1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 05 17 Released J. Bilko, NA Controlled document at www.MATS.com Copyright 2017, Ford Global Technologies, LLC Page 1 of 9 PAINT, POWDERED, THERMOSETTNG POLYESTER WSS-M70J5-C1 INTERIOR 1. SCOPE The material defined by this specifi
2、cation is for thermosetting polyester or polyester hybrid powder coatings as applied to unprimed metal substrates. The powder coating shall provide good initial appearance with adequate durability and corrosion properties. 2. APPLICATION This specification was released originally for powder coatings
3、 used on interior metal applications. All painted parts must meet WSS-M2P190-A/Latest. All paint applicators must meet the Interior Parts Painter Approval Process WSS-M2P195-A.These paint systems are typically used to decorate visible/non-visible metal surfaces (i.e. seat tracks, cargo shade compone
4、nts, brake pedals, etc.). This material is only for beltline or below applications. No IP green house or package tray areas. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used wh
5、en this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. 3.2 CONDITIONING AND TEST CONDITIONS All test values are based on material conditioned for not less than 24
6、 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 COMPOSITION 3.3.1 Specific Composition When it is necessary to obtain specific data regarding powder coating
7、formulations, suppliers will furnish such data on request. 3.3.2 Vehicle Solids The vehicle solids shall be polyester resins modified with suitable cross linking, catalytic and flow control agents as necessary to meet the requirements of para 3.4 - 3.8. 3.3.3 Pigment The pigment portion shall contai
8、n the necessary corrosion inhibiting pigments and/or flattening agents to meet the requirements of para 3.4 - 3.8. ENGINEERING MATERIAL SPECIFICATION WSS-M70J5-C1 Copyright 2017, Ford Global Technologies, LLC Page 2 of 9 3.4 PHYSICAL PROPERTIES 3.4.1 Non-Volatile Solids (ASTM D3451) 3.4.1.1 3 h at 1
9、07 C 97% min 3.4.1.2 30 min at 204 C 95% min 3.4.2 Shelf Stability The powder must be capable of satisfactory application without conditioning after 6 month storage at 20 +/- 5 C. 3.4.3 Gel Time Identified by supplier on (ASTM D4217-02 at 204 C) initial submission +/- 2 s 3.4.4 Particle Size Distrib
10、ution 75 - 95% smaller than 44 m (ASTM D5861) None larger than 70 m 3.4.5 Specific Gravity 1.45 - 1.80 (ASTM D5965-A, ISO 8130-3) 3.5 PROCESSABILITY 3.5.1 Processing Matrix Production representative electrostatic powder guns shall be used. Report fluidizing air pressure, electrostatic voltage, feed
11、and conveyance (or equivalent) air pressures, and powder flow in oz (lb) / min. 3.5.2 Fluidization Characteristics Evaluate the fluidization of the powder at different fluidization air pressures, particle size distributions, and humidity levels. The fluidization system must be production representat
12、ive. 3.5.3 Inclined Flow Test (ASTM D4242) Determine the time versus temperature profiles for flow and sintering properties as mutually agreed on between supplier and affected Materials Engineering. 3.5.4 Heat-up Rate Supplier shall demonstrate the effect that heat-up rates will have on appearance o
13、f the final coating. Also, supplier will demonstrate whether an interrupted bake, as may occur at breaks or shift change, affects appearance attributes. 3.6 PREPARATION OF TEST PANELS 3.6.1 Testing Requirement/Specimen Preparation Tests shall be performed on panels of appropriate substrate. See Tabl
14、e 1 for testing requirements and sample size. Design Verification Testing (DV) is performed on panels by the paint supplier as defined in Table 1. ENGINEERING MATERIAL SPECIFICATION WSS-M70J5-C1 Copyright 2017, Ford Global Technologies, LLC Page 3 of 9 Product/Process Validation Testing (PV) is perf
15、ormed on production painted parts as outlined in the Paint Performance, Interior Parts Metal Substrates Specification WSS-M2P190-A/Latest. 3.6.2 Substrate Cold rolled steel panels with zinc phosphate pretreatment. The surface to be coated must be cleaned to ensure the absence of oil or alkaline resi
16、dues, fingerprints, corrosion, dirt, moisture, and other foreign materials. 3.6.3 The candidate powder shall be electrostatically applied and cured per paragraph 3.6.4. 3.6.4 Bake Schedule 12 minutes at 204 C metal temp, min Supplier shall determine Cure Window as described in Paragraph 3.9. This sh
