1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 07 05 Released A. Wagenhals, NA Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 1 of 8 IN-MOLD PAINTED STEERING WHEEL PERFORMANCE WSS-M98P12-C1 1. SCOPE This specification defines the material p
2、erformance requirements for the steering wheel “Class A“ in-mold painted polyurethane material. It does not address leather wrap, switches, or internal materials; they are beyond the scope of this specification and are addressed separately. 2. APPLICATION This specification was originally released f
3、or materials used in the construction of in-mold painted polyurethane steering wheels. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 PERFORMANCE CRITERIA Excluded from this specification are top grain (WSS-M1F22-D/latest) and spl
4、it (WSS-M1F21-D/latest) leather wrap; drivers side airbag, bezel, shroud, and switches (MIC WSS-M15P4-G/latest or painted WSS-M2P188-B1/latest); wood wheel and bezel/emblem appliqu (WSS-M15P34-E/latest), and plated bezel (WSS-M1P83-E1/latest). 3.3 SAMPLE PREPARATION Each test specimen necessary for
5、all of the testing below will be prescribed in table 1. Steering wheels shall be built to production intent and conditioned as prescribed in section 3.4 for all part validation below. Some testing will require a flat surface area for proper evaluation so therefore foam plaques can be molded and used
6、 for evaluation as long as the foam block is representative of production wheel composite. The foam plaque material content must be identical to the steering wheel as well as the film build (must be verified via section 3.6.1) and production process conditions (heat, cure time, etc). 3.4 CONDITIONIN
7、G AND TEST CONDITIONS All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.5 DV/PV TEST PLAN P
8、EC/FEC/PV testing must be conducted in compliance with program milestones unless otherwise specified by Ford Engineering. Testing must be conducted on parts at DV and PV unless specified otherwise by Ford Engineering. See Table 1 for sample sizes and required testing. ENGINEERING MATERIAL SPECIFICAT
9、ION WSS-M98P12-C1 Copyright 2017, Ford Global Technologies, LLC Page 2 of 8 3.6 FILM PROPERTIES 3.6.1 Paint Film Thickness Requirements 20 - 45 micrometer Test Method must be pre-approved by Ford Materials Engineering. Cross section evaluation under microscope is appropriate. 3.7 APPEARANCE Color, g
10、loss, grain, tactile effect and surface finish shall match master Trim Sample and/or Master appearance sample as approved by Corporate Design. The coating shall exhibit no craters, pinholes, solvent popping, seediness, abnormal roughness, excessive flow or any other detrimental defect. 3.7.1 Color (
11、FLTM BI 109-01, Visual Assessment and/or SAE J1545, MA58 Three-Angle CMC) The color, pattern, and finish shall match the approved Design Center master sample, or shall be as specified on the Engineering Document. 3.7.2 Gloss (FLTM BI 110-01, ASTM D 523) As released by Engineering: A: 20 Glossmeter,
12、min 92 B: 60 Glossmeter 76 84 C: 60 Glossmeter 66 74 D: 60 Glossmeter 58 66 E: 60 Glossmeter 47 53 F: 60 Glossmeter 33 38 G: 60 Glossmeter 17 23 H: 60 Glossmeter 7 13 J: 60 Glossmeter 4 6 K: 60 Glossmeter 2 4 L: 60 Glossmeter 0.5 2.0 N: 60 Glossmeter 1.8 2.4 3.8 RESISTANCE PROPERTIES 3.8.1 Adhesion
13、5 % max (FLTM BI 106-01, Method D, knife) No complete Diamondremoved Lightly hand sand paint film surface (10 double rubs, moderate pressure) with P600 paper until dull, before knife operation and checking adhesion. Adhesion shall be performed on the full wheel in the largest grained “flat“ area. Ty
