WSB-M64J28-A1_Electrocoat Primer_Rev_0_1

ENGINEERING MATERIAL SPECIFICATION

Material Name

Specification Number

Date Action Revisions

2003 03 31 Revised

Para 3.0 inserted; para 3.1, 3.2, 3.3, 3.12 and 4 deleted, para 3.7 revised R. Lord 1992 01 27 NBOOE1004493003 Added WSB-M64J28-A4, C4 Revised Para. 3.7 1990 01 31

NB00E10080067000

Released

PAK, MP

PRIMER, WATERBORNE CATIONIC ELECTROCOAT, WSB-M64J28-A1 20 MICROMETRE FILM BUILD, INITIAL FILL, BLACK, 180 °C BAKING TEMPERATURE

MAKEUP FEED, WATERBORNE CATIONIC ELECTROCOAT WSB-M64J28-A2 20 MICROMETRE FILM BUILD, RESIN

MAKEUP FEED, WATERBORNE CATIONIC ELECTROCOAT WSB-M64J28-A3 PIGMENT, BLACK

FLOW CONTROL ADDITIVE WSB-M64J28-A4

PRIMER, WATERBORNE CATIONIC ELECTROCOAT, WSB-M64J28-C1 20 MICROMETRE FILM BUILD, INITIAL FILL, GRAY, 180 °C BAKING TEMPERATURE

MAKEUP FEED, WATERBORNE CATIONIC ELECTROCOAT WSB-M64J28-C2 20 MICROMETRE FILM BUILD, RESIN

MAKEUP FEED, WATERBORNE CATIONIC ELECTROCOAT WSB-M64J28-C3 PIGMENT, GRAY

FLOW CONTROL ADDITIVE WSB-M64J28-C4

1. SCOPE

The materials defined by these specifications are nominal 20 micrometre film build, black or gray waterborne electrocoat body primers and associated make-up feed components applied by the cathodic deposition process.

2. APPLICATION

These specifications were released originally for a paint system which, when properly electrodeposited on vehicle bodies, sheet metal components or small parts, will provide good corrosion resistance, adhesion and enamel appearance properties.

WSB-M64J28-A1, C1: This primer is applied directly over zinc phosphate coated cold rolled steel, electrodeposited zinc or zinc/zinc alloy coated steel and any other type of steel classified as precoated, as well as to aluminum substrates. Typical applications are as follows:

. Visible Exterior Surfaces: The electrocoated primer film may be followed by an approved primer-surfacer and exterior enamel color coat. The electrocoat primer, primer-surfacer,

and enamel are all baked separately.

. Visible Interior Surface: The baked electrocoated primer film is followed by an enamel color coat.

. Non-visible Interior or Underbody Surfaces: The baked electrocoated primer film is not usually followed by an additional primer or enamel color coat.

WSB-M64J28-A2, C2: This material is make-up feed material used to replenish the resins of the initial fill electrocoat bath.

WSB-M64J28-A3, C3: This material is make-up feed material used to replenish the pigments of the initial fill electrocoat bath.

WSB-M64J28-A4, C4 are make-up feed materials that correct poor flow characteristics of the primer which may develop when the bath ages. This additive is used only as recommended by the supplier following ultrafiltrate purge or when discontinuous operation of an electrocoat tank results in evaporation of bath volatiles.

3. REQUIREMENTS

WSB-M64J28-A1, C1 cationic electrocoat primer shall meet all detailed requirements of this specification. The make-up feed material shall meet the requirements of para 3.5 and 3.6. When the feed material is used in production, the resultant primer film shall conform to the requirements detailed in para 3.7 through 3.11. These requirements apply to both laboratory prepared and assembly plant electrocoat tank materials.

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).

COMPATIBILITY

MATERIAL

3.4

The supplier of this material shall keep abreast of changes in technology of related

materials e.g., sealers and adhesives, which may affect the compatibility and

performance of this product. The supplier shall notify the appropriate Ford Product

Materials Engineering Office in writing when incompatibility is anticipated.

