STM B 487, Non-Metallic Substrates, PELT or equivalent) The finished unit, part, or test specimen shall not exceed 350 micrometers total film thickness. There shall be no more than 3 in-department repairs. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-B Printed copies are uncontrolled Copyright 2005,
21、 Ford Global Technologies, LLC Page 4 of 8 3.4 RESISTANCE PROPERTIES 3.4.1 Paint Adhesion, max Grade 1 (FLTM BI 106-01, Method B) 3.4.2 Water Resistance 240 h (FLTM BI 104-01)No blistering, dulling, softening, loss of adhesion, and/or any other film failure. Adhesion shall be tested according to par
22、a 3.4.1 within 20 minutes after removal from water. 3.4.3 Humidity Resistance 240 h (FLTM BI 104-02, Method A) No blistering, dulling, softening, and/or loss of adhesion. Adhesion shall meet the requirements of para 3.4.1. 3.4.4 Corrosion Resistance, max 60 cycles (Metallic Substrates) (FLTM BI 123-
23、03 except scribe as in FLTM BI 123-01, ASTM D 610) 3 mm maximum scribe creepage No more face corrosion than grade 6, ASTM D 610. 3.4.5 Fluid Spotting Resistance (FLTM BI 113-01) Test Fluids: (Current production factory fill materials, Motorcraft products or equivalent) Liquid Soap Windshield Solutio
24、n Neat and at a 30% concentration in deionized water. Coolant Solution Neat and at a 30% concentration in deionized water. Motor Oil Bug 0.5% phosphoric acid; hydrochloric acid of 0.4 N (c 0.2%); nitric acid of 0.1% and additionally a solution in water of 0.75% CaSO4adjusted to a pH of 4; deionized
25、water and tap water, bee dropping mixture (47 g Formic Acid, 24 g Tannic Acid 10% in H2O, 24 g Honey, and 5 g Albumin 10% in H2O). Apply 0.05 mils of specified solutions along the entire length of 2 test panels. Place on gradient bar (38 - 82 C, calibrated for heat-up rate of 2 minutes or less for 0
26、.10 mm steel substrate). Remove one panel after 15 minutes temperature, other after 30 minutes. Rinse any remaining solution with water. Examine panels for etching, discoloration, pitting, etc. Report etch-free temperature for test material and control. 3.4.7 Fuel Resistance (FLTM BO 101-05) Fuel Co
27、mposition (FLTM AZ 105-02, ASTM D 471/ISO 1817) by Volume: 1) Reference Fuel F = (diesel fuel, Grade #2, 100%) 2) Reference Fuel I = CM15 3) Reference Fuel K = CM85 After 5 minute recovery time, no color change in excess of Gray Scale rating 4 - 5 (AATCC Evaluation Procedure 1/ISO 105-A02), dulling,
28、 surface distortion or permanent softening permitted. Adhesion shall meet the requirements of para 3.4.1. 3.4.8 Mar/Scratch Resistance A & B Gloss Materials 70% Gloss retention (FLTM BI 161-01) A & B Gloss Materials Fracture Load 8.0mN Nano Scratch Test (DVM-0058-PA) Deformation 0.40m C - J Gloss Ma
29、terials Rating 1 at 2N (FLTM BN 108-13, 1 mm Dia. Ball) scratch mark 3.4.9 Chip Resistance, max 3.4.9.1 Grit Blast, Split Shot Rating 4 (FLTM BI 157-06) ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-B Printed copies are uncontrolled Copyright 2005, Ford Global Technologies, LLC Page 6 of 8 3.4.9.2 St
30、one Chip (SAE J400, -18 C +/- 2 & 23 +/- 2 C) 1.4 L Gravel Rating 7B (0.6%) 4.7 L Gravel Rating 4B (5.0%) Chipping is identified as intercoat adhesion loss between any adjoining layers revealing dis-similar colors, scuffing is acceptable. Topcoat systems to be tested will include: - first run panel
31、- first run plus one in-line repair - first run plus two in-line repairs - first run plus three in-line repairs Panels will be rated versus the current production system following the same layering scenarios and must be equal to or better than current production materials. 3.4.10 Environmental Cycli
32、ng 3 Cycles (FLTM BQ 104-07, Procedure 5) Evaluation after 20 h conditioning at 23 +/- 2 C. No evidence of cracks, no blistering, no change in appearance or other failure when compared with an original unaged part. Adhesion shall meet the requirements of para 3.4.1. 3.4.11 High Performance Adhesion
