1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 10 26 Activated K.G.Tatham, G.Schuh Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 18 ENAMEL, COMPLIANCE VOC, HIGH SOLIDS, THERMOSET BASECOAT, WSS-M33J7-B4 WET ON WET PROCESS WITH WSS-M33J7-B5 CLEA
2、RCOAT, ETCH & SCRATCH RESISTANT, EXTERIOR ENAMEL, COMPLIANCE VOC, HIGH SOLIDS, THERMOSET CLEARCOAT, WSS-M33J7-B5 WET ON WET PROCESS WITH WSS-M33J7-B4 BASECOAT EXTERIOR 1. SCOPE The materials defined by these specifications are coatings which consist of a pigmented thermosetting basecoat enamel over
3、which is applied a clear thermosetting clear coat in a wet-on-wet process. These materials are mono baked. 2. APPLICATION These specifications were released originally for materials used as the topcoat finish on automobile bodies, hoods, fenders and other exterior parts, and shall be satisfactory fo
4、r use over specified primers or 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, witho
5、ut clear coat, as an interior baking enamel for some applications. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. Test shall be made on the basis of comparison with approved production material, to be chosen by approving materials engineer
6、Note: For purposes of the specification, paint systems, which utilize a standard basecoat/clear coat, shall be considered the “complete basecoat/clear coat enamel system“. For basecoat-only applications refer to Para 3.14. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and par
7、t producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 COMPOSITION 3.2.1 Resin Basecoats shall be thermosetting, synthetic resins, and clear coats will be thermoset-ting, acrylic-modified synthetic resins or equivalent. Each will be appropriatel
8、y fortified so as to meet the durability requirement of 10 years. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J7-B4/B5 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 18 3.2.2 Pigments Pigments are exterior quality automotive grade selected to meet durability Req
9、uirements. 3.2.3 Solvents The volatility of the solvents will 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 absorber All approved materials sha
10、ll contain with Initial Sample Report an UV-spectroscopic analysis. This shall be recorded and filed by Paint Engineering Laboratories of the Ford Motor Company. Subsequent material UV-spectroscopic analysis shall correspond to the data of the Initial Sample. The clear coat shall contain sufficient
11、amounts of suitable Ultra Violet light absorber packages. These will be selected by the supplier to provide 10 year long term durability. 3.2.5 Conditioning All panels shall be aged for 72 h at 23 +/- 2 C or 16 h at 43 +/- 2 C before testing for resistance properties unless otherwise specified. In t
12、he event of differences between test results, the results after aging at room temperature shall govern. All tests according to this specification shall be performed in a controlled atmosphere of 23 +/- 2 C and 50 - 65% relative humidity if not otherwise specified. 3.2.6 Flash Point The flash point s
13、hall conform to the safety regulations applicable to the plant and/or country where the material shall be used. 3.2.7 Special Data All initial and batch submissions must indicate density, non volatile content, and density of the cured film as supplied on the sample report. ENGINEERING MATERIAL SPECI
14、FICATIONWSS-M33J7-B4/B5 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 18 3.3 PHYSICAL PROPERTIES 3.3.1 Non-volatile at application viscosity Initial Sample +/- 1.0% (FLTM BI 102-01) (1 hour 105 C then 30 minutes 140 C) Minimum solid content basecoat unless 4
15、0.0% otherwise released Minimum solid content clear coat unless 50.0% otherwise released These solid limits apply to basecoats adjusted to recommended supplier application viscosity using Ford Cup 3, at 25 C (FLTM BI 111-01) and clear coat adjusted to a viscosity of 50 s Ford Cup 3, at 25 C (FLTM BI
16、 111-01). Vendor may specify solvents but shall be Ford Product Engineering approved prior to use. 3.3.2 Density Initial Sample +/- 0.02 g/ml (ASTM D 1475) 3.3.3 Viscosity (FLTM BI 111-01, Ford Cup 3, 25 C) Application Viscosity Initial Sample +/- 2 sec 3.3.4 Shelf Stability During a storage of 3 mo
17、nths at room temperature, the clear coat as received shall not gel or show any turbidity upon standing and must be free from settling which cannot be dispersed by normal agitation. The viscosity of the material shall not increase in excess of 20 seconds (FLTM BI 102-03, Ford Cup 3, 25 C) Note: After
18、 test, the material shall pass all specification requirements. 3.3.5 3.3.8 Resistivity 0.05 to 2.00 megohms (ASTM D 5682) Volatile solvents and other components affecting electrical conductivity shall be adjusted such that the resistivity at application viscosity shall be within specified limits. 3.
