1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 10 15 Revised See Summary of Revisions for details Global Paint Team 2007 12 18 Revised Note 2 in Table 1 J. Crist 2007 10 29 Activated J. Crist Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 1 of 10 PA
2、INT PERFORMANCE, RIGID SUBSTRATES, EXTERIOR WSS-M2P180-C 1. SCOPE This specification defines the performance of a multi-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 sp
3、ecified for component suppliers covering all processes including in-department and pre-delivery repairs. 2. APPLICATION This specification was released to define paint performance of exterior parts visible after assembly and is applicable to all surfaces outboard of the weatherstrip. 3. REQUIREMENTS
4、 Material Specification requirements are to be used for initial qualification of materials. All parts must also meet the appropriate DVP & R and Subsystem Design Specification requirements. Terminating exterior edges visible after assembly shall conform to the full requirements of this specification
5、. Any localized post mold operations (Flame Treating, Sanding,) prior to painting requires the additional testing as noted in the last column of Table 1. In-department, pre-delivery and refinish paint repairs shall meet the requirements of this specification. Parts must conform to the color requirem
6、ents defined by the Ford Color Harmony Team or equivalent. Body color components shall visually match the adjacent body region for orange-peel and waviness. Instrumental measurements such as Wavescan or QMS may be used as a guide if measurement is feasible. Refer to the appearance requirements of th
7、e adjacent body region. Note: For in process color check the preferred method is SAE J1545, three angle CMC (Color Measurement Committee). Effective for 2007 model year and beyond, all paint applicators must meet the Exterior Parts Painter Approval Process (AVP-T113-015) unless waived by Materials E
8、ngineering. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPONENTS 3.2.1 Substrates Auto body steel, aluminum, pre-coated or electroplated zinc or zin
9、c alloy coated steel and zinc die casting or as specified on Engineering Documents. Rigid polymers and rigid polymer blends, SMC, ABS, PC/ABS, ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 10 3.2.2 Substrate Con
10、dition 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. 3.2.3 Paint System Requirements Substrate * Pre-treat Prime Topcoat* Cold rolled steel
11、 Precoated steel Electroplate zinc Zn alloy coated steel Aluminum As Needed to meet process/performance requirements (i.e. Zinc Phosphate or equivalent) Cathodic Electrocoat(Note 2) Primer/Surfacer or equivalent Basecoat/Clearcoat, Monocoats, Powder Coat (Note 3) Thermoset Polymers SMC, BMC, DMC, et
12、c. As applicable to meet Process/Performance Specifications Primer/Surfacer Basecoat/Clearcoat, Monocoats Thermoplastic Polymers As applicable to meet Process/Performance Specifications Primer, Surfacer As applicable to meet Process/Performance Specifications Basecoat/Clearcoat, Monocoats ABS, PC/AB
13、S PA, PA/PPE, etc. As applicable to meet Process/Performance Specifications Primer, Surfacer As applicable to meet Process/Performance Specifications Basecoat/Clearcoat, Monocoats Specified Film Thickness: E-coat 20-23 m (Note 1) Primer/Surfacer 1724 m Monocoat 25-35 m Basecoat/Clearcoat 15-30 m /38
14、-50 m Powdercoat 50-100 m * - Ford Materials Engineering approved materials (Approved Source List) Note 1: These ranges are considered to be requirements unless otherwise supported by testing data agreed to by Materials Engineering. Note 2: Primer must be applied over cathodic e-coat for paint syste
15、m robustness. Note 3: For Powder coatings, Pretreatment & Cathodic E-coat must be used. Zn phosphate is the preferred pretreatment any alternative must be approved by Materials Engineering. Zinc phosphate coating per WSS-M3P1-D shall be used if steel and aluminum parts are processed concurrently and
16、 the aluminum tolerance of the process used shall not be exceeded. Dual phase Zinc phosphate may also be used where production aluminum content exceeds 7%. Control plan must specify if adhesion promoter, and/or anti-chip primer surfacer are required to meet the requirements of this specification. EN
17、GINEERING MATERIAL SPECIFICATIONWSS-M2P180-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 10 3.2.4 Repairs, In-Department and Pre-delivery Repaired areas must meet the requirements of this specification. All repair materials and processes used should be app
18、roved 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 and conform to Para 3.3. All repairs must be with the identical color to the original finish unless approved by Materials Enginee
19、ring 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. If regrind is used, testing at the maximum loading level is required and m
20、ust meet the specification requirement. These panels shall be processed together with parts and shall be representative of the parts with respect to substrate, phosphate coating, primer thickness, sanding, enamel thickness, and processing. When panels are used as a substitute, this must be clearly r
21、eported on the PSW or the laboratory test report. 3.2.6 Aging Test specimens prepared for investigations according to this specification must be aged at least 72 hours at 23 +/- 2 C (preferred) or 16 hours at 45 +/- 1 C prior to testing. 3.2.7 Process/Product Validation Test Requirements as listed i
22、n Table 1. This table is for only Approved paint technologies as shown on Ford Approved Source List otherwise full WSS-M2P180-C specification testing is required. Design Verification Testing (DV) is done on plaques by the paint supplier and is covered in the applicable paint material specification.
