1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 04 09 Revised Added G1, G2, para 3.10.7 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) available from Global Paint
2、 Engineering (North America Paint Engineering). Apply 0.05 ml of specified solutions along entire length of 2 test panels. Place on gradient bar (38 - 82 C, calibrated for heat-up rate of 2 minutes or less for 0.09 mm steel substrate). Remove 1 panel after 15 minutes at temperature, other after 30 m
3、inutes. Rinse any remaining solution with water. Examine panels for etching, discoloration, pitting, etc. Report etch-free temperature for test material and control. NOTE: Process window evaluation will be done using 2 solutions: (1) Sulfuric Acid pH3, 15 minute exposure; and (2) CaSO4 pH4, 30 minut
4、e exposure. 3.10.3 Xylene Resistance No softening, or dulling permitted Using a circular motion, rub surface of enamel 10 times with wetted cheesecloth. 3.10.4 Fluid Spotting Resistance (FLTM BI 113-01) No color change, dulling, surface distortion, spotting or permanent softening permitted. Test 2 s
5、ets of panels: (1) Aged per test method (2) Unaged and conditioned less than 8 h ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 10 of 21 Copyright 2002, Ford Global Technologies, Inc. The following fluids will be tested: . Deionized Water . Liquid Soap
6、 . Windshield Washer Fluid (Current Production Fill), Concentrated (100 %) . Coolant Solution (Current Production Fill), Concentrated (100 %) . Motor Oils (Current Production Fill) . Bug and Tar Remover* (Ford Part No. B7A-19520-AA) . Rust Preventative Coatings (including cavity waxes) *Aged panels
7、only, apply Remover as directed on package, leave on for 5 minutes. Clean and rinse panels. 3.10.5 Cold Checking Resistance 15 cycles (FLTM BI 107-02) 3.10.6 Fuel Resistance No color change, dulling, surface distortion or permanent softening permitted. 3.10.6.1 Plastic Substrates (FLTM BO 101-05)3.1
8、0.6.2 Metal Substrates Procedure for Drip Test: Run tests using Blends “A“ and “B“ separately The size of the test panels shall be 100 x 150 mm. A burette must be used to allow the Gasohol to drip at a rate which requires approximately 1 h for the 50 mL to be evacuated (equivalent to approximately 1
9、 drop every 3 s). Note: The panel shall be placed paint side up at an angle of 60 deg from the horizontal. The distance from the tip of the burette to the spot where the drop impinges on the panel is 300 mm. (The spot is centered 100 mm above the lower edge of the test panel.) The test panel shall b
10、e placed in a flat open dish to contain accumulated Gasohol. Conduct testing in a well ventilated hood at ambient room temperature of 24 +/- 2 C, away from all sources of ignition. Gasohol Composition by Volume ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2
11、 Page 11 of 21 Copyright 2002, Ford Global Technologies, Inc. Blend A: ASTM Reference Fuel C 85 % Methanol 15 % Blend B: ASTM Reference Fuel C 15 % Methanol 85 % Remove panels from test and allow them to recover for 1 h at ambient room conditions. Examine panels for color change, dulling, and surfac
12、e distortion or permanent softening. 3.10.7 Scratch and Mar Resistance Nano Scratch Test (DVM-0058-PA) Average of the weathered and un-weathered Fracture Load must be greater than: (mN) WSS-M33J3-D1-F5 6.0 WSS-M33J3-G1-G2 13.0 Average of the weathered and un-weathered Plastic deformation must not be
13、 greater than: (Micrometers) WSS-M33J3-D1-F5 0.50 WSS-M33J3-G1-G2 0.35 3.10.8 Intercoat Adhesion, max Grade 2 (FLTM BI 106-01, Part B) 3.10.9 Chipping Resistance No more than 5 % (SAE J400, as indicated) area removed with 1.41 l (-18 C and 25 C) no chip greater than 3 mm 3.10.10 High Performance Sto
14、ne Chip 4 Resistance, min (FLTM BI 157-06) 3.10.11 Sag Resistance Equal to or (FLTM BI 122-02) better than control enamel 3.10.12 Water Immersion 240 h (FLTM BI 104-01, B) No blistering, dulling, wrinkling, softening and/or loss of adhesion permitted. ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/
15、D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 12 of 21 Copyright 2002, Ford Global Technologies, Inc. 3.11 WEATHERING After exposure (para 3.11.1 and 3.11.2), panels must meet the requirements of para 3.11.3. 3.11.1 Natural Weathering Florida Exposure (SAE J1976, Procedure A) New Pigment 2 years re
16、quired, 3 - 5 years and 10 year submission New Color, Known 1 year required, 2 - 5 years and 10 year Pigments and Resins submission New Resin Technology 5 years required, 10 year submission (one panel for every year of testing as specified in para 5.2, Table 3) 3.11.2 Accelerated Weathering (SAE J19
