1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev. 0 2010 04 29 Activated T. Weingartz, NA Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 21 ENAMEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET PRIMER, WSS-M33J10-A1 PROCESSED WITH WSS-M33J10-A2/WS
2、S M33J10-A4, EXTERIOR ENAMEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET BASECOAT, PROCESSED WITH WSS-M33J10-A1/WSS-M33J10-A4, EXTERIOR WSS-M33J10-A2 ENAMEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET MIDCOAT, WSS-M33J10-A3 PROCESSED WITH WSS-M33J10-A1/WSS-M33J10-A2/WSS-M33J10-A4, EXTERIOR ENA
3、MEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET CLEARCOAT, WSS-M33J10-A4 PROCESSED WITH WSS-M33J10-A1/WSS-M33J10-A2, EXTERIOR ENAMEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET TINTED WSS-M33J10-A5 CLEARCOAT, PROCESSED WITH WSS-M33J10-A1/WSS-M33J10-A2, EXTERIOR ENAMEL, (3 WET) COMPLIANCE VOC,
4、HIGH SOLIDS THERMOSET PRIMER, WSS-M33J10-B1 PROCESSED WITH WSS-M33J10-B2/WSS-M33J10-B4, REDUCED VISCOSITY, EXTERIOR ENAMEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET BASECOAT, WSS-M33J10-B2 PROCESSED WITH WSS-M33J10-B1/WSS-M33J10-B4, REDUCED VISCOSITY, EXTERIOR ENAMEL, (3 WET) COMPLIANCE VOC, HI
5、GH SOLIDS THERMOSET MIDCOAT, WSS-M33J10-B3 PROCESSED WITH WSS-M33J10-B1/WSS-M33J10-B2/WSS-M33J10-B4, REDUCED VISCOSITY, EXTERIOR ENAMEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET CLEARCOAT, WSS-M33J10-B4 PROCESSED WITH WSS-M33J10-B1/WSS-M33J10-B2, REDUCED VISCOSITY, EXTERIOR ENAMEL, (3 WET) COMP
6、LIANCE VOC, HIGH SOLIDS THERMOSET TINTED WSS-M33J10-B5 CLEARCOAT, PROCESSED WITH WSS-M33J10-B1/WSS-M33J10-B2, REDUCED VISCOSITY, EXTERIOR 1 SCOPE The materials defined by these specifications are coatings, which consist of primer surfacers over which is applied a pigmented thermoset basecoat enamel
7、and a clear or tinted clear thermoset clearcoat in a wet-on-wet-on-wet (3 Wet) process. These materials are monobaked. Unique tricoat colors are also included in this specification. Tricoat colors consist of a pigmented basecoat followed by a non-hiding midcoat over which is applied a clear or tinte
8、d clear. Tricoat colors may be processed wet-on-wet-on-wet-on-wet application and monobaked or in a wet on bake operation. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 21 2 APPLICATI
9、ON These specifications were released originally for materials used as the combined primer surfacer (guidecoat), basecoat, and clearcoat finish when applied wet-on-wet-on-wet (3 Wet) and mono baked on automobile bodies, hoods, fenders and other exterior parts, and shall be satisfactory for use over
10、previously baked enamel, as in paint repair or two toning operations. These materials have been formulated to provide windshield bonding without the use of flange primer (direct glazing) and allow for flush glass designs. The basecoat portion is used alone, without clearcoat, as an interior baking e
11、namel for some applications. 3 REQUIREMENTS Tests shall be made on the basis of comparison with approved production material, to be chosen by the approving materials engineer. Note: For purposes of the specification, paint systems which utilize a standard primer surfacer /basecoat/clearcoat, a prime
12、r surfacer/basecoat/midcoat/clearcoat and/or a system with tinted clearcoat shall be considered the “complete enamel system“. For basecoat only applications refer to section 3.11. 3.1 STANDARD REQUREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the companys sta
13、ndard requirements for production materials (WSS-M99P1111-A). For the materials described within this specification those requirements include but are not limited to the performance specification and the system design specification. 3.2 COMPOSITION 3.2.1 Resin 3.2.1.1 Primers shall be modified polye
14、ster and/or modified polyurethane crosslinkable resin(s), with melamine and/or reactive urethane crosslinker(s) or equivalent. 3.2.1.2 Basecoats and traditional tricoat midcoat shall be thermosetting, synthetic resins with a melamine crosslinking system or equivalent. 3.2.1.3 Clearcoats will be ther
15、mosetting, acrylic-modified synthetic resins with a hybrid crosslinking system or equivalent. Each will be appropriately fortified so as to meet the durability requirement of 10 years. The primer composition will meet all performance expectations in terms of stone chip damage and adhesion. 3.2.2 Pig
16、ments Pigments are exterior quality automotive grade selected to meet durability requirements. 3.2.3 Solvents The volatility of the solvents will be such that there shall be no paint sagging, roughness or dry spray at specified film thicknesses. Solvents shall be HAPS compliant if it is required by
17、local government regulations. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 21 3.2.4 Ultra Violet Light Absorber(s) (UVA) and Hindered Amine Light Stabilizers (HALS) All approved mate
