1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW15202 Performance Requirements for Exterior Plastic Parts with Paint Film Copyright 2012 General Motors Company All Rights Reserved July 2012 Originating Department: North American Engineering Standards Page 1 of 10 1 Scope This specificatio
2、n covers basic paint film technology approval requirements and the performance requirements of exterior plastic parts decorated with paint film. The parts must be made using regular production process and tooling. The parts may be functional within themselves or they may be a subassembly of, or atta
3、ched to, decorative or functional parts. Examples are emblems, rocker moldings, air dams, body side moldings, body claddings, mirror housings, appliqus, inserts, lamp housings, and fascias. 1.1 Material Description. Finished parts are made from thermoformed sheet stock (thin and thick film). The thi
4、n film can also be thermoformed into a preform and placed into an injection mold where plastic is injected onto the back of the preform to make an insert for emblems or the finished part. Injected molded material must meet the requirements of GMW15572P-ABS-T1 or T2 for Amino Butadiene Styrene (ABS),
5、 or GMW15187 for Thermoplastic Olefin (TPO), or other regional material specifications. Thermoforming masking film is covered in 9982276 (GM North America material specification). The use of a masking film is optional and may be covered by other regional specifications. Parts which require gasoline
6、resistance will be designated by the suffix G. Example of drawing call-out of molding located under the fuel filler: GMW15202-G. Typical paint film constructions are shown in Appendix B. 1.2 Symbols. Not applicable. 1.3 Typical Applications. 1.3.1 Type I constructions are used for exterior parts suc
7、h as rockers, appliqus, fascias, etc. 1.3.2 Type II constructions are for bright film. 1.3.3 Type III constructions are used for emblems (BowTies, GMC letters). 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ISO
8、 4892-1 ISO 4892-2 ISO 7724-1 SAE J1545 SAE J2527 2.2 GM Standards/Specifications. 9982075 GMW14700 GMW14829 GMW15572 9982276 GMW14701 GMW14865 GMW15777 GMW3059 GMW14729 GMW14873 GMW15919 GMW14124 GMW14797 GMW15187 GMW16745 GMW14333 2.3 Additional References. TMC003 Material Safety Data Sheet guidan
9、ce documents (available at ). 3 Requirements See Table A1 for a moldable paint film basic technology approval matrix for test requirements. For finished parts, see GMW14797, Table A1 (Approved Paint on Parts System (APOPS) Requirements for Exterior Painted Parts, white, white repair, light metallic,
10、 and a tricoat if it is part of the color palette), and Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15202 Copyright 2012 General Moto
11、rs Company All Rights Reserved July 2012 Page 2 of 10 Table A5 (Production Part Approval Process (PPAP) Testing Matrix for Exterior Plastic Painted Parts, All Program Colors) for test requirements. The exact construction and individual layer thickness (substrate, adhesive layer, color coat or metall
12、ic layer, clear coat, and optional premask) must be detailed in GMW14797, Table A6 Exterior Paint Processing Data Sheet. Run all tests in triplicate. Appropriate static dissipation equipment must be used throughout the process to remove excess static electrical charge. 3.1 Appearance. The parts supp
13、lied to the assembly plant must meet the appearance requirements stated in GMW15202, Table A2. Reference GMW15777 for a description of appearance zones. Fascias and emblems fall within appearance Zone A, rocker panels in Zone B. The purpose of these requirements is to ensure that the level of paint
14、film appearance on thermoformed parts will meet or exceed the level shown by our competitors and expected by our customers. 3.1.1 For assembly plant and Supplier Quality Assurance (SQA) audits, the part shall be inspected in the approximate vehicle position. It shall be viewed at an approximate dist
15、ance of 600 mm (approx arms length) from the observer. Lighting conditions for inspection are defined in GMW15777. 3.1.2 Appearance must be consistent over the entire part. The part must match the high gloss paint standard plaque using a visual evaluation. Maximum variation for gloss and Distinctnes
16、s of Image (DOI) measurements is 15 units. Maximum variation for orange peel is one unit within a 120 mm span. There shall be no color variation from the paint color standard plaque for Zones A, and B. 3.1.3 All attributes are to be evaluated at a rate such that zero discrepant parts are shipped to
17、the assembly plant. 3.1.4 Training programs may be required to educate operators, monitors, and managers in the techniques and acceptability standards of Table A2 and GMW15777. 3.2 Moldable Paint Film Basic Technology Approval Tests. 3.2.1 Stone Impact Resistance of Coatings (GMW14700). Methods A or
