1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 00 2011 07 29 Activated Replaces ESB-M5P8-A C. McComb, R. Harris NA Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 1 of 5 LIGHTING METALIZATION, PLASTIC SUBSTRATES WSS-M5P8-B1 LIGHTING METALIZATION, MET
2、AL SUBSTRATES WSS-M5P8-B2 1. SCOPE This specification defines the performance requirements for metalized surfaces of reflective lighting components. This coating system involves vapor deposition of metal in a vacuum, with an associated basecoat and topcoat, as required. 2. APPLICATION This specifica
3、tion was released originally for the coatings used on reflector parabolas of exterior lighting. Two levels of types of substrates are defined as follows: WSS-M5P8-B1 Plastic WSS-M5P8-B2 Metal Specific substrate and coatings (basecoat, metal, topcoat), the coating thicknesses, and respective cure sch
4、edules are to be determined by the Process Window DOE (Per Para 4.1) and specified on the Engineering Drawing or applicable Engineering Material Specification. 2.1 LIMITATIONS Coating systems described within are not to be used for first surface exterior applications. Flaming of the substrate may ca
5、use metallization performance failures. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 FINISHED PARTS Tests shall be performed on actual compone
6、nts processed through the production process. PSW must be performed on parts, not plaques. Testing to be conducted at Design Verification (DV) or Process Validation (PV) per Table in Para 4.6 unless otherwise agreed to by Materials Engineering, 3.3 APPEARANCE All parts shall be free from any objecti
7、onable blemishes on the reflective surface. A blemish is defined as the presence of any one, or combination of the following, but not limited to: Orange peel, weld marks, substrate read through and crazing. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-B1/B2 Controlled document at www.MATS Copyright 2
8、011, Ford Global Technologies, LLC Page 2 of 5 If Minimum Reference/Acceptance Samples (Boundary Samples) exist, parts must conform to the end item mutually agreed upon by Product Development Engineering and Materials Engineering. 3.4 INITIAL ADHESION Grade 2 (FLTM BI 106-01, Method B) 3.5 RESISTANC
9、E TESTS (All tests to be conducted on components with no lens or assembly) Acceptance Criteria Reflective components tested as outlined in Section 3.5 shall conform to the following: The finished part shall not warp, craze, crack, check or sustain a dimensional change greater than the tolerances spe
10、cified on the engineering drawing. Parts shall show no indications of oxidation, peeling, blistering, tarnishing or other discoloration. If defects are evident, stress relieving may be required as referenced in 4.2. 3.5.1 Resistance to Cycling, 3 cycles 2 h at 38 +/- 2 C and 95 to 100 % humidity. 4
11、h at 60 +/- 2 C. 2 h at -30 +/- 2 C. 16 h at 60 +/- 2 C. 3.5.2 Resistance to Humidity (120 h at 98 +/- 2% relative humidity and 38 +/- 1 C) 3.5.3 Water Immersion, min 96 h (FLTM BI 104-01) 3.5.4 Resistance to Heat (3 hour exposure) The table below should be used as a guide. Generic Material Heat Agi
12、ng Temperatures, (C) ABS / ASA (80) PC-ABS (85) ABS High Heat (100) PC (110) PC High Heat / PBT (120) BMC, PEI, PES (180) Metal (200) New Materials* - *Contact Materials Engineering for any materials being considered that are not included in this guide. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-B1
13、/B2 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 3 of 5 Typical applications are including, but not limited to: General purpose ABS, ASA Rear lamp body - low service temperature High heat ABS, PC/ABS Rear lamp body - high service temperature General purpose PC H
14、eadlamp bezel - low service temperature High heat PC, PBT Headlamp bezel - high service temperature BMC, PEI, PES Reflector - high service temperature Metal Fog lamp and projector headlamp - extreme service temperature 3.5.5 Construction Details The following information shall be reported to Materia
15、ls Engineering: 1) Type of coatings 2) Thickness of coatings 3) Type of substrate 4. GENERAL INFORMATION This information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications
16、4.1 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments to determine the process window of the substrate/coatings combination. The three variables/parameters for paint layers to be included in the design are cure temperature, cure time, and film thickness. An initial screeni
17、ng experiment should be run to determine what levels should be tested for the variables/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DOE. Responses for the DOE shall include, but are not limited to, the following: Initial Adhesion, Para 3.4
18、 Water Resistance, Para 3.5.3 ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-B1/B2 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 4 of 5 4.2 MOLDED PARTS Parts shall be metalized as soon after molding as possible. The surface shall be free from dirt, lint, mold relea
19、se agents or any other contaminants. If using BMC, parts must have all flash removed prior to metalizing to minimize errant debris from subsequent manufacturing operations (lamp and bulb shield insertion). Plastic parts intended for metalizing by this specification must be molded in keeping with the
20、 best commercial practice to achieve stress-free parts and ensure good metallization. Molded-in stresses can result in part failure by loss of adhesion and / or cracking of the substrate and / or metallization. If parts show cracking, crazing, or checking when tested to Section 3.5, they must be str
21、ess relieved according to a cycle agreed upon by the supplier and the responsible product engineering office. 4.3 BASECOAT USAGE Cast aluminum and BMC reflectors require basecoat prior to metallization to achieve reflectivity sufficient to pass photometry in the end item otherwise basecoats should b
22、e avoided unless mutually agreed upon between Product Development and Materials Engineering. 4.4 DESIGN These coatings are impacted by part geometry. Cavities which are more than twice as deep as the narrowest dimension of the projected optic cavity of the part are to be avoided. This effect is made
23、 worse by the presence of sharp corners of the metalized parts. BMC reflector tools must optimize fill and gate designs to minimize flash and parting lines in areas where additional manufacturing processes will occur. Mounting bosses shall utilize reinforcement ribs and gussets where acute angles to
24、 reflector parabola are unavoidable. 4.5 SYSTEM COMPONENTS 4.5.1 Substrate Substrate material will be dictated by the performance requirements of the assembled end item. 4.5.2 Basecoat (if required) This application only applies to substrates that cant meet reflectance standards without an additiona
25、l seal coat (BMC, cast aluminum, etc.). 4.5.3 Metalize Metal coating shall be applied by evaporation or sputter in a vacuum. Processing conditions will be determined for film thickness, opacity and luster desired. 4.5.4 Topcoat Clear top coat must be applied over the metalized surface. Film thicknes
26、s and cure as recommended by supplier of the top coat. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-B1/B2 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 5 of 5 4.5.5 Aging Test components or end item specimens prepared for investigations according to this specifica
27、tion must be aged for at least 72 hours at 23 + 2C prior to testing. 4.6 DV/PV Requirements DV and PV must be conducted on parts unless approved by Design Engineering Sample size To be done at DV To be done PV 3.4 Initial Adhesion 3 X X 3.5.1 Resistance to Cycling 3 X X 3.5.2 Resistance to Humidity 3 X 3.5.3 Water Immersion 3 X 3.5.4 Resistance to Heat 3 X 3.5.5 Construction Details 1 X X = Required 5. SUMMARY OF REVISIONS
