1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action ChangesG01G02G02G03 G05G02 G06G07 G08G09G0AG0BG0CG0DG0AG0EG0F G10G11 G12G11 G12G0DG13G14G0BG13WP 3948-a Page 1 of 18ENAMEL, WATERBORNE, THERMOSET BASECOAT, BASE- WSS-M33J6-A1COAT/CLEARCOAT WET-ON-WET PROCESS, EXTERIOREN
2、AMEL, COMPLIANCE VOC, MEDIUM SOLIDS, WSS-M33J6-B1THERMOSET CLEARCOAT, BASECOAT/CLEARCOATWET-ON-WET PROCESS, EXTERIORENAMEL, COMPLIANCE VOC, MEDIUM SOLIDS, WSS-M33J6-B2THERMOSET TINTED CLEARCOAT, BASECOAT/CLEARCOAT WET-ON-WET PROCESS, EXTERIORENAMEL, COMPLIANCE VOC, MEDIUM SOLIDS, WSS-M33J6-B3THERMOS
3、ET CLEARCOAT, BASECOAT/CLEARCOATWET-ON-WET PROCESS, ETCH RESISTANT, EXTERIORENAMEL, COMPLIANCE VOC, MEDIUM SOLIDS, WSS-M33J6-B4THERMOSET TINTED CLEARCOAT, BASECOAT/CLEARCOAT WET-ON-WET PROCESS, ETCHRESISTANT, EXTERIORENAMEL, COMPLIANCE VOC, HIGH SOLIDS, THERMOSET WSS-M33J6-C1CLEARCOAT, BASECOAT/CLEA
4、RCOAT WET-ON-WETPROCESS, EXTERIORENAMEL, COMPLIANCE VOC, HIGH SOLIDS, THERMOSET WSS-M33J6-C2TINTED CLEARCOAT, BASECOAT/CLEARCOATWET-ON-WET PROCESS, EXTERIORENAMEL, COMPLIANCE VOC, HIGH SOLIDS, THERMOSET WSS-M33J6-C3CLEARCOAT, BASECOAT/CLEARCOAT WET-ON-WETPROCESS, ETCH RESISTANT, EXTERIORENAMEL, COMP
5、LIANCE VOC, HIGH SOLIDS, THERMOSET WSS-M33J6-C4TINTED CLEARCOAT, BASECOAT/CLEARCOATWET-ON-WET PROCESS, ETCH RESISTANT, EXTERIOR1. SCOPEThe materials defined by this specification are coatings which consistof a pigmented waterborne thermoset basecoat enamel over which isapplied a clear or tinted clea
6、r thermoset clearcoat in a wet-on-wetprocess. These materials are monobaked. Unique tricoat colors are alsoincluded in this specification. Tricoat colors consist of a pigmentedbasecoat followed by a non-hiding midcoat over which is applied a clearor tinted clear. Tricoat colors may be processed wet-
7、on-wet-on-wetapplication and monobaked or in a wet on bake operation. WSS-M33J6-A1/C4replaces WSB-M33J5-A1/B3.2. APPLICATIONThese specifications were released originally for materials used as thetopcoat finish on automobile bodies, hoods, fenders and other exteriorparts, and shall be satisfactory fo
8、r use over specified primers or overpreviously baked enamel, as in paint repair or two toning operations.The basecoat portion is used alone, without clearcoat, as an interiorbaking enamel for some applications.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J6-A1/B1/B2/B3/B4/C1/C2/C3/C4 WP 3948-b Page 2 of
9、 182. APPLICATIONThese specifications were released originally for materials used as thetopcoat finish on automobile bodies, hoods, fenders and other exteriorparts, and shall be satisfactory for use over specified primers or overpreviously baked enamel, as in paint repair or two toning operations.Th
10、e basecoat portion is used alone, without clearcoat, as an interiorbaking enamel for some applications.3. REQUIREMENTSTest shall be made on the basis of comparison with approved productionmaterial, to be chosen by approving materials engineer.Note: For purposes of the specificat ion, paint systems w
11、hich utilize astandard basecoat/clearcoat, a basecoat/midcoat/clearcoat and/or asystem with a tinted clearcoat shall be considered the “completebasecoat/clearcoat enamel system“. For basecoat-only applications referto para 3.12.3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers and part producers mus
12、t conform to QualitySystem Requirements, QS-9000. Material specification requirementsare to be used for initial qualification of materials. A ControlPlan for ongoing production verification is required. This planmust be reviewed and approved by the relevant Ford Materialsactivity and/or Ford Supplie
