1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 03 31 Activated J. Lott Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 4 STEEL, SHEET, ZINC/NICKEL, ALUMINUM RICH WSS-M1A325-B1 ORGANIC COATING 1. SCOPE The material defined by this specification i
2、s a mild steel sheet coated on both sides with an electrolytic zinc/nickel alloy, a pretreatment, and a roll coated aluminum rich organic coating to produce a duplex system. All coatings are free of Hexavalent Chromium. 2. APPLICATION This specification was released originally for material used for
3、fuel tanks requiring both additional corrosion protection and resistance to methanol fuel blends. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must c
4、onform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 BASE MATERIAL The base material shall conform to WSD-M1A333-A2 or -A3, coated to WSS-M1P94-A: 30N30N-EL. 3.3 PRETREATMENT A complex oxide conversion coating shall be used to increase the adhesion and durabili
5、ty of the aluminum rich organic coating by providing a clean, grease free, corrosion inhibiting bond between the base material and finish. Coating weights should be measured on samples prior to roll coating and should be tested using either an atomic absorption or inductive coupled plasma testing ap
6、paratus. 3.3.1 Cobalt Coating Weight, mg/m23.2 - 16.1 3.3.2 Titanium Coating Weight, mg/m254 - 226 3.4 ALUMINUM RICH ORGANIC COATING The coating shall comprise of an epoxy resin binder modified with aluminum metallic particles. The control plan referred to in para 3.1 shall address coating compositi
7、on. ENGINEERING MATERIAL SPECIFICATIONWSS-M1A325-B1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 4 3.4.1 System Process The coating shall be applied using a roller process. All surfaces of material to be coated must be free from oil, grease, rust, and any o
8、ther foreign material. 3.4.2 Final Hardness (ASTM D 3363) Remove any additional coatings, such as dry metal forming lubricants, prior to hardness testing. Pencil, min 8H 3.4.3 Coating Thickness, micrometers 7.5 - 0.0 + 3.8 Any suitable method may be used to measure coating thickness. In case of disp
9、ute, the umpire method shall be metallographic technique. 3.4.4 Dry Film Composition 21.5 - 25.5% (Weight percent - metallic aluminum content) 3.4.5 Appearance The coating shall be baked to a uniform film, showing no flow lines, pinholes or craters. 3.4.6 Adhesion and Flexibility Using the equipment
10、 and method described in FLTM BI 109-04, form a cup to a depth of 7.6 mm. Wash the coated surface with warm water and allow to air dry. Using firm and even pressure, apply tape across the dome area. Remove the tape within 90 seconds, pulling it with a smooth rapid motion at a 90 angle to the surface
11、. The tape sample shall have a rating of 8 or better when compared to the attached ball indent adhesion test rating sheet. 3.4.7 Adhesion Grade 1 or (FLTM BI 106-01) better 3.4.8 Proving Ground Corrosion Test (CETP 00.00-R-311 or CETP 00.00-R-339) For initial approval only. Fuel tanks manufactured f
12、rom this material must withstand 100 cycles minimum without perforation. ENGINEERING MATERIAL SPECIFICATIONWSS-M1A325-B1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 4 3.4.9 Fuel Resistance No softening or peeling. (FLTM BZ 105-03) Some allowable rust Initi
13、al source approval only. The paint film shall not soften, peel, or show any signs of defect when soaked in fuels described in FLTM AZ 105-02. Allowable rust based on testing with control samples will be specified by the Materials Engineering activity. 3.5 WELDABILITY The coated steel shall be capabl
14、e of being welded by the intended production process (seam welded, spot welded, etc.). The affected plant manufacturing engineering office must approve the weldability of this material by means of a manufacturing trial, using the equipment and manufacturing methods which are proposed for production.
15、 3.6 FORMABILITY The quality level of coated steel supplied to fabricate a specific component is to be negotiated between the manufacturing activity and the coated steel supplier. Acceptance of subsequent orders by the coated steel supplier for a given component at the agreed upon quality level impl
16、ies that all coated steel supplied will form that part satisfactorily as defined by the manufacturing activity. 3.7 MATERIAL IDENTIFICATION 3.7.1 Zinc/Nickel Coating Designation The zinc/nickel coating designation shall be as specified in para 3.2. 3.7.2 Coil Identification Unless an alternate metho
17、d is agreed upon by the steel supplier and the manufacturing activity, the coated product shall be identified with the following information stenciled within 250 mm of the coil edge and repeated at .5 meter intervals. Steel Company Name Coaters Name (if different than above) Paint Supplier Name Date
18、 and Time Produced Steel Grade (DQSK or IF) “Non-hex“ Mill Coil Number 4 GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 ADDITIONAL COATING Additional coatings, such as dry metal forming lubricants ma
19、y be required. These materials will be agreed upon between the manufacturing activity and the coated steel supplier. ENGINEERING MATERIAL SPECIFICATIONWSS-M1A325-B1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 4 4.2 INITIAL SUPPLIER APPROVAL For initial app
20、roval, the supplier must furnish the following information. A plan detailing how each requirement of para 3 will be controlled on a continuing production basis. Test results from a typical production sample for the requirements outlined in para 3. Zinc/nickel coating mass histogram including mean an
21、d standard deviations values. Data shall consist of a minimum of 500 thickness measurements randomly taken from each side of a minimum of 20 coils while the process is operating in statistical control. Conductive organic coating thickness histogram including mean and standard deviation values. Data
22、shall consist of a minimum of 500 thickness measurements randomly taken from each side of a minimum of 20 coils while the process is operating in statistical control For initial approval only, zinc/nickel chemical analysis will be made and reported “as deposited“. Upon approval, the material will be added to the Engineering Material Approved Source List. BALL INDENT ADHESION TEST RATING SHEET
