ENGINEERING MATERIAL SPECIFICATION

PAINT, ONE COMPONENT MONOCOAT OVER RIGID WSS-M16J19-B1

SUSTRATES, EXTERIOR

PAINT, TWO COMPONENT MONOCOAT OVER RIGID WSS-M16J19-B2

SUBSTRATES, EXTERIOR

1. SCOPE

The materials defined by these specifications are monocoat paints applied by a baked process.

2. APPLICATION

These specifications were released originally for paints used as the final topcoat on exterior trim
components made of rigid substrates, such as spoilers, appliqus, mirror housings, handles, grilles,
badges. It shall be satisfactory for use over specified primers or over previously baked enamel, as in
paint repair or tutone operations.

2.1 LIMITATIONS

Bake temperature should not exceed softening temperature of substrate material as agreed
upon by Ford Materials Engineering.

3. REQUIREMENTS

Testing to be used for initial qualification of materials and shall be made on the basis of comparison with
approved production material, chosen by the approving materials engineer.

3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS

Material suppliers and part producers must conform to the Company's Standard Requirements
for Production Materials (WSS-M99P1111-A).

3.2 COMPOSITION

The monocoat shall contain UV absorbers. The supplier will furnish the specific composition
and concentration of the absorbers upon request.

3.2.1 Resin

Shall be either a polyester, acrylic, modified urethane polymer or a polyurethane.

Minor amounts of modifiers and/or plasticizers are allowed.

3.2.2 Pigments

Pigments are exterior automotive grade selected to match the Ford Motor Company
master and meet the durability requirements.

Date Action Revisions

2007 07 31 Activated J. Robincheck

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3.2.3 Solvents

The volatility of solvents will be such that there shall be no paint sagging, roughness
or dry spray at specified film thicknesses. Solvents shall be HAPS compliant if it is
required by local government regulations

3.3 PHYSICAL PROPERTIES LIQUID STATE

The following evaluation must be conducted on the monocoat at application viscosity.

Throughout the application viscosity range, material shall be in compliance with local emission
regulations.

Property variation acceptability as identified below, shall be based on the recorded values of the
originally approved production sample as approved by Ford Materials Engineering. This data
will be used in developing control plan requirements.

3.3.1 Non-Volatile Content, range Initial sample +/- 4%

(ASTM D 1353)

3.3.2 Volatile Organic Compound, range Initial sample +/- 1%

(ASTM D 3960)

3.3.3 Weight per Volume, range Initial sample +/- 0.03 g/ml
(ASTM D 1475)

3.3.4 Volume Solids, range Initial sample +/- 2.0%

(ASTM D 2697)

3.3.5 Viscosity Report

(ASTM D 1200)

3.3.6 Stability No more than 30%

(ASTM D 1849) viscosity increase
permitted.

3.3.6.1 Shelf Stability, 90 days

3.3.6.2 Accelerated Stability, 60 C, 16 h

3.3.7 Resistivity 0.005 to 2.00 megohms

(ASTM D 5682)

Volatile solvents and other components affecting electrical conductivity shall be

adjusted such that the resistivity at application viscosity shall be within specified limits.

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3.4 PREPARATION OF TEST PANELS

3.4.1 Substrates

Auto body steel, aluminum, pre-coated or electroplated zinc or zinc alloy coated steel
and zinc die casting or as specified on Engineering Document.

Rigid polymer and rigid polymer blends, SMC, ABS, PPO, etc. with a flex modulus
(ASTM D 790, Method 1) typically greater than 1750 MPa.

3.4.2 Substrate Condition

The surface to be coated must be cleaned to ensure the absence of oil or alkaline
residues, fingerprints, corrosion, mold release agents, dirt, moisture, and other foreign
materials.

