1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. FEBRUARY 2011 Page 1 of 5 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER
2、: TMS-9017 srr TITLE: Gel Coat Properties for Exterior Panels CURRENT REV. No.: 1102 DATE: Feb. 2011 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. 1012 Dec. 2010 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification ma
3、y involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to use.
4、Change Notice: Corrections to Table 1, item 6; correction to 4.2.3 for Zone C. 1.0 APPLICATION This specification covers the gel coating process and requirements for fiberglass reinforced plastic (FRP) exterior body panels that will not be finish painted. Typical parts are body side panels, cab rear
5、, fascia, roofs and similar exterior parts. 2.0 SCOPE This specification covers surface appearance and dry film properties of gel coat, inspection, quality control and source approval for coated FRP parts prior to shipment to Navistar. It also includes repair of gel coated surfaces and handling of g
6、el coated parts. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standa
7、rds shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-9012 NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR CEMS D-22 CFR 29, Part 1910 NAVISTAR Design Std. A-16 NAVISTAR CEMS GT-5A NAVIST
8、AR CEMS GT-7E NAVISTAR CEMS GT-5C NAVISTAR CEMS GT-14A NAVISTAR CEMS GT-7G NAVISTAR CEMS GT-28 NAVISTAR CEMS GT-4D NAVISTAR TMS 9008 NAVISTAR CEMS GT-6B ASTM D 4138 NAVISTAR CEMS B-50 SAE J400 NAV-EV-QIS-8.2-001 4.0 GENERAL REQUIREMENTS This specification is not intended to limit or specify the exac
9、t process and materials to be used in providing FRP parts ready for installation at Navistar assembly operations. The control of the gel coat quality and its application shall be the responsibility of the FRP part supplier. All gel coated NUMBER: TMS-9017 TITLE: Gel Coat Properties for Exterior Pane
10、ls REVISION: 1102 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. FEBRUARY 2011 Page 2 of 5 parts supplied must be compatible with
11、 the assembly operations employed by the using Navistar facility. 4.1 Acceptance Criteria for Gel Coated Parts It is the responsibility of the supplier to ensure, prior to shipment to the using Navistar facility, that all gel coated parts are completely free of visible porosity and other defects, wh
12、ich would cause significant in-house rework. This will require close cooperation between the supplier and the using facility and Materials Engineering. Very minor instances of porosity or fiber read through shall not be considered rejectable. Chronic cases of these defects shall be considered a reje
13、ct condition. Consult Table I for breakdown of acceptable and unacceptable conditions (Table I based on E-Star Quality Inspection Appearance Standard, NAV-EV-QIS-8.2-001). It will be the responsibility of the supplier to correct any of these conditions. 4.2 Performance Requirements 4.2.1 Appearance
14、Parts requiring gel coat as its primary exterior coating shall be classified as Zone A, B or C. Zone A shall mean the part is a primary, exterior, glamour surface, which requires the highest cosmetic standards and fewest defects. Examples of such parts are roof exteriors, cab rear doors and cab rear
15、 panels. Zone B is a moderately visible surface which can have some defects not permitted in Zone A but still requires high cosmetic standards. Examples of these parts are fender lower surfaces, bumper vertical lips, roof top rear, and underside of steps and air takes. Zone C is the lowest visible p
16、art that can have certain defects in defined quantities. Examples are body panels that are hidden, floor undersides. See Table I for breakdown of Zone requirements. 4.2.2 Dry Film Requirements Dry film properties are given in Table II. The requirements apply to the gel coat as processed in the mold
17、after cure and part cool down. 4.2.3 Inspection Parts shall be inspected as follows: Zone A at eye level, 12-24” distance from 2-foot height to roof sides and rear panels; Zone B at 24-48” distance below 2-foot height for sides and rear; Zone C at 48-96”. 5.0 QUALITY Parts supplied shall be clean an
18、d free of dirt, oils, molding flash, sharp edges or other defects harmful of product performance. Parts shall be adherent and uniform in color and texture, with no thin spots, runs, wrinkles, porosity, pits or blisters. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers
19、to Navistar, Inc. are required to be registered to ISO 9001 Quality System Requirements. Navistar will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their ce
