1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 3 2013 11 14 Revised See Summary of Revisions L. Sinclair, NA 2008 09 16 Revised See Summary of Revisions for details L. Sinclair/Global Paint Team 2006 03 13 Activated L. Sinclair Controlled document at www.MATS Copyright 2013, Ford Glob
2、al Technologies, LLC Page 1 of 11 PAINT PERFORMANCE, INTERIOR PARTS METAL SUBSTRATES WSS-M2P190-A 1. SCOPE This specification defines the performance requirements for decorative coatings or finishes including paint, autophoretic, electrodeposition coating and powder coating on metal and metal plated
3、 substrates for interior use. 2. APPLICATION This specification was released originally to define performance requirements for various interior applications such as seat tracks, towel bars, speaker grilles, brake pedals, and shift controls. 3. REQUIREMENTS Material specification requirements are to
4、be used for initial qualification of materials. All parts must also meet the appropriate part performance specification and Subsystems Design Specification. Testing must be conducted on parts. See Table 1 and 2 for sample size and testing required. A visible component is defined as one that needs co
5、lor approval and will go through the AAR process. A visible component is also defined as a non color approved part that is visible to the end customer when seated in the vehicle or standing out of the vehicle during normal operation. This includes but is not limited to components that are in interio
6、r compartments and can be viewed when a vehicle component has been actuated. 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 Test Specime
7、n Preparation Tests shall be performed on actual components processed through the production or production intent process. Where this is not possible, panels can be used on the production or production intent process. Panels must be used when part geometry does not allow testing to be performed. Pan
8、els must be approved through Materials Engineering prior to testing. 3.2.2 Substrate Cold rolled steel, hot rolled steel, aluminum and magnesium or as specified on the Engineering Document. 3.2.3 Surface Preparation The surface to be coated shall be cleaned by an acceptable automated process, e.g. c
9、leaning line, to remove any stamping oils, dust, dirt or debris. ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A Copyright 2013, Ford Global Technologies, LLC Page 2 of 11 3.2.4 Film Thickness Film thickness of all applicators must be sufficient to meet the performance and appearance requirements of
10、 this specification. The minimum film thickness must be stated on the print. The film thickness of all test specimens shall be reported on the PSW and laboratory report. The minimums below are considered to be requirements unless otherwise supported by data and agreed to by Materials Engineering. Au
11、tophoretic 14.5 micron min Electrodeposition coating 20.0 micron min Powder Coating* 50.0 micron min * - Powder Coatings require pretreatment. 3.2.5 Aging Test panels or test specimens prepared for investigations according to this specification must be aged for at least 72 hours at 23 +/- 2 C prior
12、to testing. 3.2.6 Production Repair Repaired parts must also meet the requirements of this specification. All repair materials and processes used must be approved by the affected Product Engineering Office. Maximum film thickness and maximum number of repairs will be specified in a mutually agreed c
13、ontrol plan. 3.3 APPEARANCE Color, gloss, tactile effect and surface finish shall match master Sample and/or Master Appearance Sample as approved by Corporate Design. The coating shall exhibit no craters, pinholes, solvent popping, seediness, abnormal roughness, excessive flow or any other detriment
14、al defect. 3.3.1 Color (FLTM BI 109-01, Visual Assessment and/or SAE J1545, MA58 Three-Angle CMC) Shall match the Master Approved Sample. 3.3.2 Gloss (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 Glossmeter 6
15、8 - 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 ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A Copyright 2013, Ford Global Technologies, LLC
16、Page 3 of 11 3.4 RESISTANCE PROPERTIES 3.4.1 Interior Corrosion Resistance (RQT-001101-002492 (18-0040), Table 4, Modified CETP 00.00-L-467) Normal chamber L-467 humidity / temperature cycles Apply the 0.5% salt solution on first and eighth day of the test Showroom Review after first day (one comple
17、te day starting with salt spray solution application). High Visibility Review (6 YIS) after eleventh day Showroom Appearance No white or red corrosion. No blistering, softening, dulling, loss of adhesion, or cracking permitted. Final Appearance: No white or red corrosion Exception for seat tracks an