13、r Technical Assistance (STA) prior toproduction parts submission. Appropriate statistical tools must beused to analyze process/product data and assure consistentprocessing of the materials.Part producers using this material in their products, must use Fordapproved materials and must conform to a pro
14、cess control plan whichhas been approved by STA and/or the relevant Materials Activity.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may conduct infrared and/orthermal analysis of material/parts supplied to this specification.The IR spectra and thermograms
15、established for initial approvalshall constitute the reference standard and shall be kept on fileat the designated material laboratory. All samples shall produce IRspectra and thermograms that correspond to the reference standardwhen tested under the same conditions.3.3 CONDITIONING AND TEST CONDITI
16、ONSAll test values indicated herein are based on material conditionedin a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 hours prior to testing and testedunder the same conditions unless otherwise specified.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J6-A1/B1/B
17、2/B3/B4/C1/C2/C3/C4 WP 3948-b Page 3 of 183.4 COMPOSITION3.4.1 ResinBasecoats shall be thermosetting, waterbased syntheticresins, and clearcoats will be thermosetting, acrylic-modified synthetic resins. Each will be appropriatelyfortified so as to meet the durability requirement of 10years.3.4.2 Pig
18、mentsPigments are exterior quality automotive grade selected tomeet durability requirements.3.4.3 SolventsThe volatility of the solvents will be such that thereshall be no paint sagging, pin-holing, roughness or dryspray at specified film thicknesses.3.5 PHYSICAL PROPERTIES LIQUID STATEAt applicatio
19、n viscosity, material shall be in compliance withlocal emissions regulations.3.5.1 Non-Volatile Content, range See initial sample(ASTM D 1353) +/- 1 %3.5.2 Volatile Organic Content(VOC), range See initial sample(ASTM D 3960) +/- 1 %3.5.3 Weight per Volume, range See initial sample(ASTM D 1475) +/- 0
20、.03 g/ml3.5.4. Volume Solids, range See initial sample(ASTM D 2697) +/- 1 %3.5.4.1 Pigment Content in Tinted 0.5 %Clearcoat, max(ASTM D 2371)3.5.4 Viscosity(ASTM D 2196 - Non-Newtonian)(ASTM D 1200). Supplier shall report value at application reduction. Supplier shall present viscosity versus shear
21、ratecurves.3.5.5 Stability(ASTM D 1849)After test, the material shall pass all specificationrequirements.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J6-A1/B1/B2/B3/B4/C1/C2/C3/C4 WP 3948-b Page 4 of 183.5.5.1 Shelf Stability 90 daysNo more than 30 % increase in viscositypermitted.3.5.5.2 Accelerated St
22、ability(60 C, 16 h)No more than 30 % increase in viscosity permittedwhen tested per para 3.5.4.3.5.6 Resistivity-Clearcoat Only 0.05 to 2.00(ASTM D 5682) megohmsVolatile solvents and other components affecting electricalconductivity shall be adjusted such that the resistivity atapplication viscosity
23、 shall be within specified limits.3.6 PREPARATION OF TEST PANELSSubstrate: Current production phosphated galvanized steeland current production primed exteriorthermosetting plastic. Record all substrateinformation. See para 5.1.Electrocoat: Current production medium build gray cathodicelectrocoat, a
24、pplied at 20 - 23 micrometers andbaked 10 minutes at 182 C metal temperature (MT).Record electrocoat and oven type used.Primer: Current production primer surfacer in a colorconsistent with production, applied at 25 - 28micrometers and baked 10 minutes at 150 C (metaltemperature). Record primer and o
