1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2014 01 02 Released T. Honey, T. Weingartz NA Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 1 of 21 ENAMEL, WATERBORNE, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET WSS-M33J12-A1 PRIMER, PROCESSED
2、WITH WSS-M33J12-A2/WSS-M33J12-A4, EXTERIOR ENAMEL, WATERBORNE, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET WSS-M33J12-A2 BASECOAT PROCESSED WITH WSS-M33J12-A1/WSS-M33J12-A4, EXTERIOR ENAMEL, WATERBORNE, (3 WET) COMPLIANCE VOC, HIGH SOLIDS THERMOSET WSS-M33J12-A3 MIDCOAT, PROCESSED WITH WSS-M33J12-
3、A1/WSS-M33J12-A2/WSS-M33J12-A4, EXTERIOR ENAMEL, 2-COMPONENT URETHANE, (3 WET) COMPLIANCE VOC, HIGH SOLIDS WSS-M33J12-A4 THERMOSET CLEARCOAT, PROCESSED WITH WSS-M33J12-A1/WSS-M33J12-A2, EXTERIORCOMPOSED OF WSS-M33J12-A6/WSS-M33J12-A7 ENAMEL, 2-COMPONENT URETHANE, (3 WET) COMPLIANCE VOC, HIGH SOLIDS
4、WSS-M33J12-A5 THERMOSET TINTED CLEARCOAT, PROCESSED WITH WSS-M33J12-A1/ WSS-M33J12-A2, EXTERIORCOMPOSED OF WSS-M33J12-A6/WSS-M33J12-A7 PART A - POLYOL COMPONENT, (3WET) COMPLIANCE VOC, PROCESSED WITH WSS-M33J12-A6 WSS-M33J12-A7 PART B - ISO COMPONENT, (3WET) COMPLIANCE VOC, PROCESSED WITH WSS-M33J12
5、-A7 WSS-M33J12-A6 1 SCOPE The materials defined by these specifications are coatings, which consist of primer surfacers over which is applied a pigmented 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. U
6、nique 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 tinted clear. Tricoat colors may be processed wet-on-wet-on-wet-on-wet application and monobaked or in a wet on bake operatio
7、n. 2 APPLICATION 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 monobaked on automobile bodies, hoods, fenders and other exterior parts, and shall be satisfactory
8、for use over 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 interi
9、or baking enamel for some applications. 3 REQUIREMENTS Tests shall be made on the basis of comparison with an approved production material chosen by the approving materials engineer. ENGINEERING MATERIAL SPECIFICATION WSS-M33J12-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page
10、 2 of 21 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). For the materials described within this specification those requirements include but are not limited to the p
11、erformance specification and the system design specification. 3.2 COMPOSITION 3.2.1 Resin 3.2.1.1 Primers shall be waterborne modified polyester and/or modified polyurethane crosslinkable resin(s), with melamine and/or reactive urethane crosslinker(s) or equivalent. 3.2.1.2 Basecoats and traditional
12、 tricoat midcoat shall be waterborne thermosetting, synthetic resins with a melamine crosslinking system or equivalent. 3.2.1.3 Clearcoats will be thermosetting, 2-component urethane synthetic resins with a hybrid crosslinking system or equivalent. Each will be appropriately fortified so as to meet
13、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 Pigments Pigments are exterior quality automotive grade selected to meet durability requirements. 3.2.3 Solvents The volatility of the solvents will
14、 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 local government regulations. 3.2.4 Ultra Violet Light Absorber(s) (UVA) and Hindered Amine Light Stabilizers (HALS) All approved materials shall
15、 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 contain suffi
16、cient 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. ENGINEERING MATERIAL SPECIFICATION WSS-M33J12-A1/A2/A3/A4/A5/A6/A7 Copy
17、right 2014, Ford Global Technologies, LLC Page 3 of 21 3.3 PHYSICAL PROPERTIES LIQUID STATE The following evaluation 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 C
18、ontent See initial sample +/- 2% (ASTM D2369-07 for North America) (FLTM BI 102-01 for Europe) 3.3.2 Volatile Organic Content See initial sample +/- 1.5% (ASTM D3960) 3.3.3 Weight per Volume See initial sample +/- 0.025 g/ml (ASTM D1475) 3.3.4 Volume Solids, range at Application Viscosity See initia
19、l sample +/-1.3% (ASTM D2697 or FLTM BI 154-02) Primer 30% minimum Basecoat 19% minimum Clearcoat 48% minimum 3.3.5 Pigment Content in Tinted Clearcoat 0.25% max (ASTM D2471, max weight % on total formula of colored pigment) 3.3.6 Viscosity Report at application (ASTM D7395) rate 3.3.7 Stability (AS
20、TM D1849) 3.3.7.1 Shelf Stability 90 days No more than 30% increase in viscosity permitted. 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 specification requirements. Critical testing must
21、 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 WSS-M33J12-A7 Polyol Clearcoat Component (ASTM D5682) 3.3.9 pH 7.8 8.6 WSS-M33J12-A1,A2,A3 Waterborne Coatings