18、 B of chip resistance are to be performed. Minimum rating of 9. 3.2.2 Tape Adhesion Test for Paint Finishes (GMW14829). Initial adhesion maximum rating of 1. 3.2.3 Procedures for High Humidity Test (GMW14729, Option A, or Option B. The Option must be called out on the part drawing). Unless otherwise
19、 stated, standard test time is 240 h. Adhesion per GMW14829 shall be conducted in two separate areas on the panel. Maximum rating of 1. 3.2.3.1 After 96 h of test environment, panels must be returned to the humidity cabinet within 10 to 15 minutes of removal from the cabinet. 3.2.3.2 After 240 h of
20、Test Environment. Run tape adhesion within 15 minutes. Report the results of both intervals. No blistering, discoloration or adhesion loss. 3.2.4 Automotive Environmental Cycles (GMW14124, Cycle A). No cracking or adhesion loss. Run 15 cycles plus 96 h humidity (GMW14729, Option A). Tape Adhesion (G
21、MW14829) must be run after humidity (within 15 minutes of removal from humidity chamber). 3.2.5 Determination of Scratch Resistance of Organic Coatings - Simulation of Car Wash Installations (GMW14865). The performance must be equal to or better than a relevant control. 3.2.6 Resistance of Coatings
22、to Chemical Etching and Distortion (GMW14701). 3.2.6.1 Environmental and Plant Materials. Specific environmental materials and typical plant materials are listed in GMW14701. The performance must be equal to or better than a relevant control. Note: Use plant-specific materials in addition to the mat
23、erials called out in GMW14701, if there is a target plant. 3.2.7 High Pressure Wand Car Wash (GMW16745). No lifting or adhesion loss. 3.2.8 Thermal Shock Test for Paint Adhesion (GMW15919). No loss of adhesion. 3.2.9 Environmental Damage Resistance. Comparison with controls in Jacksonville, Florida.
24、 This 14-week test is performed on a yearly basis, beginning in May and ending in September, for clearcoat evaluation only with the appropriate basecoat/clearcoat technology in black only. “Etch Resistance” is classified by a Jacksonville rating from 1 to 10 with 1 being the best. The performance mu
25、st be equal to or better than a relevant control. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15202 Copyright 2012 General Motors Com
26、pany All Rights Reserved July 2012 Page 3 of 10 3.2.10 Resistance to Fuels of Exterior Automotive Materials and Components (GMW14333, Method A). Use rating 2 under Method A (Dip) for evaluation. 3.2.11 Accelerated Weathering (SAE J2527 with Extended Ultraviolet (UV) Filters), 2500 kJ/m and 4500 kJ/m
27、. Accelerated weathering tests are used as an aid in predicting long-term durability performance. Testing must be done against a control. New technologies must be taken to failure. Note that white panels have a history of yellowing in accelerated tests and must be compared to controls in accelerated
28、 testing and in Florida exposure tests (one year minimum). 3.2.11.1 Xenon Exposure (SAE J2527 with Extended UV Filters). Exposure to SAE J2527, 2500 kJ/m +96 h humidity, (GMW14729, Option A, or Option B. The Option must be called out on the part drawing.) Unless otherwise stated, standard test time
29、is 240 h. Adhesion per GMW14829 and tape adhesion (GMW14829). Inspect test materials at periodic points (per engineering agreement) throughout the test. Rate panels for gloss and Distinctness of Image retention, cracking, color change, and yellowing. Evaluate polish-back (hand polish only) if gloss
30、retention is below minimum specification using 9982075. Note: An additional panel must be run to failure or to 5500 kJ. Gloss loss after 2500 kJ/m2 is 15% (polished and unpolished) maximum, and after 4500 kJ/m2 is 20% (polished and unpolished) maximum. Run one sample to failure or 5500 kJ/m2. These
31、requirements are for weatherometers supplied by Atlas. If weatherometers from other suppliers are used, correlation must be demonstrated with long term open rack weathering results (see 3.2.12). Test various constructions (clear and pigmented films), and various colors, using good and poor weatherin
32、g samples. For visual examination, see paragraph 3.2.13. 3.2.12 Florida Outdoor Weathering of Automotive Exterior Materials (GMW14873). New technologies must have a minimum of 24 months exposure history. Five degrees open rack exposure is to be followed. Also, expose samples for 36, 48 and 60 months
33、. Gloss loss after 24 months Florida exposure shall be 20% (unpolished) and 10% (polished) maximum, and 35% (unpolished) and 25% (polished) maximum after 60 months. There shall be no mildew/fungus growth observed after a minimum of 24 months exposure. For visual examination, see paragraph 3.2.13. No
