1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2013 01 14 Activated J. Cottrell, NA Controlled document at www.MATS Copyright 2013, Ford Global Technologies, LLC Page 1 of 20 ENAMEL, (2 WET), HIGH SOLIDS THERMOSET WSS-M33J11-A1 STRAIGHT SHADE (NON-METALLIC) MONOCOAT, PROCESSED WITH
2、 WSS-M33J10-A1, EXTERIOR ENAMEL, (2 WET), HIGH SOLIDS THERMOSET WSS-M33J11-B1 STRAIGHT SHADE (NON-METALLIC) MONOCOAT, PROCESSED WITH WSS-M33J10-B1, REDUCED VISCOSITY, EXTERIOR 1 SCOPE The materials defined by these specifications are coatings, which consist of a pigmented thermoset straight shade (n
3、on-metallic) monocoat enamel in a wet-on-wet (2 Wet) process. These materials are monobaked. Note: for baked primer use with WSS-M6J152-B1, B2 and for Wet on Wet use with WSS-M33J10-A1, B1 2 APPLICATION These specifications were released originally for materials used over baked primer or as the comb
4、ined primer surfacer (guidecoat) and monocoat finish when applied wet-on-wet (2 Wet) and mono baked on automobile bodies, hoods, fenders and other exterior parts. These materials shall be satisfactory for use over previously baked enamel, as in paint repair or two toning operations. These materials
5、have been formulated to provide windshield bonding without the use of flange primer (direct glazing) and allow for flush glass designs. The monocoat portion is used alone, without primer, as an interior baking enamel for some applications. 3 REQUIREMENTS The responsible Materials Engineer will desig
6、nate the appropriate material to be used as a control for testing 3.1 STANDARD REQUREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the companys standard requirements for production materials (WSS-M99P1111-A). Requirements may also include, but are not limited t
7、o, any applicable performance specification(s) and system design specification(s) as directed by Ford. 3.2 COMPOSITION 3.2.1 Resin 3.2.1.1 Primers shall be modified polyester and/or modified polyurethane crosslinkable resin(s), with melamine and/or reactive urethane crosslinker(s) or equivalent. 3.2
8、.1.2 Topcoats shall be thermosetting, synthetic resins with a melamine 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 adhesio
9、n. ENGINEERING MATERIAL SPECIFICATION WSS-M33J11-A1/B1 Copyright 2013, Ford Global Technologies, LLC Page 2 of 20 3.2.2 Pigments 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
10、paint sagging, roughness or dry spray at specified film thicknesses. Solvents shall be HAPS compliant if it is required by local government regulations. 3.2.4 Ultra Violet Light Absorber(s) (UVA) and Hindered Amine Light Stabilizers (HALS) All approved materials shall include with the initial Sample
11、 Report an Ultra-Violet/Visible spectroscopic analysis. This shall be recorded and filed by the approving Paint Engineering Laboratory of the Ford Motor Company as a reference standard for future use and recertification. The coating system shall contain sufficient fortification of suitable UVA and H
12、ALS 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 and application vi
13、scosity. Over the application viscosity range, material shall be in compliance with local emissions regulations. 3.3.1 Non-Volatile Content See initial sample +/- 2 % (ASTM D2369-07) 3.3.2 Volatile Organic Content See initial sample +/- 1.5 % (ASTM D3960) 3.3.3 Weight per Volume See initial sample (
14、ASTM D1475) +/-0.025 g/ml 3.3.4 Volume Solids See initial sample +/-1.3 % (ASTM D2697) Primer 42%minimum Topcoat 49% minimum 3.3.5 Viscosity Report (ASTM D1200) Supplier shall report value at application reduction. 3.3.6 Stability (ASTM D1849) 3.3.6.1 Shelf Stability No more than 30% increase (90 da
15、ys) in viscosity permitted. ENGINEERING MATERIAL SPECIFICATION WSS-M33J11-A1/B1 Copyright 2013, Ford Global Technologies, LLC Page 3 of 20 3.3.6.2 Accelerated Stability No more than 30 % (60 C, 16 h) increase in viscosity permitted. After the accelerated stability test, the material shall pass all s
16、pecification requirements. Critical testing must include; solvent pop, sag resistance, appearance, direct to glass bonding, intercoat adhesion, repair paint system wetting, and tape/label adhesion. 3.3.7 Resistivity 0.05 to 2.00 megohms (ASTM D5682) Volatile solvents and other components affecting e