25、ven type used.Enamel: Apply basecoat to required dry film thickness by(OEM) spray under conditions appropriate for waterbornebasecoats, and flash (or prebake) as required.Apply clearcoat to required dry film thickness.Bake using appropriate bake schedule. Recordenamel and oven type used.Catalyzed Lo
26、w For catalyzed low-bake repair, a currentBake Repair: production basecoat/clearcoat system from the(LBR) same manufacturer that has been approved for usemay be substituted, provided that it meets allthe catalyzed repair systems criteria. Catalyzeenamel as per manufacturers recommen-dations.Prepare
27、panels at target conditions (# 3). Wipepanels using naphtha and mask half of panelvertically. Apply low bake system, removemasking, flash and bake 10 minutes at 100 C metaltemperature.See para. 5.2 Table 1 for Topcoat Processing Matrix, Table 2 and 3for New Technology Test Matrices, and Table 4 for
28、New Pigments/NewColors Test Matrix.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J6-A1/B1/B2/B3/B4/C1/C2/C3/C4 WP 3948-b Page 5 of 183.7 PROCESS WINDOW DEFINITION - NEW TECHNOLOGIES ONLYThe supplier shall perform a Design of Experiments (DOE) (ResponseSurface Analysis is recommended) to determine the pro
29、cess window ofthe control and candidate materials. The three variables/parametersto be included in the design are bake temperature, bake time, andclearcoat film thickness (basecoats applied at hiding). An initialscreening experiment should be run to determine what levels shouldbe tested for the vari
30、ables/parameters. This screening experimentshould be reviewed with the materials engineer to set up the finalDOE. Responses to the DOE will be based on the materials tested andwill be chosen from tests listed within the specification. Minimalcritical testing required: cross-hatch adhesion, condensin
31、ghumidity, acid/alkali resistance, mar resistance, stone chip (SAEJ400 and Erichsen), intercoat adhesion (ICA). Information will beused by materials engineer to determine acceptable plant processingconditions. See also para 5.2.3.8 APPEARANCENote: Appearance panels will be sprayed using standard pla
32、ntprocessing 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), min 70(FLTM BI 110-03)3.8.3 Gloss, min 90(ASTM D 523, 20 degree Glossmeter)3.8.3.1 Gloss After Rebake, max 4 unit decrea
33、seRebake panel at target bakeconditions.3.8.4 LevelingThe surface of material under test shall be equal to orbetter than currently approved production material forsmoothness when applied and baked under identicalconditions. Orange peel values taken from QualityMeasurement System (QMS) data obtained
34、using Autospectshall be reported.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J6-A1/B1/B2/B3/B4/C1/C2/C3/C4 WP 3948-b Page 6 of 183.8.5 Sanding3.8.5.1 HoldoutThere shall be no evidence of dulling, gloss lossor change of image clarity when enamel color coatis applied over sanded (P400 and P800 gritsandpa
35、per) or unsanded primer surfacer. Thereshall be no prominence of sand scratches.3.8.5.2 TelegraphingThere shall be no evidence of color shift whenenamel color coat is applied over sanded (P400and P800 grit sandpaper) or unsanded primersurfacer.3.8.6 GeneralThe enamel shall cure to a presentable, ser
36、viceable, mar-resistant film showing no craters, pinholing, seediness,abnormal roughness or excessive metallic mottling. It shallhave reasonable tolerance for ordinary cleaning (such asautomatic car washes) and exhibit excellent polishingcharacteristics when wheel polished with a wide range ofvariou
37、s compounds and cleaners.3.9 FILM PROPERTIES3.9.1 Film Thickness(ASTM D 1186)Target values shall be defined from process window 3.9.2 Dry Hiding - Pigmented Basecoat 15 - 25(FLTM BI 158-01) micrometersThe basecoat is required to p rovide complete visual hidingover black and gray hiding chart.When an
