1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions Rev 01 2012 05 04 N Status No usage or replacement N. Benipal, NA 1998 08 12 Activated E. Mangin Page 1 of 8 ENAMEL, BAKING, HIGH SOLIDS, EXTERIOR LOW WSS-M32J126-B AND MEDIUM GLOSS NOT TO BE USED FOR NEW DE
2、SIGN 1. SCOPE The material defined by this specification is a thermosetting acrylic baking enamel suitable for exterior exposure on large, highly visible sheet metal surfaces. 2. APPLICATION This specification was released originally for enamels used on exterior parts where a low or medium gloss is
3、required. It shall be satisfactory for use on wet-on-wet application with WSS-M6J152 primer or equivalent. 3. REQUIREMENTS Test shall be made on the basis of comparison with approved production material, to be chosen by approving materials engineer. 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers
4、 and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for initial qualification of materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials
5、activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to analyze process/product data and assure consistent processing of the materials. Part producers using this material in their products, must use Ford approved ma
6、terials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. ENGINEERING MATERIAL SPECIFICATION WSS-M32J126-B Page 2 of 8 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or
7、 thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that corre
8、spond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested
9、under the same conditions unless otherwise specified. 3.4 COMPOSITION The enamel shall be composed of durable resins wet-on-wet compatible with current production primers. The enamel shall be pigmented as required to obtain the specified color and gloss, and to meet the performance requirements of t
10、his specification. 3.5 PHYSICAL PROPERTIES LIQUID STATE The following evaluation must be conducted at application viscosity. Over the application viscosity range, material shall be in compliance with local emissions regulations. 3.5.1 Non-Volatile Content, range See initial (ASTM D 1353) sample +/-
11、2 % 3.5.2 Volatile Organic Content (VOC), range See initial (ASTM D 3960) sample +/- 1 % 3.5.3 Weight per Volume, range See initial (ASTM D 1475) sample +/- 0.03 g/ml 3.5.4 Volume Solids, range See initial (ASTM D 2697) sample +/- 2 % 3.5.5 Dry Hiding 15 - 18 (FLTM BI 158-01) micrometers Complete vi
12、sual hiding over black and gray hiding chart. ENGINEERING MATERIAL SPECIFICATION WSS-M32J126-B Page 3 of 8 3.5.6 Viscosity (ASTM D 1200) Supplier shall report value at package and at application reduction. 3.5.7 Stability (ASTM D 1849) After test, the material shall pass all specification requiremen
13、ts. 3.5.7.1 Shelf Stability 90 days The material shall not jell or liver on standing and must be free from settling which can not be dispersed by normal agitation. No more than 30 % increase in viscosity permitted. 3.5.7.2 Accelerated Stability (60 C, 16 h) No more than 30 % increase in viscosity pe
14、rmitted. 3.6 PREPARATION OF TEST PANELS Substrate: Current production phosphated galvanized steel. Record all substrate information. Electrocoat: Current production electrocoat, applied at 20 - 23 micrometers and baked 10 minutes at 182 C metal temperature (MT). Record electrocoat and oven type used
15、. Primer: Current production primer surfacer in a color consistent with production, applied at 25 - 28 micrometers. Record primer used. Enamel: Apply candidate material to required dry film thickness of 25 - 28 by spray. Apply wet-on-wet over current production primer, flash between primer and black
16、out. Bake 10 minutes at 163 C metal temperature. Record oven type used. ENGINEERING MATERIAL SPECIFICATION WSS-M32J126-B Page 4 of 8 3.7 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments (Box-Behnken is recommended) to determine the process window of the material. The thre
17、e variables to be included in the design are bake time, bake temperature and film thickness. An initial screening experiment should be conducted to determine the levels which will be tested for the above design variables. The screening experiment should be reviewed with the materials engineer to set
18、 up the final DOE. Responses to the DOE will be chosen from tests listed within this specification. 3.8 APPEARANCE Consideration should be given to an application process window Design of Experiments to assess impact of key process variables on final appearance. 3.8.1 Color (FLTM BI 109-01) Color sh
