1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 1 2017 01 27 Revised See Summary of Revisions M. Jones, NA 1997 09 25 Released E. M. Mangin Controlled document at www.MATSCopyright 2017, Ford Global Technologies, LLC Page 1 of 17 ENAMEL, WATERBORNE, THERMOSET BASECOAT, BASE- WSS-M33J6
2、-A1 COAT/CLEARCOAT WET-ON-WET PROCESS, EXTERIOR ENAMEL, COMPLIANCE VOC, MEDIUM SOLIDS, WSS-M33J6-B1 THERMOSET CLEARCOAT, BASECOAT/CLEARCOAT WET-ON-WET PROCESS, EXTERIOR ENAMEL, COMPLIANCE VOC, MEDIUM SOLIDS, WSS-M33J6-B3 THERMOSET CLEARCOAT, BASECOAT/CLEARCOAT WET-ON-WET PROCESS, ETCH RESISTANT, EXT
3、ERIOR ENAMEL, COMPLIANCE VOC, HIGH SOLIDS, THERMOSET WSS-M33J6-C3 CLEARCOAT, BASECOAT/CLEARCOAT WET-ON-WET PROCESS, ETCH RESISTANT, EXTERIOR ENAMEL, COMPLIANCE VOC, HIGH SOLIDS, THERMOSET WSS-M33J6-C4 TINTED CLEARCOAT, BASECOAT/CLEARCOAT WET-ON-WET PROCESS, ETCH RESISTANT, EXTERIOR 1. SCOPE The mate
4、rials defined by this specification are coatings which consist of a pigmented waterborne thermoset basecoat enamel over which is applied a clear or tinted clear thermoset clearcoat in a wet-on-wet process. These materials are monobaked. Unique tricoat colors are also included in this specification.
5、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 application and monobaked or in a wet on bake operation. WSS-M33J6-A1/C4 replaces WSB-M33J5-A1/B3. 2. APPLICATION These spe
6、cifications were released originally for materials used as the topcoat finish on automobile bodies, hoods, fenders and other exterior parts, and shall be satisfactory for use over specified primers or over previously baked enamel, as in paint repair or two toning operations. The basecoat portion is
7、used alone, without clearcoat, as an interior baking enamel for some applications 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the draw
8、ing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. 3.2 CONDITIONING AND TEST CONDITIONS ENGINEERING MATERIAL SPECIFICATION WSS-M33J6-A1/B1/B3/ C3/C4 Copyright 2017, Ford Global Technologies, LLC Page 2
9、 of 17 All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 INFRARED SPECTROPHOTOMETRY AND/O
10、R THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated mat
11、erial laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 COMPOSITION Test shall be made on the basis of comparison with approved production material, to be chosen by approving materials engineer. Note:
12、 For purposes of the specification, paint systems which utilize a standard basecoat/clearcoat, a basecoat/midcoat/clearcoat and/or a system with a tinted clearcoat shall be considered the “complete basecoat/clearcoat enamel system“. For basecoat-only applications refer to para 3.12. 3.4.1 Resin Base
13、coats shall be thermosetting, waterbased synthetic resins, and clearcoats will be thermosetting, acrylic-modified synthetic resins. Each will be appropriately fortified so as to meet the durability requirement of 10 years. 3.4.2 Pigments Pigments are exterior quality automotive grade selected to mee
14、t durability requirements. 3.4.3 Solvents The volatility of the solvents will be such that there shall be no paint sagging, pin-holing, roughness or dry spray at specified film thicknesses. 3.5 PHYSICAL PROPERTIES LIQUID STATE At application viscosity, material shall be in compliance with local emis
15、sions regulations. 3.5.1 Non-Volatile Content See initial sample (ASTM D1353) +/- 1 % 3.5.2 Volatile Organic Content(VOC) See initial sample (ASTM D3960) +/- 1 % 3.5.3 Weight per Volume See initial sample (ASTM D1475) +/- 0.03 g/ml 3.5.4. Volume Solids See initial sample (ASTM D2697) +/- 1 % 3.5.4.1
16、 Pigment Content in Tinted Clearcoat 0.5 % max (ASTM D2371) ENGINEERING MATERIAL SPECIFICATION WSS-M33J6-A1/B1/B3/ C3/C4 Copyright 2017, Ford Global Technologies, LLC Page 3 of 17 3.5.5 Viscosity (ASTM D2196 - Non-Newtonian) (ASTM D1200) Supplier shall report value at application reduction. Supplier
17、 shall present viscosity versus shear rate curves. 3.5.6 Stability (ASTM D1849) After test, the material shall pass all specification requirements. 3.5.6.1 Shelf Stability 90 days No more than 30 % increase in viscosity permitted. 3.5.6.2 Accelerated Stability (60 C, 16 h) No more than 30 % increase
