1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2014 03 03 Revised See Summary of Revisions 5.0 J. Crist/Global Paint Team 2011 03 01 Released Replaces WSS-M2P180-C A. Weakley/J. Crist Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 1 of 11 PAINT
2、PERFORMANCE, RIGID SUBSTRATES, EXTERIOR WSS-M2P180-D 1. SCOPE This specification defines the performance requirement of a painted part 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 com
3、ponent 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. This specification is not inte
4、nded for paint over chrome applications. 3. REQUIREMENTS The paint materials must be selected from the Painted Parts Strategy List using paints from suppliers on the Ford Approved Source List (ASL), unless a waiver is granted by Materials Engineering. All parts must also meet the appropriate DVP&R a
5、nd Subsystem Design Specification requirements. All visible parts of the component, including terminating exterior edges visible after assembly shall conform to the full requirements of this specification. Any localized post mold operations (Flame Treating, Sanding) prior to painting requires the ad
6、ditional testing as noted in the last column of Table 1. All areas of the component visible after assembly must be evaluated /tested. These areas include flanges, parting lines, areas subject to post-mould treatment, styling lines and grooves. In-department, pre-delivery and refinish paint repairs s
7、hall meet the requirements of this specification. Parts must conform to the color requirements 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
8、 be used as a guide if measurement is feasible. Refer to the appearance requirements of the adjacent body region. Note: For in process color check the preferred method is SAE J1545, three angle CMC (Color Measurement Committee). Effective 2007 model year and beyond, all paint applicators must meet t
9、he Exterior Parts Painter Approval Process (AVP-T113-015) unless waived by Materials Engineering. 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). ENGINEERING MATERIA
10、L SPECIFICATION WSS-M2P180-D Copyright 2014, Ford Global Technologies, LLC Page 2 of 11 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 rigi
11、d polymer blends, SMC, ABS, PC/ABS, 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. Surface energy/resistivity or c
12、hemical 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 the PFMEA, Engineering Drawing and Control Plan. 3.2.3 Paint System Requirements Substrate * Pre-treat Prime
13、 Topcoat* Cold rolled steel Precoated steel Electroplate zinc Zn alloy coated steel Aluminum As needed to meet process/performance requirements (i.e. zinc phosphate or equivalent) Primer/Surfacer or equivalent Cathodic Electrocoat(Note 2) Basecoat/Clearcoat (2-layer), Monocoats (1-layer), and Tri-co
14、at (3-layer) Powder coat (Note 3) Thermoset Polymers SMC,BMC, DMC, etc. As applicable to meet process/performance specifications Primer/surfacer Basecoat/Clearcoat (2-layer), Monocoats (1-layer), and Tri-coat (3-layer) Thermoplastic Polymers ABS, PC/ABS PA,PA/PPE, etc. As applicable to meet process/
15、performance specifications Primer, surfacer as applicable to meet process/performance specifications Basecoat/Clearcoat (2-layer), Monocoats (1-layer), and Tri-coat (3-layer) * - Ford Materials Engineering approved materials (Approved Source List) Specified Film Thickness: Note 1: These ranges are c
16、onsidered to be requirements unless otherwise supported by testing data agreed to by Materials Engineering and noted on the MCDCC. E-coat 17-24 m Primer/Surfacer 1724 m Monocoat (1-layer) 38 -50 m Basecoat/Clearcoat (2-layer) 15-30 m /38-50 m Tri-Coat (Basecoat/Midcoat/Clearcoat) 20-30 m/15-30 m/38-
17、50 m Powdercoat 50-100 m ENGINEERING MATERIAL SPECIFICATION WSS-M2P180-D Copyright 2014, Ford Global Technologies, LLC Page 3 of 11 Note 2: Primer must be applied over cathodic e-coat for paint system robustness. Note 3: For Powder coatings, Pretreatment & Cathodic E-coat must be used unless approve
18、d by Materials Engineering. 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 the aluminum tolerance of the process used shall not be exc
19、eeded. 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. 3.2.4 Repairs, In-Department and Pre-delivery Repaired areas m
20、ust 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 and conform to the requirem