22、(ISO 976:1996) ENGINEERING MATERIAL SPECIFICATION WSS-M33J12-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page 4 of 21 3.4 PREPARATION OF TEST PANELS Substrate: All current production substrates, including but not limited to, pretreated galvanized steel, pretreated electro galv
23、aneal 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 electrocoat, applied at 20 - 23 micrometers
24、 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 (10-25 microns) by spray under conditions appropriate for primes, and flash prime coat 120 seconds (+
25、5 x 82C) 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 color dependent range 15- 30 mic
26、rons) by spray under (OEM) conditions appropriate for basecoats, and flash 120 seconds (+4 x 82C) 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 (60 microns) and flash
27、 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 with the submission data pa
28、ckage 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 criteria. Catalyze ename
29、l 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. A blocked ISO Part B is recommended for LBR. See para 4.2 Table
30、 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 3.5 process window. 3.5 PROCESS WINDOW DEFINITION
31、- 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 the design are bake temperature, bake time, primer
32、 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 engineer to set up the final DOE. Responses to the respon
33、se 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, stone chip (SAE J400 and Erichsen), intercoat adh
34、esion (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 ENGINEERING MATERIAL SPECIFICATION WSS-M33J12-A1/A2/A3/A4/A5/A6/A7 Copyright
35、 2014, Ford Global Technologies, LLC Page 5 of 21 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 parameters. Consideratio
36、n 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 directional targets fo
37、r 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 equal or better (Appearance is to be measured with than control a reliable instrument such as Byk Gardner Wave S
38、can.) Target Values: Horizontal Vertical Dark Solids (L15 90) 65 55 Dark Metallic (L15 90) 60 50 Tricoat 60 45 3.6.3 Gloss 92 min (ASTM D523, 20 degree Glossmeter) 3.6.3.1 Gloss After Rebake 4 unit decrease max Rebake panel at target bake conditions. 3.6.4 Leveling The surface of material(s) under t
39、est 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 There shall be no evidence of dulling, gloss loss or change of im
40、age 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. ENGINEERING MATERIAL SPECIFICATION WSS-M33J12-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Glob
41、al Technologies, LLC Page 6 of 21 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 substrate. 3.6.6 General The material system shall cure to a present
42、able, 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 polishing characteristics when wheel polished with a wide range of var
43、ious compounds and cleaners. 3.7 FILM PROPERTIES 3.7.1 Film Thickness (ASTM D1186) 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
44、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 hiding of the basecoat does not occur. The max allowable pigment to bi
45、nder ratio (P:B) is 0.15. 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 system shall at 80% of minimum film builds (e.g. Primer 12 mircrons, Base
46、coat 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
47、 Acid solution H2SO4). Apply 2.0 ml of specified solutions along entire length of 2 test panels. Place the uncovered panels in a test cabinet at 40 C for 1 hour. Repeat at 50 C and 60 C. Rinse any remaining solution with water. Examine panels for etching, discoloration, pitting, etc. Report etch-fre
48、e temperature for test material and control. ENGINEERING MATERIAL SPECIFICATION WSS-M33J12-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page 8 of 21 3.8.3 Xylene Resistance No softening, or dulling permitted Using a circular motion, rub surface of enamel 10 times with wetted ch
49、eesecloth. 3.8.4 Fluid Spotting Resistance (FLTM BI 113-01) No color change, dulling, surface distortion, spotting or permanent softening permitted. Test 2 sets of panels: (1) Aged per test method (2) Unaged and conditioned less than 8 h The following fluids will be tested: . Deionized Water . Liquid Soap . Windshield Washer Fluid (Current Production Fill), Concentrated (100%) . Coolant Solution (Current Production Fill), Concentrated (100%) . Motor Oils (Current Production Fill) . Bug and Tar Re
