1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 01 2013 06 10 Revised See Summary of revisions. A.Reilly, EU 2010 04 29 Activated T. Weingartz, NA Copyright 2013, Ford Global Technologies, LLC Page 1 of 22 ENAMEL, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET PRIMER, WSS-M33J10-A1 PRO
2、CESSED WITH WSS-M33J10-A2/WSS 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
3、/WSS-M33J10-A4, EXTERIOR ENAMEL, (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 ENAM
4、EL, (3 WET) COMPLIANCE VOC, 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
5、, (3 WET) COMPLIANCE VOC, HIGH 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, E
6、XTERIOR ENAMEL, (3 WET) COMPLIANCE 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 pigmente
7、d thermoset basecoat enamel 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
8、 is applied a clear or tinted 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 SPECIFICATION WSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Copyright 2013, Ford Global Technologies, LLC Page 2 of 22 2 APPLICATION
9、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 pre
10、viously 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 enam
11、el 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 primer s
12、urfacer/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 standa
13、rd 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 polyeste
14、r 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 thermos
15、etting, 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 Pigmen
16、ts 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 loc
17、al government regulations. ENGINEERING MATERIAL SPECIFICATION WSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Copyright 2013, Ford Global Technologies, LLC Page 3 of 22 3.2.4 Ultra Violet Light Absorber(s) (UVA) and Hindered Amine Light Stabilizers (HALS) All approved materials shall include with the initi
18、al 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 contain sufficient fortification of
19、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 evaluation must be conducted at as shipped
20、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 Volatile Organic Content, range See init
21、ial 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% minimum Clearcoat 49% minimum 3.3.5 Pigment
22、Content in Tinted Clearcoat 0.25% max (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% increase in viscosity permitted. EN
23、GINEERING MATERIAL SPECIFICATION WSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Copyright 2013, Ford Global Technologies, LLC Page 4 of 22 3.3.7.2 Accelerated Stability (60 C, 16 h) No more than 30% increase in viscosity permitted. After the accelerated stability test, the material shall pass all specific
24、ation 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 D 5682) Volatile solvents and other components affecting electri
25、cal 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 galvanized steel, pretreated electro galvaneal steel, pretreat
26、ed 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 electrocoat, applied at 20 - 23 micrometers and baked utilizing
27、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 primes, and flash prime coat 180 seconds or as specified, prio
28、r 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 color dependent range 15- 30 microns) by spray under (OEM) con
29、ditions 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 (40-55 microns) and flash 10 minutes or as required. Bake for 2
30、0 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 with the submission data package for system approval. Catalyzed L
31、ow 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 criteria. Catalyze enamel as per manufacturers recommendations
32、. 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 SPECIFICATION WSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Copyright 2013, Ford Globa
33、l Technologies, LLC Page 5 of 22 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 application and coating thickness optimization including target ranges are to be defined within para
34、 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 window of the control and candidate materials. The four variables/parameters to be included in
35、 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 variables/parameters. This screening experiment should be reviewed with the materials engine
36、er 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 required: cross-hatch adhesion, condensing humidity, acid/alkali resistance, scratch resistance
37、, 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 application robustness utilizing DOEs agreed upon by the Ford responsible Approving Engineer. Infor
38、mation 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 parameters. Consideration should be given to an application process window DOE to assess impact of
39、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 directional targets for production. 3.6.1 Color (FLTM BI 109-01) (SAE J1545 X-Rite MA68II Multi-A
40、ngle Spectrophotometer or equivalent) Shall match the Master Appearance Standard color panel. 3.6.2 Wave Scan CF equal or better (Appearance is to be measured with than control a reliable instrument such as Byk Gardner Wave Scan.) Target Values: Horizontal Vertical Dark Solids (L15 90) 65 55 Dark Me
41、tallic (L15 90) 60 50 Tricoat 60 45 ENGINEERING MATERIAL SPECIFICATION WSS-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Copyright 2013, Ford Global Technologies, LLC Page 6 of 22 3.6.3 Gloss 92 min. (ASTM D 523, 20 degree Glossmeter) 3.6.3.1 Gloss After Rebake 4 unit decrease max Rebake panel at target bake
42、 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 baked under identical conditions. Orange peel values taken from Wavescan data shall be reported. 3.6.5 Sanding 3.6.5.1 Holdout The
43、re 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 ecoat, OEM repaired topcoat, and plastic substrate. There shall be no prominence of sand scratches. 3.6.5.2 Telegraphing There sha
44、ll 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 substrate. 3.6.6 General The material system shall cure to a presentable, serviceable, mar-resistant film showing no craters, seedin
45、ess, abnormal roughness or excessive metallic mottling. It shall have reasonable tolerance for ordinary cleaning (such as automatic car washes) and exhibit excellent polishing characteristics when wheel polished with a wide range of various compounds and cleaners. 3.7 FILM PROPERTIES 3.7.1 Film Thic
46、kness (ASTM D 1186) 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 is required to provide complete visual hiding over black and gray hiding chart. When an exception to this hiding requirement is n
47、eeded 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 hiding of the basecoat does not occur. The max allowable pigment to binder ratio (P:B) is 0.15.ENGINEERING MATERIAL SPECIFICATION WSS
48、-M33J10-A1/A2/A3/A4/A5/B1/B2/B3/B4/B5 Copyright 2013, Ford Global Technologies, LLC Page 7 of 22 3.7.3 Ultraviolet Light Transmittance Max light 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 sy
49、stem 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 CaSO4 adjusted 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 solutions are both available from Global Paint Engineering. Apply 2.0 ml of specified solutions along entire length of 2 test panels. Pla
