Description
ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1 PAINT PERFORMANCE, VISIBLE METALLIC INTERIOR PARTS 1.
Tracking # M50061
SCOPE This specification defines the performance requirements for decorative coatings or finishes including paint, electrodeposition coating and powder coating on metal and metal plated substrates for interior use.
2.
APPLICATION This specification was released originally to define performance requirements for various interior applications such as seat tracks, towel bars, speaker grilles, brake pedals, and shift controls.
3.
REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. All parts must also meet the appropriate part performance specification and Subsystems Design Specification. 3.0
STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Company's Standard Requirements for Production Materials (WSS-M99P1111-A).
3.4
SYSTEM COMPONENTS 3.4.1
Test Specimen Preparation Tests shall be performed on actual components processed through the production or production intent process. Where this is not possible, panels can be used on the production or production intent process. Panels must be used when part geometry does not allow testing to be performed. Panels must be approved through Materials Engineering prior to testing.
3.4.2
Substrate Cold rolled steel, hot rolled steel, aluminum and magnesium or as specified on the Engineering Document.
3.4.3
Surface Preparation The surface to be coated shall be cleaned by an acceptable process, e.g. cleaning line, to remove any stamping oils, dust, dirt or debris.
3.4.4
Film Thickness Film thickness of all applicators must be sufficient to meet the performance and appearance requirements of this specification. The film thickness of all test specimens shall be reported on the PSW and laboratory report.
3.4.5
Aging Test panels or test specimens prepared for investigations according to this specification must be aged for at least 72 hours at 23 + 2 °C prior to testing.
Date
Action
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Revisions
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ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1 3.4.6
Production Repair Repaired parts must also meet the requirements of this specification. All repair materials and processes used must be approved by the affected Product Engineering Office. Maximum film thickness and maximum number of repairs will be specified in a mutually agreed control plan.
3.5
APPEARANCE Color, gloss, tactile effect and surface finish shall match master Sample and/or Master Appearance Sample as approved by Corporate Design. The coating shall exhibit no craters, pinholes, solvent popping, seediness, abnormal roughness, excessive flow or any other detrimental defect. 3.5.1
Color (SAE J1767) Shall match the Master Approved Sample color panel if applicable.
3.5.2
Gloss (FLTM BI 110-01, ASTM D 523) As released by Engineering: A: B: C: D: E: F: G: H: J: K: L: N:
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20° Glossmeter, min 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter 60° Glossmeter
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92 76 - 84 66 - 74 68 - 66 47 - 53 33 - 38 17 - 23 7 - 13 4-6 2-4 0.5 – 2.0 1.8 – 2.4
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ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1 3.6
RESISTANCE PROPERTIES 3.6.1
Interior Corrosion Resistance, min. (FLTM BI 123-03, ASTM D610) Part Location
Description
Visible components on the floor near heavy foot traffic High visible components
Risers, tracks, towel bars, etc.
Low visible components (Components not in the previous two categories)
Rating 6
Minimum Number of Cycles 10
Head rest rods, isofix wires, actuator rods, mirror stems, etc. Recliners, dump mechanisms, etc.
5
2
No blistering, softening, dulling, loss of adhesion, or cracking permitted. 3.6.2
Adhesion, max (FLTM BI 106-01, Method B)
Grade 0
No flaking or chipping allowed. 3.6.3
3.6.4
Chipping (SAE J400, Method C, Chip counting procedure Method II) Number of Chips, max. Size of Chips, max. Point of Failure, max.
Rating 6 Rating B Rating S/T
Water Resistance, min. (FLTM BI 104-01, 240h, ISO 105-A02/AATCC Procedure 1),
Rating 4
No blistering, softening, dulling, or loss of adhesion when tested for adhesion within 30 minutes of removal from water on all paint systems. 3.6.5
Abrasion Resistance, min (SAE J948, CS-10 wheels) Abrasion resistance shall be determined on test panels if it is impossible to test a specimen taken from a component. The control plan shall state the film thickness. The film shall show no abrasion through to the substrate. 500 g load 1,000 cycles min and 1,000 cycles/25 µm paint thickness
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ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1 3.6.6
Resistance to Cleaning Agents, min discoloration (FLTM BN 107-01, 10 cycles, AATCC Evaluation Procedure 2)
Rating 4
Test Modifications: Saturate white cotton cloth with the cleaners listed. Cleaners (see also paragraph on Cleaning Agents) 1) 2) 3.6.7
Window cleaner with ammonia All purpose cleaner
Cure Test, min. (FLTM BN107-01, ISO 105-A02/AATCC Evaluation Procedure 2)
Rating 3
Test Procedure: Perform a 10 cycle double rub with 1 part MEK/17 parts toluene applying moderate pressure with wetted cheesecloth. 3.6.8
Long Term Heat Exposure, min. (ISO 105 A-02/AATCC evaluation Procedure 1)
Rating 4
Test one previously unexposed part as follows: 3.6.8.1
Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. speaker grilles, shift levers): 7 days at 100 + 2 °C
3.6.8.2
Horizontal or vertical parts BELOW THE BELT-LINE (e.g. speaker grilles, shifter levers): 7 days at 90 + 2 °C
3.6.8.3
Horizontal or vertical parts in NON – SUN LOADED FLOOR LEVEL LOCATIONS (e.g. track rails, mounting feet, brake pedals). 7 days at 80 + 2˚ C
Appearance Evaluation: No evidence of cracks, blisters or change in gloss when compared with original unaged sample. 3.6.9
Short Term Heat, Humidity and Cold Cycle, min. (ISO 105 A-02/AATCC evaluation procedure 1) 3.6.9.1
Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. speaker grilles, shift levers): . . . . . .
