ENGINEERING MATERIAL SPECIFICATION

PAINT, POWDERED, THERMOSETTNG POLYESTER WSS-M70J5-C1

INTERIOR

1. SCOPE

The material defined by this specification 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 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 components, 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 when this specification is listed on the drawing, CAD
file, or other documents. The list of approved sources is located within Ford at
www.mats.ford.com 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 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 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 contain the necessary corrosion inhibiting pigments and/or
flattening agents to meet the requirements of para 3.4 - 3.8.

Date Action Revisions Rev. 00

2017 05 17 Released J. Bilko, NA

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3.4 PHYSICAL PROPERTIES

3.4.1 Non-Volatile Solids

(ASTM D3451)

3.4.1.1 3 h at 107 °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 Distribution 75 - 95% smaller than 44 µm

(ASTM D5861) None larger than 70 µm

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 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 representative.

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 of 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 Table 1 for testing
requirements and sample size.

Design Verification Testing (DV) is performed on panels by the paint supplier as defined in
Table 1.

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Product/Process Validation Testing (PV) is performed 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 residues,
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 should 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 otherwise 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, solvent 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° glossmeter 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

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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 & approved by visual evaluation by Design Quality.
An accurate gloss reading needs to be performed on a flat smooth surface otherwise an
accurate gloss reading cannot be obtained.

3.7.4 Final Hardness

(After aging 72 h above 20 °C)

Tukon K10 7.5 KHN min

(FLTM BI 112-02)

Sward Rocker (alternate) 36 min

(FLTM BI 112-01)

3.7.5 Polishing

Shall be capable of being sanded and polished only, to minimize orange peel or to remove
defects. No noticeable change in gloss or appearance, except for a minimum of polishing
lines shall result. Deep polishing lines or swirl marks are not acceptable.

3.8 RESISTANCE PROPERTIES

3.8.1 Adhesion Grade 0

(FLTM BI 106-01 Part A and B)

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

No flaking or chipping of the coating when tested according to both Part "A" and Part "B" of
this Test Method.

3.8.2 Water Resistance Grade 0

(FLTM BI 104-01, 96h)

No blistering, softening or loss of adhesion per para 3.8.1 within 30 minutes of removal from
water.

3.8.3 Cure Test

The coating shall exhibit only slight dulling and slight color transfer to the cloth when tested
as follows:

Test Method: Rub a soft cloth saturated with a solution of 1 part methyl ethyl ketone (MEK)
to 17 parts of xylene, over the coating in one area for 30 s and examine.

3.8.4 Abrasion Resistance, The paint film shall show no

(SAE J948, Taber method, 500 g load, abrasion through to the
CS-10 wheels) substrate

Abrasion resistance shall be determined on test panels with smooth surface. Measure and
report the sample's paint film thickness and run a min of 1000 cycles for every 25
micrometers of paint thickness on the panel. Paint must be sprayed on panels of contrasting
color (ex. Black paint on gray substrate) to prevent dry hiding issues.

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Use the following formula to calculate the number of cycles;

#cycles = (Xµm)(1000) Where Xµm = microns of film build

25µm

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 spray
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: Red 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 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. 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 +/- 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 requirements for adhesion per para 3.8.1 within 30 minutes
of removal from water.
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3.8.10 Short Term Heat, Humidity and Cold Cycle, Rating 4 min
(ISO 105-A02/AATCC Eval. Proc. 1)

5 h at -30 +/- 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 evidence 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
of 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/m²,
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 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 year 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 and 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.

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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 adhesion 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 Perspiration 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 paint 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/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.

• 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 PFMEA’S

The supplier Control Plan must include but is not 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 closed system specifically designed for their use because of
the possibility of dust explosion present in powdered material.

3.12 HANDLING PRECAUTION

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This material shall be considered as relatively 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 assistance in meeting the requirements of this
specification. Contact gmfs@ford.com 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 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 compliance 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 Plans, Certification testing) with
Ford.

4.2 SUPPLIER'S ONGOING RESPONSIBILITY

All materials must be equivalent 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 material's ability to meet the specification requirements, the supplier shall notify the affected
Supplier Technical 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
specifications 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 supplier’s responsibility
to comply with this standard on a continuing basis through IMDS and or GMAP reporting.

5. SUMMARY OF REVISIONS

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Table 1 –Test Requirements for Design Validation and Approval

*New color
approved paint
Sample New paint technology
size/color technology (MCDCC signoff)
One light,
one dark,
Test Colors
& one
metallic
3.6.5 Film Thickness 1 X X
3.7 Appearance 1 X X
3.8.1 Adhesion 3 X X
3.8.2 Water Resistance 3 X X
3.8.3 Cure Test 1 X
3.8.4 Abrasion Resistance 3 X
3.8.5 Interior Corrosion Resistance 3 X
3.8.6 Resistance to Water and Soap Spotting 1 X
3.8.7 Resistance to Acid Spotting 1 X
3.8.8 Resistance to Cleaning Agents 1 X
3.8.9 Long Term Heat Exposure 1 X
3.8.10 Short Term Heat, Humidity and Cold Cycle 1 X X
3.8.11.1 Resistance to Artificial Weathering 1 X X
3.8.11.2 Resistance to Florida Weathering 1 X
3.8.12 High Performance Paint Adhesion 3 X X
3.8.13 Resistance to Grease 3 X
3.8.14 Resistance to Suntan Lotion/Insect 1 X X
3.8.15 Perspiration Resistance 1 X
3.8.16 Abrasion and Paint Wear Resistance (Metallic only) 1 X X

*Approved paint technology on Ford ASL.

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