21、ents in Para 3.3. All repairs must be with the identical color to the original finish unless approved by Materials Engineering. 3 in department repairs = 1st run part + 2 in line repairs 3.2.5 Finished Parts Testing must be conducted on actual production parts. Where part dimensions limit equipment
22、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 must meet the specification requirement. These panels shall be processed together with parts and shall be representativ
23、e of the parts with respect to substrate, phosphate coating, primer thickness, sanding, Paint thickness, and processing. When panels are used as a substitute, this must be clearly reported on the PSW or the laboratory test report. 3.2.6 Aging Test specimens prepared for investigations according to t
24、his 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 in Table 1. This table is for only approved paint technologies as shown on Ford Approved Source List, otherwise full WSS
25、-M2P180-D specification testing is required. Design Verification Testing (DV or pre-DV) is done on plaques by the paint supplier and is covered in the applicable paint material specification. Product/Process Validation Testing (PV) is done on production painted parts as defined in Table 1. ENGINEERI
26、NG MATERIAL SPECIFICATION WSS-M2P180-D Copyright 2014, Ford Global Technologies, LLC Page 4 of 11 3.2.8 Cure Profile A temperature part profile curve (Time/Temp) from the production process for the partmust be included in the PPAP. 3.3 FILM PROPERTIES 3.3.1 Color (FLTM BI 109-01 Visual Assessment, S
27、AE 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 Report (FLTM BI 110-01, ASTM D 523) Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. Gloss A: 20 Glossme
28、ter 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 - 2.0 N: 60 Glossmeter 1.8 - 2.4 R: 60 Glossmete
29、r 1.2 1.6 3.3.3 Film Thickness As defined in (FLTM BI 117-01, Metallic Substrates, PELT or equivalent, paragraph 3.2.3 ASTM B 487, Non-Metallic Substrates, PELT or equivalent) All areas of the component visible after assembly must be evaluated/tested, including flanges, parting lines, styling lines
30、and grooves. Film thickness must meet paragraph 3.2.3 unless mutually agreed upon by Materials Engineering and noted MCDCC. 3.3.4 Film Thickness 350 m max (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
31、in-department repairs as defined in paragraph 3.2.4. ENGINEERING MATERIAL SPECIFICATION WSS-M2P180-D Copyright 2014, Ford Global Technologies, LLC Page 5 of 11 3.4 RESISTANCE PROPERTIES 3.4.1 Paint Adhesion, (See Table 1, Note 6) Grade 2 max (FLTM BI 106-01, Method B for flat area & Method E for cur
32、ved/radius areas, carbide tip scribe for Metal & Thermoset resins and knife blade for all other, note method used on test data) All areas of the component visible after assembly must be evaluated/tested, including flanges, parting lines, areas subject to post-mould treatment, styling lines and groov
33、es. 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 No blistering, dulling, (FLTM BI 104-01, 240h, scribe per 3.4.1) softening, and/or any other film failure. After exposure, ad
34、hesion shall be tested and met Para 3.4.1 within 30 minutes after removal from water. 3.4.3 Condensing Humidity Resistance Rating 4-5 min (FLTM BI 104-02, Method A, 240h AATCC Evaluation Procedure 1/ISO 105-A02) Alternative Methods (Must be agreed upon by Materials Engineering) 3.4.3.1 Humidity Resi
35、stance 168hr at 85C & 90%R.H. Rating 4-5 min 3.4.3.2 Humidity Resistance 240hr at 85C & 90%R.H. Report After exposure, adhesion shall be tested and met Para 3.4.1 within 60 minutes after exposure. No blistering, dulling, softening, and/or any other film failure. 3.4.4 Corrosion Resistance 3.4.4.1 Al
36、uminum Substrates Only (e.g. Badges, wheel ornaments) (SAE J2635, No scribe, 672hrs) No Filiform corrosion or white corrosion on any visible part of the component. 3.4.4.2 All other Metallic Substrates and Aluminum Badges Grade 6 max (CETP 00.00-L-467, 9 weeks except scribe as in FLTM BI 123-01, AST
37、M D 610) No obvious corrosion from visible cut edges. 3 mm maximum creepage from scribed lines ENGINEERING MATERIAL SPECIFICATION WSS-M2P180-D Copyright 2014, Ford Global Technologies, LLC Page 6 of 11 3.4.5 Fluid Spotting Resistance Rating 4-5 min (FLTM BI 168-01, Method A and B, AATCC Evaluation P
38、rocedure 1/ISO 105-A02) Test Fluids: Body and Exterior Trim. For Wheel Trim and Ornaments, include Brake Fluid (DOT 3 or DOT 4) and Wheel Cleaner Resistance (Motorcraft P/N ZC-37-A) and tire sealant (TMK Kit, P/N 4G7Z-19L523-AA. No color dulling, surface distortion or permanent softening permitted.
