1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 10 17 Activated T. Dusbiber Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 14 ENAMEL, THERMOSET BASECOAT, WET-ON-WET WSS-M33J8-A1 IN PRIME PROCESS, EXTERIOR 1. SCOPE The materials defined by this
2、specification are coatings, which consist of pigmented thermoset basecoat enamels, which are applied and cured concurrently with the body prime operation. Over, which is, applied a clear thermoset clearcoat that is cured during the body basecoat/ clearcoat bake operation. 2. APPLICATION This specifi
3、cation was released originally for materials used as the low line accent finish, when mono baked with the primer operation, on automobile bodies, or other exterior parts as deemed feasible, and shall be satisfactory for use over specified primers or over previously baked enamel, as in paint repair o
4、perations. The applicable clearcoat specifications for this process are WSS-M33J3-D2, D3, D5, E1, a=90 Record individual un-weathered and weathered values for normal force at fracture and permanent deformation at 5mN, for each of 3 runs. The normal force at fracture is determined by taking the avera
5、ge of the first 3 incidents of fracture that are greater than 1/3 the distance of the scratch width. Report the average combined un-weathered and weathered results for normal force at fracture and permanent deformation at 5mN. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J8-A1Printed copies are uncontro
6、lled Copyright 2003, Ford Global Technologies, Inc. Page 7 of 14 3.8.8 Sag Resistance Equal to or better than standard process Test variables and levels: Prime/basecoat bake: 5 min at 141 C, 25 min at 168 C Basecoat film build: 10, 15, and 30 micrometers. Constants: Prime/Basecoat Flash 30 sec. at 2
7、5 C +/- 3, 70% RH For each variable and level, prepare a 30.5 x 45.7 cm sag panel with a wedge of primer from 0 38 micrometers from top to bottom of panel. Flash panels 30 sec. and apply basecoat and cure for each variable condition above. Measure and record for each condition the primer film thickn
8、ess where the sag measures 5 mm. Measure appearance. 3.8.9 Water Immersion 240 h (FLTM BI 104-01, B) No blistering, dulling, wrinkling, softening and/or loss of adhesion permitted. 3.9 WEATHERING After exposure (para 3.9.1 and 3.9.2), panels must meet the requirements of para 3.9.3. 3.9.1 Natural We
9、athering Florida Exposure (SAE J1976, Procedure A) New Pigment 2 years required, 3 years and 5 year submission New Color, Known 1 year required, 2 - 3 years and Pigments and Resins 5 year submission New Resin Technology 3 years required, 5 year submission (one panel for every year of testing as spec
10、ified in para 4.2, Table 3) 3.9.2 Accelerated Weathering (SAE J1960, 0.55 W/m2 Irradiance) New Pigment 2500 h in applicable resin system New Color, Known 1250 h required Pigment and Resins New Resin Technology 3750 h required, Borosilicate Inner and Outer Filters (para 4.2, Table 3) ENGINEERING MATE
11、RIAL SPECIFICATIONWSS-M33J8-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 8 of 14 3.9.3 Testing After Exposure (FLTM BI 160-01, B) 3.9.3.1 Appearance After 1 year exposure, there shall be no visual color change, minimal gloss and DOI loss not to exceed 2 year
12、requirement. There shall be no blistering, cracking, peeling or microchecking. After 2 years Florida exposure or 2500 h Accelerated weathering, no less than AATCC color rating 4. There shall be no blistering, cracking, peeling or microchecking. After 3 Florida years exposure or 3750 h Accelerated we
13、athering, there shall be no excessive color change, blistering, cracking, peeling or microchecking. 3.9.3.2 Gloss After Exposure (ASTM D 523, 20 degree Glossmeter) 2 year exposure, min 2500 h, min Clearcoated Accent, max 15% loss 3.9.3.3 QMS or Wave Scan DOI After Exposure (Appearance is to be measu
14、red with a reliable instrument such as Autospect Inc QMS-BP or Byk Gardner Wave Scan.) 2 year exposure, min 2500 h, min Clearcoated Accent, max 20% loss 3.9.3.4 Basecoat/Clearcoat Durability Index New Resin Technology Only (TBC/1250) + (X/2000) greater than or equal to 4 X = TICC if TICC is less tha
15、n 1.2(TCC) otherwise X= TCC Method to Determine: TBC - Stability of UVA free basecoat/clearcoat interface Report TBC (stability of UVA free basecoat/clearcoat interface) defined as the time for clearcoat delamination failure for each color. If the color has not failed by 5000 h, TBC = 5000. ENGINEER
16、ING MATERIAL SPECIFICATIONWSS-M33J8-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 9 of 14 TICC - Time to zero UVA absorbance using isolated clearcoat film Prepare quartz slides with clearcoat only. Adjust clearcoat thickness to obtain a starting absorbance (34