19、3.6 Density of the cured film Initial Sample +/- 0.05 g/ml (FLTM BI 154-02) 3.4 PREPARATION OF TEST PANELS (FLTM BI 103-02, Method B, b) 3.4.1 Substrate Ford Engineering Approved Standard Steel Test Panels coated with Ford Engineering approved zinc phosphate and prepared in with accordance with Ford
20、 Engineering Materials Specification WSS-M3P1-D. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J7-B4/B5 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 18 3.4.2 Cathodic Electrocoat Ford Engineering approved current production materials. Apply the above primer to a
21、 minimum dry film thickness of 22 micrometer and bake as defined in relevant material specification. 3.4.3 Primer Surfacer Ford Engineering approved current production material. Apply the above primer to a minimum dry film thickness of 30 micrometer, and bake as defined in relevant material specific
22、ation. Do not sand the primer surface. 3.4.4 Base Coat Apply approved base coat to a dry film thickness of 15 - 30 micrometer. 3.4.5 Clear Coat Apply clear coat under test to a dry film thickness of 35 - 45 micrometer. Minimum total dry film thickness Base coat and clear coat 50 micrometer 3.4.6 Fla
23、sh-Off Time 1 minute 40 seconds between base and clear coat application 3.4.7 Baking Cycles Base coat and clear coat baked simultaneously 3.4.7.1 Standard Bake Tests Bake 10 minutes at 140 C metal temperature. 3.4.7.2 Rebake Tests Standard Bake and then bake 10 minutes at 150 C metal temperature. 3.
24、4.7.3 In Plant Repair (Catalyzed Low Bake Repair LBR, approved L. B. Basecoat and approved Low Bake catalyzed clearcoat to be used) Enamels containing acid catalyst as requested. Bake 10 minutes at 100 C metal temperature. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J7-B4/B5 Printed copies are uncontro
25、lled Copyright 2006, Ford Global Technologies, LLC Page 5 of 18 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
26、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 tested for the variables/parameters. This screening experiment should
27、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 adhesion, condensing humidity, acid spot resistance, mar resistanc
28、e, stone chip (FLTM BI 157-06 Erichsen), intercoat adhesion, ICA 4. 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. Consideration
29、should be given to an application process window DOE to assess impact of key process variables/parameters on final appearance. 3.6.1 Color (FLTM BI 109-01) Color of clear coat film shall remain water white after all baking cycles described in para 3.4.7. Color of base coat and clear coat shall match
30、 the relevant approved Master Appearance Sample (MAS) Panel. 3.6.2 Wavescan (QMS) Targets (Appearance) Combined Orange Peel, DORI and Gloss values for the material under test when measured with a reliable instrument such as Wave Scan DOI must meet the targets outlined below. The combined (QMS) value
31、 is calculated by taking 50% of the Orange Peel value, 35% of the DORI value, and 15% of the Gloss value. Targets: Horizontal Vertical Light Metallics 60 50 Dark Metallics 65 55 Light Solids 65 Dark Solids 55 3.6.3 Gloss (FLTM BI 110-01, 20 glossmeter) 3.6.3.1 Standard Bake, min 90 3.6.3.2 Rebake Gl
32、oss A decrease of not more than 4 units gloss is permitted when panel is rebaked per para 3.4.7.2 ENGINEERING MATERIAL SPECIFICATIONWSS-M33J7-B4/B5 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 18 3.6.4 Leveling The surface of the material under test shall b
33、e equal to or better than current approved production material for smoothness when applied and baked under identical conditions. Orange peel values taken from (QMS) data obtained using Wave Scan DOI or equivalent shall be reported 3.6.5 Holdout There shall be no evidence of dulling or change of imag
34、e clarity when enamel color coat is applied over sanded and unsanded primer surfacer, and no difference in gloss of the color coat between sanded and unsanded primer. There shall be no prominence of sand scratches. Tests shall be made at both maximum and minimum bake cycles. There shall be no eviden
35、ce of color shift or telegraphing when enamel color coat is applied over sanded or unsanded primer surfacer 3.6.6 General The enamel shall cure to a presentable, serviceable, mar-resistant film showing no craters, seediness, abnormal roughness or excessive metallic mottling. It shall have reasonable