18、rials shall include with the initial Sample Report an Ultra-Violet/Visible spectroscopic analysis. This shall be recorded and filed by the approving Paint Material Engineering Laboratory of the Ford Motor Company as a reference standard for future use and recertification. The coating system shall co
19、ntain sufficient fortification of suitable UVA and HALS to provide 10 year long term durability. 3.2.5 Flash Point The flash point shall conform to the safety regulations applicable to the plant and/or country where the materials are used. 3.3 PHYSICAL PROPERTIES LIQUID STATE The following evaluatio
20、n must be conducted at as shipped and application viscosity. Over the application viscosity range, material shall be in compliance with local emissions regulations. 3.3.1 Non-Volatile Content, range See initial sample +/- 2% (ASTM D 2369-07 for North America) (FLTM BI 102-01 for Europe) 3.3.2 Volati
21、le Organic Content, range See initial sample +/- 1.5% (ASTM D 3960) 3.3.3 Weight per Volume, range See initial sample +/- 0.025 g/ml (ASTM D 1475) 3.3.4 Volume Solids, range at Application Viscosity See initial sample +/-1.3% (ASTM D 2697 or FLTM BI 154-02) Primer 42% minimum Basecoat 37% minimuClea
22、rcoat 49% minimum 3.3.5 Pigment Content in Tinted Clearcoat, max 0.25% (ASTM D 2471, max weight % on total formula of colored pigment) 3.3.6 Viscosity (ASTM D 1200) Supplier shall report value at application reduction. 3.3.7 Stability (ASTM D 1849) 3.3.7.1 Shelf Stability 90 days No more than 30% in
23、crease in viscosity permitted. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 21 3.3.7.2 Accelerated Stability (60 C, 16 h) No more than 30% increase in viscosity permitted. After the
24、accelerated stability test, the material shall pass all specification requirements. Critical testing must include; solvent pop, sag resistance, appearance, direct to glass bonding, intercoat adhesion, repair paint system wetting, and tape/label adhesion. 3.3.8 Resistivity 0.05 to 2.00 megohms (ASTM
25、D5682)Volatile solvents and other components affecting electrical conductivity shall be adjusted such that the resistivity at application viscosity shall be within specified limits. 3.4 PREPARATION OF TEST PANELS Substrate: All current production substrates, including but not limited to, pretreated
26、galvanized steel, pretreated electro galvaneal steel, pretreated aluminum, unpolished pretreated cold rolled steel and current production primed exterior thermosetting plastic. Record all substrate information. See para 4.1. Electrocoat: Current Ford production approved medium build gray cathodic el
27、ectrocoat, applied at 20 - 23 micrometers and baked utilizing the appropriate bake schedule. Record electrocoat and oven type used. Primer: Within a wet-on-wet-on-wet application process apply primer surfacer to required dry film thickness (22.5 30 microns) by spray under conditions appropriate for
28、primes, and flash prime coat 180 seconds or as specified, prior to basecoat application. Record primer application information and include with the submission data package for system approval. Basecoat: Apply basecoat, directly to the just flashed primer, to the required dry film thickness (typical
29、color dependent range 15- 30 microns) by spray under (OEM) conditions appropriate for basecoats, and flash 180 seconds or as required. Record basecoat application information and include with the submission data package for system approval. Clearcoat: Apply clearcoat to required dry film thickness (
30、40-55 microns) and flash 10 minutes or as required. Bake for 20 minutes at 140 degrees centigrade metal temperature with 10 minute ramp-up. Bake target is obtained using appropriate bake schedule as defined by paragraph 3.5. Record clearcoat application information and oven type used and include wit
31、h the submission data package for system approval. Catalyzed Low For catalyzed low-bake repair, a current production basecoat/clearcoat system Bake Repair: from the same manufacturer that has been (LBR) approved for use may be LBR substituted, provided that it meets all the catalyzed repair systems
32、criteria. Catalyze enamel as per manufacturers recommendations. Prepare (OEM) panels at target conditions. Wipe panels using naphtha and mask half of panel vertically. Apply low bake system, remove masking, flash and bake 10 minutes at 100 C metal temperature ENGINEERING MATERIAL SPECIFICATIONWSS-M3
33、3J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 21 See para 4.2 Table 1 for Topcoat Processing Matrix, Table 2 and 3 for New Resin Technology Test Matrices, and Table 4 for New Pigments/New Colors Test Matrix. Process applica