34、te: Florida exposure performance takes precedence over accelerated weathering tests. 3.2.12.1 Natural Weathering Test Location Areas. Any of the following locations are considered equivalent as a test sample location. Obtain agreement from the regional GM Engineering group prior to sending test samp
35、les out for exposure. Miami or Southern Area, Florida, USA Jurez, Mexico Allunga, Queensland, Australia Cruz Alta, Brazil Okinawa, Japan 3.2.13 Visual Examination. Wash weathered specimens prior to making measurements and observations. Wash with scrubbing action, using a sponge that is saturated wit
36、h a solution consisting of soap and deionized water at +23 C 3 C. Exposed parts shall not exhibit any indications of surface tackiness or embrittlement, change in hardness, blooming, blistering or other factors that might affect the function or appearance of the part. The color change shall not exce
37、ed a E of 3.0 units. The color change shall be measured per ISO 7724-1 or SAE J1545 (CIELAB color space, 10 observer, metering orifice 10 mm, Illuminant D65, specular component included). Visual color change that is considered objectionable shall override the E measurement. Part must not exhibit obj
38、ectionable color change. Note: Completion of Florida testing is not required for initial Engineering approval. The testing, however, shall be ongoing (with a minimum of 24 months Florida and 4500 kJ/m2 Xenon exposures completed) before an approval is granted. 4 Manufacturing Process Not applicable.
39、Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15202 Copyright 2012 General Motors Company All Rights Reserved July 2012 Page 4 of 10 5
40、Rules and Regulations 5.1 Legal Regulations. All materials must satisfy applicable laws, rules, regulations and recommendations valid in the country of usage. 5.2 Language. In the event of conflict between the English and domestic language, the English language shall take precedence. 5.3 Inspection
41、and Rejection. Samples of components or materials released to a GM material specification shall be tested for conformity with the requirements of this material specification and approved by the responsible Engineering department prior to commencement of delivery of bulk supplies. A new approval must
42、 be received for any changes, e.g., properties, manufacturing process, location of manufacture, etc. If not otherwise agreed, all testing and documentation normally required for initial release must be completed. It is the responsibility of the supplier to inform the customer in a timely manner, wit
43、hout solicitation, and to include documentation of all modifications of materials and/or processes and to apply for a new release. If not otherwise agreed, all release tests shall be repeated and documented by the supplier prior to commencement of delivery of non-conforming bulk supplies. In individ
44、ual cases, a shorter test can be agreed to between the responsible Engineering department and the supplier. 5.4 Initial Source Approval. No shipments shall be made by any supplier until representative initial production samples have been approved by the appropriate Materials Engineering department(s
45、) as meeting the requirements of this specification. 5.5 Material Safety Data Sheets/Safety Data Sheets (MSDS/SDS). For new product submissions, or when a change in chemical composition of an existing product has occurred, a complete copy of the Material Safety Data Sheet/Safety Data Sheet must be s
46、ubmitted in compliance with the Globally Harmonized System of Classification and Labeling of Chemicals (GHS) requirements or other country-specific MSDS/SDS requirements. In addition, product MSDS/SDS submissions must be in compliance with specific country General Motors TMC003 Material Safety Data
47、Sheet/Safety Data Sheet guidance documents where available. 5.6 All materials supplied to this standard must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts. 6 Approved Sources Engineering qualifications of an approved source are required for this standard. On
48、ly sources listed in the GM Materials File, GM Supply Power, under this standard number have been qualified by Engineering as meeting the requirements of this standard. For other GM locations, the responsible Engineering group should be contacted to obtain the approved source in that individual coun
49、try. 7 Notes 7.1 Glossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. ABS Amino Butadiene Styrene APOPS Approved Paint on Parts System DOI Distinctness of Image GHS Globally Harmonized System of Classification and Labeling of Chemicals ISO International Organization for Standardization MSDS Material Safety Data Sheet PPAP Production Part Approval Process SDS Safety Data Sheet SAE SAE International SQA Supplier Quality Assurance TPO Th