18、 in viscosity permitted when tested per para 3.5.5. 3.5.7 Resistivity-Clearcoat Only 0.05 to 2.00 megohms (ASTM D5682) Volatile solvents and other components affecting electrical conductivity shall be adjusted such that the resistivity at application viscosity shall be within specified limits. 3.6 P
19、REPARATION OF TEST PANELS Substrate: Current production phosphated galvanized steel and current production primed exterior thermosetting plastic. Record all substrate information. See para 4.1. Electrocoat: Current production medium build gray cathodic electrocoat, applied at 20 - 23 micrometers and
20、 baked 10 minutes at 182 C metal temperature (MT). Record electrocoat and oven type used. Primer: Current production primer surfacer in a color consistent with production, applied at 25 - 28 micrometers and baked 10 minutes at 150 C (metal temperature). Record primer and oven type used. Enamel: Appl
21、y basecoat to required dry film thickness by (OEM) spray under conditions appropriate for waterborne basecoats, and flash (or prebake) as required. Apply clearcoat to required dry film thickness. Bake using appropriate bake schedule. Record enamel and oven type used. Catalyzed For catalyzed low-bake
22、 repair, a current production basecoat/clearcoat system from the Low Bake same manufacturer that has been approved for use may be substituted, provided that Repair: it meets all the catalyzed repair systems criteria. Catalyze enamel as per manufacturers(LBR) recommendations. Prepare panels at target
23、 conditions (# 3). 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. See Table 1 for Topcoat Processing Matrix, Table 2 and 3 for New Technology Test Matrices, and Table 4 for New Pigments/New Col
24、ors Test Matrix. ENGINEERING MATERIAL SPECIFICATION WSS-M33J6-A1/B1/B3/ C3/C4 Copyright 2017, Ford Global Technologies, LLC Page 4 of 17 3.7 PROCESS WINDOW DEFINITION - NEW TECHNOLOGIES ONLY The supplier shall perform a Design of Experiments (DOE) (Response Surface Analysis is recommended) to determ
25、ine the process window of the control and candidate materials. The three variables/parameters to be included in the design are bake temperature, bake time, and clearcoat film thickness (basecoats applied at hiding). An initial screening experiment should be run to determine what levels should be tes
26、ted for the variables/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DOE. Responses to the DOE will be based on the materials tested and will be chosen from tests listed within the specification. Minimal critical testing required: cross-hatch
27、 adhesion, condensing humidity, acid/alkali resistance, mar resistance, stone chip (SAE J400 and Erichsen), intercoat adhesion (ICA). Information will be used by materials engineer to determine acceptable plant processing conditions. See also para 4.2. 3.8 APPEARANCE Note: Appearance panels will be
28、sprayed using standard plant processing parameters. 3.8.1 Color (FLTM BI 109-01) (SAE J1545 X-Rite MA58 Three-Angle CMC) Shall match the Master Appearance Standard color panel. 3.8.2 Distinctness of Image (DOI) 70 min (FLTM BI 110-03) 3.8.3 Gloss 90 min (ASTM D 523, 20 degree Glossmeter) 3.8.3.1 Glo
29、ss After Rebake 4 unit decrease max Rebake panel at target bake conditions. ENGINEERING MATERIAL SPECIFICATION WSS-M33J6-A1/B1/B3/ C3/C4 Copyright 2017, Ford Global Technologies, LLC Page 5 of 17 3.8.4 Leveling The surface of material under test shall be equal to or better than currently approved pr
30、oduction material for smoothness when applied and baked under identical conditions. Orange peel values taken from Quality Measurement System (QMS) data obtained using Autospect shall be reported. 3.8.5 Sanding 3.8.5.1 Holdout There shall be no evidence of dulling, gloss loss or change of image clari
31、ty when enamel color coat is applied over sanded (P400 and P800 grit sandpaper) or unsanded primer surfacer. There shall be no prominence of sand scratches. 3.8.5.2 Telegraphing There shall be no evidence of color shift when enamel color coat is applied over sanded (P400 and P800 grit sandpaper) or
32、unsanded primer surfacer. 3.8.6 General The enamel shall cure to a presentable, serviceable, mar-resistant film showing no craters, pinholing, seediness, abnormal roughness or excessive metallic mottling. It shall have reasonable tolerance for ordinary cleaning (such as automatic car washes) and exh