19、all match the Ford Motor Company master panel. 3.8.2 Gloss (ASTM D 523, 60 degree glossmeter) The gloss shall be specified by means of a letter suffix to the color number assigned by Styling as follows: B 80 +/- 4 F 35 +/- 3 C 70 +/- 4 G 20 +/- 3 D 62 +/- 3 H 10 +/- 3 E 50 +/- 3 J 6 max 3.8.3 Heat S
20、ensitivity A commercial color match shall be obtained with no significant change in gloss as defined in para 3.8.2, or more than 4 units change in Tukon hardness, when the enamel is baked at the following schedule: . Standard bake plus 20 minutes at 138 C 3.8.4 General The enamels shall bake out to
21、a presentable, serviceable film showing no craters, pinholes, seediness, abnormal roughness or excessive metallic mottling. ENGINEERING MATERIAL SPECIFICATION WSS-M32J126-B Page 5 of 8 3.9 FILM PROPERTIES 3.9.1 Film Thickness 25 - 28 (ASTM D 1186) micrometers 3.9.2 Adhesion, max Grade 2 (FLTM BI 106
22、-01, Method B) 3.9.2.1 Intercoat Adhesion, max Grade 2 (FLTM BI 106-01, Method B) Test panels prepared according to para 3.6, shall be painted with current production white topcoat material (target film thickness and target bake conditions). 3.9.3 Chip Resistance Equal to or (SAE J400, 1 pint, 25 C)
23、 better than control 3.10 RESISTANCE PROPERTIES 3.10.1 Condensing Humidity, min 240 h (FLTM BI 104-02, Method A) There shall be no blistering, whitening, dulling, peeling, or loss in holdout. 3.10.2 Water and Soap Spotting (FLTM BI 113-01) 3.10.2.1 Water Spot Discoloration None permitted 3.10.2.2 So
24、ap Spot Discoloration None permitted 3.10.3 Acid Spotting (FLTM BI 113-02) No discoloration after 10 minutes. Discoloration after 20 and 30 minutes shall be no greater than the standard on file. 3.10.4 Natural Weathering, Florida Exposure (SAE J1976, Procedure A) 3.10.4.1 Gloss After Exposure (ASTM
25、D 523, 60 degree glossmeter) 18 months 25 % loss, max 30 months 40 % loss, max ENGINEERING MATERIAL SPECIFICATION WSS-M32J126-B Page 6 of 8 3.10.4.2 Adhesion After Water Immersion (FLTM BI 104-01) 16 h (FLTM BI 106-01, Grade 2, max Method B) There shall be no blistering or delamination. To be evalua
26、ted at all exposures. 3.10.4.3 Color After Exposure (X-Rite, 75 degree) 18 Months Delta L 5, Max 3.10.5 Accelerated Weathering (Modified SAE J1960, 0.55 W/m2 irradiance, Borosilicate inner and outer filters) 3.10.5.1 Gloss After Exposure (ASTM D 523, 60 degree glossmeter) 1875 h 25 % loss, max 3125
27、h 40 % loss, max 3.10.5.2 Adhesion After Water Immersion (FLTM BI 104-01) 16 h (FLTM BI 106-01, Grade 2, max Method B) There shall be no blistering or delamination between any layer of painted system. To be evaluated at all exposures. 3.10.5.3 Color After Exposure (X-Rite, 75 degree) 1875 h Delta L
28、5, Max ENGINEERING MATERIAL SPECIFICATION WSS-M32J126-B Page 7 of 8 3.11 REPAIR The material under test must also fulfill the requirements regarding: Color (para 3.8.1) Gloss (para 3.8.2) Adhesion (para 3.9.2) Condensing Humidity (para 3.10.1) when test panels are prepared as follows: 3.11.1 Test pa
29、nels prepared according to para 3.6 shall be dry sanded using 320 grit paper. One half of the panel, an area approximately 30 mm in diameter shall be sanded through to substrate using 320 grit paper. Clean the substrate and enamel dust off of the panel. Apply current production flash primer to sande
30、d through area following suppliers recommendations. Spray candidate material to a dry film thickness of 25 28 micrometers, and bake 10 minutes at 163 C metal temperature. 3.11.2 Test panels prepared according to para 3.6 shall be dry sanded using 320 grit paper. Catalyze candidate material as per su
31、ppliers recommendation. Spray to a dry film thickness of 25 - 28 micrometers, and bake 10 minutes at 100 C metal temperature. 3.12 COMPATIBILITY The material must be compatible with all related materials, i.e., primers and topcoats. Additionally, the material must be compatible with subsequent repai
32、r materials. 3.13 FINAL APPROVAL/PRODUCTION TRIAL Final approval of all functional and sanding characteristics shall be made by the manufacturing division using the material or painted part on the basis of a shop trial under production conditions (Form 371 report and WW 520 report). ENGINEERING MATE
33、RIAL SPECIFICATION WSS-M32J126-B Page 8 of 8 3.14 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color
34、, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed cha
35、nges and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The regulations are d
36、efined in Engineering Materials Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from
37、 the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full
38、compliance with all the requirements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List.
