1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev. 0 2010 12 16 Activated Replaces WSS-M1A343-A2 T. Covert, FNA Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 8 PERFORMANCE, FUEL FILLER PIPE, COATED AND UNCOATED METAL WSS-M2P192-A1 1. SCOPE The fue
2、l filler pipe material system defined by this specification requires corrosion protection and resistance to Ford Test Fuels. The pipe construction is typically a low carbon electroplated sheet steel, formed and welded into tubing, with an organic immersion top coat which may form a duplex system. St
3、ainless steel could also be used and may not require coating. Approved suppliers are on the Approved Source List. 2. APPLICATION This specification was released originally for materials used for chassis mounted fuel filler pipes that may or may not be seen with wheels on ground and do not experience
4、 continuous operating temperatures above 121 C (250 F). This specification is not intended to limit the substrate or coating to any specific material type or process, but define the performance of the system. This specification is intended for global use, unless noted on the Approved Source List. Th
5、e coatings and materials approved to this specification may have fuel type restrictions. 2.1 LIMITATIONS FOR FUEL COMPATIBILITY ONLY Note: All approved suppliers may not be approved for all of the Ford Test Fuels for liquid phase and vapor phase. See Product Engineerings Strategy/Design Rule for the
6、 fuel material compatibility approvals. Contact Materials Engineering for fuel compatibility data. 3. REQUIREMENTS 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.
7、2 BASE MATERIAL AND COATING PROPERTIES (COATED PIPE ONLY) 3.2.1 Base Material and Coating The Engineering Drawing shall specify the product trade name/product code number, substrate, pretreatment and all coating thicknesses in m for outside and inside surfaces. All requirements must be validated wit
8、h actual production intent processes and tests performed on actual components. 3.2.2 Metal Preparation The surface to be coated must be free from oil, alkaline residues, rust, dirt, moisture and other foreign materials that may prevent adhesion. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P192-A1 Printe
9、d copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 8 3.3 FILM PROPERTIES (COATED PIPE ONLY) 3.3.1 Color Black or as specified on the engineering drawing. 3.3.2 Initial Hardness The finish shall be sufficiently cured at the time of packing to withstand normal handling a
10、nd shipping without damage. 3.3.3 Appearance The coating shall be a uniform film, showing no flow lines, pinholes, craters, flaking, cracking, peeling, blistering or excessive buildup that will affect sealing. Critical sealing surfaces with additional surface criteria (i.e. surface roughness) are to
11、 be noted on the Engineering Drawing. Part racking exceptions must be shown on the Engineering Drawing. 3.3.4 Coating Thickness, m As specified on (FLTM BI 117-01, ASTM B 487) engineering drawing Any suitable method may be used to measure coating thickness. Metallurgical cross-section is the final d
12、eterminant. A minimum of twelve measurements are to be taken per pipe: three in the funnel/bowl area, three in the midsection, three near the end of the pipe and three in the inside of the funnel bowl, unless otherwise specified on the Engineering Drawing. Each individual measurement must meet the m
13、inimum thickness, as specified on the Engineering Drawing. The minimum thickness will be established based on original test samples for the Corrosion and Fuel Compatibility Testing. 3.4 RESISTANCE PROPERTIES 3.4.1 Fuel Resistance (Coated and uncoated pipe) No softening or peeling (Fuels per FLTM AZ
14、105-02, of coating on coated Tests per FLTM BZ 105-03) pipes (See note) Note: Uncoated pipes could exhibit discoloration or oxide formation. The amount of allowable discoloration or oxide formation can vary depending on fuel and pipe material. Requirement: Pass/Fail decision for fuel resistance must
15、 be determined by Materials Engineering and Core Fuel Product Engineering via the attached sign off form (Appendix 1). Reference FLTM BZ 105-03 for evaluation criteria. Additionally, coated pipes shall exhibit no permanent softening of coating after 24h drying at 23 +/-2 C and 50% relative humidity.