33、ibit excellent polishing characteristics when wheel polished with a wide range of various compounds and cleaners. 3.9 FILM PROPERTIES 3.9.1 Film Thickness (ASTM D1186) Target values shall be defined from process window (para 3.7). 3.9.2 Dry Hiding - Pigmented Basecoat 15 30 micrometers (FLTM BI 158-
34、01) The basecoat is 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. 3.9.2.1 Pigmented Midcoat The pigmentation of the midcoat shall
35、be such that hiding of the basecoat does not occur. 3.9.3 Ultraviolet Light Transmittance Maximum light transmission through basecoat applied at 80 % of dry hiding directly over epoxy-free spray primer shall be no more than 0.1 % at 360 nm and 5 % at 400 nm. The equipment used for this measurement i
36、s a Lambda 6 Integrating Sphere spectrophotometer or equivalent. Non-fortified (without UV pkg) clearcoat is used for this evaluation. ENGINEERING MATERIAL SPECIFICATION WSS-M33J6-A1/B1/B3/ C3/C4 Copyright 2017, Ford Global Technologies, LLC Page 6 of 17 3.9.4 Bleeding of Pigments None Permitted (AS
37、TM D279) 3.9.5 Hardness (ASTM D1474) Record value at target film and bake conditions. Coating shall be sufficiently cured after baking so that it can meet the polishing requirements of para 3.9.7. 3.9.6 Adhesion 3.9.6.1 Scratch Test No chipping or (FLTM BI 106-01, Part A) loss of adhesion permitted
38、3.9.6.2 Scribe Test Grade 2 max (FLTM BI 106-01, Part B) 3.9.7 Polishing Shall be capable of being sanded with 1200 grit sandpaper and polished in accordance with current plant processes to minimize orange peel or to remove defects. No noticeable change in gloss or appearance except for a minimum of
39、 swirl marks is permitted. Deep polishing lines or swirl marks are unacceptable. 3.10 RESISTANCE PROPERTIES 3.10.1 Condensing Humidity 240 h (ASTM D4585, 43 C) No blistering, dulling, wrinkling, softening and/or loss of adhesion permitted. Within 15 - 20 minutes of removal from water resistance test
40、, panels will be checked for adhesion and meet the requirements of para 3.9.6.2. 3.10.2 Acid/Alkali Resistance Equal or better than control The Gradient Bar Method shall be used. The following solutions shall be tested on candidate materials: Solutions of sulfuric acid (H2SO4) adjusted to pH of 2, 3
41、, 4; 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). 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 f
42、or 0.09 mm steel substrate). Remove 1 panel after 15 minutes at temperature, other after 30 minutes. Rinse any remaining solution with water. Examine panels for etching, dis-coloration, pitting, etc. Report etch-free temperature for test material and control. NOTE: Process window evaluation will be
43、done using 2 solutions: (1) Sulfuric Acid pH3, 15 minute exposure; and (2) CaSO4 pH4, 30 minute exposure. ENGINEERING MATERIAL SPECIFICATION WSS-M33J6-A1/B1/B3/ C3/C4 Copyright 2017, Ford Global Technologies, LLC Page 7 of 17 3.10.3 Xylene Resistance No softening, or dulling permitted Using a circul
44、ar 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 sets of panels: (1) Aged per test method (2) Unaged and conditioned less than 8 h The f
45、ollowing 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 Remover* (Ford Part No. B7A-19520-AA) . Ru
46、st Preventative Coatings (including cavity waxes) *Aged panels 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 softe
47、ning permitted. 3.10.6.1 Plastic Substrates (FLTM BO 101-05) 3.10.6.2 Metal Substrates, Drip Test 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 app
48、roximately 1 h for the 50 mL to be evacuated (equivalent to approximately 1 drop every 3 s). Note: The panel shall be placed paint side up at an angle of 60 degrees 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
49、centered 100 mm above the lower edge of the test panel.) The test panel shall be 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. ENGINEERING MATERIAL SPECIFICATION WSS-M33J6-A1/B1/B3/ C3/C4 Copyright 2017, Ford Global Technologies, LLC Page 8 of 17 Gasohol Composition by Volume Blend A: ASTM Reference Fuel C 85 % Methanol 15 % Blend B: ASTM Reference Fuel C 15 % Methanol 85 % Remove panels from test