17、ould be included in the submission package and DFMEA. 3.6.5 Cured Film Thickness, range 50.8 101.6 microns (FLTM BI 117-01) Apply powder topcoat at 51 microns minimum or the optimal performance thickness as recommended by the supplier. Note: This range is considered to be a requirement unless otherw
18、ise supported by testing data agreed to by Materials Engineering. 3.7 APPEARANCE 3.7.1 General Color, gloss, grain, tactile effect and surface finish shall match master Trim Sample and/or Master Appearance Sample as approved by Corporate Design. The coating shall exhibit no craters, pinholes, solven
19、t popping, seediness, abnormal roughness, excessive flow or any other detrimental defect. 3.7.2 Color Shall match the (FLTM BI 109-01, Visual Assessment and/or Master Approved SAE J1545, MA58 Three-Angle CMC) Sample. 3.7.3 Gloss (FLTM BI 110-01, ASTM D523) As released by Engineering: A: 20 glossmete
20、r min 92 B: 60 glossmeter 76 - 84 C: 60 glossmeter 66 - 74 D: 60 glossmeter 58 - 66 E: 60 glossmeter 47 - 53 F: 60 glossmeter 33 - 38 G: 60 glossmeter 17 - 23 H: 60 glossmeter 7 - 13 J: 60 glossmeter 4 - 6 K: 60 glossmeter 2 - 4 ENGINEERING MATERIAL SPECIFICATION WSS-M70J5-C1 Copyright 2017, Ford Gl
21、obal Technologies, LLC Page 4 of 9 The color, pattern and finish shall match the approved Design Center master sample, or shall be as specified on the Engineering Document. Gloss can be affected by grain so the end gloss for the part will be determined #cycles = (Xm)(1000) Where Xm = microns of film
22、 build 25m 3.8.5 Interior Corrosion Resistance (RQT-001101-002492 (18-0040), Table 4, Modified CETP 00.00-L-467) Normal chamber L-467 humidity / temperature cycles Apply the 0.5% salt solution on first and eighth day of the test Showroom Review after first day (one complete day starting with salt sp
23、ray solution application). High Visibility Review (6 YIS) after eleventh day Showroom Appearance No white or red corrosion. No blistering, softening, dulling, loss of adhesion, or cracking permitted. Final Appearance: No white or red corrosion Exception for seat tracks and seat mounting hardware: Re
24、d rust allowed at welds, crimps, edges of coated components, and drive areas of fasteners. No undercutting of coating from allowable areas of red rust. 3.8.6 Resistance to Water and Soap Spotting Rating 4 (FLTM BI 113-01, ISO 105-A02/AATCC Max discoloration Evaluation Procedure 1) No film softening
25、allowed for any solution. 3.8.7 Resistance to Acid Spotting No discoloration (FLTM BI 113-05) after 10 min 3.8.8 Resistance to Cleaning Agents Rating 4 (FLTM BN 107-01, 10 cycles, AATCC Max discoloration Evaluation Procedure 2) Test Procedure: Saturate the white cotton cloth with the cleaners listed
26、. Evaluate according to the AATCC Scale. Record manufacturer brand. 1) Deionized water 2) Window cleaner Any commercially available 3) All purpose cleaner Any commercially available 4) Dry (no cleaners or water) 5) 50/50 IPA/Clean water 3.8.9 Long Term Heat Exposure, Rating 4 min (7 days at 100 +/-
27、2 C, ISO 105-A02/ AATCC Eval. Proc. 1) Appearance Evaluation: No evidence of cracks, no blistering, no change in appearance or other failure when compared with original unaged sample. Panels or parts exposed per para 3.8.9 shall be immersed in water for 24 h per FLTM BI 104-01 and then must meet the
28、 requirements for adhesion per para 3.8.1 within 30 minutes of removal from water. ENGINEERING MATERIAL SPECIFICATION WSS-M70J5-C1 Copyright 2017, Ford Global Technologies, LLC Page 6 of 9 3.8.10 Short Term Heat, Humidity and Cold Cycle, Rating 4 min (ISO 105-A02/AATCC Eval. Proc. 1) 5 h at -30 +/-
29、2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H. 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C One hour ramp time between each step. Appearance Evaluation: No ev
30、idence of cracks, no blistering, no change in appearance or other failure when compared with original unaged test sample. Panels or parts exposed per para 3.8.10 shall be immersed in water for 24 h per FLTM BI 104-01 and then must meet the requirements for adhesion per para 3.8.1 within 30 minutes o
31、f removal from water. 3.8.11 Resistance To Fade 3.8.11.1 Accelerated Xenon Weathering, Rating 4 min (FLTM BO 116-01 at 977.6 kJ/m, ISO 105 A-02/AATCC Evaluation Procedure 1) Duplicate panels are required, one for appearance evaluation and one for water immersion. After the color measurements, one of