23、Product/Process Validation Testing (PV) is done on production painted parts as defined in Table 1. 3.3 FILM PROPERTIES 3.3.1 Color (FLTM BI 109-01 Visual Assessment, SAE J1545, Three-Angle CMC) Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. ENG
24、INEERING MATERIAL SPECIFICATIONWSS-M2P180-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 10 3.3.2 Gloss Report (FLTM BI 110-01, ASTM D 523) As released by Engineering: A: 20 Glossmeter min 92 B: 60 Glossmeter 76 - 84 C: 60 Glossmeter 66 - 74 D: 60 Glossmete
25、r 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: 60 Glossmeter 1.8 - 2.4 Shall match the Master Approved Sample color panel or the initial sample as approved by Des
26、ign Center. 3.3.4 Film Thickness. Min (See Table 1, Note 3) Report (FLTM BI 117-01, Metallic Substrates, PELT or equivalent, ASTM B 487, Non-Metallic Substrates, PELT or equivalent) Coating thickness must be sufficient to meet all requirements of this material specification. Refer to applicable mate
27、rials specifications and will be specified on the mutually agreed upon control plan. 3.3.5 Film Thickness, max 350 micrometers (FLTM BI 117-01, Metallic Substrates, PELT or equivalent, ASTM B 487, Non-Metallic Substrates, PELT or equivalent) There shall be no more than 3 in-department repairs. 3.4 R
28、ESISTANCE PROPERTIES 3.4.1 Paint Adhesion, max (See Table 1, Note 3) 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. 3.4.2 Water Resistance N
29、o blistering, dulling, (FLTM BI 104-01, 240h) softening, loss of adhesion,and/or any other film failure. Adhesion shall be tested according to Para 3.4.1 within 20 minutes after removal from water. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-C Printed copies are uncontrolled Copyright 2008, Ford Gl
30、obal Technologies, LLC Page 5 of 10 3.4.3 Condensing Humidity Resistance Rating 4-5 min (FLTM BI 104-02, Method A, 240h 8.0mN Nano Scratch Test (DVM-0058-PA) Deformation 3mm Dia. first run plus three in-line repairs Rating 3B or 93% Paint (apply 2K repairs, 7 days after retention, no chips prior app
31、lication) 3mm Dia. Chipping is identified as intercoat adhesion loss between any adjoining layers revealing dis-similar colors, scuffing is acceptable. Chipping metrics are obtained by image analysis (Atlas VIEEW software or equivalent). 3.4.10 Environmental Cycling, Total of 15 cycles Rating 4-5 (F
32、LTM BQ 104-07, Procedure 1 or 10, 25% Gloss Loss AATCC Evaluation Procedure 1/ISO 105-A02) No evidence of cracks, no blistering, no change in appearance or other failure when compared with original material approval. After exposure Adhesion testing performance must be met per Para. 3.4.1. 3.4.11 Hig
33、h Performance Adhesion (See Table 1, Note 3) 3.4.11.1 Thermal Shock, Max Rating 19 (FLTM BI 107-05) Alternate method: . 3.4.11.2 Resistance Against High Pressure Cleaner 2 mm2max (FLTM BO 160-04, Method B) Prior to testing the painted surface shall be X-scribed through to the substrate (30 angle). T
34、he test must be performed on the X-scribe. The test method must be noted in initial submission package 3.4.12 Heat Resistance, min Rating 4-5 (7days at 80 +/-2 C, AATCC Evaluation Procedure 1/ 25% Gloss Loss ISO 105-A02) Return to room temperature before evaluation. After exposure Adhesion testing p
35、erformance must be met per Para. 3.4.1. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 7 of 10 3.5 ACCELERATED WEATHERING RESISTANCE 3.5.1 Xenon Weatherometer (SAE J2527, 0.55 W/m2Irradiance, 3000h, Borosilicate inner