COMPOSITION

3.5

3.5.1 Density, kg/L at 25 °C

1475)

D

(ASTM

The density of the materials defined by these specifications shall be within +/-

.05 % of that shown on the Initial Sample Report.

%

wt

Non-volatile,

3.5.2

102-01)

(FLTM

BI

The non-volatile content of the material types specified by these specifications

shall match the values shown on the initial sample report within +/- 1 %.

max

Loss,

Weight

3.5.3

(FLTM BI 120-15, after 10 minutes

at 182 +/- 2 °C metal temperature

bake

cycle)

Initial Fill and Assembly Plant

Electrocoat Tank Material 12.0 %

3.5.4 Solvent Emissions, max 0.096 kg/L of wet paint

3960)

D

(ASTM

This requirement is as determined by the United States Environmental

Protection Agency Reference Method #24 but is only applicable to materials

used in the USA.

3.6

STABILITY

Stability

3.6.1

Pumping

120-04)

(FLTM

BI

After 21 days minimum agitation, the bath prepared from the initial fill or feed

materials shall meet all requirements of the specification.

months

Stability 2

Storage

3.6.2

During a storage of 2 months between 5 and 32 °C temperature the material as

supplied shall not settle or cake.

3.7 PREPARATION of TEST PANELS

Prepare panels per FLTM BI 120-01 with the exceptions noted below:

The substrates used shall be as follows, (ref. para. 5.1):

Standard

Steel

Panels

Production

Steel

Panels

Electrodeposited Zinc or Zinc/Nickel Alloy Coated Panels

Aluminum

or as designated by the responsible Product Materials Engineering Laboratory.

The electrocoat bath temperature should be maintained at 27 +/- 2 °C or as

recommended by the supplier during the coating process.

All substrates except aluminum shall be zinc phosphated and conform to the

requirements of WSK-M3P1-C using the most widely adopted assembly plant processes.

Use current approved primer surfacer for all tests. Use current approved black enamel

topcoat for the holdout evaluation (para 3.8.5). Use current approved white enamel

topcoat for all other tests requiring an enamel topcoat.

3.7.1 Paint Systems for Testing

The following four different coating conditions will be utilized to test the cationic

electrocoat primer. EAO only to test conditions II - IV. The following chart

specifies the coating conditions and the film thickness requirements:

CONDITION

I

II

III

IV

Dry Film Thickness Requirements in micrometres E-Coat

Primer

E-Coat

Primer

E-Coat

Primer

with Topcoat

E-Coat

Primer

with Primer

Surfacer

with Topcoat

E-Coat Primer 13 – 15 20 – 23 20 – 23 23 – 23

Primer

Surfacer

- - - 20

min* Enamel Topcoat - - 40 -50 40 - 50

*Unless otherwise specified in the applicable Primer Surfacer Engineering

Material Specification

Requirements

Bake

3.7.2

E-coat Primer - EAO 175 C & 190 C.

- NAAO 10 min at 165, 180 & 200 C Mt. Temp.

per

As

current Production Material Spec.

Primer

Surfacer

-

Enamel Topcoat - As per current Production Material Spec.

Note: Sanding is not permitted.

Ageing

3.7.3

All panels shall be aged 72 h at 23 +/- 2 °C or 16 h at 43 +/- 1 °C prior to

testing.

APPEARANCE

3.8

3.8.1

Color

(FLTM BI 109-01) A1, A3 Black

C3

Gray

C1,

The color shall match the originally approved master appearance sample. For

assembly line operations, master panels approved by Product Materials

Engineering may be used.

Leveling

3.8.2

3.8.2.1 Smoothness

The surface of the electrocoat primer shall be smooth without any

structure and not more than a minimum of orange peel when

applied and baked as required in 3.7.

3.8.2.2 Gloss

110-01)

BI

(FLTM

Gloss shall not exceed 65 % when measured on a 60° glossmeter

or as agreed upon by the applicable Product Engineering Office.

