FORD WSS-M21P30-A4-2018 CORROSION PROTECTIVE COATING EXTRUDED CONDUCTIVE POLYAMIDE 12 OVER A ZINC ALUMINUM ALLOY COATED STEEL TUBE TO BE USED WITH FORD WSS-M99P1111-A (Shown on F.pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 5 2018 03 06 Revised Updated substrate and electrical resistance requirements L. Click NA 2012 12 04 Revised Clarified the Fluid Resistance Requirements A.Wedepoh, FNA 1996 02 12 Activated J. Spencer Controlled document at www.MATS Copyr

2、ight 2018, Ford Global Technologies, LLC Page 1 of 9 CORROSION PROTECTIVE COATING, EXTRUDED WSS-M21P30-A1 POLYAMIDE OVER A ZINC/ALUMINIUM ALLOY COATED STEEL TUBE CORROSION PROTECTIVE COATING, EXTRUDED WSS-M21P30-A2 POLYAMIDE OVER ELECTRO-PLATED ZINC COATED STEEL TUBE CORROSION PROTECTIVE COATING, EX

3、TRUDED WSS-M21P30-A3 POLYAMIDE OVER HOT DIP ALUMINIZED STEEL TUBE CORROSION PROTECTIVE COATING, EXTRUDED WSS-M21P30-A4 CONDUCTIVE POLYAMIDE 12 OVER A ZINC/ALUMINUM ALLOY COATED STEEL TUBE 1. SCOPE The material defined by these specifications is an extruded polyamide 12 or polyamide 612 bonded to a p

4、rimer that has been applied to a zinc/aluminum alloy coated steel tube, electro-plated zinc coated steel or hot dip aluminized steel tube. 2. APPLICATION These specifications were released originally to specify the performance requirements for a secondary coating extruded over coated steel tube. The

5、 extruded coating provides additional protection for fuel lines, brake lines, power steering lines, and transmission oil cooler lines. 3. REQUIREMENTS 3.1 APPROVED SOURCES WSS-M21P30-A1/A4 This specification requires the use of approved sources. Only the sources identified on the Ford Approved Sourc

6、e List (ASL) can be used when 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. WSS-M21P30-A2/A3 This specification does not use approved sources. Any reliable

7、supplier meeting these requirements may be used. 3.2 SUBSTRATE The substrate shall be low carbon steel butt welded or double wall brazed construction which conforms to one of the following specifications: SAE J526 Welded Low Carbon Steel Tubing SAE J527 Brazed Double Wall Low Carbon Steel Tubing WSA

8、-M1A308-A1/A2 Tubing, single/double wall low carbon steel ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 2 of 9 The above tubing shall be coated with the following systems: 3.2.1 WSS-M21P30-A1 and A4 ESA-M1A270-A (zinc/aluminum alloy coated ste

9、el) 3.2.2 WSS-M21P30-A2 WSS-M1P85-B2/B3 (electro-plated zinc coated steel) 3.2.3 WSS-M21P30-A3 ASTM A463 or EN 10346 (hot dipped aluminized steel) If necessary, a hexavalent chromium free conversion coating may be used over the coated steel systems to enhance the adhesion and corrosion resistance pr

10、operties of the tube. 3.3 POLYAMIDE PHYSICAL PROPERTIES 3.3.1 Polyamide 12 Melt Point (ASTM D3418) 3.3.1.1 WSS-M21P30-A1/A2/A3 170 - 185 C 3.3.1.2 WSS-M21P30-A4 173 - 179 C 3.3.2 Polyamide 612 Melt Point (ASTM D3418) 3.3.2.1 WSS-M21P30-A1/A2/A3 210- 221 C Note: Conductive PA612 per WSS-M21P30-A4 is

11、unavailable at this time. 3.4 FILM PROPERTIES 3.4.1 Topcoat Type The topcoat shall consist of polyamide 12 or polyamide 612 for A1, A2, and A3. Only polyamide 12 is allowed for A4. 3.4.2 Primer/Base Coat Must be sufficiently cured to enhance adhesion of the polyamide. An adhesion test must be part o

