1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 05 31 Released C. Weller, FNA Controlled document at www.MATS Copyright 2017, Ford Global Technologies, Inc. Page 1 of 5 PERFORMANCE, PHOSPHATE COATING, ZINC WSS-M3P1-E1 1. SCOPE This specification defines the performance require
2、ments of a zinc phosphate coating on automotive parts which are subsequently painted. 2. APPLICATION This specification was released originally for phosphate coatings used for iron, steel, zinc or zinc alloy coated steel or zinc parts where maximum paint adhesion and corrosion resistance are require
3、d. It is to be used for aluminum only when processed concurrently with steel parts. The coating provides a clean grease-free surface for painting, improves adhesion of the paint film and inhibits spread of corrosion when the paint film is broken. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specificati
4、on is performance based and does not have approved sources. 3.2 MASS SPECTROSCOPY Ford Motor Company, at its option, may conduct mass spectroscopy and/or other analysis of material/parts supplied to this specification. The analyses established for initial approval shall constitute the reference stan
5、dard and shall be kept on file at the designated material laboratory. All samples shall produce the same analyses that correspond to the reference standard when tested under the same conditions. 3.3 PHYSICAL PROPERTIES 3.3.1 Coating Weight (FLTM AQ 101-01 or FLTM AQ 101-02) The coating weight as def
6、ined below must only be used with the materials described. Note: When phosphate solutions with high Nickel or Manganese contents are in use, the chromic acid test (FLTM AQ 101-01) should be used. 3.3.1.1 Coating Weights-Dip Systems with Conditioner Spec WSS-M3B74-A Cold Rolled Steel 1.3 - 3.8 g/m2 Z
7、inc coated Steel 1.6 - 4.3 g/m2 Galvannealed Steel 2.5 - 6.0 g/m2 Aluminum 1.6 - 4.5 g/m2 ENGINEERING MATERIAL SPECIFICATION WSS-M3P1-E1 Copyright 2017, Ford Global Technologies, Inc. Page 2 of 5 3.3.1.2 Coating Weights-Dip Systems with Conditioner Spec WSS-M3B81-A Cold Rolled Steel 1.3 - 3.8 g/m2 Z
8、inc coated Steel 1.4 - 4.3 g/m2 Galvannealed Steel 2.0 - 5.5 g/m2 Aluminum 1.0 - 3.2 g/m2 3.2.1.3 Coating Weights for Spray Systems Cold Rolled Steel 1.3 - 3.8 g/m2 Hot Rolled Steel 1.5 - 3.0 g/m2 Zinc coated Steel 1.6 - 4.0 g/m2 Galvannealed Steel 2.5 - 6.4 g/m2 Aluminum 1.3 - 3.5 g/m2 3.3.2 Crysta
9、l Size Measurements conducted at 1000 magnification in a scanning electron microscope. 3.3.2.1 Crystal Sizes for Dip Systems 25 microns max (for all substrates) 3.2.2.2 Crystal Sized for Spray Systems 25 microns max (for all substrates) 3.4 PROCESS WINDOW DEFINITION The final testing requirements sh
10、all be defined by the responsible Materials Engineer. The supplier shall perform a Design of Experiments (DOE) (Response Surface Analysis is recommended) to determine the process window of the pretreatment process controls. At a minimum the DOE shall include the concentrations of the main bath compo
11、nents (such as Free Acid, Total Acid, coating deposition accelerators, etc.), pH, process time and process temperature. Additional study variables may include any other pretreatment bath key components or parameters, and the substrate cleaning conditions (fresh vs. aged alkaline cleaner bath). Appro
12、priate screening experiments should be run to determine what variables/parameters and their levels should be tested. The results of the screening experiments should be reviewed with the responsible Materials Engineer in order to set up the final DOE. Response attributes to the DOE will be based on t
13、he materials tested, and will be chosen from tests listed within this specification. Minimal testing required: Coating Weight, Paint Adhesion (FLTM BI 106-01, Method B) before and after Water Immersion (FLTM BI 104-01), Stone Chip Resistance (SAE J400 and FLTM BI 157-06), Corrosion Resistance (L-467
14、 and L-3190). The process window characteristics must be submitted with the initial approval package. 3.5 PREPARATION OF TEST PANELS In order to eliminate variables in testing production parts, test shall be conducted on standard test panels prepared in accordance with Ford Engineering Material Stan
15、dard WSS-M2P180-D (or current revision) and relevant precoated steel substrates in current production quality according to para 4.2. Three panels must be prepared representing nominal conditions. 3.5.1 Phosphate Coat Process panels through complete cycle of phosphate coating system under test, inclu
16、ding cleaning, crystal refinement, phosphating, passivation, deionized water final rise and drying. ENGINEERING MATERIAL SPECIFICATION WSS-M3P1-E1 Copyright 2017, Ford Global Technologies, Inc. Page 3 of 5 Panels processed to this point shall be used for coating weight determination (para 3.3.1) and
17、 crystal size (para 3.3.2). Panels for paint adhesion and resistance tests shall be further processed as indicated in para 3.5.2. 3.5.2 Paint System Apply paint system as used in production with electrocoat primer, primer surfacer and white top coat as appropriate. Materials shall be applied, baked
18、and aged in accordance with individual material specifications. 3.6 RESISTANCE PROPERTIES 3.6.1 Paint Adhesion Grade 1 max (FLTM BI 106-01, Method B) 3.6.2 Water Resistance Grade 1 max (FLTM BI 104-01, 240 hr.) No blistering or loss of paint adhesion accepted. Paint adhesion shall be tested accordin
19、g to paragraph 3.6.1 within 30 minutes after removal from water. 3.6.3 Humidity Resistance Grade 1 max (FLTM BI 104-02, Method A, 240 hr.) No blistering, or loss of paint adhesion accepted. Paint adhesion shall be tested according to paragraph 3.6.1 within 30 minutes after removal from cabinet. 3.6.