18、d seat mounting hardware: Red rust allowed at welds, crimps, edges of coated components, and drive areas of fasteners. No undercutting of coating from allowable areas of red rust. 3.4.2 Adhesion Grade 0 max (FLTM BI 106-01, Method B) No flaking or chipping allowed. 3.4.3 Water Resistance (FLTM BI 10
19、4-01, 96h) Must meet adhesion requirement in 3.4.2 after 96 h. No blistering, softening, dulling, or loss of adhesion when tested for adhesion within 30 minutes of removal from water on all paint systems. 3.4.4 Abrasion Resistance (SAE J948, CS-10 wheels) Abrasion resistance shall be determined on s
20、mooth test panels if it is impossible to test a specimen taken from a component. The control plan shall state the film thickness. The film shall show no abrasion through to the substrate. 500 g load 1,000 cycles min and 1,000 cycles/25 m paint thickness ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-
21、A Copyright 2013, Ford Global Technologies, LLC Page 4 of 11 3.4.5 Resistance to Cleaning Agents Rating 4 min (FLTM BN 107-01, 10 cycles, AATCC Evaluation Procedure 2) Test Modifications: Saturate white cotton cloth with the cleaners listed. Cleaners (see also paragraph on Cleaning Agents) 1) Window
22、 cleaner 2) All purpose cleaner 3.4.6 Cure Test Rating 3 min. (FLTM BN107-01, ISO 105-A02/AATCC Evaluation Procedure 2) Test Procedure: Perform a 10 cycle double rub with 1 part MEK/17 parts toluene applying moderate pressure with wetted cheesecloth. 3.4.7 Long Term Heat Exposure Rating 4 min (ISO 1
23、05 A-02/AATCC evaluation Procedure 1) Test three previously unexposed part as follows: 3.4.7.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. speaker grilles, shift levers): 7 days at 100 +/- 2 C 3.4.7.2 Horizontal or vertical parts BELOW THE BELT-LINE (e.g. speaker grilles, shifter le
24、vers): 7 days at 90 +/- 2 C 3.4.7.3 Horizontal or vertical parts in NONSUN LOADED FLOOR LEVEL LOCATIONS (e.g. track rails, mounting feet, brake pedals). 7 days at 80 +/- 2 C Appearance Evaluation: No evidence of cracks, blisters or change in gloss when compared with original unaged sample. After lon
25、g term heat exposure and 24 h water immersion the parts must meet the requirements in 3.4.2 for adhesion properties. ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A Copyright 2013, Ford Global Technologies, LLC Page 5 of 11 3.4.8 Short Term Heat, Humidity and Cold Cycle Rating 4 min (ISO 105 A-02/AA
26、TCC evaluation procedure 1) 3.4.8.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. speaker grilles, shift levers): . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at 100 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 2 h at 50 +/- 2 C
27、 and 95 +/- 5% Relative humidity . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at 100 +/- 2 C 3.4.8.2 Horizontal or vertical parts BELOW THE BELT LINE (e.g. speaker grilles, shifter levers). . 5 h at -40 +/- 2
28、 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at 90 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 2 h at 50 +/- 2 C and 95 +/- 5% Relative humidity . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Re
29、lative humidity . 5 h at 90 +/- 2 C 3.4.8.3 Horizontal or vertical parts in NONSUN LOADED FLOOR LEVEL LOCATIONS (e.g. track rails, mounting feet, brake pedals). - 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at 80 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relati
30、ve humidity . 2 h at 50 +/- 2 C and 95 +/- 5% Relative humidity . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50 +/- 5% Relative humidity . 5 h at 80 +/- 2 C Appearance Evaluation: No evidence of cracks, blisters or change in gloss when compar
31、ed with original unaged sample. After short term heat exposure and 24 h water immersion the parts must meet the requirements in 3.4.2 for adhesion properties. ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A Copyright 2013, Ford Global Technologies, LLC Page 6 of 11 3.4.9 Resistance to Fade (Color Ke
32、yed Parts Only) Rating 4 min. (FLTM BO 116-01 ISO 105 A-02/AATCC Evaluation Procedure 1) Evaluation: The parts shall be completely free from evidence of cracking, blistering, checking and peeling. Read and report the gloss change per FLTM BI-110-01. The gloss should not increase and if the gloss dec
33、reases it should be less than 30%. Parts must be used unless impossible. If panels are used the panel size shall be approximately 60 +/- 5 x 150 +/- 5 mm with 1/3 area protected from exposure. Duplicate parts or panels are required, one for appearance evaluation and one for water immersion. The part
