1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2012 11 19 Released E. Kapic, R. Starbowski, FNA Controlled document at www.MATS Copyright 2012, Ford Global Technologies, LLC Page 1 of 5 PERFORMANCE, ZINC PHOSPHATE AND ZIRCONIUM OXIDE, WSS-M3P38-A FOR ALUMINUM INTENSIVE PRODUCTION 1
2、. SCOPE This specification defines the performance requirements for conversion coatings produced on assemblies made from steel and aluminum. The zinc phosphate coating forms on iron based substrates and zirconium oxide coating on aluminum substrates. The assemblies are subsequently painted. 2. APPLI
3、CATION This specification was released originally for the conversion coatings produced in a process for aluminum intensive assemblies. In this process, iron, steel, and zinc or zinc alloy coated steel are coated with the zinc phosphate coating and aluminum substrates are coated in a subsequent step
4、with a system based on zirconium oxide technologies. 2.1 LIMITATIONS This process is intended to be used in aluminum intensive automotive applications where the aluminum content in production is approximately 30% 70% of the total substrate mix. 3. REQUIREMENTS The supplier shall contact the responsi
5、ble Materials Engineer prior to initiating qualification testing. Material(s) technical data sheet(s), Design Matrix, Design FMEA, and all other material related processing information shall be made available for review at the same time. Process P-Diagram and plant specific Process FMEA shall be dev
6、eloped before the material can be introduced to a production facility. All materials approved under this specification shall meet all engineering requirements when applied under assembly plant conditions. In some instances, a partial qualification submission will be allowed (e.g. when minor changes
7、are made to a previously approved material). In this case, the qualification requirements will depend on the degree of changes made to the material. The test requirements shall be agreed upon between the responsible Materials Engineer and the supplier prior to testing. 3.1 STANDARD REQUIREMENTS FOR
8、PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 MATERIAL ANALYSIS Ford Motor Company, as its option, may conduct analysis of materials, and representative parts/panels supplied to this specif
9、ication. The analysis that may be conducted, but not limited to, material chemical analysis, coating analysis, and corrosion and mechanical resistance testing. Any material analyses established for the initial approval shall constitute reference standards, and all samples shall produce the same anal
10、yses as the corresponding reference standards when tested under the same conditions. All the key material component ranges, and the key material manufacturing control limits must pass standard Gauge Repeatability and Reproducibility requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M3P38-A Copyri
11、ght 2012, Ford Global Technologies, LLC Page 2 of 5 3.3 MATERIAL COMPATIBILITY The supplier shall notify the appropriate Ford Materials Engineering Office if any incompatibility with other process related materials (e.g. sealers, adhesives, electrocoat, etc.) is anticipated. The supplier shall keep
12、abreast of changes in technology of the process related materials which may affect the compatibility and performance of the pretreatment products. Consequently, the appropriate material compatibility testing shall be done to ensure the process will deliver required performance. 3.4 PHYSICAL PROPERTI
13、ES 3.4.1 Zinc Phosphate Coating Weight (FLTM AQ 101-01, FLTM AQ 101-03) Note: The zinc phosphate coating weight ranges as defined below only apply to the described materials. 3.4.1.1 Zinc Phosphate Coating Weight Dip System Cold Rolled Steel 1.3 3.8 g/m2 Electro Galvanized Steel 1.6 4.3 g/m2 Hot Dip
14、 Galvanized Steel 1.6 4.3 g/m2 Galvannealed Steel 2.5 6.0 g/m2 Aluminum* 1.0 g/m2 3.4.1.2 Zinc Phosphate Coating Weight Spray System Cold Rolled Steel 1.3 3.8 g/m2 Electro Galvanized Steel 1.6 4.0 g/m2 Hot Dip Galvanized Steel 1.6 4.0 g/m2 Galvannealed Steel 2.5 6.4 g/m2 Aluminum* 1.0 g/m2 * The zin
15、c phosphate coating on aluminum can range from no zinc phosphate coating to light, open, uniform coating. 3.4.2 Zinc Phosphate Crystal Size 25 m (SEM analysis at 1000X magnification, for all substrates) 3.4.3 Zirconium Coating Weight (XRF Analysis, other analytical method approved by the responsible
16、 Materials Engineer) Aluminum 10 100 mg/m2 Note: The supplier is responsible for setting up an appropriate analytical method for measuring the zirconium coating weight. The coating weight measurement method shall be reviewed with the responsible Materials Engineer, and must pass standard Gauge Repea
17、tability and Reproducibility requirements. 3.5 PREPARATION OF TEST PANELS Testing shall be conducted on standard test panels representing the current production substrates, and current mill oils and lubricants. Test panels shall be prepared according to the exterior performance specification WSS-M2P