20、4 Corrosion Resistance 3.6.4.1 Laboratory Accelerated Corrosion Test, 6 weeks exposure. (Test Method (formerly CETP) 00.00-L-467, evaluate according to FLTM BI 169-01) Corrosion creep across the scribe Cold Rolled Steel 10 mm max Electro Galvanized Steel 6 mm max Hot Dip Galvanized Steel 6 mm max Ga
21、lvannealed Steel 6 mm max 3.6.4.2 Laboratory Accelerated Corrosion Test, 6 weeks exposure. (Test Method (formerly CETP) 00.00-L-3190, evaluate according to FLTM BI 169-01) Corrosion creep across the scribe Aluminum 4 mm max 3.6.5 Chip Resistance 3.6.5.1 Grit Blast, Split Shot Rating 5 min (FLTM BI 1
22、57-06) ENGINEERING MATERIAL SPECIFICATION WSS-M3P1-E1 Copyright 2017, Ford Global Technologies, Inc. Page 4 of 5 3.6.5.2 Stone Chip, Rating 5B or 97% min (SAE J400, 1.4 L, -20 2C and 23 2C) Paint Retention, no Chips 3 mm Dia. Evaluate substrate-to-topcoat (S/T) point of failure only. During the chip
23、 testing make sure that test the panels have appropriate backing to prevent excessive panel bending. 3.6.6 Cylindrical Mandrel Test (ASTM D522, Method B, 25 mm (1 inch) mandrel, 1 sec bend time) No paint peeling is produced at the paint to substrate interface. Equal to, or better than the current pr
24、ocess control panels. 3.6.7 Glass Bonding/Paint System Compatibility Materials Engineering Procedure AVP-T118-001, Pretreatment Material Technology Change Section, consult with the responsible Global Paint Materials Engineer for appropriate testing requirements equal to, or better than the current p
25、rocess control panels. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 Material(s) technical data sheet(s), Design Matrix, Des
26、ign FMEA, and other material related processing information shall be made available for review prior to qualification testing. Process P-Diagram and plant specific Process FMEA shall be developed before the material can be introduced to a production facility. Under agreed-upon circumstances, certain
27、 previously submitted data may be applied to subsequent data submissions. In this case, the qualification requirements will depend on the degree of changes made to the material. The final test requirements shall be agreed upon between the responsible Materials Engineer and the supplier prior to test
28、ing. 4.2 PANEL INFORMATION 4.2.1 Cold Rolled Steel panels Use panels in accordance with WSS-M1A365-A12. Class 3 (Non Nickel-flash) CRS panels are laboratory quality mild CRS available from ACT Test Panel Technologies*. 4.2.2 Hot Dip Galvanized Steel panels Use panels in accordance with WSS-M1A365-A1
29、2, coated to WSS-M1P94-A: 70G70G-GI, Class 1 Qualified coil stock is available from ACT Test Panel Technologies*. 4.2.3 Electro Galvanized Steel panels Use panels in accordance with WSS-M1A365-A12, coated to WSS-M1P94-A: 60G60G-EG, Class 1 Qualified coil stock is available from ACT Test Panel Techno
30、logies*. 4.2.4 Galvannealed Steel panels Use panels in accordance with WSS-M1A365-A12, coated to WSS-M1P94-A: 45A45A-HD, Class 3 Qualified coil stock is available from ACT Test Panel Technologies*. 4.2.5 Aluminum panels Qualified alloys are available from ACT Test Panel Technologies*. ENGINEERING MA
31、TERIAL SPECIFICATION WSS-M3P1-E1 Copyright 2017, Ford Global Technologies, Inc. Page 5 of 5 *The panels can be ordered from: ACT Test Panel Technologies 273 Industrial Drive Hillsdale, MI 49242 (517) 439-1485 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain
32、 an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier 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 requ
33、irements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testi
34、ng) with Ford. 4.4 SUPPLIERS ONGOING RESPONSIBILITY All materials 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, whether or not such changes affect the materials ability to meet th
35、e specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components us
36、ing Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.5 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed
37、 by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting.
