1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 12 05 Revised Rev para 3.5.1.1, updated and renumbered R. Lord 2000 10 26 Revised Rev para 3.5, 3.7, 3.9, 3.10 & updated T. Horoszy 1999 09 02 Activated T. Horoszy Printed copies are uncontrolled Page 1
2、 of 7 Copyright 2002, Ford Global Technologies, Inc. PAINT, WATERBORNE CATIONIC EPOXY ELECTROCOAT WSS-M64J40-A1 PRIMER, INITIAL FILL MAKEUP FEED, WATERBORNE CATIONIC EPOXY WSS-M64J40-A2 ELECTROCOAT, RESIN MAKEUP FEED, WATERBORNE CATIONIC EPOXY WSS-M64J40-A3 ELECTROCOAT, PIGMENT, BLACK FLOW CONTROL A
3、DDITIVE WSS-M64J40-A4 1. SCOPE The materials defined by these specifications are heat curing, water-borne epoxy electrocoat primers and associated makeup feed components feed applied by the cathodic deposition process. 2. APPLICATION These specifications were released originally for a paint system w
4、hich, when properly electrodeposited will provide good corrosion resistance and adhesion for underbody components such as frames/subframes and suspension members. Components painted to this specification are not generally top coated and must have minimal direct ultraviolet light exposure. WSS-M64J40
5、-A1: This primer is applied directly over zinc phosphate coated hot or cold rolled steel. Although the original intent of this specification is to provide corrosion protection to non-precoated steel material, electrodeposited zinc or zinc/zinc alloy coated steel and any other type of steel classifie
6、d as precoated can be painted to this specification. WSS-M64J40-A2: This material is make-up feed material used to replenish the resins of the initial fill electrocoat bath. WSS-M64J40-A3: This material is make-up feed material used to replenish the pigments of the initial fill electrocoat bath. WSS
7、-M64J40-A4 are make-up feed materials that correct poor flow characteristics of the primer which may develop when the bath ages. This additive is used only as recommended by the supplier following ultrafiltrate purge or when discontinuous operation of an electrocoat tank results in evaporation of ba
8、th volatiles. ENGINEERING MATERIAL SPECIFICATION WSS-M64J40-A1/A4 Page 2 of 7 Copyright 2002, Ford Global Technologies, Inc. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material supplier
9、s and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 MATERIAL COMPATIBILITY The supplier of this material shall keep abreast of changes in technology of related materials e.g., sealers and adhesives, which may affect the compatibility
10、 and performance of this product. The supplier shall notify the appropriate Ford Product Materials Engineering Office in writing when incompatibility is anticipated. 3.3 COMPOSITION 3.3.1 Density, kg/L at 25 C (ASTM D 1475) The density of the materials defined by these specifications shall be within
11、 +/- .05 % of that shown on the Initial Sample Report. 3.3.2 Non-volatile, wt % (FLTM BI 102-01) The non-volatile content of the material types specified by these specifications shall match the values shown on the initial sample report within +/- 1 %. 3.3.3 Weight Loss, max (FLTM BI 120-15, after 20
12、 minutes at 163 +/- 2 C metal temperature bake cycle) Initial Fill and Assembly Plant 15.0 % Electrocoat Tank Material 3.3.4 Solvent Emissions, max 0.1 kg/L of (ASTM D 3960) wet paint This requirement is as determined by the United States Environmental Protection Agency Reference Method #24 but is o
13、nly applicable to materials used in the USA. ENGINEERING MATERIAL SPECIFICATION WSS-M64J40-A1/A4 Page 3 of 7 Copyright 2002, Ford Global Technologies, Inc. 3.4 STABILITY 3.4.1 Pumping Stability (FLTM BI 120-04) After 21 days minimum agitation, the bath prepared from the initial fill or feed material
14、s shall meet all requirements of the specification. 3.4.2 Storage Stability 2 months During a storage of 2 months between 5 and 32 C temperature the material as supplied shall not settle or cake. 3.5 PREPARATION OF TEST PANELS Prepare panels per FLTM BI 120-01 with the exceptions noted below: The su
15、bstrates used shall be as follows, (ref. para. 4.1): Standard Steel Panel - Hot Rolled Low Carbon Steel P&O (HRLC P&O) or as designated by the responsible Product Materials Engineering Department. The electrocoat bath temperature should be maintained at 27 +/- 2 C or as recommended by the supplier d
16、uring the coating process. All substrates shall be zinc phosphated and conform to the requirements of WSS-M3P1-D. 3.5.1 Paint Film Build 3.5.1.1 Thickness 0.020 - 0.025 mm (FLTM BI 117-01) 3.5.2 Bake Requirements Coatings shall meet the requirements of para. 3.5 when painted at the following bake ti
17、mes & temperatures. Standard Bake at paint suppliers recommended minimum bake time & temperature Undercure - Bake at 14 C below paint suppliers recommended minimum bake time & temperature. Overbake - Bake at 14 C above paint suppliers recommended minimum bake time & temperature. ENGINEERING MATERIAL
18、 SPECIFICATION WSS-M64J40-A1/A4 Page 4 of 7 Copyright 2002, Ford Global Technologies, Inc. 3.5.3 Aging All panels shall be aged at room temperature for 72 h prior to testing unless otherwise specified. 3.6 APPEARANCE 3.6.1 Color Black 3.6.2 Gloss 30 to 80 at 60 (FLTM BI 110-01) 3.6.3 Leveling 3.6.3.