36、 tolerance for ordinary cleaning (such as automatic car washes) and exhibit excellent polishing characteristics when wheel polished with a wide range of various compounds and cleaners. 3.7 FILM PROPERTIES 3.7.1 Film Thickness (FLTM BI 117-01) Base coat 15 - 30 micrometer Clear coat 35 - 50 micromete
37、r Base Clearcoat plus clear coat, min 50 micrometer Coating must be sufficient to meet all performance requirements of this specification. 3.7.2 Dry Hiding Power 15 - 30 micrometer (FLTM BI 158-01) The basecoat is required to provide complete visual hiding over black and grey hiding chart. When an e
38、xception to this hiding requirement is needed for special colors, concurrence must be obtained from all affected Ford activities 3.7.3 Final Hardness 3.7.3.1 Penetration, full system, age 72 h at 23 +/- 2 C Tukon, min 7.5 KHN (FLTM BI 112-02) ENGINEERING MATERIAL SPECIFICATIONWSS-M33J7-B4/B5 Printed
39、 copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 7 of 18 3.7.4 Bleeding of Pigments None permitted (ASTM D 279) New pigments only 3.7.5 Polishing The coating surface shall be capable of being sanded with 1200 grit and polished, or polished only. No noticeable change in glo
40、ss or appearance, except for a minimum of polishing lines shall result. Deep polishing lines or swirl marks are not acceptable. Hardness and polishing characteristics shall be such that air-borne dirt dried in the film and dry spray areas or other surface defects can be removed by sanding and polish
41、ing. 3.7.6 UV Absorber Crystallization Store 1 L of the clear coat as supplied in a beaker for 24 h at -10 C and then allow the temperature to increase to 20 C. Do not stir. No turbidity nor any tendency to crystallization nor any other visible change of the material permitted. 3.7.7 Paint Adhesion
42、Grade 0 (FLTM BI 106-01, Method B) No chipping There shall be no flaking of clearcoat from the basecoat. 3.7.8 Glass bonding/Paint System Compatibility Shall meet all requirements of Ford Automotive Operations Procedure No. AVP-T118-001, latest revision Prior to making any changes in properties and/
43、or composition of originally approved paint, the supplier must certify compliance to all requirements of Direct Glazing System specification (test values, not nominal values) and obtain approval from the responsible Materials Engineering activity. For approved Direct Glazing System contact the respo
44、nsible Materials Engineering activity. 3.8 RESISTANCE PROPERTIES 3.8.1 Water Resistance 240 h (FLTM BI 104-01) No blistering, softening, dulling, color change and/or loss of adhesion. Adhesion shall be tested according to para 3.11.1 Method B. 3.8.2 Fluid Spot Resistance (FLTM BI 113-01) 3.8.2.1 Wat
45、er Spotting AATCC max discoloration Rating 4 - 5 3.8.2.2 Soap Spotting AATCC max discoloration Rating 4 - 5 ENGINEERING MATERIAL SPECIFICATIONWSS-M33J7-B4/B5 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 8 of 18 3.8.2.3 Windshield Washer Fluid current production
46、fill AATCC Rating 4 - 5 3.8.2.4 Windshield Washer Fluid concentrated (100%) AATCC Rating 4 - 5 3.8.3 Acid Spot Resistance 3.8.3.1 0.5N HCL Place 2 ml of 0.5N HCl onto the test panel. The uncovered panel is then placed in the oven at 40 C for one hour. No discoloration or swelling should be observed
47、at 40 C. Repeat the test at 50 C and 60 C. Report on any discoloration or swelling. 3.8.3.2 Ford US Solution 24 Formic Acid 47 gm Tannic Acid in 10% water 24 gm Honey 24 gm Albumin 5 gm Place 2 ml of Ford US solution 24 onto the test panel. The uncovered panel is then placed in the oven at 40 C for
48、one hour. No discoloration or swelling should be observed at 40 C. Repeat the test at 50 C and 60 C. Report on any discoloration or swelling. 3.8.3.3 Ford European Solution 10 Iron Sulphate 10 gm 1N Sulphuric Acid 90 gm Place 2 ml of Ford European Solution 10 onto the test panel. The uncovered panel
49、 is then placed in the oven at 40 C for one hour. No discoloration or swelling should be observed at 40 C. Repeat the test at 50 C and 60 C. Report on any discoloration or swelling 3.8.4 Xylene Wipe Resistance No dulling, softening or other undesirable effects after the enamel, which has been aged 72 h, is rubbed 10 times in a circular motion with a wad of cheesecloth wetted with Xylene and allowed a 30 minute recovery period. 3.8.5 Stone Chip Resistance, min Rating 4 (FLTM BI 157-06) First run and up to three high bake repairs ENGINEERING M