14、pically, this will be on the “back“ face of the wheel in the spoke area. Due to the contour of the part, substrate material may be removed when performing this test. This is not cause for rejection; adhesion of the paint to the substrate material must be evaluated. ENGINEERING MATERIAL SPECIFICATION
15、 WSS-M98P12-C1 Copyright 2017, Ford Global Technologies, LLC Page 3 of 8 3.8.2 Water Resistance No blistering, (FLTM BI 104-01, 96 h) softening After exposure, adhesion shall be tested according to para 3.8.1 within 30 minutes of removal from water on all paint systems. 3.8.3 Flexibility Required fo
16、r substrates with a flexural modulus less than 450 MPa. Specimen shall be taken from the steering wheel rim as follows: cut along the parting lines in the 12:00 region and remove a sample of the material from the “front“ at least 100 mm in length. The material sample shall be cleanly removed from th
17、e metal support. The test specimen will be taken from this sample and must use the material along the parting line of the outer diameter. 3.8.3.1 Room Temperature (23 +/- 2 C) Test Method: Cut 13 x 100 mm sample from the specimen. Grasp sample firmly at each end, place over mandrel painted side up,
18、and bend around mandrel 180 degrees min. Use a 25 mm diameter mandrel. No cracking of “Class A“ surface when bent over mandrel. 3.8.3.2 Cold Temperature (- 30 +/- 2 C) Test Method: Cut 13 x 100 mm sample from the specimen. Place sample, mandrel and gloves into a freezer at - 30 +/- 2 C for 4 h min.
19、Open freezer, put on gloves and grasp sample firmly at each end, place over mandrel painted side up, and bend around mandrel 180 min. Use a 25 mm mandrel. (A room temperature pair of gloves may be worn inside the gloves that have been conditioned at - 30 C.) No cracking of “Class A” surface when ben
20、t over mandrel. 3.8.4 Long Term Heat Exposure Rating 4 min (AATCC Evaluation Procedure 1) 7 days at 107 +/- 2 C Appearance Evaluation: No evidence of cracks, blisters, peeling, delamination, or change in gloss when compared with original unaged sample. After exposure, immerse one of the weathered pa
21、nels in water for 24 h per FLTM BI 104-01 and then perform adhesion test per para 3.8.1 within 30 minutes of removal from the water on all paint systems. Part must meet the adhesion requirements of 3.8.1 and show no blistering or softening. 3.8.5 Short Term Environmental Cycling (FLTM BO 040-01 Proc
22、edure A, 100 C) Rating 4 min After exposure, immerse one of the weathered panels in water for 24 h per FLTM BI 104-01 and then perform adhesion test per para 3.8.1 within 30 minutes of removal from the water on all paint systems. Part must meet the adhesion requirements of 3.8.1 and show no blisteri
23、ng or softening. ENGINEERING MATERIAL SPECIFICATION WSS-M98P12-C1 Copyright 2017, Ford Global Technologies, LLC Page 4 of 8 3.8.6 Accelerated Xenon Weathering, Rating 4 min (FLTM BO 116-01 at 2406.4 kJ/m2 AATCC Evaluation Procedure 1) The parts tested shall be completely free from evidence of cracki
24、ng, checking, blistering, and peeling. Read and report the gloss change per FLTM BI 110-01. Note gloss change will be a factor in the overall AATCC rating. Duplicate panels are required, one for appearance evaluation and one for water immersion. After the color and gloss measurements, immerse one of
25、 the weathered panels in water for 24 h per FLTM BI 104-01 and then perform adhesion test per para 3.8.1 within 30 minutes of removal from the water on all paint systems. Part must meet the adhesion requirements of 3.8.1 and show no blistering or softening. Perform Flexibility following Xenon Exposu