3.8.3 Film Yellowing No more than slight

permitted (TBD) yellowing

Coat 1/2 of a 100 mm x 300 mm panel with electrocoat to a film thickness of 20

micrometres and bake 10 minutes at 180 +/-2 C metal temperature. Cool to

room temperature. Apply 40 micrometres of current approved production

quality white enamel to the entire panel and bake 10 min at 130 +/-2 C metal

temperature. Measure the change in Y value using a colorimeter between the

electrocoated versus non-electro-coated areas.

3.8.4 Fume Yellowing No more than slight

(FLTM BI 120-16) yellowing permitted

This test shall be performed with a white enamel system and a white colored

primer system.

Holdout

3.8.5

No evidence of dulling or change in image clarity when enamel color coat is

applied over unsanded electrocoat primer as compared to current approved

production electrocoat enamel (Condition III panels as per 3.7.1).

PROPERTIES

3.9

RESISTANCE

Note: All resistance tests shall be carried out in comparison with current approved

production electrocoat primer and shall demonstrate equal or better performance.

max Grade

Adhesion,

3.9.1

(FLTM BI 106-01, Method B)

Prepare panels per para 3.7. There shall be no chipping or other evidence of

film separation between any coating interface as applicable.

3.9.2 Stone Chip Resistance, max Rating 1

(FLTM BI 157-04, or equiv.)

Prepare panels according to para 3.7 using current quality white top coat

enamel. Chipping between any coating interface shall not exceed above limit.

3.9.3 Salt Spray, min 500 h

(FLTM BI 103-01, cold rolled steel

5.1.1)

panels

per

Panels prepared according to para 3.7 shall exhibit no blistering, rusting or loss

of adhesion more than 3 mm from a line scribed to bare metal.

3.9.4 Resistance to Scab Corrosion

(FLTM BI 123-01, 50 test cycles)

Bimetallic split coach joint panels (ref. to para. 5.1.5) prepared according to

para. 3.7, shall be scribed to base metal across the two substrates. After

exposure, there shall be no more than 10 mm rust, blister creepage, or loss of

adhesion at the joint of the bimetallic coach joint.

Standard steel panels (ref. to para. 5.1.1) prepared according to para. 3.7, shall

be scribed to the base metal. After exposure there shall be no blistering,

rusting or loss of adhesion more than 3 mm from the scribe line.

3.9.5 Adhesion/Water Immersion Test, max 0 mm

104-04)

(FLTM

BI

Prepared production steel and electroplated zinc or zinc alloy coated steel

panels only, according to para 3.7 (omit primer only systems). Test for the loss

of adhesion after the panels have been immersed in a deionized water bath

maintained at 49 +/- 2 °C for 120 h. Blistering of the paint film is not permitted.

months

Weathering 12

3.9.6

Florida

160-01)

(FLTM

BI

Panels shall be prepared according to para. 3.7 Condition IV only

Test panels, scribed with an "X" shall be exposed in the area of Miami, Florida,

5° facing south for one year exposure time.

After the exposure the surface shall show neither blistering nor peeling nor any

other defect caused by the electrocoat primer.

3.9.6.1 Condensing humidity test, 24 h No blistering

2247)

(ASTM

D

The Florida panels shall be tested after evaluation 3.9.6.

chipping

3.9.6.2 Adhesion No

(FLTM BI 106-01, Method B)

Adhesion shall be performed 24 h after test 3.9.6.1

POWER

3.10

THROWING

3.10.1 Preparation of Throw Power Panels

(FLTM BI 120-02, Method C)

Throw power panels shall be prepared as per above test method with the

following exceptions: The substrates used shall be standard steel and

production steel panels but unscribed (see para 5.1). The surface condition of

the substrates are designated in para 3.10.2.

All substrates which are required to be phosphated, shall be zinc phosphated

per WSK-M3P1-C prior to painting. The oiled substrates shall be prepared as

follows: The oil solution shall be a mixture of 5 % by volume of ASTM Oil #1

(see ASTM D 471) in toluene. Pour the oil mixture on the test panels and hang

in a vertical position to dry for 24 h before applying the electrocoat.

