1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions Rev 02 2012 02 16 N Status No Replacement named N. Benipal, NA 2000 11 22 Revised Updated & renumbered A. Cockman 1985 04 05 Released CTP1-MF-531289 Controlled document at www.MATS Page 1 of 6 Copyright 2012
2、, Ford Global Technologies, Inc. MOLDED COATING FOR COMPRESSION ESB-M99J331-A MOLDED FRP - ONE COMPONENT NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a thermosetting modified acrylic compound applied to compression molded fiberglass reinforced polyester (FRP)
3、parts during the molding operation. This material is designed to fill porosity, voids, and provide good adhesion and enamel holdout properties when applied to FRP. 2. APPLICATION This specification was released originally for material used as a molded-in primer surfacer on high visibility exterior F
4、RP parts such as hoods, grille opening panels and other body panels. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to the Companys Quality System Requiremen
5、ts. 3.2 PHYSICAL PROPERTIES 3.2.1 Solids, min 65% (FLTM BI 2-1) 3.2.2 Weight per Volume 1.26 +/- .02 kg/L (FLTM BI 2-2) 3.2.3 Viscosity 6 000 - 17 000 (ASTM D 1824, #7 Spindle at centipoises 100 RPM and 30 C) 3.2.4 Gel Time 4 - 20 min (TBD, based on 0.75 to 138 C Peak 1.5 parts per 100 catalyst) Exo
6、therm ENGINEERING MATERIAL SPECIFICATION ESB-M99J331-A Page 2 of 6 Copyright 2012, Ford Global Technologies, Inc. 3.3 PREPARATION OF TEST SPECIMENS 3.3.1 Substrate Compression molded FRP, ESB-M3D105-B, Type II. Each FRP formulation must be approved separately for use with these materials. 3.3.2 Mold
7、 Shall be representative of production tooling. Testing of samples from production level tooling is required before final approval to these specifications. 3.3.3 Molded Coating Components ESB-M99J331-A and tertiary butyl perbenzoate (TBPB) 98% pure min, are to be applied in the ratio recommended by
8、the manufacturer to the test specimen by means of an automatic injection system or hand pour (laboratory test panels only). Minimum dry film thickness per FLTM BI 17-1, using the Mark II, Tooke Gage shall be 13 m. Each fabricator must be approved separately to use these materials. 3.3.4 Electrocoat
9、Test specimens shall be prepared both with and without an exposure to a simulated electrocoat bake of 30 min at 205 C ambient on the molded coating. 3.3.5 Primer(s) Apply the current approved production primer(s) at 13 m minimum dry film thickness in accordance with the pertinent engineering materia
10、l specification at both the minimum and the maximum bakes (see para 5). 3.3.6 Topcoat Apply the current approved body production exterior enamel used in the assembly plants in accordance with the pertinent engineering material specification (see para 5). Use white enamel for the following: Adhesion
11、(para 3.5.1). Chip resistance (para 3.6.1). Use black enamel for all other tests requiring topcoated samples. ENGINEERING MATERIAL SPECIFICATION ESB-M99J331-A Page 3 of 6 Copyright 2012, Ford Global Technologies, Inc. 3.4 APPEARANCE 3.4.1 Color Black 3.4.2 Leveling The molded coating as applied per
12、para 3.3.3 shall provide a smooth uniform appearance free from pits, cracks, bubbles, etc. 3.4.3 Gloss 40 min (As Processed on a (FLTM BI 10-1, 60 Polished Chrome Tool) Glossmeter as applied per para 3.3.3) 3.4.4 Distinctness of Image 90 min (FLTM BI 10-3, prepare test specimen per para 3.3 using bl
13、ack high gloss exterior enamel) When it is not feasible to obtain a distinctness of image reading due to the contour and/or size of the part, evidence of dulling or strike-in of the topcoat shall be cause for rejection. 3.5 FILM PROPERTIES 3.5.1 Adhesion Part “A“ No flaking or chipping. (FLTM BI 6-1
14、 Part “B“ Both molded coating adhesion on samples prepared per para 3.3) to substrate and guidecoat adhesion to molded coating shall be no worse than grade 3, figure 1. 3.5.2 Hardness F - 2H (ASTM D 3363, samples prepared per para 3.3.1-3.3.3. Use Eagle Turquoise T 2375 pencils) 3.5.3 Electrical Con
15、ductivity (Type I), min 125 (Ransburg Electro-Coating Corp., Model 236 Sprayability Meter or Equivalent) 3.5.4 Dry Sanding Characteristics The molded coating when applied as outlined in para 3.3.3, shall dry sand (using a new sheet of 280 grit stearate filled paper for each panel) smoothly without c
16、logging the paper and with a minimum of sand scratches. The material shall be equivalent in all respects to current approved production molded coating applied and tested under identical conditions. ENGINEERING MATERIAL SPECIFICATION ESB-M99J331-A Page 4 of 6 Copyright 2012, Ford Global Technologies,