36、 and outer filters, Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only ) 3.5.1.1 Color Change, min Rating 4 (AATCC Evaluation Procedure 1/ISO 105-A02, prior to 3.5.1.4) 3.5.1.2 Gloss Change, max 25% (FLTM BI 110-01, prior to 3.5.1.4) 3.5.1.3 “X“ scribe tape pull adhesion, min retention 90% (DV
37、O 7097 pictorial rating scale) 3.5.1.4 Adhesion after Water Immersion 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, i
38、s scribed. The “X“ shall be 30 mm in height and 20 mm wide. Tape the “X“ with 3M 898 tape and check for peeling and delamination between any layers. There shall be no blistering or delamination of any of the coating layers. The panels shall be completely free from evidence of cracking, checking, rus
39、ting, 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 color change is permitted. These samples shall show no color change, or iridescence in excess of specified AATCC rating (AATCC Grey Scale for Eval
40、uating Change in Color, 10 step). 3.5.2 Outdoor Weathering 1 & 2 year submission (SAE J 1976, Procedure A) required for new technology only 3.5.2.1 Color Change, min Rating 4 (AATCC Evaluation Procedure 1/ ISO 105-A02, prior to 3.3.1) 3.5.2.2 Gloss Change, max 25% (FLTM BI 110-01, prior to 3.3.2) 3.
41、5.2.3 “X“ scribe tape pull adhesion, min retention 90% (DVO 7097) ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 8 of 10 3.5.2.4 Adhesion after Water Immersion 24h Exposure panels will be placed in a deionized water b
42、ath 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. Tape the “X“ with 3M 898 tape and check for peeling and delamin
43、ation between any layers. There shall be no blistering or delamination of any of the coating layers The panels shall be completely free from evidence of cracking, checking, blistering, and peeling. Both original and repair shall alter in color, tone and gloss to the same degree in the same direction
44、. Only the slightest color change is permitted. These samples shall show no color change, or iridescence in excess of specified AATCC rating (AATCC Gray Scale Evaluation Procedure 1/ISO 105-A02). 3.6 PROCESS WINDOW The applicator will determine their process (Bake Time/Temperature & DFT) is within t
45、he process window/limitations of the paint technology being used to assure compliance to the specification requirements. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 HARDNESS (ASTM D 1474) Recor
46、d value at target film and bake conditions. Shall be sufficiently cured at time of packing to withstand normal handling without damage. Properly cured paint finish shall be hard enough to dry sand easily with 360 grit paper without gumminess or severe scratching. 4.2 POLISHING A and B Gloss surfaces
47、 shall be capable of being sanded with 1200 grit or finer 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. 4.3 WAVESCAN TARGET VALUES (BYK-Gardner or equivalent) Color Horizontal Vertic
48、al Ford EU Ford NA Ford EU Ford NA Dark Metallics 65 55 55 42 Light Metallics 60 50 50 37 Light Solids 60 55 50 42 Dark Solids 65 60 55 47 ENGINEERING MATERIAL SPECIFICATIONWSS-M2P180-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 9 of 10 5.0 SUMMARY OF REVISION
49、S Revisions 2008 10 15 o Paragraph 3.0 added sentence about testing required for post mold operations o Paragraph 3.2.3 added DFTs for BC/CC and Powder and added Note 3 o Paragraph 3.2.7 added Paint definitions of DV & PV testing o Paragraph 3.4.11 removed NA only o Added Paragraph 3.5.2 o Updated Wavescan Numbers o Table 1 added Note 3 ENGINEERING MATERIAL SPECIFICATIONWS