38、 exception to this hiding requirement is needed forspecial colors, concurrence must be obtained from allaffected Ford activities.3.9.2.1 Pigmented MidcoatThe pigmentation of the midcoat shall be suchthat hiding of the basecoat does not occur.3.9.3 Ultraviolet Light TransmittanceMaximum light transmi
39、ssion through basecoat applied at 80 %of dry hiding directly over epoxy-free spray primer shallbe no more than 0.1 % at 360 nm and 5 % at 400 nm. Theequipment used for this measurement is a Lambda 6Integrating Sphere spectrophotometer or equivalent. Non-fortified (without UV pkg) clearcoat is used f
40、or thisevaluation.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J6-A1/B1/B2/B3/B4/C1/C2/C3/C4 WP 3948-b Page 7 of 183.9.4 Bleeding of Pigments None Permitted(ASTM D 279)3.9.5 Hardness(ASTM D 1474)Record value at target film and bake conditions. Coatingshall be sufficiently cured after baking so that it c
41、anmeet the polishing requirements of para 3.9.7.3.9.6 Adhesion3.9.6.1 Scratch Test No chipping or(FLTM BI 106-01, Part A) loss of adhesionpermitted3.9.6.2 Scribe Test, max Grade 2(FLTM BI 106-01, Part B)3.9.7 PolishingShall be capable of being sanded with 1200 grit sandpaperand polished in accordanc
42、e with current plant processes tominimize orange peel or to remove defects. No noticeablechange in gloss or appearance except for a minimum of swirlmarks is permitted. Deep polishing lines or swirl marks areunacceptable.3.10 RESISTANCE PROPERTIES3.10.1 Condensing Humidity 240 h(ASTM D 4585, 43 C)No
43、blistering, dulling, wrinkling, softening and/or loss ofadhesion permitted. Within 15 - 20 minutes of removal fromwater resistance test, panels will be checked for adhesionand meet the requirements of para 3.9.6.2.3.10.2 Acid/Alkali Resistance Equal or betterthan controlThe Gradient Bar Method shall
44、 be used. The followingsolutions shall be tested on candidate materials: Solutionsof sulfuric acid (H2SO4) adjusted to pH of 2, 3, 4; asolution in water of 0.75 % by weight CaSO4 adjusted to apH of 4; deionized water (DI) and tap water, Bee Dropping(Ford Method 24).Apply 0.05 mls of specified soluti
45、ons along entire lengthof 2 test panels. Place on gradient bar (38 - 82 C,calibrated for heat-up rate of 2 minutes or less for 0.09mm steel substrate). Remove 1 panel after 15 minutes attemperature, other after 30 minutes. Rinse any remainingsolution with water. Examine panels for etching, dis-color
46、ation, pitting, etc. Report etch-free temperature fortest material and control.ENGINEERING MATERIAL SPECIFICATIONWSS-M33J6-A1/B1/B2/B3/B4/C1/C2/C3/C4 WP 3948-b Page 8 of 18NOTE: Process window evaluation will be done using 2solutions: (1) Sulfuric Acid pH3, 15 minute exposure; and(2) CaSO4 pH4, 30 m
47、inute exposure.3.10.3 Xylene Resistance No softening, ordulling permittedUsing a circular motion, rub surface of enamel 10 timeswith wetted cheesecloth.3.10.4 Fluid Spotting Resistance(FLTM BI 113-01)No color change, dulling, surface distortion, spotting orpermanent softening permitted.Test 2 sets o
48、f panels:(1) Aged per test method(2) Unaged and conditioned less than 8 hThe 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 Pr
49、oduction Fill). Bug and Tar Remover* (Ford Part No. B7A-19520-AA). Rust 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 ResistanceNo color change, dulling, surface distortion or permanent3.10.6.1 Plastic Substrates(FLTM BO 101-05)3.10.6.2 Metal Substrates, Drip TestProcedure for Drip Test:Run tests using Blends “A“ and “B“ separatelyThe size of the test panels shall be 100 x 150 mm. Aburette must be used to allow