17、lectrical 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, pr
18、etreated aluminum, unpolished pretreated cold rolled steel and current production primed exterior thermosetting plastic. Record all substrate information. Electrocoat: Current Ford production approved medium build gray cathodic electrocoat, applied at 20 - 23 micrometers and baked utilizing the appr
19、opriate bake schedule. Record electrocoat and oven type used. Primer: Within a wet-on-wet application process apply primer surfacer to required dry film thickness by spray under conditions appropriate for primers, and flash prime coat 180 seconds or as specified, prior to topcoat application. Record
20、 primer application information and include with the submission data package for system approval. Topcoat: Apply topcoat to required dry film thickness (40-55 microns) and flash 10 minutes or as required. Bake using appropriate bake schedule as defined by paragraph 3.5. Record topcoat application in
21、formation and oven type used and include with the submission data package for system approval. Catalyzed Low Bake Repair: LBR 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 s
22、ystem, remove masking, flash and bake 10 minutes at 100 C metal temperature. 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
23、 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 window of the control and candidate materials. The
24、 four variables/parameters to be included in the design are bake temperature, bake time, primer and topcoat film thickness. 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 mate
25、rials engineer to set up the final DOE. Responses to the response surface DOEs will be based ENGINEERING MATERIAL SPECIFICATION WSS-M33J11-A1/B1 Copyright 2013, Ford Global Technologies, LLC Page 4 of 20 on the materials tested and will be chosen from tests listed within the specification. Minimal c
26、ritical performance testing required: cross-hatch adhesion, condensing humidity, acid/alkali resistance, scratch resistance, stone chip (SAE J400), intercoat adhesion (ICA), and quick knife glass bonding adhesive adhesion. The candidate coating system versus a control will also be required to be eva
27、luated for application 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
28、processing parameters. 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 mean values defined by the process window, and should be used a
29、s directional targets for production. 3.6.1 Color (FLTM BI 109-01) (SAE J1545 X-Rite MA-68 five angle CMC or equivalent) Shall match the Master Appearance Standard color panel at the 45 angle 3.6.2 Wave Scan CF equal or better (Appearance is to be measured with than control a reliable instrument suc
30、h as Byk Gardner Wave Scan.) Target Values Horizontal Vertical Light Straight Shades (L15 80) 50 40 Medium Straight Shades (L15 79-50) 50 40 Dark Straight Shades (L15 2.5 Mpa Over Humidity Exposure Initial Cure: 3 days 23C / 50% RH + 14 Days 38C / 100% RH White Target Target Under Pull Strength 2.5
31、Mpa Over Heat Age Initial Cure: 3 days 23C / 50% RH + 14 Days 90 White Target Target Under Pull Strength 2.5 Mpa Over Cold Pull Initial Cure: 3 days 23C / 50% RH Followed by -9C cold pull White Target Target Under Pull Strength 2.5 Mpa Over Hot Pull Initial Cure: 3 days 23C / 50% RH Followed by 43C
32、hot pull White Target Target Under Pull Strength 2.5 Mpa Over WSS-M2G316 WOM & Fla Exp. (10 sets lap shears) 2000h WOM White Target Target Target Pull Strength 2.5 Mpa 1 & 2 yr. Fla Exposure AVP T118-001 Table 3, Column 3 Wedge / Quick-knife panels Primer Wedge Initial Cure: 3 days 23C / 50% RH Post
33、 Hum.: 14 Days 38C / 100% RH White .4 to 2.0 mils 1 mil Under 95% CF Failure of the urethane bead Target Over Monocoat Wedge (over low primer FB) Initial Cure: 3 days 23C / 50% RH Post Hum.: 14 Days 38C / 100% RH White Target -25% .5 to 2.5 mils Under Target Over Monocoat Wedge (over high primer FB) Initial Cure: 3 days 23C / 50% RH Post Hum.: 14 Days 38C / 100% RH White Target +25% .5 to 2.5 mils Under Target Over Repair Two repaint /rebake cyles (three total layers) Initial Cure: 3 days 23C / 50% RH Post Hum.: 14 Days 38C / 100% RH White 1.5 0.8 mils Under