12、f the control plan. 3.4.3 Appearance The coating shall be uniform in color and free from discontinuities such as flow lines, pin holes, craters or abnormal roughness. The coating shall be black in color unless otherwise specified on Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-

13、A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 3 of 9 3.4.4 Film Thickness (FLTM BI 117-01 or an approved equivalent) 3.4.4.1 WSS-M21P30-A1 Polyamide, 170 m, min 3.4.4.2 WSS-M21P30-A2 Polyamide, 150 m, min 3.4.4.3 WSS-M21P30-A3 Polyamide, 120 m, min 3.4.4.4 WSS-M21P30-A4 Polyamide, 170 m,

14、min 3.4.5 Film Properties Tube Size, nominal Coated Tube O.D., max 4.76 mm 5.21 mm 6.00 mm 6.45 mm 6.35 mm 6.80 mm 7.94 mm 8.39 mm 8.00 mm 8.45 mm 9.53 mm 9.97 mm 10.00 mm 10.45 mm 11.11 mm 11.59 mm 12.70 mm 13.17 mm 14.29 mm 14.76 mm 15.88 mm 16.35 mm 3.5 RESISTANCE PROPERTIES 3.5.1 Gravelometer/Sa

15、lt Spray Evaluation 3.5.1.1 Room Temperature Gravelometer Test Method: Perform gravelometer testing per SAE J400 using five pints of gravel and salt spray per ASTM B 117. Tubing shall show no red rust after 2000 hours of exposure time at non-gravel impacted areas; red rust is allowable up to 1 mm fr

16、om impacted areas. 3.5.1.2 Low Temperature Gravelometer Test Method: The tube is to be conditioned at -40 C for a minimum of four hours prior to performing gravelometer test per SAE J400 using five pints of gravel. Sample should be impacted with gravel within 30 seconds of removal from freezer. Then

17、 salt spray per ASTM B 117. Tubing shall show no red rust after 2000 hours of exposure time at non-gravel impacted areas; red rust is allowable up to 1 mm from impacted areas. ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 4 of 9 3.5.2 Staggere

18、d knife/Salt Spray Evaluation Make six cuts, which are deep enough to expose the steel substrate, on each leg. The cuts can be either circumferential or parallel to the tube. Each circumferential cut will cover 60 of the tubes surface. Separate each cut by 1 cm. Start the second cut 1 cm above the e

19、nd of first cut. Continue to stagger the cuts in this matter. Alternatively, use two rows of parallel cuts. The first row will have 2 cm long cuts at 0, 120, and 240. The second row, separated by 2 cm from the first row, will have cuts at 60, 180, and 300 (see Figure 1). After the tubes have been cu

20、t, do the thermal cycling described below: Raise temperature to 125 C at a rate of 5 C/min. Hold at 125 C for 1 hour. Lower temperature to -40 C at a rate of 3 C/min. Hold at -40 C for two hours. This cycle is to be repeated six times. Then expose tubes to salt spray per ASTM B 117 for 1500 h. After

21、 exposure the polyamide extrusion coating shall show no lifting or delamination. Red rust is allowed only at the knife cut. 3.5.3 Water Resistance Properties No rust or blistering. (FLTM BI 104-01, 240 h) 3.5.4 Fluid Resistance FLUID TYPE TEST TEMPERATURE EXPOSURE TIME Brake fluid 50 +/- 2 C 504 hou

22、rs Power Steering/Transmission 50 +/- 2 C 504 hours Motor oil (SAE 10W30) 50 +/- 2 C 504 hours Battery Acid (35 % by weight H2SO4) 23 +/- 2 C 504 hours Gasoline (unleaded) 23 +/- 2 C 504 hours Anti-Freeze 23 +/- 2 C 504 hours Windshield Washer 23 +/- 2 C 504 hours Test Method: The fluid samples will