39、After exposure, adhesion testing performance must be met per Para. 3.4.1 within 60 minutes after exposure. 3.4.6 Acid Resistance (Not for Wheel Trim/Ornamentation) Equal or better than (FLTM BI 113-01 except at 60 C and current production 80 C for 30 minutes) material The following solutions shall b
40、e tested on candidate materials: 3.4.6.1 Sulfuric acid (H2SO4) adjusted to pH of 2 3.4.6.2 Phosphoric acid (H3PO4), 0.5% 3.4.6.3 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 specified solutions to 2 test panels. Place one each in
41、 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. 3.4.7 Mar Resistance (A& B Gloss Materials) 70% Gloss retention (FLTM BI 161-01) No visual Mar at all angles 3.4.8 Scratch Resista
42、nce 3.4.8.1 A & B Gloss Materials Fracture Load 8.0 Nm Nano Scratch Test (DVM-0058-PA) Deformation 3mm dia. First run plus three in-line repairs Rating 3B or 93% (apply 2K repairs, 7 days after Paint retention. prior application, as defined in 3.2.4) No chips 3mm dia. Chipping is identified as inter
43、coat adhesion loss between any adjoining layers revealing dis-similar colors, scuffing is acceptable. Chipping metrics may be obtained by image analysis (Atlas VIEEW software or equivalent). 3.4.10 Environmental Cycling, Total of 15 cycles Rating 4-5 min (FLTM BQ 104-07, Procedure 1 or 10, AATCC Eva
44、luation 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 within 60 minutes after exposure. Note: For procedure 1 test pieces
45、shall be maintained at 38 C+/-2 C and 95-98% R.H. during any weekend break in cycling 3.4.11 High Performance Adhesion (See Table 1, Note 6) All areas of the component visible after assembly must be evaluated/tested, including flanges, parting lines, areas subject to post-mould treatment, styling li
46、nes and grooves. 3.4.11.1 Thermal Shock (FLTM BI 107-05) For Exterior Badging, 0.125 cm max For all other Applications, Rating 19 min ENGINEERING MATERIAL SPECIFICATION WSS-M2P180-D Copyright 2014, Ford Global Technologies, LLC Page 8 of 11 Alternate Method: 3.4.11.2 Resistance Against High Pressure
47、 Cleaner 2 mm2 max (FLTM BO 160-04, Method B & Method C) For Method B 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. For Method C prior to test run Split Shot per FLTM BI 157-06 (1st shot only) then run test at
48、 23C. No X-Scribe. The test method must be noted in initial submission package 3.4.12 Heat Resistance Rating 4-5 min (7 days at 80 +/-2 C, AATCC Evaluation 90) 57 / 44 62 / 49 50 / 37 Medium Metallic (L15 50-89) 60 / 47 65 / 52 53 / 40 Dark Metallics (L15 75) 62 / 49 67 / 54 55 / 42 Medium Solids (L
49、15 30-75) 65 / 52 70 / 57 58 / 45 Dark Solids (L15 30) 67 / 54 72 / 59 60 / 47 5. SUMMARY OF REVISIONS 2014 03 03 3.2.3 Update film builds added 3-layer systems 3.3.2 Added R Gloss 3.4.1 Added Knife 3.4.2 Changed after removal time from 20 to 30 minutes align with FLTM 3.4.5 Changed ZC-37 to ZC-37-A and 4G7V-19L523-AB to 4G7Z-19L523-AA 3.4.8.2 Added Whitening requirement 3.4.11.2 Updated method C added 23C and no X-scribe 3.5.1 Added AST D 786