Surface energy/resistivity or chemical reaction(s) enhancements (flaming, corona

discharge or plasma) and/or addition of conductive materials, necessary to meet the
requirements of this specification, shall be specified on Engineering Documents

3.4.3 Electrocoat

For metallic substrates requiring e-coat, apply 20 - 23 m and bake 10 minutes at

182 C metal temperature or as otherwise recommended. Record e-coat and oven
type used.

3.4.4 Primer

Apply 17 - 24 m DFT (Dry Film Thickness) of the primer or as otherwise

recommended, as specified for the substrate.

3.4.5 Monocoat

Apply monocoat to required dry film thickness by spray under conditions appropriate
for monocoats, and flash as required. Bake using appropriate bake schedule.
Record paint and oven type used. (As developed by para 3.5).

3.4.6 Design Verification/Initial Qualification Test Requirements as listed in Table 1

3.4.7 Aging

After application of the top coat, all panels shall be aged at least 72 h at 23 +/- 2 C,
50 +/- 5% relative humidity or 16 hours at 45 +/- 1 C before testing.

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3.5 PROCESS WINDOW DEFINITION - NEW RESIN TECHNOLOGIES ONLY

The supplier shall perform a DOE utilizing response surface analysis to determine the Process
Window of the system. The three variables to be included in the design are Bake Time, Bake
Temperature, and Film Thickness. An initial screening experiment should be run to determine
what level will generate a window which includes testing to failure. This screening experiment
should be reviewed with the Materials Engineer to set up the final DOE. Response attributes to
the DOE should be based on the materials tested and should include, but not be limited to:

Film Thickness (Para 3.6.3, 3.6.4)

Ultraviolet Light Transmittance (Para 3.6.5)
Adhesion (Para 3.7.1)
Water Immersion (Para 3.7.2)
Chipping (Para 3.7.8)
Environmental Cycling (Para 3.7.9)
High Performance Adhesion (Para 3.7.10)

Report minimum, maximum, and target values for time, temperature, and film thickness.

3.6 FILM PROPERTIES

3.6.1 Color
(FLTM BI 109-01, SAE J1545 Three Angle CMC)

Shall match the Master Approved Sample color panel or the initial sample as
approved by Design Center.

3.6.2 Gloss
(FLTM BI 110-01, ASTM D 523)

Shall match the Master Approved Sample color panel or the initial sample as
approved by Design Center.

3.6.2.1 Gloss After Rebake, max 4 unit decrease

Rebake panel at target bake conditions per Para 3.5.

3.6.3 Film Thickness, min Report

(FLTM BI 117-01, Metallic Substrates, PELT or equivalent,
ASTM B 487, Non-Metallic Substrates, PELT or equivalent)

Target values shall be defined from process window (Para 3.5) and must be sufficient
to meet all requirements of this Specification. Will be specified on the mutually
agreed upon control plan.

3.6.4 Film Thickness, max Report, not to exceed

(FLTM BI 117-01, Metallic Substrates, PELT or equivalent, 350 micrometers
ASTM B 487, Non-Metallic Substrates, PELT or equivalent)

There shall be no more than 3 in-department repairs.

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3.6.5 Ultraviolet Light Transmittance

For each color, report the minimum film build of monocoat required to meet a
maximum light transmission of no more than 0.1% at 360 nm and 0.5% at 400 nm.
Achieving compliance may require the use of a primer-surfacer.

The equipment used for this measurement is an integrating sphere

spectrophotometer or equivalent. These values shall be used to help determine
minimum film thickness for the process window in section 3.5.

3.6.6 General

The paint shall bake out to a presentable serviceable film showing no craters,
pinholes, seediness, abnormal roughness or excessive metallic mottling. It shall have
a reasonable tolerance for ordinary cleaning, and exhibit no dulling or color change
when washed with commercially available cleaners.

3.7 RESISTANCE PROPERTIES

3.7.1 Paint Adhesion, max Grade 2

(FLTM BI 106-01, Method B, carbide tip scribe only)

Lightly hand sand paint film surface (10 double rubs, moderate pressure) with P600
paper until dull, before scribe operation and checking adhesion.