23、 be divided into two groups. Group 1. (Knife cut, Fluid Soak, Salt Spray, Burst) Step 1. Cut the tubes as described in section 3.5.2 at the locations shown in Figure 3 for all but the battery acid. This tube is left uncut because the acid reacts with the zinc aluminum coating. After removal from the

24、 fluids, the tubes will be evaluated for coating degradation. Step 2. Soak the tubes for the given time and temperatures in the fluids listed above Step 3. Expose tubes to 2000 hours salt spray per ASTM B117. Visually examine the parts for red rust. Step 4. Determine the burst pressure and compare i

25、t to the original. Group 2. (Gravel, Fluid Soak, Salt Spray, Burst) Step 1. Gravelometer test the tubes as described in section 3.5.1.1. ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 5 of 9 Step 2. Soak the tubes for the given time and tempera

26、tures in the fluids listed above Step 3. Expose tubes to 2000 hours salt spray per ASTM B117. Visually examine the parts for red rust. Step 4. Determine the burst pressure and compare it to the original. Requirements: Visual Inspection: After fluid soak, no lifting of the coating should be evident a

27、t knife cut under 10X magnification. The coating should not show any signs of degradation or loss of adhesion. Report any changes and contact Materials Engineering for review. Burst Pressure: All tubes must retain 80% of their original burst pressure. Corrosion Resistance: No red rust allowed at und

28、amaged areas. Red rust allowed up to 1 mm away from knife cuts and gravel impacts 3.5.5 Electrical Resistance (WSS-M21P30-A4 only) 1 Mega Ohm Max (CETP 10.00-L-411) 4. GENERAL INFORMATION This information given below is provided for clarification and assistance in meeting the requirements of this sp

29、ecification. Contact for questions concerning Engineering Material Specifications. Example drawing callouts for the tube and coating materials for brake and fuel lines. Brake tube with Nylon 612 BRAZED DOUBLE WALL LOW CARBON STEEL TUBE PER SAE J527, NOMINAL O.D. X.XX. COAT WITH ZINC/ALUMINUM ALLOY

30、PLUS EXTRUDED PA612 PER WSS-M21P30-A1 MAXIMUM COATED TUBE O.D. PER WSS-M21P30-A1 Fuel tube with Nylon 612 WELDED LOW CARBON STEEL TUBE PER SAE J526, NOMINAL O.D. X.XX. COAT WITH ZINC/ALUMINUM ALLOY PLUS EXTRUDED PA612 PER WSS-M21P30-A1 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their m

31、aterials shall first obtain 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 c

32、ompliance with all the requirements 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

33、 Plans, Certification testing) with Ford. 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 6

34、of 9 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 Technical Assistance (STA), Purchasing, and Materials Engineering activities of the p

35、roposed 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 specifications for Design Verification (DV), Production Verification (PV) and Production Pa

36、rt 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 St

37、andard 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. 5. SUMMARY OF REVISIONS 2018 03 06 Updated Substrate (3.2.2, 3.2.3) and Electrical Resistance (3.5.5) requirements, updated genera

38、l notes 2012 12 04 Revised Fluid Resistance (3.5.4) to make test method and requirements more clear. 2011 07 14 Added PA612 material option due to PA12 shortage. Conductive PA612 still under development. Deleted Viscosity Range requirement Removed A1 and A2 (5 and 8 m) for the zinc plating per WSD-M

39、1P85- A1/A2/A3 Added example drawing callouts. 2004 10 26 Added -A4, revised para 2.1, 2.3, 3.2.1, 3.3, 3.3.2; added 3.3.1.1, 3.3.1.2, 3.3.2.1, 3.3.2.2, 3.4.4.4 & 3.5.5ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 7 of 9 FIGURE 1 STAGGERED KNI

40、FE CUTS ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 8 of 9 FIGURE 2 APPROXIMATE DIMENSIONS FOR FLUID RESISTANCE ENGINEERING MATERIAL SPECIFICATION WSS-M21P30-A1/A4 Copyright 2018, Ford Global Technologies, LLC Page 9 of 9 FIGURE 3 LOCATION OF STAGGERED CUTS