17、60, 0.55 W/m2 Irradiance) New Pigment 4000 h in applicable resin system New Color, Known 3000 h required Pigment and Resins New Resin Technology 6000 h required, Borosilicate Inner and Outer Filters (para 5.2, Table 3) 3.11.3 Testing After Exposure (FLTM BI 160-01, B) 3.11.3.1 Appearance After 1 yea
18、r exposure, there shall be no visual color change, minimal gloss and DOI loss not to exceed 2 year requirement. There shall be no blistering, cracking, peeling or microchecking. After 2 years Florida exposure or 3000 h Accelerated weathering, no less than AATCC color rating 4. There shall be no blis
19、tering, cracking, peeling or microchecking. After 5 Florida years exposure or 6000 h Accelerated weathering, there shall be no excessive color change, blistering, cracking, peeling or microchecking. ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 13 of
20、21 Copyright 2002, Ford Global Technologies, Inc. 3.11.3.2 Gloss After Exposure (ASTM D 523, 20 degree Glossmeter) 2 year exposure, min 3000 h, min Non-Tinted Clearcoats, max 15 % loss (WSS-M33J3-D2, D5, E1, E3) Tinted Clearcoats, max 20 % loss (WSS-M33J3-F1, F3, F4, F5) 3.11.3.3 DOI After Exposure
21、(FLTM BI 110-03) 2 year exposure, min 3000 h, min Non-Tinted Clearcoats, max 20 % loss (WSS-M33J3-D2, D5, E1, E3) Tinted Clearcoats, max 30 % loss (WSS-M33J3-F1, F3, F4, F5) 3.11.3.4 UVA Retention Report values (FLTM AI 103-02) as function of New Technology Only exposure time 3.11.3.5 Photooxidation
22、 Report values (FLTM AI 103-03, B) as function of New Technology Only exposure time 3.11.3.6 Adhesion After Water Immersion (FLTM BI 104-01) 16 h (FLTM BI 106-01, Part B) Grade 2, max There shall be no blistering or delamination between any layer of enamel system. To be evaluated on all exposure int
23、ervals. 3.12 BASECOAT WSS-M33J3-D1, D4, E2 ONLY FOR INTERIOR APPLICATIONS (Non-visible or non-UV-exposed areas) 3.12.1 Physical Properties 3.12.1.1 The physical properties of basecoat WSS-M33J3-D1, D4, E2 are determined by requirements of the basecoat/clearcoat enamel. Refer to para 3.5 for specific
24、 requirements. 3.12.2 Preparation of Test Panels Panels will be prepared as in para 3.6 and 5.2. ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 14 of 21 Copyright 2002, Ford Global Technologies, Inc. 3.12.3 Appearance 3.12.3.1 Color (FLTM BI 109-01) Th
25、e color of the basecoat is determined by the requirements of the basecoat/clearcoat enamel to match the Ford master panel. 3.12.3.2 Gloss, All Colors (ASTM D 523, 20 degree Glossmeter) Gloss varies with each color due to pigmentation requirements. 3.12.3.3 Gloss, After Rebake (ASTM D 523, 20 degree
26、Glossmeter) No more than 4 units decrease in gloss is permitted when rebaked at target bake conditions. 3.12.3.4 General The basecoat shall bake out to a presentable, serviceable film showing no craters, seediness, abnormal roughness or excessive metallic mottling. It shall have reasonable tolerance
27、 for ordinary cleaning. 3.12.4 Film Properties 3.12.4.1 Film Thickness (ASTM D 1186)See para 5.2, Table 1. 3.12.4.2 Adhesion No chipping or flaking (FLTM BI 106-01) 3.12.4.3 Hardness (ASTM D 1474) Record values. Coating shall be sufficiently cured after baking so that it can meet the requirement of
28、para 3.12.5. ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 15 of 21 Copyright 2002, Ford Global Technologies, Inc. 3.12.5 Resistance Properties 3.12.5.1 Water and Soap Spotting AATCC Rating 4 - 5 (FLTM BI 113-01) 3.12.5.2 Acid Spotting AATCC Rating 4
29、- 5 (FLTM BI 113-05) 3.12.5.3 Resistance to Xylene (See para 3.10.3) No dulling, softening or other undesirable effects are permitted. 3.12.5.4 Abrasion Resistance, min 700 cycles (FLTM BN 108-02, CS #10 wheels 500 g load) Failure is defined as wear through of the paint film, exposing primer. 3.12.5
30、.5 Performance with Component Items Material shall be compatible with components with which it must perform in unison. Candidate material shall not adversely affect adhesion of said systems. 3.13 COMPATIBILITY REQUIREMENTS 3.13.1 The approved coating shall have good compatibility with sealers, body
31、side moldings, decals, striping materials, stone guard primers and pressure sensitive tapes, etc. 3.13.2 Supplier of material shall keep abreast of changes in technology of related materials which may affect the compatibility and performance of this product. In the advent of adverse performance, the
32、 supplier shall notify all affected Ford activities in writing. 3.13.3 All materials approved under this specification shall meet all engineering requirements when applied under assembly plant conditions. 3.14 ADDITIONAL REQUIREMENTS Additional requirements for material and/or manufactured parts may