26、re per para 3.7.3.1. 3.8.7 Soiling and Cleanability, Rating 4 min (FLTM BN 112-08, AATCC Evaluation Procedure 2) Testing Agents: Synthetic Soil, Grease 3.8.8 Resistance to Scuffing 1000 cycles min (SAE J365) Measure and report the paint film thickness of the panel and run a min of 1000 cycles for ev
27、ery 25 micrometer of paint thickness on the panel. No evidence of lifting or peeling of the surface. No wear through of the coating to the substrate. For paint film thickness less than or equal to 25 micrometers run 1000 cycles. For paint film thickness greater than 25 micrometers use the following
28、formula to calculate the number of cycles to run. Use the following formula to calculate additional cycles; Number or cycles= (Xm)(1000) Where Xm = additional microns of film build 25m 3.8.9 Abrasion Resistance, No Wear through to the substrate (SAE J948, Taber method, 500 g load, CS-10 wheels) The
29、paint film shall show no abrasion through to the substrate. Abrasion resistance shall be determined on test panels with grained surface. Paint must be sprayed on foam panels of contrasting color (ex. black paint on gray substrate) to improve judgment of wear to the substrate. Measure and report the
30、samples paint film thickness. The Control Plan shall state the film thickness as specified in para. 3.6.1. 3.8.9.1 Fully Grained Plaques 500 g load 1,000 cycles min 1,000 cycles/25 m paint thickness ENGINEERING MATERIAL SPECIFICATION WSS-M98P12-C1 Copyright 2017, Ford Global Technologies, LLC Page 5
31、 of 8 For paint film thickness less than or equal to 25 micrometers run 1000 cycles. For paint film thickness greater than 25 micrometers use the following formula to calculate the number of cycles to run. Use the following formula to calculate additional cycles; Number or cycles= (Xm)(1000) Where X
32、m = additional microns of film build 25m 3.8.10 High Performance Paint Adhesion* *Note method used on data submission form FLTM BI 107-05 Adhesion Rating 19 min Alternate Method : High Pressure Cleaning FLTM BO 160-04 Adhesion No Adhesion Loss No loss of gloss or any other surface deterioration. 3.8
33、.11 Color Fastness-Rub Resistance (ISO 11640, 10% elongation/mount felt pad 2-3 mm in the holder/ ISO 105-A03/AATCC Evaluation Procedure 2) The surface shall show no evidence of wear through of top coat or painted layer, including bubbling of surface coating or particulate transfer onto felt pad. Ea
34、ch chemical agent shall completely saturate the felt pad prior to the execution of this test. Place the felt pad in the solution and allow it to sink to the bottom of its container. After saturation 3.8.11.1 Dry Felt 2000 cycles Rating 4 min 3.8.11.2 Wet Felt 500 cycles Rating 4 min 3.8.11.3 Commerc
35、ially Available 100 cycles Rating 4 min Window Cleaner Report Brand Used 3.8.11.4 All Purpose Cleaner 100 cycles Rating 4 min (FLTM BN 112-08) 3.8.11.5 Acetic Acid Solution 100 cycles Rating 4 min (5% in deionized water) 3.8.11.6 Alkaline Perspiration Solution 100 cycles Rating 4 min (Sodium Chlorid
36、e 10g, Ammonium Carbonate 4g, Disodium hydrogen orthophosphate 1g Water 1 liter) 3.8.11.7 Sodium Chloride Solution 100 cycles Rating 4 min (Sodium Chloride 10g Lactic Acid 1g Disodium hydrogen orthophosphate 1g Water 1 liter) ENGINEERING MATERIAL SPECIFICATION WSS-M98P12-C1 Copyright 2017, Ford Glob
37、al Technologies, LLC Page 6 of 8 3.8.11.8 Ethyl Alcohol/ 100 cycles Rating 4 min Deionized water 70% v/v 3.8.11.9 IPA (50 % V/V. IPA and deionized water) 100 cycles Rating 4 min 3.8.11.10 Suntan Lotion 100 cycles Rating 4 min (Apply 0.16 +/- 0.01 grams of Sunscreen or sunblock lotion with SPF factor
