1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 1 2012 04 05 Revised General Information C. McComb, R. Harris NA 2011 07 29 Activated Replaces ESB-M5P8-A C. McComb, R. Harris NA Controlled document at www.MATS Copyright 2012, Ford Global Technologies, LLC Page 1 of 5 LIGHTING METALIZA
2、TION, PLASTIC SUBSTRATES WSS-M5P8-B1 LIGHTING METALIZATION, METAL 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 b
3、asecoat and topcoat, as required. 2. APPLICATION This specification 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, me
4、tal, topcoat), the coating thicknesses, and respective cure schedules 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
5、 surface exterior applications. Flaming of the substrate may cause 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)
6、. 3.2 FINISHED PARTS Tests shall be performed on actual components 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 Engin
7、eering, 3.3 APPEARANCE All parts shall be free from any objectionable 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 SPECIFICA
8、TION WSS-M5P8-B1/B2 Copyright 2012, Ford Global Technologies, LLC Page 2 of 5 If a Minimum Reference/Acceptance Sample (Boundary Samples) exists, parts must conform to the end item mutually agreed upon by Product Development Engineering and Materials Engineering. 3.4 INITIAL ADHESION Grade 2 (FLTM B
9、I 106-01, Method B) 3.5 RESISTANCE 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 chang
10、e greater than the tolerances specified 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 +/-
11、 2 C and 95 to 100 % humidity. 4 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
12、 guide. Generic Material Heat Aging 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 SPECIFIC
13、ATION WSS-M5P8-B1/B2 Copyright 2012, 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 Headlamp bezel -
14、 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 Materials Engineering:
15、 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 4.1 PROCESS WIN
16、DOW 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 screening experiment s
17、hould 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 Water Resistan
18、ce, Para 3.5.3 ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-B1/B2 Copyright 2012, 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 release agents or any other contaminants. If using B
19、MC, parts must have all flash removed prior to metalizing to minimize errant debris from subsequent manufacturing operations (bulb and bulb shield insertion). Plastic parts intended for metalizing by this specification must be molded in keeping with the best commercial practice to achieve stress-fre
20、e 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 stress relieved according to a cycle agreed upon b
21、y 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 be avoided unless mutually agreed upon between P
22、roduct 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 worse by the presence of sharp corners of the
23、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 reflector parabola are unavoidable. 4.5 SYSTEM
24、 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 additional seal coat (BMC, cast aluminum, etc.). 4.5.3 M
25、etalize 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 thickness and cure as recommended by supplier of the to
26、p coat. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-B1/B2 Copyright 2012, Ford Global Technologies, LLC Page 5 of 5 4.5.5 Aging Basecoated test components or end item specimens prepared for investigations according to this specification shall be conditioned for at least 72 hours at 23 + 2C prior to
27、testing. Direct metallization parts shall be conditioned for at least 24 hours at 23 + 2C prior to testing. 4.6 DV/PV Requirements Design Validation and Production Validation testing must be conducted on parts unless approved by Design Engineering. Sample size To be done at DV To be done at PV 3.4 I
28、nitial Adhesion 3 X X 3.5.1 Resistance to Cycling 3 for basecoated, 1 for direct metalization 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 2012 04 05 Updated General Information for guidance on basecoat and metallization testing and DV/PV requirements.
