1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 05 21 Revised See Summary of Revisions for details Global Paint Team 2004 03 25 Revised Para 3.0 inserted; para 3.1, 3.2, 3.3, 3.4.1, 3.4.2, 3.7.11, 3.7.24, 3.9, 3.10 para 3.5.3, 3.7, 3.7.8, 3.7.13, 3.7.14, 3.7.15, 3.7.18, 3.7.21 and 5.1
2、revised C. Lin 1997 10 01 Activated D. Bogrette, A. Weakley, L. Soreide Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 8 PAINT, ONE COMPONENT COLOR COAT FOR PLASTIC, INTERIOR WSS-M99J385-A 1. SCOPE The material defined by this specification is a pigmented one
3、-component paint suitable for first surface application to interior plastic parts. No metallic paints are allowed under this specification. 2. APPLICATION This specification was released originally as a decorative finish for interior parts. All painted parts must meet WSS-M2P188-A1. All paint applic
4、ators must meet the Painted Part Approval Process (AVP-T113-0116). These paint systems are typical used to decorate interior visible surfaces solid colors only (i.e. bezels, switches, buttons, console, etc.). 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and p
5、art producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.4 PHYSICAL PROPERTIES 3.4.5 Stability (6 months at 23 +/- 2 C) Shall not liver or jell upon standing and must be free from settling which is not dispersed by normal agitation. The viscosity
6、of the material shall not increase or decrease more than 10 s. 3.5 PREPARATION OF TEST PANELS 3.5.1 Testing Requirement/ Specimen Preparation Tests shall be performed on plaques of appropriate substrate. See Table 1 for testing requirements & sample size. Design Verification Testing (DV) is done on
7、plaques by the paint supplier as defined in Table 1. Product/Process Validation Testing (PV) is done on production painted parts as outlined in the painted part Performance Specification WSS-M2P188-A1. 3.5.2 Substrate Polymers and polymer blends (i.e ABS, PC, PC/ABS). All test specimens shall be inj
8、ection molded plaques or parts having a nominal thickness of 2.5 +/- 0.2 mm or as specified on the engineering document. ENGINEERING MATERIAL SPECIFICATIONWSS-M99J385-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 8 3.5.3 Plastic Preparation The surface to
9、be painted shall be cleaned by an acceptable process, e.g. power wash, to remove mold releasing agents, fingerprints, oils, dirt and moisture. 3.5.4 Primer When necessary in order to meet the requirements of this specification, an adhesion primer, primer surfacer or sealer may be needed. Surface enh
10、ancements, such as flaming or plasma treatment that modify surface tension, surface resistivity may also be required in order to meet the requirements. This must be noted in the initial submission package and recorded on the Ford Approved Source List (ASL). 3.5.5 Cure Supplier shall define Cure Wind
11、ow as described in Paragraph 3.6. This should be included in the submission package and DFMEA. 3.5.6 Ageing Test panels or test specimens prepared for investigations according to this specification must be aged for at least 72 hours at 23 +/- 2 C or 16 hours at 45 +/- 1 C prior to testing. 3.6 APPEA
12、RANCE 3.6.1 General Color, gloss, 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, or excessive flow. 3.6.2 Color (FL
13、TM BI 109-01, Visual Assessment) (SAE J1545, MA58 Three-Angle CMC) Shall match the Master Approved Sample. 3.6.3 Gloss (FLTM BI 110-01, ASTM D 523) As released by Engineering: A: 20 Glossmeter, min 92 B: 60 Glossmeter 76 - 84 C: 60 Glossmeter 66 - 74 D: 60 Glossmeter 58 - 66 E: 60 Glossmeter 47 - 53
14、 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: 60oGlossmeter 1.8 - 2.4 ENGINEERING MATERIAL SPECIFICATIONWSS-M99J385-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC
15、 Page 3 of 8 The color, pattern and finish shall match the approved Design Center master sample, or shall be as specified on the Engineering Document. Gloss can be affected by grain so the end gloss for the part will be determined & approved by visual evaluation by Design Quality. An accurate gloss
16、reading needs to be performed on a flat smooth surface otherwise an accurate gloss reading cant be obtained. 3.7 FILM PROPERTIES All film properties are based on the proper preparation per para 3.5 with acceptable appearance, gloss reading, film thickness and after post cure per paragraph 3.5.6. 3.7
17、.1 Film Thickness, range 20 - 30 micrometer (ASTM B 487 or other mutually agreed upon method) Note : These ranges are considered to be requirements unless otherwise supported by testing data agreed to by Materials Engineering. 3.7.2 Adhesion Grade 0 (FLTM BI 106-01, Method B) 3.7.3 Water Resistance