17、 Inc. 3.5.5 Repairability Samples prepared per para 3.3.1-3.3.3 shall be repaired using approved repair materials under conditions representing actual production processing (see para 5). Repaired samples should be subsequently processed according to para 3.3.4-3.3.6. All repair materials shall meet
18、the following requirements outlined in these specifications: Distinctness of Image 3.4.4 Adhesion 3.5.1 All Resistance Properties 3.6 3.6 RESISTANCE PROPERTIES Test samples shall be prepared per para 3.3 and tested with color coat enamel. Samples shall be aged a minimum of 72 h before testing for re
19、sistance properties. 3.6.1 Chip Resistance (SAE J 400) No more chipping than Figure 4B when a finished part is subjected to 1 cycle. 3.6.2 Water Immersion, min 240 h Test Method: Immerse the part for 240 h in distilled or deionized water maintained at 32 +/- 1 C. Remove parts from the water and imme
20、diately scribe an X through the finish to the substrate. Dry the scribed area with a paper towel, cloth, or air (oil and moisture-free) and immediately apply, with firm thumb pressure, a minimum of 13 cm2 of ESF-M3G48 tape. Remove the tape by pulling one end at a 90 angle at moderate speed. 3.6.3 Th
21、ermal Shock Resistance (FLTM BI 7-3) The finish shall exhibit no blistering or loss of adhesion when subjected to the following cycle. 4 h water immersion 4 h minimum exposure at -29 C Direct steam blast on scribed X at 45 angle 50-75mm from panel for 15 s minimum. 3.6.4 Weathering Resistance Panels
22、, prepared as in para 3.4, scribed with an X to bare plastic and exposed as follows shall show a minimum degree of fading, chalking or dulling and shall be completely free from evidence of cracking, checking, blistering or peeling. ENGINEERING MATERIAL SPECIFICATION ESB-M99J331-A Page 5 of 6 Copyrig
23、ht 2012, Ford Global Technologies, Inc. Florida Direct Weathering 12 months at 5 (Miami area) facing south Accelerated Weathering 400 h (FLTM BO 1-1, in XW Atlas Weatherometer) (ASTM G53-77, in Atlas UVCON 500 h (or equivalent) with a cycle of 4 h UV exposure at 60 C and 4 h condensing humidity at 5
24、0 C) Note: Florida exposure results shall take precedence over accelerated weathering results. 3.7 PRODUCTION TRIAL Final approval of all functional and sanding characteristics shall be made by the using Manufacturing Division of the material or painted part on the basis of a shop trial under produc
25、tion conditions (Paint Test Report - Functional - Form 371). 3.8 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved
26、 under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify the affected Purchasing, and Materials Engineering activities (with reasons) of the proposed changes. Upon notification of the Company, further instru
27、ctions will be provided. Note: Suppliers should be prepared to provide test data and samples demonstrating compliance to this specification, if requested. Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are iden
28、tified in Restricted Substance Management Standard WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification for direct supply to the Company must have prior approval. Certain materials subcontracted by part suppliers may also require prior approval. These include materials c
29、ritical to the Companys business for regulatory, safety, environmental or compatibility requirements or contractual agreements. Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Materials Engineering activity. Upon request, the Sup
30、plier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification. ENGINEERING MATERIAL SPECIFICATION ESB-M99J331-A Page 6 of 6 Copyright 2012,
31、Ford Global Technologies, Inc. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 FLASH POINT, min 68 C (ASTM D 92) 5.2 POT LIFE (CATALYZED) 1.5 Parts TBPB/100 Parts Resin by Weight 17 days min at 25
32、C 3 days min at 38 C 5.3 FLAMMABILITY These materials represent a potential fire hazard. The Manufacturing Engineering Department shall notify both the Plant Security and the Safety Units of its presence in the Plant or assure that proper fire precautions are provided. The location in which it is us
33、ed or stored shall be included in the notifications. 5.4 STORAGE (UNCATALYZED) ESB-M99J331-A may be stored 3 months at 25 C or below. 5.5 APPLICABLE SPECIFICATIONS 5.5.1 Performance ESB-M2P124 5.5.2 Substrate ESB-M3D105 5.5.3 Conductive Primer ESB-M6J106 5.5.4 Primer ESB-M6J119 ESB-M6J141 ESB-M6J120 5.5.5 Topcoat ESB-M50J100 ESB-M50J103 ESB-M32J105 ESB-M32J101 ESB-M50J107 5.5.6 Pit Fillers ESB-M18P6 5.5.7 Repair Primer ESB-M6J57 ESB-M6J65/111 ESB-M6J106