38、 of 30, water-proof and commercially available) 3.8.11.11 Insect Repellant 100 cycles Rating 4 min (20-30% DEET commercially available) 3.8.12 Resistance to Water and Soap Spotting Rating 4 min (FLTM BI 113-01, AATCC Evaluation Procedure 1) No film softening allowed for any solution. 3.8.13 Resistan
39、ce to Chemicals Rating 4 min (AATCC Evaluation Procedure 2) 1. Petroleum Naphtha 2. SAE 10 W 30 Motor Oil Test Method: Apply 2 to 5 ml of each chemical to separate areas (do not allow mixing) of the part. Cover each spot with a watch glass to prevent evaporation. Expose for 1 h at 23 +/- 2 C. Remove
40、 watch glass and wipe with a soft white cloth. Thoroughly wash test area with soap and water and dry. Perform adhesion per (FLTM BI 106-01, Method D) on test area within 1 h. Requirement per para 3.8.1. 3.9 FLAMMABILITY (ISO 3795) Burn Rate 100 mm/minute max The specimen size required for material a
41、pproval is 355 x 100 x 2.0 +/- 0.1 mm with a smooth surface. 3.10 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. All materials, parts and components should be stored in
42、 an open environment for 14-28 days after manufacture, and then must be bagged in sealed polyethylene (PE) or PE coated aluminum bags for shipping. Parts for testing must be labelled with supplier and date of manufacture. ENGINEERING MATERIAL SPECIFICATION WSS-M98P12-C1 Copyright 2017, Ford Global T
43、echnologies, LLC Page 7 of 8 Sample shall be tested as part of a production assembly composite if it is 100% bonded. If not 100% bonded, test each component separately. 3.11 ODOR (FLTM BO 131-03) Condition 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.12 PROCESS WINDOW DEFINITIO
44、N The supplier shall perform a Design of Experiment (Response Surface Analysis is recommended) to determine the process window of the substrate/paint combination. The three variables/parameters to be included in the design are bake temperature, bake time, and film thickness. An initial screening exp
45、eriment 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: Film Thickness, para 3.6.1 Gloss
46、, para 3.7.2 Initial Adhesion, para 3.8.1 Water Resistance, para 3.8.12 Naptha or Xylene Crocking, FLTM BN 107-01, 10 cycles ENGINEERING MATERIAL SPECIFICATION WSS-M98P12-C1 Copyright 2017, Ford Global Technologies, LLC Page 8 of 8 Table 1 Test Sample Sizes DV* PV* New Manufacturing Location/Line MC
47、DCC Approval Paragraph Sample Size Sample Type* New Top Coat / PUR Foam Change * Grain Change (Approved Top coat and PUR) Required for all new colors 3.6.1 Film Thickness 1 Wheel X X X X X 3.7 Appearance 1 Wheel X X X X X 3.8.1 Adhesion 3 Wheel X X X X X 3.8.2 Water Resistance 3 Wheel X X X X X 3.8.
48、3 Flexibility (N/A for wood) 3 Wheel X X X 3.8.4 Long Term Heat Exposure 1 Wheel X X X 3.8.5 Short Term Environmental Cycling 1 Wheel X X X 3.8.6 Accelerated Weathering 1 Wheel X X 3.8.7 Soiling and Cleanability 3 Foam Plaque / Wheel X X X 3.8.8 Resistance to Scuffing 3 Foam Plaque / Wheel X X X 3.8
49、.9 Abrasion Resistance 3 Foam Plaque / Wheel X X X 3.8.10 High Performance Paint Adhesion 3 Wheel X X X X 3.8.11 Color Fastness-Rub Resistance 1/agent Foam Plaque / Wheel X X X X 3.8.12 Resistance to Water and Soap Spotting 1 Wheel X X X 3.8.13 Resistance to Chemicals 1 Wheel X 3.9 Flammability * 5 Wheel X 3.10 Fogging 3 specimens per part Wheel X X 3.11 Odor 1 per part per condition Wheel X X *Pre-DV and DV testing to be performed on plaques or part
