1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2018 02 26 Released C. Wilson, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 6 LIGHTING METALIZATION, PLASTIC SUBSTRATES WSS-M5P8-C1 LIGHTING METALIZATION, METAL SUBSTRATES WSS-M5P8-C2 1. SC
2、OPE This specification defines the performance requirements for metalized surfaces of reflective and inner lighting components. This coating system involves vapor deposition of metal in a vacuum, with an associated basecoat and topcoat, as required. 2. APPLICATION This specification was released ori
3、ginally for the coatings used on reflector parabolas of exterior lighting. Two levels of types of substrates are defined as follows: WSS-M5P8-C1 Plastic WSS-M5P8-C2 Metal Specific substrate and coatings (basecoat, metal, topcoat), the coating thicknesses, and respective cure schedules are to be dete
4、rmined 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 cause metallization per
5、formance failures. 3. REQUIREMENTS Parts must conform to the color requirements defined by the Ford Color Harmony Team or equivalent. 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 FINISHED PARTS Testing must be conducted on actual production par
6、ts. If regrind is used, testing at the maximum loading level is required and must meet the specification requirement. Testing to be conducted at Design Verification (DV) or Process Validation (PV) per Table in Para 4.8 unless otherwise agreed to by Materials Engineering. All tested production parts
7、must be reviewed by Ford Materials Engineering for MCDCC sign-off. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-C1/C2 Copyright 2018, Ford Global Technologies, LLC Page 2 of 6 3.3 APPEARANCE All parts shall be free from any objectionable blemishes on the reflective surface. A blemish is defined as th
8、e presence of any one, or combination of the following, but not limited to: orange peel, weld marks, substrate read through and crazing. If a Minimum Reference/Acceptance Sample (Boundary Samples) exists, parts must conform to the end item mutually agreed upon by Product Development Engineering and
9、Materials Engineering. 3.3.1 Color (FLTM BI 109-01 Visual Assessment) (SAE J1545, Three-Angle CMC) Shall match the Master Approved Sample color panel or the initial sample as approved by Design Center. 3.4 INITIAL ADHESION Grade 2 max (FLTM BI 106-01, Method B) Where part dimensions limit equipment
10、access and testing, include the maximum grid area in the available part surface area provided. No substitute-tested plaques may be provided. 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
11、 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 specified on the engineering drawing. Parts shall show no indications of oxidation, peeling, blistering, tarnishing or other discoloration. If defect
12、s 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 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
13、Water Immersion, min 96 h No blistering, dulling, (FLTM BI 104-01, Adhesion testing per 3.4) softening, loss of adhesion greater than 5% and/or any other film failure. No loss of adhesion within 30 minutes of removal from water. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-C1/C2 Copyright 2018, Ford
14、Global Technologies, LLC Page 3 of 6 3.5.4 Resistance to Heat (3 hour exposure) The table below should be used as a 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 Material
15、s Engineering for any materials being considered that are not included in this guide. 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
16、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 Materials Engin
17、eering: 1) Type of coatings 2) Thickness of coatings 3) Type of substrate 3.6 FOGGING (SAE J1756, 3h at 100C heating, 21C cooling plate, post test conditioning 16h) Cut 3 specimens (approx. 80mm diameter X 3.2mm) from the production part. Fog Number 90 min Formation of clear film, droplets or crysta
18、ls is cause for rejection. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-C1/C2 Copyright 2018, Ford Global Technologies, LLC Page 4 of 6 4. GENERAL INFORMATION This information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for ques
19、tions concerning Engineering Material Specifications. 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 temperat
20、ure, cure time, and film thickness. An initial screening 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
21、 limited to, the following: Initial Adhesion, Para 3.4 Water Immersion, Para 3.5.3 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 BMC, parts must have all flash removed pr
22、ior 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-free parts and ensure good metallization. M
23、olded-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 by the supplier and the responsible produ
24、ct 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 Product Development and Materials Enginee
25、ring. 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 metalized parts. BMC reflector tools mus
26、t 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 SUPPLIERS ONGOING RESPONSIBILITY All materials
27、 must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the ENGIN
28、EERING MATERIAL SPECIFICATION WSS-M5P8-C1/C2 Copyright 2018, Ford Global Technologies, LLC Page 5 of 6 affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering
29、Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.6 RESTRICTED SUBSTANCE MANAGEM
30、ENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply w
31、ith this standard on a continuing basis through IMDS and or GMAP reporting. 4.7 SYSTEM COMPONENTS 4.7.1 Substrate Substrate material will be dictated by the performance requirements of the assembled end item. 4.7.2 Basecoat (if required) This application only applies to substrates that cant meet ref
32、lectance standards without an additional seal coat (BMC, cast aluminum, etc.). 4.7.3 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. 4.7.4 Topcoat Clear top coat must be applied ov
33、er the metalized surface. Film thickness and cure as recommended by supplier of the top coat. 4.7.5 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 testing. Direct metall
34、ization parts shall be conditioned for at least 24 hours at 23 + 2C prior to testing. ENGINEERING MATERIAL SPECIFICATION WSS-M5P8-C1/C2 Copyright 2018, Ford Global Technologies, LLC Page 6 of 6 4.8 DV/PV REQUIREMENTS Design Validation and Production Validation testing must be conducted on parts unle
35、ss approved by Design Engineering. Sample size To be done at DV To be done at PV To be done for MCDCC sign-off 3.3.1 Color 1 X X 3.4 Initial Adhesion 3 X X X 3.5.1 Resistance to Cycling 3 for basecoated, 1 for direct metallization X X X 3.5.2 Resistance to Humidity 3 X X 3.5.3 Water Immersion 3 X X 3.5.4 Resistance to Heat 3 X X 3.5.5 Construction Details 1 X X 3.6 Fogging 3 X X X = Required 5. SUMMARY OF REVISIONS
