1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2004 09 30 Activated B. Harris Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 1 of 7 PAINT, POWDERED, THERMOSETTING POLYESTER WSS-M70J5-B 1. SCOPE The material defined within this specification is for an ext
2、erior thermosetting polyester powder coating applied to metal parts. The powder coating shall provide good initial appearance with adequate durability and corrosion resistance. 2. APPLICATION This specification was released originally as a polyester powder topcoat finish on exterior parts providing
3、excellent corrosion resistance with specified color and gloss. It is intended for electrostatic spray or fluidized bed application over such substrates as cold rolled steel, galvanized, zinc die cast, aluminum and stainless steel parts. 3. REQUIREMENTS After a technology is approved to this specific
4、ation, every color must be evaluated to determine the effects of specific color or physical properties and must comply with the Exterior Parts Painter Approval Process per AVP-T113-015 (North American Production only). All painted parts must meet the performance requirements of WSS-M2P180-A1 and app
5、ropriate Subsystems Design Specification. Only exceptions or requirements specific to this type of material are noted herein. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material Suppliers and part producers must conform to the Companys Standard For Production Materials (WSS-M99P1111-A). 3.2
6、COMPOSITION 3.2.1 Resin Powder coatings must be Thermosetting Polyesters or equivalent. Each will be appropriately fortified or used in conjunction with a primer-surfacer and/or clearcoat, the resulting paint system to meet the durability requirements of 5 years. 3.2.2 Pigment/Metal Flake Pigments a
7、nd metal flake components are exterior quality automotive grade selected to meet appearance and durability requirements. 3.2.3 Toxicity In addition to MSDS reports, all suppliers of powder must provide a toxicological study to the Industrial Hygiene Department of Ford Motor Company for evaluation of
8、 any potential health hazards associated with the use of their product. ENGINEERING MATERIAL SPECIFICATIONWSS-M70J5-BPrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 2 of 7 3.3 MATERIAL PROPERTIES 3.3.1 Particle Size and Distribution, target (ASTM D 5861) Significan
9、t differences in particle size may affect handling and the appearance of powder coatings. Supplier shall submit particle size and distribution, and equipment used from the original control plan to maintain color. 3.3.2 Specific Gravity Identified by supplier (ASTM D 5965, Method A or B) on initial s
10、ubmission +/- 0.05 maximum. 3.3.3 Gel Time Identified by supplier (ASTM D 4217-02 204 C) on initial submission +/- 2 s. 3.3.4 Storage Stability, 8 weeks No caking or change in application or other properties. To an 8 ounce glass jar, fill to 2/3 capacity with the powder under test, and seal with a l
11、id. Carefully place a floating cover and a 100 gram weight on the surface of the powder before sealing the container. Place the container into a 40 C water bath noting the time and date. Immerse the container only to the level of the powder inside. At one-week intervals, the container is removed fro
12、m the water bath, blotted dry, and allowed to cool to room temperature. To evaluate physical stability, gently rotate the container and note the free flowing nature of the powder. If the powder is not free flowing or contains lumps, the lid is removed and the powder probed with a small spatula to de
13、termine the degree of compaction or sintering. The test is ended when the powder is not free flowing or agglomerates may not be easily broken. To determine chemical stability, evaluate gel time, inclined plate flow, and / or cured film properties and compare to initial values. The test is ended when
14、 any property has become unacceptable. 3.4 PROCESSABILITY Pertinent sections of this specification must be performed. 3.4.1 Processing Matrix Production representative electrostatic powder guns shall be used. Report fluidizing air pressure, electrostatic voltage, feed and conveyance (or equivalent)
15、air pressures, and powder flow in oz (lb) / min. ENGINEERING MATERIAL SPECIFICATIONWSS-M70J5-BPrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 3 of 7 3.4.2 Fluidization Characteristics Evaluate the fluidization of the powder at different fluidization air pressures,
16、particle size distributions, and humidity levels. The fluidization system must be production representative. 3.4.3 Inclined Flow Test (ASTM D 4242) Determine the time versus temperature profiles for flow and sintering properties as mutually agreed on between supplier and affected Materials Engineeri