18、Grade 0 (FLTM BI 104-01, 96h) No blistering, softening, dulling, or loss of adhesion per para 3.7.2 within 30 minutes of removal from water. 3.7.4 Abrasion Resistance, min 1000 cycles (SAE J948, Taber method, 500 g load, CS-10 wheels) Abrasion resistance shall be determined on test panels with smoot
19、h surface. Measure and report the panels paint film thickness and run a min of 1000 cycles for every 25 micrometer of paint thickness on the panel. The paint film shall show no abrasion through to the substrate. 3.7.5 Resistance to Cleaning Agents, max Rating 4 discoloration (FLTM BN 107-01, 10 cycl
20、es, AATCC Evaluation Procedure 2) Test Procedure: Saturate white cotton cloth with the cleaners listed. Evaluation according to the AATCC Scale. Cleaners (see also para 5.1) 1) Deionized water 2) Window cleaner with ammonia 3) All purpose cleaner 4) Dry (no cleaners or water) ENGINEERING MATERIAL SP
21、ECIFICATIONWSS-M99J385-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 8 3.7.6 Long Term Heat Exposure Rating 4 (7 d at 100 +/- 2 C, ISO 105-A02/ AATCC Eval. Proc. 1) Appearance Evaluation: No evidence of cracks, no blistering, or other failure when compared
22、 with original unaged sample. Panels or parts exposed per para 3.7.7 shall be immersed in water for 24 h per FLTM BI 104-01 and then tested for adhesion per para 3.7.2. 3.7.7 Short Term Heat, Humidity and Cold Cycle Rating 4 (ISO 105-A02/AATCC Eval. Proc. 1) . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2
23、 C and 50% R.H. . 5 h at 100 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 100 +/- 2 C 1 h ramp time between each step. Appearance Evaluation: No evidence of cra
24、cks, no blistering, or other failure when compared with original unaged test sample. Panels or parts exposed per para 3.7.7 shall be immersed in water for 24 h per FLTM BI 104-01 and then tested for adhesion per para 3.7.2. 3.7.8 Accelerated Xenon Weathering, min Rating 4 (FLTM BO 116-01 at 2406.4kJ
25、/m2 Gloss Change 30% or SAE J2412* at 1240kJ/m2, L.a.b. delta 1.9 ISO 105 A-02/AATCC Evaluation Procedure 1) *note the FLTM is the preferred method note method used on data submission form. Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only Duplicate panels are required, one for appearance eva
26、luation and one for water immersion. After the color and gloss measurements, one of the weathered panels shall be subjected to the water immersion test for 24 h per FLTM BI 104-01 and must meet requirements of para 3.7.2 3.7.9 Florida Weathering Under Glass 1 year submission (FLTM BI 160-01, ISO 105
27、 A-02/AATCC required for new Evaluation Procedure 1) technology only 12 months Rating 4, min Gloss change 30% L.a.b. delta E 1.9 ENGINEERING MATERIAL SPECIFICATIONWSS-M99J385-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 8 Test parts shall be exposed under
28、 glass in the Miami, Florida area, black box, under glass at a 5 angle facing South. After the color and gloss measurements, one of the weathered panels shall be subjected to the water immersion test for 24 h per FLTM BI 104-01 and meet the requirements of para 3.7.2.1. 3.7.10 Fogging (SAE J1756, 3
29、h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number, min 70 Formation of a clear film, droplets or crystals is cause for rejection. 3.7.12 Intercoat Adhesion (FLTM BI 106-01, Method D) The first coat shall cover the entire test panel and the repair/tutone coat shall only
30、cover half of the panel. Good adhesion is required for either same color repair or two-tone combination. Color and gloss shall match between the virgin coat and the repair coat of the same color. The processing window (3.6) for the repair/two-tone coat shall be identified to ensure good adhesion pro
31、perties. 3.7.13 Migration Staining, min Rating 5 (FLTM BN 103-01, ISO 105 A-02/AATCC Evaluation Procedure 1) No evidence of exudation, adhesion (tackiness), separation, color transfer, or flattening of embossing when placed face to face with itself. 3.7.14 High Performance Paint Adhesion* * note met
32、hod used on data submission form Test Method: Expose the samples at 80 +/- 2 C and 80 +/- 5% Relative Humidity for 96 hours then follow all steps of FLTM BI 107-05 and FLTM 160-04. FLTM BI 107-05 Adhesion, min Rating 19 No loss of gloss or any other surface deterioration. Alternate Method FLTM BO 16
33、0-04 Adhesion, min No Adhesion Loss No loss of gloss or any other surface deterioration. ENGINEERING MATERIAL SPECIFICATIONWSS-M99J385-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 8 3.7.15 Resistance to Water and Soap Rating 4 Spotting, max discoloration
34、(FLTM BI 113-01, ISO 105-A02/AATCC Evaluation Procedure 1) No film softening allowed for any solution. 3.7.16 Resistance to Window Cleaner Spotting Rating 4 Apply 0.25 ml of window cleaner per section 4.1 on test sample using a non-reactive O-ring. Expose the sample at the room temperature for 1 h.