18、180. ENGINEERING MATERIAL SPECIFICATION WSS-M3P38-A Copyright 2012, Ford Global Technologies, LLC Page 3 of 5 3.5.1 Test Substrates Cold Rolled Steel (CRS) Electro Galvanized Steel (EG) Hot Dip Galvanized Steel (HDG) Galvannealed Steel (GA) Aluminum 6111 Alloy (AL6111) Aluminum 6022 Alloy (AL6022) O
19、ther aluminum alloys may be requested as needed, and should be included in plant specific testing when appropriate as specified by the responsible Materials Engineer. 3.5.2 Paint System Test panels shall be painted with a Ford approved fully layered paint system that includes electrocoat primer, pri
20、mer surfacer, and topcoat (basecoat + clearcoat). Unless otherwise specified by the responsible Materials Engineer, the panels shall be painted with a white topcoat system. Materials shall be applied, baked and aged according to individual material specifications. 3.5.3 Testing Sample Size A minimum
21、 of three (3) test panels shall be prepared for each test variation, unless a different agreement is made between the responsible Materials Engineer and the supplier prior to testing. The same number of control panels shall be prepared with the pretreatment system currently approved and used in Ford
22、 Motor Company assembly production. 3.6 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments (DOE) (Response Surface Analysis is recommended) to determine the process window of the pretreatment process controls. For zirconium oxide pretreatment, a minimum (but not limited to)
23、 four variable DOE is recommended, including zirconium concentration, pH, process time and process temperature. Additional study variables may include fluoride control (in zinc phosphate, and zirconium oxide pretreatment baths), any other pretreatment bath key components/parameters, and the substrat
24、e cleaning conditions (fresh vs. aged alkaline cleaner bath). Appropriate screening experiments should be run to determine what variables/parameters and their levels should be tested. The results of the screening experiments should be reviewed with the responsible Materials Engineer in order to set
25、up the final DOE. Response attributes to the DOE will be based on the materials tested, and will be chosen from tests listed within this specification. Minimal testing required: Coating Weights, Paint Adhesion (FLTM BI 106-01, Method B) before and after Water Immersion (FLTM BI 104-01), Stone Chip R
26、esistance (SAE J400 and FLTM BI 157-06), and Corrosion Resistance (L-467 and L-3190). The final test requirements shall be defined by the responsible Materials Engineer. The process window characteristics must be submitted with the initial approval package. 3.7 RESISTANCE PROPERTIES 3.7.1 Paint Adhe
27、sion, max Grade 1 (FLTM BI 106-01, Method B) 3.7.2 Water Resistance 240 h (FLTM BI 104-01) No blistering, dulling, softening, loss of paint adhesion, or any other paint film failure. Paint adhesion shall be tested according to paragraph 3.7.1 within 30 minutes after removal from water. ENGINEERING M
28、ATERIAL SPECIFICATION WSS-M3P38-A Copyright 2012, Ford Global Technologies, LLC Page 4 of 5 3.7.3 Humidity Resistance 240 h (FLTM BI 104-02, Method A) No blistering, dulling, softening, loss of paint adhesion, or any other paint film failure. Paint adhesion shall be tested according to paragraph 3.7
29、.1 within 30 minutes after removal from cabinet. 3.7.4 Corrosion Resistance 3.7.4.1 Laboratory Accelerated Corrosion Test, 6 weeks exposure. Test Method (formerly CETP) 00.00-L-467, evaluate according to FLTM BI 169-01. Corrosion creep across the scribe, maximum. Cold Rolled Steel 10 mm Electro Galv
30、anized Steel 6 mm Hot Dip Galvanized Steel 6 mm Galvannealed Steel 6 mm 3.7.4.2 Laboratory Accelerated Corrosion Test, 6 weeks exposure. Test Method (formerly CETP) 00.00-L-3190, evaluate according to FLTM BI 169-01 Corrosion creep across the scribe, maximum. Aluminum 4 mm 3.7.5 Chip Resistance 3.7.
31、5.1 Grit Blast, Split Shot , min Rating 5 (FLTM BI 157-06) 3.7.5.2 Stone Chip, 1.4 L, min Rating 5B or 97% (SAE J400, -20 2C and 23 2C) paint retention, no chips 3 mm dia. Evaluate substrate-to-topcoat (S/T) point of failure only. During the chip testing make sure that the aluminum panels have appro
32、priate backing to prevent excessive panel bending. 3.7.6 Cylindrical Mandrel Test (ASTM D522, Method B, 25 mm (1 inch) mandrel, 1 sec bend time) No paint peeling is produced at the paint to substrate interface. Equal or better than the control. 3.7.7 Glass Bonding/Paint System Compatibility (Materia
33、ls Engineering Procedure AVP-T118-001, Pretreatment Material Technology Change Section, consult with the responsible Materials Engineer for appropriate testing requirements) Equal or better than the control. ENGINEERING MATERIAL SPECIFICATION WSS-M3P38-A Copyright 2012, Ford Global Technologies, LLC Page 5 of 5 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications.