16、 Data and signoff will be stored in the Materials Engineering share drive. The pipe must be requalified every 5 years. If a new fuel is added to FLTM AZ 105-02, the part must be retested to the new fuel. 3.4.2 Laboratory Accelerated Cyclic Corrosion Test (Coated and uncoated pipes) (CETP 00.00-L-467
17、 for 12 weeks, X-scribe and Gravelometer ) Note: Precondition one side of the pipe using an X-scribe (Figure 1) with a carbide tip tool, per ASTM D 3359, and stone chip (Figure 2) one location on the other side of the pipe, per SAE J400 (Figures 3 and 4), 1 pint at room temperature. ENGINEERING MATE
18、RIAL SPECIFICATIONWSS-M2P192-A1 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 8 3.4.2.1 Air Pressure Test No air bubbles. The pipes shall be pressure tested underwater to 140 kPa (20 psi) of air. There shall be no air leakage as indicated by air bubbles. 3.4
19、.2.2 Gauge Loss Gauge loss x 3 50% (FLTM CA 005-01) of original gauge. The pipe should be reviewed to find the most severe corrosion areas. The most severe corrosion shall be lightly glass bead blasted to remove the corrosion. Using a point micrometer, find the thinnest area, triple it and compare t
20、o the original gauge in percent. 3.4.3 Vehicle Testing (Coated and uncoated pipes) Must pass (CETP 00.00-R343 for 12 weeks) requirements in GES 18-0040 One vehicle test is required (See note). Note: Vehicle testing is required and should be planned for up front in order to validate the laboratory te
21、sting. Materials Engineering and Core Fuel Product Engineering may wave the vehicle test following successful laboratory testing of a new fill pipe construction if no corrosion vehicles are planned prior to J1. 3.4.4 Electrical Resistance (Coated and uncoated pipe) 1X106ohms, max. (SAE J1645) Measur
22、ement of the finished component will be tested to ensure adequate conductivity to discharge any static electricity that may be generated. 3.4.5 Water Resistance, (Coated pipe only) No blistering or loss of (FLTM BI 104-01) adhesion X-scribe samples. Immerse samples 240 hours. Allow paint film to rec
23、over 1 hour at room temperature after immersion before evaluating. 3.4.6 Chip Resistance, (Coated pipe only) 6A, max (SAE J400, 1 pint, room temperature) (less than 24 chips Chip size 1 m) Test shall be conducted on production intent components. The test component must be painted on the same system
24、as the production intent component. Note: See Figure 3 and Figure 4 for additional information. 3.4.7 Paint Adhesion, (Coated pipe only) No loss of adhesion (ASTM D 3359, Method A, X-scribe with carbide tip.) in scribe area. 3.4.8 Thermal Shock, (Coated pipe only) No loss of adhesion (FLTM BI 107-05
25、, in scribe area. Carbide tip scribe only) ENGINEERING MATERIAL SPECIFICATIONWSS-M2P192-A1 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 8 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirem
26、ents of this specification. 4.1 PRETREATMENT (COATED PIPE ONLY) A pretreatment may be used to increase the adhesion and durability of the organic top coating by providing a clean, grease free, corrosion inhibiting bond between the base material and finish. The specification of the pretreatment syste
27、m (including cleaning requirements, pretreatment type and coating weight) is to be determined on initial qualification of materials and process. A control plan with detailed material description and process parameters is required for approval submission. Once the system is approved, any further chan
28、ges will need to be re-submitted to the appropriate Ford Materials Engineer for evaluation and approval. Coating weights should be measured on samples prior to immersion coating and should be tested using x-ray spectroscopy, atomic absorption or inductive coupled plasma testing apparatus. A chromium
29、-free pretreatment is preferable, but at a minimum the pretreatment shall be free of hexavalent chromium. 4.2 RECOMMENDED TESTING FOR COATING CHANGES For coating process changes, see Table 1 for test requirement guidelines. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P192-A1 Printed copies are uncontrol
30、led Copyright 2010, Ford Global Technologies, LLC Page 5 of 8 Table 1. New Substrate or Coating Material Established Coating All Applicators New Paint Line (No Ford History) Existing Paint Line (Applicator) Test Requirements Example A Existing part Example B New Part for a different fuel application
31、 Example C Switching Known Paints on same part Example D New Part/Same materials Example E Process Change Example F 3.3.4 Coating Thickness X X X X X 3.4.1 Fuel Resistance X 3.4.2 Laboratory Accelerated Cyclic Corrosion X X X13.4.5 Water Resistance X X X X 3.4.6 Chip Resistance X X X1 3.4.7 Adhesion
32、 Adhesion X X X X X Contact Materials EngineeringExample A. A new substrate and/or coating is developed by a paint manufacture for automotive applications Example B. Painter goes out of business. New painter uses the same paint, but has never painted parts for Ford. Example C. Tier 2 painter for fil
33、l pipes is asked to coat brackets on the same paint line. Example D. Fuel filler pipe supplier is switching from one coating used at Ford to another coating used at Ford. (i.e. Ford has experience with both coatings) Example E. Fuel filler pipe supplier is painting the first run of PPAP parts for th
34、e new model program on the paint line that supports current model. Example F. The level of testing is highly dependant on what is changing. Contact Materials Engineering. 1Potential use of surrogate data Note: This specification cannot prove out parts or coatings that involve changes in vehicle envi
35、ronment such as increased stone chipping or increased temperature. These changes may require vehicle testing, consult SDS/ARL requirements. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P192-A1 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 8 Figure 1. X-Scribe on
36、pipe. Figure 2. Gravel damage on pipe. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P192-A1 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 7 of 8 Figure 3. Q G R Gravelometer by Q-Panel Figure 4. Gravelometer preconditioning: Pipe installed in Gravelometer. Pipe contac
37、t area is 13 inches from gun nozzle. ENGINEERING MATERIAL SPECIFICATIONWSS-M2P192-A1 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 8 of 8 Appendix 1 Sign off Form Results from FLTM BZ 105-03 Trade Name Fuel Type Vapor Phase Liquid Phase Fuel C Auto Oxidizing Fuel CM15A CM85A CE10A CE20A / CE25A CE85A E93A per XE-M4CX652-93A Ultra Low Sulfur (15ppm) B30A per XE-M4CX732-B30B Core Fuel Product Engineering_ Date _ Materials Engineering _ Date _