34、tion and coating thickness optimization including target ranges are to be defined within para 3.5 process window. 3.5 PROCESS WINDOW DEFINITION - NEW RESIN TECHNOLOGIES ONLY The supplier shall perform a Design of Experiments (DOE) (Response Surface Analysis is recommended) to determine the process w
35、indow of the control and candidate materials. The four variables/parameters to be included in the design are bake temperature, bake time, primer and clearcoat film thickness (basecoats applied at hiding). An initial screening experiment should be run to determine what levels should be tested for the
36、 variables/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DOE. Responses to the response surface DOEs will be based on the materials tested and will be chosen from tests listed within the specification. Minimal critical performance testing re
37、quired: cross-hatch adhesion, condensing humidity, acid/alkali resistance, scratch resistance, stone chip (SAE J400 and Erichsen), intercoat adhesion (ICA), and quick knife glass bonding adhesive adhesion. The candidate coating system versus a control will also be required to be evaluated for applic
38、ation robustness utilizing DOEs agreed upon by the Ford responsible Approving Engineer. Information will be used by materials engineer to determine acceptable plant processing conditions. See also para 4.2. 3.6 APPEARANCE Note: Appearance panels will be sprayed using standard plant processing parame
39、ters. Consideration should be given to an application process window DOE to assess impact of key process variables/parameters on final appearance. The appearance target values herein listed should be consistent with the fourth quartile values defined by the process window, and should be used as dire
40、ctional targets for production. 3.6.1 Color (FLTM BI 109-01) (SAE J1545 X-Rite MA68II Multi-Angle Spectrophotometer or equivalent) Shall match the Master Appearance Standard color panel. 3.6.2 Wave Scan CF, min equal or better (Appearance is to be measured with than control a reliable instrument suc
41、h as Byk Gardner Wave Scan.) Target Values: Horizontal Vertical Dark Solids (L15 90) 65 55 Dark Metallic (L15 90) 60 50 Tricoat 60 45 ENGINEERING MATERIAL SPECIFICATIONWSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 21
42、3.6.3 Gloss, min 92 (ASTM D 523, 20 degree Glossmeter) 3.6.3.1 Gloss After Rebake, max 4 unit decrease Rebake panel at target bake conditions. 3.6.4 Leveling The surface of material(s) under test shall be equal to or better than currently approved production material for smoothness when applied and
43、baked under identical conditions. Orange peel values taken from Wavescan data shall be reported. 3.6.5 Sanding 3.6.5.1 Holdout There shall be no evidence of dulling, gloss loss or change of image clarity when the 3 Wet paint system is applied over sanded (P400 and P800 grit sand-paper) and unsanded
44、ecoat, OEM repaired topcoat, and plastic substrate. There shall be no prominence of sand scratches. 3.6.5.2 Telegraphing There shall be no evidence of color shift when the 3 Wet paint system is applied over sanded (P400 and P800 grit sandpaper) and unsanded ecoat OEM repaired topcoat, and plastic su
45、bstrate. 3.6.6 General The material system shall cure to a presentable, serviceable, mar-resistant film showing no craters, seediness, abnormal roughness or excessive metallic mottling. It shall have reasonable tolerance for ordinary cleaning (such as automatic car washes) and exhibit excellent poli
46、shing characteristics when wheel polished with a wide range of various compounds and cleaners. 3.7 FILM PROPERTIES 3.7.1 Film Thickness (ASTM D186) Target values shall be defined from process window (para 3.5). 3.7.2 Dry Hiding - Pigmented Basecoat 15 - 30 micrometers (FLTM BI 158-01) The basecoat i
47、s required to provide complete visual hiding over black and gray hiding chart. When an exception to this hiding requirement is needed for special colors, concurrence must be obtained from all affected Ford activities. 3.7.2.1 Pigmented Midcoat The pigmentation of the midcoat shall be such that hidin
48、g of the basecoat does not occur. The max allowable pigment to binder ratio (P:B) is 0.15.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 7 of 21 3.7.3 Ultraviolet Light Transmittance Max li
49、ght transmission through basecoat applied at 80% of dry hiding shall be no more than 0.1% at 360 nm and 5% at 400 nm. The complete primer/basecoat/clearcoat system shall at 80% of minimum film builds (e.g. Primer 18 mircrons, Basecoat 80% of dry hiding, a solution in water of 0.75% by weight CaSO4adjusted to a pH of 4; deionized water (DI) and tap water, Bee Dropping (Ford Method 24; Formic Acid 47 gm, Tannic Acid in 10% water 24 gm, Honey 24 gm, Albumin 5 gm) and Ford European Solution 10 (10 grams Iron Sulfate/1N Sulfuric Acid solution H2SO4). The latter two soluti