17、ng Office. 3.4.4 Heat-up Rate Supplier shall demonstrate the effect that heat-up rates will have on appearance of the final coating. Also, supplier will demonstrate whether an interrupted bake, as may occur at breaks or shift change, affects appearance attributes. 3.5 PREPARATION OF TEST PANELS Subs
18、trate: Current production phosphated cold rolled steel or galvanized steel, zinc die-cast or AA 3003, H-14 aluminum. Record all information. Substrate approvals will be documented in the Approved Source List. Electrocoat: Current production cathodic electrocoat applied at 20 23 microns, baked 10 min
19、utes at 182 C metal temperature (MT). Record electrocoat and oven type used. Primer: If required, primer surfacer applied at 51 76 microns, and baked 10 minutes at 149 C MT. Record primer and oven type used, baked. Powder Coat: Apply powder topcoat at 51 microns or the optimal performance thickness
20、as recommended by the supplier and bake to parameters defined in Para. 3.6. Record the powder coat material and application (whether a basecoat or clearcoat) and oven type used. Clearcoat: If required, apply wet clearcoat to 51 102 microns, baked per clearcoat material specification. Record clearcoa
21、t and oven type used. 3.6 PROCESS WINDOW DEFINITION NEW PAINT TECHNOLOGIES ONLY The supplier shall perform a Design of Experiments (DOE) (Response Surface Analysis is recommended) to determine the process window of the control and candidate materials. Variables included in the design are bake time,
22、bake temperature and film thickness and particle size distribution. An initial screening experiment should be conducted 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. Response
23、s to the DOE will be based on the materials tested and will be chosen from the tests listed within the specification. Minimal critical testing required: Initial UV Transmittance at various film thickness, initial Cross Hatch Adhesion, Thermal Shock, Condensing Humidity, Chemical Resistance and Stone
24、 Chip (SAE J400 and Erichsen). The materials engineer will use this information to determine acceptable plant processing conditions. See also Para 4.2. ENGINEERING MATERIAL SPECIFICATIONWSS-M70J5-BPrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 4 of 7 3.7 APPEARANC
25、E Note: Appearance panels will be prepared using standard paint processing parameters. Consideration should be given to an application process window DOE to assess impact of key process variables / parameters on final appearance. 3.7.1 Color (FLTM BI 109-01) Shall match the Master Appearance Sample
26、approved by the Design Center. 3.7.2 Wave Scan DOI, min Equal or better than (Byk Gardner Wave Scan) Master Appearance Standard. 3.7.3 Gloss As specified by letter (FLTM BI 110-01) suffix to the Styling color number. A: 20 glossmeter, min - 72 F: 60 glossmeter - 35 +/- 3 B: 60 glossmeter, min - 76 G
27、: 60 glossmeter - 20 +/- 3 C: 60 glossmeter - 70 +/- 4 H: 60 glossmeter - 10 +/- 3 D: 60 glossmeter - 62 +/- 4 J: 60 glossmeter - 6 E: 60 glossmeter - 50 +/- 3 3.8 FILM PROPERTIES 3.8.1 Film Thickness As identified in (ASTM D 1186) Para 3.5. 3.8.2 Hardness (ASTM D 1474, after aging 72 h, min above 2
28、0 C) Record value at target film thickness and bake conditions. Coating shall be sufficiently cured after baking so that it can meet the polishing requirements of Para 3.8.4. 3.8.3 Ultraviolet Light Transmittance (DVM 5886 v2, Requirement PA-0149) Max light transmission through powder (applied at mi
29、nimal performance thickness as recommended by the supplier) shall be no more than 0.1% at 360 nm and 0.5% at 400 nm at time zero and 2500 h Accelerated Weathering according to paragraph 3.10.2. Achieving compliance may require the use of polyester primer-surfacer. The equipment used for this measure
30、ment is an integrating sphere, Lamda 18 spectrophotometer or equivalent. 3.8.4 Polishing Shall be capable of being sanded with 1200 grit sandpaper and polished in accordance with current plant processes to minimize orange peel or to remove defects. No noticeable change in gloss or appearance except
31、for a minimum of swirl marks is permitted. Deep polishing lines or swirl marks are not acceptable. ENGINEERING MATERIAL SPECIFICATIONWSS-M70J5-BPrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 5 of 7 3.9 RESISTANCE PROPERTIES 3.9.1 Adhesion Grade 0, no chipping (FLT