17、0 nm region) of 2 - 2.5 after clearcoat nominal bake. Measure clearcoat thickness in micrometers. Calculate absorbance per micrometer. Correct for absorbance per micrometer assuming 100% theoretical mixing of basecoat and clearcoat UVA. Evaluate clearcoat UVA absorbance using a UV-VIS spectrophotome
18、ter. Observe the UV spectrum from 450 nm to 250 nm. Determine maximum 340nm region absorbance on initial (baseline) sample and after 1000, 3000 and 5000 hour exposure to Xenon Arc weatherometer (SAE J1960, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure). Plot
19、absorbance as a function of exposure time to determine absorbance loss rate (absorbance loss per hour). Calculate TICC (time to zero UVA absorbance using isolated clearcoat film) by the following equation: - 1(absorbance/micrometer) (clearcoat film thickness)/(absorbance loss rate) = hours to clearc
20、oat absorbance equals zero. TCC - Time to zero UVA absorbance using full paint system. Remove clearcoat from the sample (avoid basecoat layer) with a razor or equivalent scraping device or by in-plane microtomy. Using either solvent extraction from the scraping method or direct measurement with a UV
21、 microscope and summing the layers, and evaluate clearcoat UVA absorbance using a UV-VIS spectrophotometer. Observe the UV spectrum from 450 nm to 250 nm. Determine absorbance on initial (baseline) sample and after 1000, 3000 and 5000 hour exposure to Xenon Arc weatherometer (SAE J1960, modified wit
22、h type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure). Plot absorbance loss as a function of exposure time to determine UVA loss rate (absorbance loss per hour). Extrapolate UVA loss rate plot to zero absorbance. Determine the exposure hours at zero clearcoat UVA absorbance. Re
23、port as TCC. 3.9.3.5 Clearcoat Photooxidation 2.5 max New Technology Only Clearcoat photooxidation value, max 2.5 change in (- OH, -NH)/-CH)ratio Method: Photochemical stability is determined by a comparison of the chemical state change of the topcoat surface before and after exposure to 5000 hour X
24、enon Arc weatherometer (SAE J1960, modified with type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure). Evaluate the topcoat photooxidation stability using Fourier Transform Infrared Photo-Acoustic Spectroscopy (FTIR-PAS). Obtain spectra of the surface layer of topcoat, approxima
25、tely the top 7 micron, experimentally defined as the photo-acoustic sampling depth by modulation at 3 kHz at 3000 wave numbers in a rapid-scan FTIR-PAS experiment or 3 kHz phase modulation in a step-scan FTIR-PAS experiment. The reference material, used to obtain the Relative PAS Intensity spectrum,
26、 should be a polymer filled with carbon black to at least 50% for a rapid-scan experiment and to at least 65% for a step-scan experiment. Compression set rubber works best. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J8-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Pa
27、ge 10 of 14 Resolution - laser sampling at every second laser crossing, 4000 data points, 8K transform, triangle apodization, phase corrected. Noise (definition) - root mean square(rms) noise in 3600 - 2500 wavenumbers region based on two carbon black filled polymer background spectra, ratioed to ob
28、tain 100% Relative PAS Intensity line. Noise limit - 0.75% rms, Relative PAS Intensity. 100% line - flat from 4000 - 2000 wavenumbers, +/- 10% Determine the ratio of the integrated intensity of the O-H plus N-H stretching region to that of the C-H stretching region, i.e. (- OH, - NH)/CH, on a retain
29、 and 5000 hour exposed sample. Integrate the intensity under the PAS spectrum (between the spectrum and the baseline) between 3700 and 2200 wavenumbers (the entire - OH, - NH, -CH stretch region). Integrate the intensity under the PAS spectrum between 3125 and 2750 wavenumbers (the - CH stretch regi
30、on). Subtract the - CH area from the total area to obtain the (- OH, - NH) area. Divide the ( -OH, - NH) area by the - CH area to obtain the (- OH, - NH)/CH area. Subtract (- OH, - NH)/CH at time zero from (- OH, - NH)/CH at 5000 hour exposure to provide the change in the ratio (-OH, - NH)/CH. Repor
31、t the change in ratio (- OH, - NH)/CH as the photooxidation value. Note: Absorbed water contributes strongly to the (- OH, - NH) area and results in a false measure of polymer based OH, NH photooxidation products. Therefore, it is important to remove samples at the end of a dry, light cycle of the w
32、eatherometer before FTIR-PAS evaluation. 3.9.3.6 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 intervals. 3.10 COMPATIBILITY REQUIREMENTS 3.10