34、s should be exposed per the chart below: LOCATION FLTM BO 116-01 Test Exposure Severe Exposure: Defroster Grille 3609.6 kJ/m2 Heavy Exposure: Actuator rods, etc. 2406.4 kJ/m2 Above the Beltline: Head restraints 977.6 kJ/m2 Below the Beltline: Door Speaker Grilles 601.6 kJ/m2 Mild Exposure: Risers, t
35、racks 225.6 kJ/m2 After weathering parts shall be water immersed for 24 h and meet the adhesion requirements in 3.4.2. 3.4.10 High Performance Paint Adhesion* (Thermal Shock) Rating 19 max (FLTM BI 107-05) No loss of gloss or any other surface deterioration. Or FLTM BO 160-04 (Method B) 2 mm2 max No
36、 loss of gloss or any other surface deterioration. * Note the method used on data submission form 3.4.11 Resistance to Water and Soap Rating 4 max Spotting (FLTM BI 113-01, ISO 105-A02/AATCC Evaluation Procedure 1) No film softening allowed for any solution. ENGINEERING MATERIAL SPECIFICATION WSS-M2
37、P190-A Copyright 2013, Ford Global Technologies, LLC Page 7 of 11 3.4.12 Resistance to Grease Rating 4 min (FLTM BJ 126-01) To be tested with the greases listed in the PSW that will come in contact with the coated components. Appearance evaluation: No film softening, blistering, dulling or loss of a
38、dhesion allowed for any grease. 3.4.13 Resistance to Marring (SAE J365, 10 cycles) A and B gloss surfaces Shall be capable of being sanded with 1200 grit or finer and polished. No noticeable change in gloss or appearance except for a minimum of polishing lines shall result. C L gloss surfaces No evi
39、dence of discoloration, mar can be removed with four rubs of the thumb across the mar. Seat tracks do not need to meet this requirement. 3.4.14 Resistance to Suntan Lotion Rating 3 max and Insect Repellent No Loss of Adhesion (FLTM BI 113-08, Method A ) 3.4.15 Perspiration Resistance (FLTM BI 113-07
40、, ISO 105-A02/AATCC Evaluation Procedure 1) Acid Perspiration Solution Rating 4 min Alkaline Perspiration Solution Rating 4 min 3.5 ABRASION AND PAINT WEAR RESISTANCE USING THE ABREX MACHINE (METALLIC COLORS ONLY) (FLTM BN 155-01, ISO 105-A02/AATCC Procedure 1) Materials Load (N) # of Cycles AATCC C
41、olor and Gloss Change Abraded Area Metallic Color 5 30,000 4 min No paint wear through Rate and report the initial and final color, initial gloss and paint film thickness. Paint film thickness must meet the requirements in 3.2.4. 3.6 PROCESS WINDOW DEFINITION The supplier shall perform a Design of E
42、xperiments (Response Surface Analysis is recommended) to determine the process window of the substrate/paint combination. The three variables/parameters to be included in the design are bake temperature, bake time, and film thickness. An initial screening experiment should be run to determine what l
43、evels should be tested for the variables/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DOE. Responses to the DOE will be based on the materials tested and will be chosen from tests listed within the specification. ENGINEERING MATERIAL SPECIF
44、ICATION WSS-M2P190-A Copyright 2013, Ford Global Technologies, LLC Page 8 of 11 Film Thickness, 3.2.4 Gloss 3.3.2 Initial Adhesion 3.4.2 Water Resistance 3.4.3 Cure Test 3.4.6 3.7 CONTROL PLANS AND PFMEAS The supplier Control Plan must include but is not limited to the following information: 1) Film
45、 Thickness 3.2.4 once per shift/ color 2) Color and Gloss (If applicable) 3.3.1, 3.3.2 once per shift/ color 3) Initial Adhesion 3.4.2 once per shift/ color 4) Cure 3.4.6 once per shift/ color 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting
46、the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 CLEANING AGENTS (See paragraph Resistance to Cleaning Agents) 1) Window cleaner ZC-23* 2) All purpose cleaner ZC-56* *or Ford Motor Company Recommended Equivalents. ENGINEERING MATERIAL
47、 SPECIFICATION WSS-M2P190-A Copyright 2013, Ford Global Technologies, LLC Page 9 of 11 Table 1: Test Matrix for Visible Components New Coating Materials (DV Testing) Established Coating (PV Testing) Sample Size All Applicators New Paint Line (No Ford History) Existing Paint Line (Applicator) New Coa
48、ting Material MCDCC Sign Off Existing Part New Part for a different application Switching known paints on the same part New Part/Same Material Process Changes Test Method Example A Example B Example C Example D Example E Example F Example G Test Colors Any Each Color One Dark/ One Light Any Any Any
49、Contact Materials Engineering3.2.4 Film Thickness 1 X X X X X X 3.3.2 Gloss 1 X X X 3.4.1 Interior Corrosion Resistance 3 X X 3.4.2 Adhesion 3 X X X X X X 3.4.3 Water Resistance 3 X X X X X X 3.4.4 Abrasion Resistance 3 X 3.4.5 Resistance to Cleaning 1 X 3.4.6 Cure Test 1 X X X X X 3.4.7 Long Term Heat Exposure 1 X 3.4.8 Short Term Heat Humidity and Cold Cycle 1 X X 3.4.9 Resistance to Fade 1 X X 3.4.10 High Performance Paint Adhesion 3 X X