32、 the weathered panels shall be subjected to the water immersion test for 24 h per FLTM BI 104-01 and must meet requirements of para 3.8.1 within 30 of removal from water. 3.8.11.2 Florida Weathering Under Glass Rating 4, min (FLTM BI 160-01, 12 months, ISO 105 A-02/AATCC Evaluation Procedure 1) 1 ye
33、ar submission required for new technology only In addition: Panels shall be free of severe chalking, blistering, checking, peeling and gloss loss. 3.8.12 High Performance Paint Adhesion (Test Method 1 or 2, Record method used on data submission form) Test Method 1 Expose the samples at 80 +/- 2 C an
34、d 80 +/- 5% Relative Humidity for 96 hours. FLTM BI 107-05 Adhesion Rating 20 min No loss of gloss or any other surface deterioration. Test Method 2 FLTM BO 160-04 Adhesion (Method A or B) No Adhesion Loss No loss of gloss or any other surface deterioration. ENGINEERING MATERIAL SPECIFICATION WSS-M7
35、0J5-C1 Copyright 2017, Ford Global Technologies, LLC Page 7 of 9 3.8.13 Resistance to Grease Rating 4 min (FLTM BJ 126-01) To be tested with the greases listed in the PSW that will come in contact with the coated components. Appearance evaluation: No film softening, blistering, dulling or loss of ad
36、hesion allowed for any grease. 3.8.14 Resistance to Suntan Lotion Rating 3 max and Insect Repellent, No film degradation (FLTM BI 113-08, 23 C and 74 C) 3.8.15 Perspiration Resistance (FLTM BI 113-06, ISO 105-A02/AATCC Evaluation Procedure 1) Acid Perspiration Solution Rating 4 min Alkaline Perspira
37、tion Solution Rating 4 min Sodium Chloride Solution Rating 4 min 3.8.16 Abrasion and Paint Wear Resistance using the Rating 4 min Abrex Machine, Metallic Only (FLTM BN 155-01, 30,000 cycles, ISO 105-A02/AATCC Evaluation Procedure 1) Rate and report the initial and final color, initial gloss and pain
38、t film thickness. Paint film thickness must meet requirements of paragraph 3.6.5. 3.9 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments (Response Surface Analysis is recommended) to determine the process window of the substrate/paint combination. The three variables/parame
39、ters to be included in the design are bake temperature, bake time, and film thickness. An initial screening experiment should be run to determine what levels should be tested for the variables/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DO
40、E. Responses to the DOE will be based on the materials tested and will be chosen from tests listed within the specification. Film Thickness, 3.6.5 Gloss 3.7.3 Initial Adhesion 3.8.1 Water Resistance 3.8.2 Cure Test 3.8.3 3.10 CONTROL PLANS AND PFMEAS The supplier Control Plan must include but is not
41、 limited to the following information: 1) Film Thickness 3.6.5 once per shift/ color 2) Color and Gloss (If applicable) 3.7.2, 3.7.3 once per shift/ color 3) Initial Adhesion 3.8.1 once per shift/ color 4) Cure 3.8.3 once per shift/ color 3.11 EXPLOSION HAZARD These materials should be used in a clo
42、sed system specifically designed for their use because of the possibility of dust explosion present in powdered material. 3.12 HANDLING PRECAUTION ENGINEERING MATERIAL SPECIFICATION WSS-M70J5-C1 Copyright 2017, Ford Global Technologies, LLC Page 8 of 9 This material shall be considered as relatively
43、 non-toxic compared to liquid paint. However, care should be taken to avoid prolonged exposure to the skin. This material should be used in a closed system to reduce the possibility of breathing the powder. 4. GENERAL INFORMATION The information given below is provided for clarification and assistan
44、ce in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Mater
45、ials 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 requirements of the Material Specification. Tested material samples must be available fo
46、r 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 testing) with Ford. 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent
47、 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 the specification requirements, the supplier shall notify the affected Supplier Techni
48、cal 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 using Ford Engineering Material Specifications, all samples tested to the specificatio
49、ns for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed 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