The voltage used to prepare throw power panels shall be the same voltage

required to obtain a 20 micrometre electrocoat paint film thickness on a

standard phosphated test panel prepared per FLTM BI 120-01. Bake the

electrocoat primed panels 10 minutes at 175 °C (EAO) or 180 (NAAO) metal

temperature. Electrocoat painted test panels shall be exposed to salt spray per

FLTM BI 103-01 for the test periods designated in para 3.10.2. Panel edges

shall be sealed and the uncoated end placed downwards in the salt spray

cabinet.

Requirements

Power

3.10.2

Throw

The minimum requirements and specified test periods for the defined

substrates, are indicated below:

Salt Spray mm of protection before

Substrate/Surface Condition Hours and after salt spray

Before After Standard Panel - Phosphated 240 275 170

Production Panel - Phosphated 240 275 170

Standard Panel - Clean 240 275 120

Production Panel - Oiled 120 275 50

There shall be no blistering, red rusting or corrosion greater than the minimum

requirements, measured from the electrocoated end of the electrocoated test

panel when salt spray tested per FLTM BI 103-01.

QUALITY

3.11

Must be adaptable for application in accordance with appropriate Ford Motor Company

Process Specifications. When applied in this manner, it shall bake out to a presentable,

serviceable film showing no craters or pinholes.

5. GENERAL INFORMATION

The information below is provided for clarification and assistance in meeting the requirements of

the specification.

INFORMATION

5.1

PANEL

Panels

5.1.1

Steel

Standard

Standard steel panels are laboratory quality mild cold rolled steel available

clean or zinc phosphated. They are available from the Advanced Coating

Technologies, Inc., P.O. Box 735, 273 Industrial Dr., Hillsdale, Michigan 49242

or the Parker Co., 322 Main Street, Morenci, Michigan 49256

For EAO only, use panels prepared in accordance with Ford Manufacturing

Standard U-MA001-8001

Panels

Steel

5.1.2

Production

Production steel panels are produced from selected coils of automotive quality

steel and are available oiled or zinc phosphated. They are available from the

Advanced Coating Technologies, Inc., P.O. 735, 273 Industrial Dr., Hillsdale,

Michigan 49242

5.1.3 Electrogalvanized Steel 50 - 80 g/m2

Two side electrogalvanized panels may be obtained from Advanced Coating

Technologies, Inc., P.O. Box 735, 273 Industrial Dr., Hillsdale, Michigan 49242.

For EAO only, use panels complying with the relevant grades of

WSK-M1A250-C3 and ESD-M1A311-A.

Panels

5.1.4

Aluminum

SAE 2036 Aluminum panels can be obtained from Advanced Coating

Technologies, Inc., P.O. Box 735, 273 Industrial Dr., Hillsdale, Michigan 49242.

5.1.5 Split Coach Joint Bimetallic Panels

Split coach joint bimetallic panels are manufactured by welding production steel

panels to electrogalvanized panels and then cutting the panel into two sections

prior to zinc phosphating. This allows the candidate material and the control

material to be evaluated over identical substrate. These panels can be

obtained from Advanced Coating Technologies, Inc., P.O. Box 735, 273

Industrial Dr., Hillsdale, Michigan 49242.

PREPARATION

5.2

PANEL

Panels can be prepared and/or tested at:

ACT Testing Laboratories, Inc.

P.O. Box 735, 273 Industrial Dr.

Hillsdale, Mi. 49242

439-1485

(517)

5.3 CONTINUOUS PROCESS STABILITY

(FLTM BI 120-05 and/or designated plant trial)

The bath prepared from the initial fill or feed materials shall meet the requirements of

para 3.8 and 3.9 after 5, 10, 15 and 20 turnover cycles.

ADDITIVES

CORRECTIVE

5.4

These additives are used only as recommended by the supplier.

EAO:

5.4.1 Control Additive, Butyl Glycol SK-M14J9581-A

5.4.2 Control Additive, Ethyl Glycol SK-M99J9567-A

5.4.3 Control Additive, Binder Solution SK-M99J9566-A/-B

5.4.4 Control Additive, pH - Value SK-M99J9591-A

NAAO:

5.4.5 Butyl Cellosolve (Ethylene Glycol M97B10-A

Ether)

Monobutyl