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Rating 4
5 h at -40 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at 100 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 2 h at 50 + 2 °C and 95 + 5% Relative humidity 30 min at 23 + 2 °C and 50 + 5% Relative humidity Copyright © 2004, Ford Global Technologies, LLC
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ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1 . . . 3.6.9.2
Horizontal or vertical parts BELOW THE BELT LINE (e.g. speaker grilles, shifter levers). . . . . . . . . .
3.6.9.3
5 h at –40 + 2° C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at 100 + 2 °C
5 h at -40 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at 90 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 2 h at 50 + 2 °C and 95 + 5% Relative humidity 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at -40 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at 90 + 2 °C
Horizontal or vertical parts in NON – SUN LOADED FLOOR LEVEL LOCATIONS (e.g. track rails, mounting feet, brake pedals). . . . . . . . .
5 h at -40 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at 80 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 2 h at 50 + 2 °C and 95 + 5% Relative humidity 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at -40 + 2 °C 30 min at 23 + 2 °C and 50 + 5% Relative humidity 5 h at 80 + 2 °C
Appearance Evaluation: No evidence of cracks, blisters or change in gloss when compared with original unaged sample. 3.6.10
Resistance to Artificial Weathering, min (FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1)
Rating 4
Evaluation: The parts shall be completely free from evidence of cracking, blistering, checking and peeling. Read and report the gloss change per FLTM BI-110-01. The gloss should not increase and if the gloss decreases it should be less than 30%. Parts must be used unless impossible. If panels are used the panel size shall be approximately 60 + 5 x 150 + 5 mm with 1/3 area protected from exposure. Duplicate parts or panels are required, one for appearance evaluation and one for water immersion. The parts should be exposed per the chart below: LOCATION Heavy Exposure
DESCRIPTION Actuator rods, etc
EXPOSURE (kJ/m2) 2406.4
Above the Beltline
Head restraints, etc
902
Below the Beltline
Door Speaker Grilles, etc. Risers, etc.
451
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ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1
3.6.11
High Performance Paint Adhesion (Thermoshock), min (FLTM BI 107-05)
Rate and Report
Test Method: Expose the samples at 80 + 2 °C and 80 + 5% Relative Humidity for 96 hours then follow all steps of FLTM BI 107-05. No loss of gloss or any other surface deterioration. 3.6.12
Resistance to Water and Soap Spotting, max discoloration (FLTM BI 113-01, ISO 105-A02/AATCC Evaluation Procedure 1)
Rating 4
No film softening allowed for any solution. 3.6.13
Resistance to Grease, min (FLTM BJ 126-01)
Rating 4
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 adhesion allowed for any grease. 3.6.14
Resistance to Marring, min (SAE J365, 10 cycles) A and B gloss surfaces Shall be capable of being sanded with 1200 grit or finer and polished. No noticeable change in gloss or appearance except for a minimum of polishing lines shall result. C – L gloss surfaces No evidence of discoloration, mar can be removed with four rubs of the thumb across the mar.
3.6.15
Resistance to Suntan Lotion and Insect Repellent, max (DVM-0036-MA, DVM-0039-MA)
3.6.17
Perspiration Resistance, min (FLTM BI 113-06, ISO 105-A02/AATCC Evaluation Procedure 1) Acid Perspiration Solution Alkaline Perspiration Solution
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Rating 3
Rating 4 Rating 4
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ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1 3.7
FOGGING (SAE J1756, 3 h at 100˚C heating, 21˚C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min
70
Formation of clear film, droplets or crystals is cause for rejection. 3.8
FLAMMABILITY (ISO 3795) Burn Rate, max
100 mm/min
The specimen size required for material approval is 355 x 100 x 2.0 + 0.1 mm with a smooth surface. Rating 2
3.9
ODOR (FLTM BO 131-01, SAE J1351), max
3.10
ABRASION AND PAINT WEAR RESISTANCE USING THE ABREX MACHINE (NORTH AMERICA METALLICS ONLY) For master approved components. (DVM-0055-MA, wet and dry, ISO I105-A02/AATCC Procedure 1)
Load (N)
# of Cycles
AATCC Color and Gloss Change
High Touch Areas
5
50,000
4
No paint wear through
Low Touch Areas
5
30,000
4
No paint wear through
Interior Regions
Abraded Area
Rate and report the initial and final color and gloss. High Touch Areas are defined as switches and switch bezels. Low Touch areas are defined as regions such as seat tracks, risers and speaker grilles. 3.11
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/parameters 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 DOE. Responses to the DOE will be based on the materials tested and will be chosen from tests listed within the specification.
5.
GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification.
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ENGINEERING MATERIAL SPECIFICATION WSS-M2P190-A1 5.1
CLEANING AGENTS (See paragraph Resistance to Cleaning Agents) 1)
Window cleaner
ZC-36-A/B/C*
2)
All purpose cleaner
ZC-11-A/B/C*
*or Ford Motor Company Recommended Equivalents
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