33、3.4.11.1 Resistance Against High Pressure Cleaner No Removal, NA only (FLTM BO 160-04, Method B) 2 mm2max, Euro Prior to testing the painted surface shall be X-scribed through to the substrate (30 angle). The test must be performed on the X-scribe. 3.4.11.2 Thermal Shock (alternate method) No loss o
34、f adhesion (FLTM BI 107-05) to the substrate or between film layers permitted. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-B Printed copies are uncontrolled Copyright 2005, Ford Global Technologies, LLC Page 7 of 8 3.5 WEATHER RESISTANCE Note: Accelerated Weathering is only to be considered if, for
35、 Engineering concurred special reasons, no Florida results are available. Under such circumstances comparative testing only is allowed against materials of known Florida stability with an identical chemical type of resin. In case of differences in the test results of Florida exposure and the acceler
36、ated weathering the results of the Florida exposure shall prevail. The panels shall be completely free from evidence of cracking, checking, rusting, blistering, and peeling. Both original and repair shall alter in color, tone and gloss to the same degree in the same direction. Only the slightest col
37、or change is permitted. These samples shall show no color change, or iridescence in excess of specified AATCC rating (AATCC Grey Scale for Evaluating Change in Color, 10 step). The film shall be free from mildew and show a minimum of dirt retention. Wash panels from exposure per FLTM BI 160-01, B, 1
38、. Clean exposure panels will be placed in a deionized water bath for 24 h per FLTM BI 104-01. After panels are removed from water bath and thoroughly blown dry, an “X“, to be located at the center of the panel and 50 mm from the bottom, is scribed. The “X“ shall be 30 mm in height and 20 mm wide. Ta
39、pe the “X“ with 3M 898-2 tape and check for peeling and delamination between any layers. There shall be no blistering or delamination of any of the coating layers. 3.5.1 Natural, Exposure Time 1 & 2 yr submission (SAE J1976, Procedure A) 3.5.1.1 Color Change, min Rating 4 (AATCC Evaluation Procedure
40、 1/ ISO 105-A02) 3.5.1.2 Gloss Change, max 25% (FLTM BI 110-01) 3.5.1.3 “X“ scribe tape pull adhesion, min retention 90% 3.5.2 Accelerated Weathering, New Colors 3000 h required (SAE J1960, 0.55 W/m2Irradiance, Borosilicate inner and outer filters, 3.5.2.1 Color Change, min Rating 4 (AATCC Evaluatio
41、n Procedure 1/ ISO 105-A02) 3.5.2.2 Gloss Change, max 25% (FLTM BI 110-01) 3.5.2.3 “X“ scribe tape pull adhesion, min retention 90% ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-B Printed copies are uncontrolled Copyright 2005, Ford Global Technologies, LLC Page 8 of 8 3.6 PROCESS WINDOW DEFINITION T
42、he supplier shall perform a DOE utilizing response surface analysis to determine the Process Window of the system. 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
43、 a window which includes testing to failure. This screening experiment should be reviewed with the Materials Engineer to set up the final DOE. Response attributes to the DOE should be based on the materials tested and should be chosen from the following tests: adhesion (para 3.4.1), water resistance
44、 (para 3.4.2), stone chipping (para 3.4.9), and high performance adhesion (para 3.4.11). 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 QMS TARGET VALUES, min Material Horizontal Vertical Dark Met
45、allics 65 55 Light Metallics 60 50 Light Solids BC/CC 65 55 Dark Solids BC/CC 67 57 Light Solids 60 50 Dark Solids 65 55 4.2 WAVESCAN TARGET VALUES, max (BYK-Gardner or equivalent) du 15 Structures 0.1 mm wavelength Wa 15 Structures from 0.1 0.3 mm wavelength Wb 30 Structures from 0.3 1 mm wavelength Wc 20 Structures from 1 3 mm wavelength Wd 20 Structures from 3 10 mm wavelength We 20 Structures from 10 30 mm wavelength