3.7.2 Water Immersion No blistering, dulling,

(FLTM BI 104-01, 240 h) softening, loss of
adhesion, and/or any
other film failure

Adhesion shall be tested according to Para 3.7.1 within 20 minutes after removal from
water.

3.7.3 Condensing Humidity Resistance No blistering, dulling,

(FLTM BI 104-02, Method A, 240 h) softening, loss of
adhesion, and/or any
other film failure

After exposure, adhesion testing performance must be met per Para 3.7.1.

3.7.4 Fluid Spotting Resistance, min Rating 4-5

(FLTM BI 168-01, Method A and B, AATCC Evaluation
Procedure 1/ISO 105-A02)

Test Fluids: (Body and Exterior Trim use)

No color dulling, surface distortion or permanent softening permitted.

After exposure, adhesion testing performance must be met per Para 3.7.1.

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3.7.5 Acid Resistance Equal or better than

(FLTM BI 113-01 except at 60 and current production
80 C for 30 minutes) material

The following solutions shall be tested on candidate materials:

Sulfuric acid (H2SO4) adjusted to pH of 2

Phosphoric acid (H3PO4), 0.5%
Bee dropping mixture (47 g Formic Acid, 24 g Tannic Acid 10% in H2O, 24 g
Honey, and 5 g Albumin 10% in H2O).

Apply specified solutions 2 test panels. Place one each in preheated ovens at 60 and
80 C, respectively. Remove after 30 minutes. Rinse any remaining solution with
water. Examine panels for etching, discoloration, pitting, etc. Report etch-free
temperature for test material and control.

3.7.6 Mar Resistance

A & B Gloss Materials 70% Gloss retention

(FLTM BI 161-01)

3.7.7 Scratch Resistance

A & B Gloss Materials Fracture Load >8.0mN

(DVM-0058-PA, Nano Scratch Test) Deformation <0.40m

C - J Gloss Materials Rating 2

(FLTM BN 108-13, 1 mm Dia., 2N)

3.7.8 Chip Resistance

3.7.8.1 Grit Blast, Split Shot, min Rating 4

(FLTM BI 157-06)

3.7.8.2 Stone Chip

(SAE J400, 1.4 L at -20 +/- 2 C and 1.4 L at 23 C +/- 2 C)

Topcoat systems to be tested will include:

first run panel Rating 5B or

97% paint retention,
no chips > 3 mm Dia

first run plus three in-line repairs Rating 3B or

93% paint retention
no chips > 3 mm Dia

Chipping is identified as intercoat adhesion loss between any adjoining

layers revealing dis-similar colors, scuffing is acceptable.

Chipping metrics may be obtained by image analysis software if

available.

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3.7.9 Environmental Cycling, 15 cycles No evidence of cracks,

(FLTM BQ 104-07, Procedure 10, no blistering, no
evaluate after 20 h at 23 +/-2 C) change in appearance
or other failure when
compared with an
original part.

After exposure, adhesion testing performance must be met per Para 3.8.1.

3.7.10 High Performance Adhesion

Thermal Shock, Max Rating 19

(FLTM BI 107-05)

Alternate method

Resistance Against High Pressure Cleaner No Removal, NA only

(FLTM BO 160-04, Method B) 2 mm2 max, Euro

Prior to testing the painted surface shall be X-scribed through to the substrate
(30 angle). The test must be performed on the X-scribe.

3.7.11 Heat Resistance, min Rating 4 - 5

(7 days at 80 +/- 2 C, AATCC Evaluation Procedure1, No gloss loss
ISO 105-A02)

Return to room temperature before evaluation.

After exposure, adhesion testing performance must be met per Para 3.8.1.

3.8 WEATHER RESISTANCE

Accelerated Weathering is acceptable for new substrate or new colors (existing pigments/resins
only). In case of differences in the test results of Florida exposure and the accelerated
weathering the results of the Florida exposure shall prevail. Data derived from Florida
Weathering takes precedence over Accelerate Weathering.