19、1 Smoothness The surface of the electrocoat primer shall be smooth without any structure and not more than a minimum of orange peel when applied and baked as required in 3.5. 3.7 RESISTANCE PROPERTIES 3.7.1 Adhesion, max Grade 0 (FLTM BI 106-01, Method B) Prepare panels per para 3.5. There shall be
20、no flaking, chipping or other evidence of film separation. 3.7.2 Stone Chip Resistance, max (SAE J400 or FLTM BI 157-04) SAE J400 4B FLTM BI 157-04 Rating 2 Prepare panels according to para 3.5. Chipping shall not exceed above limit. 3.7.3 Salt Spray, min 960 h (FLTM BI 103-01) Panels prepared accor
21、ding to para 3.5 shall exhibit no rusting or loss of adhesion more than 3 mm from a line scribed to bare metal. ENGINEERING MATERIAL SPECIFICATION WSS-M64J40-A1/A4 Page 5 of 7 Copyright 2002, Ford Global Technologies, Inc. 3.7.4 Resistance to Scab Corrosion (FLTM BI 123-01, 50 test cycles) Standard
22、steel panels (ref. to para. 4.1.1) prepared according to para. 3.5, shall be scribed to the base metal. After exposure there shall be no blistering, rusting or loss of adhesion more than 3 mm from the scribe line. 3.7.5 Adhesion/Water Immersion Test, max 0 mm (FLTM BI 104-04) Prepare panels accordin
23、g to para 3.7. Test for the loss of adhesion after the panels have been immersed in a deionized water bath maintained at 49 +/- 2 C for 120 h. Blistering of the paint film is not permitted. 3.7.6.1 Condensing humidity test, 24 h No blistering (ASTM D 2247) 3.7.6.2 Adhesion No chipping (FLTM BI 106-0
24、1, Method B) Adhesion shall be performed 24 h after test 3.7.6.1 3.7.7 Resistance to Edge Corrosion, max Less than 5 (FLTM BI 127-01, 168 h) Rust Spots 3.7.8 Thermal Shock Resistance No loss of (FLTM BI 107-05) adhesion or blistering 3.7.9 Heat Resistance Coat panels to the minimum film build per 3.
25、5.1. Place panel into a room temperature circulating air oven and heat to 204 C. Soak panels for 48 h and quench in ice water. Salt spray per 3.7.3 for 960 h. Panels must meet the same requirements as shown on 3.7.3. 3.7.10 Hardness, min 2H (FLTM BI 151-01) ENGINEERING MATERIAL SPECIFICATION WSS-M64
26、J40-A1/A4 Page 6 of 7 Copyright 2002, Ford Global Technologies, Inc. 3.8 THROWING POWER 3.8.1 Preparation of Throw Power Panels (FLTM BI 120-02, Method C) Throw power panels shall be prepared as per above test method with the following exceptions: The substrates used shall be standard steel panels b
27、ut unscribed (see para 4.1). The surface condition of the substrates are designated in para 3.8.2. All substrates which are required to be phosphated, shall be zinc phosphated per WSS-M3P1-D prior to painting. The oiled substrates shall be prepared as follows: The oil solution shall be a mixture of
28、5 % by volume of ASTM Oil #1 (see ASTM D 471) in toluene. Pour the oil mixture on the test panels and hang in a vertical position to dry for 24 h before applying the electrocoat. The voltage used to prepare throw power panels shall be the same voltage required to obtain a 20 micrometer electrocoat p
29、aint film thickness on a standard phosphated test panel prepared per FLTM BI 120-01. Bake the electrocoat primed panels 20 minutes at 163 C metal temperature. Electrocoat painted test panels shall be exposed to salt spray per FLTM BI 103-01 for the test periods designated in para 3.8.2. Panel edges
30、shall be sealed and the uncoated end placed downwards in the salt spray cabinet. 3.8.2 Throw Power Requirements The minimum requirements and specified test periods for the defined substrates, are indicated below: Salt Spray Substrate - Surface Condition mm of protection before and after salt spray H
31、ours Before After Standard Panel - Phosphated 240 200 180 Standard Panel Clean 240 170 130 Standard Panel Oiled 120 170 60 There shall be no blistering, red rusting or corrosion greater than the minimum requirements, measured from the electrocoated end of the electrocoated test panel when salt spray
32、 tested per FLTM BI 103-01. ENGINEERING MATERIAL SPECIFICATION WSS-M64J40-A1/A4 Page 7 of 7 Copyright 2002, Ford Global Technologies, Inc. 3.9 QUALITY Must be adaptable for application in accordance with appropriate Ford Motor Company Process Specifications. When applied in this manner, it shall bak
33、e out to a presentable, serviceable film showing no craters or pinholes. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 PANEL INFORMATION 4.1.1 Standard Steel Panels Hot rolled low carbon P&O test
34、 panels are manufactured from commercial quality hot rolled steel(HRLC P&O). They are available from the Advanced Coating Technologies, Inc., P.O. Box 735, 273 Industrial Dr., Hillsdale, Michigan 49242 Co., 322 Main. 4.2 PANEL PREPARATION Panels can be prepared and/or tested at: ACT Testing Laborato
35、ries, Inc. P.O. Box 735, 273 Industrial Dr. Hillsdale, Michigan 49242 (517) 439-1485 or Ford Central Laboratory 15000 Century Drive North Dearborn, Michigan 48126 (313) 337-8278 4.3 CONTINUOUS PROCESS STABILITY (FLTM BI 120-05 and/or designated plant trial) The bath prepared from the initial fill or feed materials shall meet the requirements of para 3.6 and 3.7 after 5, 10, 15 and 20 turnover cycles.