35、Evaluate per ISO 105-A02/AATCC Evaluation Procedure 1. 3.7.17 Scratch Resistance, max (FLTM BO 162-01, visual inspection of paint surface, 1mm scratch pins) Scratch, 2N Rating 1 Marring, 2N Rating 2 3.7.18 Resistance to Marring (SAE J365, 10 cycles) A and B gloss surfaces (see 3.6.3) Shall be capabl
36、e of being sanded with 1200 grit or finer and polished. No noticeable change in gloss or appearance except for a minimum of polishing lines shall result. C L gloss surfaces (see 3.6.3) No evidence of discoloration, mar can be removed with four rubs of the thumb across the mar. 3.7.19 Resistance to S
37、cuffing, min 1000 cycles (SAE J365) Measure and report the paint film thickness of the panel and run a min of 1000 cycles for every 25 micrometer of paint thickness on the panel. No evidence of lifting, peeling, or excessive scuffing. No permanent parallel deformation to the surface. 3.7.20 Soiling
38、and Cleanability (FLTM BN 112-08, ISO 105-A02/AATCC Evaluation Procedure 1) Cleanability Rating 3 3.7.21 Resistance to Suntan Lotion Rating 3 and Insect Repellent, max No loss of adhesion (FLTM BI 113-08, 23C & 74C) 3.7.22 Perspiration Resistance (FLTM BI 113-06, ISO 105-A02/AATCC Evaluation Procedu
39、re 1) Acid Perspiration Solution Rating 4 Alkaline Perspiration Solution Rating 4 Sodium Chloride Solution Rating 4 ENGINEERING MATERIAL SPECIFICATIONWSS-M99J385-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7 of 8 3.7.24 Odor, max Rating 3 (FLTM BO 131-03) 3.7
40、.25 Humidity Resistance (85C and 90 %R.H for 96hr) No blistering, softening, or loss of adhesion per 3.7.2. 3.8 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments (Response Surface Analysis is recommended) to determine the process window of the material. The three variables
41、/parameters to be included in the design are bake temperature, bake 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 f
42、inal DOE. Responses for the DOE shall include, but are not limited to, the following: Film Thickness, para 3.7.1 Gloss, para 3.6.3 Initial Adhesion, para 3.7.2 Water Resistance, para 3.7.3 50/50 Isopropyl Alcohol (1K only), FLTM BN 107-01, 10 cycles Odor para 3.7.24 5. GENERAL INFORMATION The inform
43、ation given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 CLEANING AGENTS (See para 3.7.5) 1) Window cleaner ZC-23* 2) All Purpose Cleaner ZC-11-A* * or Ford Motor Company recommended equivalents 6. SUMMARY OF REVISIONS 2009 05 21 Removed 3
44、.4.3 & 3.4.4 Updated 3.5 to align with WSS-M2P188-A1 Updated 3.6.3 3.7.8 Updated/Added FLTM BO 116-01 3.7.14 Changed Name and added Alternative Method BO 160-04 3.7.21 Removed DVM replaced by FLTM BI 113-08 3.7.22 Changed method aligned with WSS-M2P188-A Removed 3.7.23 Added 3.7.24 & 3.7.25 Updated
45、3.8 Added Table 1 ENGINEERING MATERIAL SPECIFICATIONWSS-M99J385-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 8 of 8 Table 1 Approval Test Requirements for Design Validation Sample size/color New paint technology New Substrate New color approved paint technolog
46、y (MCDCC signoff) 3.6 Appearance 1 X X X 3.7.1 Film Thickness 1 X X X 3.7.2 Adhesion 3 X X X 3.7.3 Water Resistance 3 X X X 3.7.4 Abrasion Resistance 3 X X 3.7.5 Resistance to Cleaning Agents 3 X 3.7.6 Long Term Heat Exposure 1 X X X 3.7.7 Short Term Heat, Humidity and Cold Cycle 1 X X 3.7.8 Resista
47、nce to Artificial Weathering 1 X X X 3.7.9 Resistance to Florida Weathering 1 X 3.7.10 Fogging 1 X X 3.7.12 Intercoat Adhesion 3 X 3.7.13 Migration Staining 1 X 3.7.14 High Performance Paint Adhesion 3 X X X 3.7.15 Resistance to Water and Soap 1 X 3.7.16 Resistance to Window Cleaner Spotting 1 X 3.7.17 Resistance to Scratching 1 X X 3.7.18 Resistance to Marring 3 X X 3.7.19 Resistance to Scuffing 3 X 3.7.20 Soiling and Cleanability 1 X 3.7.21 Resistance to Suntan Lotion/Insect 1 X X X 3.7.22 Perspiration Resistance 1 X 3.7.24 Odor 1 X 3.7.25 Humidity Resistance 3 X X X