The panels shall be completely free from evidence of cracking, checking, blistering, and
peeling.

After exposure (Para 3.9.1 and Para 3.9.2), panels must meet Para 3.9.3 requirements as
applicable.

3.8.1 Natural Weathering Florida Exposure

(SAE J1976, Procedure A)

New Pigment 3 years required

New Color (known pigments / resins) Not required

New Resin Technology 5 years required

The film shall be free from mildew and show a minimum of dirt retention.

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3.8.2 Accelerated Weathering

(SAE J2527, 0.55 W/m2 Irradiance,
Borosilicate Inner and Outer Filters)

New Pigment 3000 h,

applicable resin

New Color (known pigments / resins) 3000 h required

New Resin Technology 5000 h required

3.8.3 Testing After Exposure

3.8.3.1 Appearance

After 1 year Florida exposure or 1000 h accelerated weathering, there

shall be no visual color change and 10% maximum gloss loss. There
shall be no blistering, cracking, peeling or micro checking.

After 3 years Florida exposure or 3000 h accelerated weathering;

AATCC Evaluation procedure 1: Rating 4 max

Gloss Change per ASTM D 523 25% loss max
Color Change per FLTM BI 109-01 E 2.0 max

After 5 years Florida exposure or 5000 h accelerated weathering:

AATCC Evaluation procedure 1: Rating 3 max

Gloss Change per ASTM D 523 50% loss max
Color Change per FLTM BI 109-01 E 5.0 max

3.8.3.2 Adhesion After Water Immersion 90% adhesion

(FLTM BI 104-01, 24 h) retention

There shall be no blistering or delamination between any layers of the

total paint system. To be evaluated on all exposure intervals.

4. GENERAL INFORMATION

The information given below is provided for clarification and assistance in meeting the requirements of
these specifications.

4.1 HARDNESS
(ASTM D 1474)

Record value at target film and bake conditions. Shall be sufficiently cured at time of packing to
withstand normal handling without damage.

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4.2 POLISHING

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 min of polishing lines shall result.
Deep polishing lines or swirl marks are not acceptable.

4.3 WAVESCAN TARGET VALUES

(BYK-Gardner or equivalent)

Color Target Minimums

Light Metallics 55-59/42-46 50/37

Dark Metallics 60-64/47-51 55/42
Light Solids 60-64/47-51 55/42
Dark Solids 65-69/52-56 60/47

4.4 TOPCOAT PROCESSING CONDITIONS REQUIRED FOR PARA 3.6, 3.7 AND 3.8.

Conditions Topcoat Bake Bake

Filmbuild Time Temperature

1 Low Max Max

2 High Min Min
3 Target Target Target

Note 1: Control testing panel requirements to be chosen at discretion of approving materials

engineer.

Note 2: Testing of one specimen is required of every color per each condition listed above.

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Table 1, Approval Test Requirements, Design Verification/Initial Qualification

NEW COLOR
NEW PAINT
NEW SUBSTRATE (Existing Pigment/
TECHNOLOGY
Resin)

Black, Light Metallic, Black, Light Metallic,

Minimum Colors to be Tested: New Color
Dark Metallic Dark Metallic

3.3 Physical Properties X X X

3.6.1 Color X X X

3.6.2 Gloss X X X

3.6.3-4 Film Thickness X X X

3.6.5 UV Transmission X X X

3.7.1 Adhesion X X X

3.7.2 Water Immersion X X X

3.7.3 Humidity X X

3.7.4 Fluid Spot X Bug & Tar only Bug & Tar only

3.7.5. Acid X X X

3.7.6 Mar Resistance X

3.7.7 Scratch Resistance X X

3.7.8 Chip Resistance X X X

3.7.9 Environmental Cycling X X

3.7.10 High Performance Adhesion X X X

3.8.1, 3 Florida Exposure X

3.8.2, 3 Weatherometer X X X

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