32、M BI 106-01, Part A and B) or flaking permitted. 3.9.2 Chip Resistance 3.9.2.1 Gravelometer, max 4B with no chips (SAE J400, 1.41 liter) exceeding 3 mm dia. 3.9.2.2 High Performance Chip Rating 4, min (FLTM BI 157-06) 3.9.3 Condensing Humidity, 240 h No blistering, dulling (ASTM D 4585, 43 C) or adh
33、esion loss. Panels will be checked for adhesion upon removal from humidity cabinet, at no greater than 20 minutes elapsed time from removal and meet the requirements of Para 3.9.1. 3.9.4 Solvent Rub, Cure Test Slight dulling and color (1 part MEK / 17 parts toluene) transfer permitted. Perform 10 do
34、uble rubs, moderate pressure with a wetted cheesecloth. 3.9.5 Abrasion Resistance No wear through (FLTM BN 108-02, CS10, 1000 g) to primer permitted. Conduct test to 1000 cycles per 25 microns film thickness. 3.9.6 Scab Corrosion Resistance 3 mm creepage, max (FLTM BI 123-01) 3.9.6.1 Aluminum and St
35、eel substrates 15 cycles 3.9.6.2 Galvanized and Zinc die-cast substrates 50 cycles 3.9.7 Fluid Spotting Resistance Rating 4, max (FLTM BI 113-01, AATCC evaluation procedure 2) dulling or permanent Test Fluids: Deionized Water Liquid Soap Windshield Solution 100% and 30% concentration in de-ionized w
36、ater Coolant Solution 100% and 30% concentration in de-ionized water Motor Oil (current production factory fill) Bug and Tar Remover (Ford Part No. B7A-19520-AA) ENGINEERING MATERIAL SPECIFICATIONWSS-M70J5-BPrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 6 of 7 3.9
37、.8 Thermal Shock No discoloration or (FLTM BI 107-05) adhesion loss. 3.10 WEATHERING After exposure (Para 3.10.1 and 3.10.2), panels must meet Para 3.10.3 requirements. 3.10.1 Natural Weathering Florida Exposure 5 years required, 8 (SAE J1976, Procedure A) year submission (one panel for each year. 3
38、.10.2 Accelerated Weathering 6000 h required (SAE J1960, 0.55 W/m2 Irradiance, Borosilicate Inner and Outer Filters) 3.10.3 Testing After Exposure (FLTM BI 160-01, B) 3.10.3.1 Appearance After 1 year Florida exposure, there shall be no visual color change, minimal gloss and DOI loss not to exceed 2
39、year requirement. There shall be no blistering, cracking, peeling or microchecking. After 2 years Florida exposure or 3000 h accelerated weathering; . AATCC Evaluation procedure 1: Rating 4 max . Gloss Change per FLTM BI 110-01 20% loss max . Color Change per FLTM BI 109-01 E 2.0 max After 5 years F
40、lorida exposure or 6000 h accelerated weathering, no excessive color change, blistering cracking, peeling or microchecking. 3.10.3.2 Gloss After Exposure 50% loss max (ASTM D 523, 60 gloss meter) 5 year Florida exposure or 6000 h 3.10.3.3 Adhesion After Water Immersion (FLTM BI 104-01) 16 h (FLTM BI
41、 106-01, Part B) Grade 0, max There shall be no blistering or delamination between any layer of the total paint system. To be evaluated on all exposure intervals. 4. GENERAL INFORMATION The material data included herein is for information only and not a requirement for the supplier. Contact The Desi
42、gn Responsible Materials Engineering Activity for the substances currently used in production. ENGINEERING MATERIAL SPECIFICATIONWSS-M70J5-BPrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 7 of 7 4.1 PAINT SYSTEMS (potential paint systems usage for production) 4.1.1
43、 Electrocoat primer (baked) + powder topcoat (baked) 4.1.2 Electrocoat primer (baked) + primer surfacer (baked) + powder topcoat (baked) 4.1.3 Electrocoat primer (baked) + powder topcoat (baked) + clearcoat (baked) 4.1.4 Electrocoat primer (baked) + primer surfacer (baked) + powder topcoat (baked) +
44、 clearcoat (baked) Primer selection based on Para. 3.8.3, UV Light Transmittance results. Clearcoat selection based on chemical and weathering resistance of color coat. 4.2 TOPCOAT PROCESSING CONDITIONS AND TEST REQUIREMENTS MATRICES Process window (Para 3.6) will be used to define targets, high / m
45、ax, and low / min. Target film thickness is defined as the optimal thickness range as defined by the supplier, min and max is target range +/- 20%. These values will be used to establish the conditions in Table 1 and shall be used to prepare panels for all tests in Para 3.7, 3.8, 3.9, 3.10. TABLE 1:
46、 TOPCOAT PROCESSING CONDITIONS REQUIRED FOR PARA 3.7, 3.8, 3.9 AND 3.10. Conditions Powder Bake Bake Filmbuild Time Temperature 1 Low Min Min 2 Low Max Max 3 Target Target Target 4 High Min Min 5 High Max Max Note: Control testing panel requirements to be chosen at discretion of approving materials engineer. 4.3 EXPLOSION HAZARD These materials should be used in a closed system specifically designed for their use because of the possibility of dust explosion present in powdered material.