33、.1 The approved coating shall have good compatibility with sealers, body side moldings, decals, striping materials, stone guard primers and pressure sensitive tapes, etc. 3.10.2 Supplier of material shall keep abreast of changes in technology of related materials which may affect the compatibility a
34、nd performance of this product. In the advent of adverse performance, the supplier shall notify all affected Ford activities in writing. 3.10.3 All materials approved under this specification shall meet all engineering requirements when applied under assembly plant conditions. 4. GENERAL INFORMATION
35、 The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 PAINT SYSTEMS (used in current production applications) ENGINEERING MATERIAL SPECIFICATIONWSS-M33J8-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technolog
36、ies, Inc. Page 11 of 14 4.1.1 Electrocoat primer (baked) + spray primer (baked) + basecoat/clearcoat applied wet-on-wet and monobaked. 4.1.2 Electrocoat primer (baked) + spray primer (baked) + basecoat + midcoat + clearcoat applied wet-on-wet-on-wet and mono-baked. 4.1.3 Electrocoat primer (baked) +
37、 spray primer (baked) + basecoat (baked) + midcoat + clearcoat applied wet-on-wet and mono-baked. 4.2 TOPCOAT PROCESSING CONDITIONS AND TEST REQUIREMENTS MATRICES Process window (para 3.5) will be used to define targets, high/ max, and lows/min. These values will be used to establish the conditions
38、in Table 1 and shall be used to prepare panels for all tests in para 3.6, 3.7, 3.8, and 3.9. System Colors to be tested Applicable Tables New Technologies Silver, beige & additional Tables 1, 2, 3 colors as agreed with approving Engineer. New Pigments/ All Colors Tables 1, 4 New Colors TABLE 1: TOPC
39、OAT PROCESSING CONDITIONS REQUIRED FOR PARA 3.6, 3.7, 3.8, AND 3.9 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 Y
40、es 1 7 Target Target Target Yes 2 8 Target Target Target Yes 3 9 Target Min Min Yes 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
41、 at Target 6 C) 14 Low Target Target Yes LBR 15 Target Target Target Yes LBR 16 Low Max Max Yes LBR 17 Target Target Target No N.A. 18 Low Max Max No N.A. ENGINEERING MATERIAL SPECIFICATIONWSS-M33J8-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 12 of 14 NOTE 1
42、: All accent basecoats applied at dry hiding filmbuilds cured concurrently with the primer for conditions 1 - 18. NOTE 2: Recoats are prepared using main body basecoat and clearcoat cured together (in the same color) as used on OEM topcoat, except for condition 14, 15 and 16 which uses catalyzed low
43、 bake repair system. NOTE 3: For all ICA 5 panels (condition # 11) primer and accent 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 stabiliz
44、ers (HALS), if normally used in formulation, shall be present in all systems regardless of UVA or not. NOTE 5: Conditions 6 - 13 shall be run with the accent/primer layer baked both 1 time and 2 times as specified for each condition. TABLE 2: TEST MATRIX FOR NEW TECHNOLOGIES Section Panel Conditions
45、 Candidate Control Colors 3.3 Physical Properties See para 3.3 N.A. See para 4.2 3.6.2 QMS or Wave Scan 1, 2, 3, 4, 5 3 See para 4.2 3.6.3 3.6.3.1 Gloss Gloss After Rebake 1, 2, 3, 4, 5, 15 3, 15 See para 4.2 3.7.4 Hardness 1, 2, 3, 4, 5, 15 3, 15 See para 4.2 3.7.5 Adhesion 1, 2, 3, 4, 5, 15 3, 15
46、See para 4.2 3.7.6 Polishing 1, 2, 3, 4, 5, 15 3, 15 See para 4.2 3.8.1 Condensing Humidity 1, 2, 3, 4, 5, 15 3, 15 See para 4.2 3.8.2 Xylene Resistance 3, 4, 15 3, 15 See para 4.2 3.8.3 Cold Checking Resistance 8, 9, 10 8, 9, 10 See para 4.2 3.8.4 Intercoat Adhesion 6, 7, 8, 11, 12, 13 6, 7, 8, 11,
47、 12, 13 See para 4.2 3.8.5 Chip Resistance 1 - 13 1 - 13 See para 4.2 3.8.6 High Performance Chip Resistance 6, 7, 8, 11, 12, 13, 15 5, 6, 7, 8, 11, 12, 13, 15 See para 4.2 3.8.7 Scratch Resistance 1, 2, 3, 4, 5 3 See para 4.2 3.8.9 Water Immersion 1, 2, 3, 4, 5, 15 3, 15 See para 4.2 3.9 Weathering
48、 Florida Accelerated See Table 3 for Requirements ENGINEERING MATERIAL SPECIFICATIONWSS-M33J8-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 13 of 14 TABLE 3: WEATHERING EXPOSURE TEST MATRIX FOR NEW TECHNOLOGIES Section Panel Conditions Candidate Control Colors
49、 Exposure Tests 3.9.1 Florida 1, 2, 3, 4, 5, 16, 17 Same See para 4.2 0, 1*, 2*, 3*, 4 5*, 6, 7*, 8 9, 10* years Gloss, DOI Adhesion, Durability Index Photooxidation* 18 Same See para 4.2 0, 1, 2, 3, 4 5 years Gloss, DOI Adhesion 2, 16 Same See para 4.2 0, 1, 2, 5, 10 years Gloss, DOI Adhesion 3.9.1 Accelerated 1, 2, 3, 4, 5, 16, 17, 18 Same See para 4.2 0, 2500, 3750 h Gloss, DOI Adhesion, Durability Index Photooxidation* NOTE 1: All basecoats applied at hiding filmbuilds over wet primer and cured concurrent with primer. NOTE 2: Panels 17 and