33、 be specified on the Engineering drawing, Engineering parts specification, performance specification, System Design Specification (SDS) and/or Component Design Specification (CDS). ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 16 of 21 Copyright 2002,
34、 Ford Global Technologies, Inc. 3.15 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 changes to the material originally approved under this specification, w
35、hether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify the affected Purchasing, and Materials Engineering activities (with reasons) of the proposed changes. Upon notification of the Company, further instructions will be provided. Not
36、e: Suppliers should be prepared to provide test data and samples demonstrating compliance to this specification, if requested. Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in Restricted Substan
37、ce Management Standard WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification for direct supply to the Company must have prior approval. Certain materials subcontracted by part suppliers may also require prior approval. These include materials critical to the Companys busi
38、ness for regulatory, safety, environmental or compatibility requirements or contractual agreements. Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Materials Engineering activity. Upon request, the Supplier shall submit a complet
39、ed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification. 5. GENERAL INFORMATION The material data included herein is for information only and is not a requirement
40、 for the supplier. Contact The Design Responsible Materials Engineering Activity for substrates currently used in production. 5.1 PAINT SYSTEMS (used in current production applications) 5.1.1 Electrocoat primer (baked) + spray primer (baked) + basecoat/clearcoat applied wet-on-wet and monobaked. 5.1
41、.2 Electrocoat primer (baked) + spray primer (baked) + basecoat + midcoat + clearcoat applied wet-on-wet-on-wet and mono-baked. 5.1.3 Electrocoat primer (baked) + spray primer (baked) + basecoat (baked) + midcoat + clearcoat applied wet-on-wet and mono-baked. ENGINEERING MATERIAL SPECIFICATION WSS-M
42、33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 17 of 21 Copyright 2002, Ford Global Technologies, Inc. 5.2 TOPCOAT PROCESSING CONDITIONS AND TEST REQUIREMENTS MATRICES Process window (para 3.7) will be used to define targets, high/ max, and lows/min. These values will be used to establish th
43、e conditions in Table 1 and shall be used to prepare panels for all tests in para 3.8, 3.9, 3.10, 3.11 and 3.12. System Colors to be tested Applicable Tables New Technologies Black, White, Light Metallic, Tables 1, 2, 3 Med. Red Metallic and Dark Metallic New Pigments/ All Colors Tables 1, 4 New Col
44、ors ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 18 of 21 Copyright 2002, Ford Global Technologies, Inc. TABLE 1: TOPCOAT PROCESSING CONDITIONS REQUIRED FOR PARA 3.8, 3.9, 3.10, 3.11 AND 3.12 BASECOAT/CLEARCOAT PROCESSING CONDITIONS FOR PARA 3.8, 3.9
45、, 3.10 AND 3.11 Conditions OEM Clearcoat Filmbuild Bake Time Bake Temperature Recoats Number of Recoats 1 Low Min Min No N.A. 2 Low Max Max No N.A 3 Target Target Target No N.A 4 High Min Min No N.A 5 High Max Max No N.A 6 Target Target Target Yes 1 7 Target Target Target Yes 2 8 Target Target Targe
46、t Yes 3 9 Target Min Min Yes 3 10 Target Max Max Yes 3 11 (ICA5) Target 10 minutes MT Target 6 C No N.A 12 (ICA4) Target 53 minutes MT Target + 13 C Yes 1 (10 minutes at Target 6 C) 13 (ICA3) Target 23 minutes MT Target + 13 C Yes 1 (10 minutes at Target 6 C) 14 Low Target Target Yes LBR 15 Target T
47、arget Target Yes LBR 16 Low Max Max Yes LBR 17 Target Target Target No N.A. 18 Low Max Max No N.A. BASECOAT PROCESSING CONDITIONS FOR PARA 3.12 Conditions Basecoat Filmbuild Bake Time Bake Temperature Recoats Number of Recoats 19 80 % of Dry Hiding Min Min No N.A. 20 Dry Hiding Max Max No N.A NOTE 1
48、: All basecoats applied at dry hiding filmbuilds for conditions 1 - 18. NOTE 2: Recoats are prepared using same basecoat/clearcoat (in the same color) as used on OEM topcoat, except for condition 14, 15 and 16 which uses catalyzed low bake repair system. NOTE 3: For all ICA 5 panels (condition # 11)
49、 primer is to be baked 53 minutes at 193 C (metal temperature). NOTE 4: Panels for conditions # 17 and 18 are prepared using basecoats and clearcoats with no ultraviolet light absorbers (UVAs). Hindered amine light stabilizers (HALS), if normally used in formulation, shall be present in all systems regardless of UVA or not. ENGINEERING MATERIAL SPECIFICATION WSS-M33J3-D1/D2/D3/D4/D5/E1/E2 E3/F1/F2/F3/F4/F5/G1/G2 Page 19 of 21 Copyright 2002, Ford Global Technologies, Inc. TABLE 2: TEST MATRIX FOR NEW TECHNOLOGIES Section Panel Conditions Candidate Contro