20、rtification with an accredited registrar and must furnish copies of registration certificates to their Navistar Corporate Buyer upon request. NUMBER: TMS-9017 TITLE: Gel Coat Properties for Exterior Panels REVISION: 1102 This document is restricted and may not be sent outside Navistar, Inc. or repro
21、duced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. FEBRUARY 2011 Page 3 of 5 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those
22、 samples that were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials E
23、ngineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted wi
24、th the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process
25、capable of providing all required properties. The part supplier, Materials Engineering and/or the quality control manager of the using plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Shipping, packing and identification shall be i
26、n accordance with NAVISTAR Manufacturing Standard MS-D-13. Parts shall be packaged and shipped in such a manner so as to protect the surface finish in transit. 8.0 DESIGNATION ON DRAWINGS Example: Gel coat per TMS-90179.0 TECHNICAL INFORMATION For further information related to the technical content
27、 of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. Truck Development and Technology Center 2911 Meyer Road Fort Wayne, IN 46803 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East E
28、nglewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ NUMBER: TMS-9017 TITLE: Gel Coat Properties for Exterior Panels REVISION: 1102 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Stand
29、ards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. FEBRUARY 2011 Page 4 of 5 TABLE 1. APPEARANCE REQUIREMENTS Item Appearance Attribute Description Measurement State Condition Max. acceptable size / count per part*. Separated by 100mm Zone A Zone B Zone C 1 Boiling /
30、 pinholes / popping Small bubbles in coating which may have small holes at top Visual evaluation Finish None Up to 3 2mm dia. Acceptable 2 Chips Removal of coating from underlying coating or substrate in small irregular pieces Visual evaluation Finish No color change None 1 per surface 1mm dia., no
31、closer than 200mm Acceptable 3 Cracked part Cracks / split / puncture in substrate or gel coat Visual evaluation Finish None None None 4 Contamination Foreign object or containment in coating film Visual evaluation Finish Same color Up to 4 per part 1mm separated by 100mm Up to 5 per part 1mm Accept
32、able 5 Gloss Shininess of coated surface Gloss meter / Master Plaque Finish 85 85 N/A 6 Mottle Blotchy, non-uniform appearance Visual Evaluation Finish None Slight, uniform Acceptable 7 Off-color Variation in color within a surface Visual evaluation Finish None Acceptable Acceptable 8 Orange peel Ro
33、ugh or wavy appearance of coating surface resembling the skin of an orange Visual comparison to sample plaques Finish Sample 8B Sample 8C Sample 8D 9 Peeling Loss of adhesion between coating films or between coating and substrate Visual evaluation Finish None None None 10 Pits / porosity Small holes
34、 in the coating surface Visual evaluation Finish Same color 2 per part 2mm dia. 3 per part 3mm dia. Acceptable 11 Poor repair Inferior coating appearance due to improper coating repair techniques Visual evaluation Finish None None Acceptable 12 See through Area of coating surface where film is missi
35、ng or thin, exposing the underlying surface Visual evaluation Finish None None None 13 Scratches after coating Scratches on coated surface caused by improper handling, etc. Visual evaluation Finish Seen, or felt with the finger nail None 12mm long Acceptable 14 Glass fibre mat pattern read through T
36、he glass fibre mat pattern is visible through the coated surface Compare to master sample Finish Sample 14B Sample 14C Sample 14D 15 Moulding split lines Visible line created by tool split lines Visual evaluation Finish 0.25mm height Acceptable Acceptable 16 Master model block lines Block joint line
37、s visible on A surface of part Visual evaluation Finish None Acceptable Acceptable * Acceptable count per part, e.g. Body side, roof, bulkhead, etc. NUMBER: TMS-9017 TITLE: Gel Coat Properties for Exterior Panels REVISION: 1102 This document is restricted and may not be sent outside Navistar, Inc. o
38、r reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. FEBRUARY 2011 Page 5 of 5 TABLE 2. DRY FILM PROPERTIES FILM PROPERTY REQUIREMENT Test Method Adhesion, % min. 90 CEMS GT-5A Xylene Rub Pass CEMS GT-14A Ac
39、celerated Adhesion, % min. 90 (3B) CEMS GT-5C Initial Gloss 85 min. CEMS GT-6B 500 hours Humidity % adhesion min. 90 CEMS GT-7E blisters None Gravelometer Test Requirement 2A per CEMS GT-28 SAE J400 Distilled Water Immersion No blisters or color change CEMS GT-7G Film Thickness, mils (min/max) 15.0/25.0 ASTM D 4138
