ENGINEERING MATERIAL SPECIFICATION

PAINT PERFORMANCE, RIGID SUBSTRATES, EXTERIOR WSS-M2P180-D

1. SCOPE

This specification defines the performance requirement of a painted part for all exterior rigid body sheet
metal and all exterior rigid body parts where best appearance and highest durability are required. This
system is specified for component suppliers covering all processes including in-department and pre-
delivery repairs.

2. APPLICATION

This specification was released to define paint performance of exterior parts visible after assembly and is
applicable to all surfaces outboard of the weatherstrip. This specification is not intended for paint over
chrome applications.

3. REQUIREMENTS

All visible parts of the component, including terminating exterior edges visible after assembly shall
conform to the full requirements of this specification.

Any localized post mold operations (Flame Treating, Sanding) prior to painting requires the additional
testing as noted in the last column of Table 1.

All areas of the component visible after assembly must be evaluated /tested. These areas include
flanges, parting lines, areas subject to post-mould treatment, styling lines and grooves.

In-department, pre-delivery and refinish paint repairs shall meet the requirements of this specification.

Parts must conform to the color requirements defined by the Ford Color Harmony Team or equivalent.
Body color components shall visually match the adjacent body region for orange-peel and waviness.
Instrumental measurements such as Wavescan or QMS may be used as a guide if measurement is
feasible. Refer to the appearance requirements of the adjacent body region.

Note: For in process color check the preferred method is SAE J1545, three angle CMC (Color
Measurement Committee).

3.1 APPROVED SOURCES

This specification is performance based and does not have approved sources.

Paint materials must be selected from the Painted Parts Strategy List using paints from suppliers on
the Ford Approved Source List (ASL), unless a waiver is granted by Materials Engineering. All parts
must also meet the appropriate DVP&R and Subsystem Design Specification requirements

Effective 2007 model year and beyond, all paint applicators must meet the Exterior Parts
Painter Approval Process (AVP-T113-015) unless waived by Materials Engineering.

Date Action Revisions Rev. 03

2017 05 17 Revised See Summary of Revisions 5.0 C. Taylor/Global Paint Team
2016 02 17 Revised See Summary of Revisions 5.0 J. Crist/Global Paint Team
2011 03 01 Released Replaces WSS-M2P180-C A. Weakley/J. Crist
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 ENGINEERING MATERIAL SPECIFICATION

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3.2 SYSTEM COMPONENTS

3.2.1 Substrates

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

Rigid polymers and rigid polymer blends, SMC, ABS, PC/ABS,

3.2.2 Substrate Condition

The surface to be coated must be cleaned by an automated process 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 the PFMEA, Engineering Drawing and Control Plan.

3.2.3 Paint System Requirements

Substrate * Pre-treat Prime Topcoat*

Basecoat/Clearcoat
Cold rolled steel As needed to meet
Primer/Surfacer or (2-layer),
Precoated steel process/performance
equivalent Monocoats (1-layer),
Electroplate zinc requirements (i.e. zinc
and Tri-coat (3-layer)
Zn alloy coated phosphate or
Cathodic
steel equivalent)
Electrocoat(Note 2) Powder coat (Note 3)
Aluminum

Thermoset Basecoat/Clearcoat
As applicable to meet
Polymers (2-layer),
process/performance Primer/surfacer
SMC,BMC, DMC, Monocoats (1-layer),
specifications
etc. and Tri-coat (3-layer)

Thermoplastic
Primer, surfacer Basecoat/Clearcoat
Polymers As applicable to meet
as applicable to meet (2-layer),
ABS, PC/ABS process/performance
process/performance Monocoats (1-layer),
PA,PA/PPE, etc. specifications
specifications and Tri-coat (3-layer)

* - Ford Materials Engineering approved materials (Approved Source List)

Specified Film Thickness:

Note 1: These ranges are considered to be requirements unless otherwise supported by

testing data agreed to by Materials Engineering and noted on the MCDCC.

E-coat 17-24 m
Primer/Surfacer 1724 m
Monocoat (1-layer) 38 -50 m
Basecoat/Clearcoat (2-layer) 15-30 m /38-50 m
Tri-Coat (Basecoat/Midcoat/Clearcoat) 20-30 m/15-30 m/38-50 m
Powdercoat 50-100 m
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 ENGINEERING MATERIAL SPECIFICATION

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Note 2: Primer must be applied over cathodic e-coat for paint system robustness.

Note 3: For Powder coatings, Pretreatment & Cathodic E-coat must be used unless
approved by Materials Engineering. Zn phosphate is the preferred pretreatment any
alternative must be approved by Materials Engineering.

Zinc phosphate coating per WSS-M3P1-D shall be used if steel and aluminum parts
are processed concurrently and the aluminum tolerance of the process used shall
not be exceeded. Dual phase Zinc phosphate may also be used where production
aluminum content exceeds 7%.

Control plan must specify if adhesion promoter, and/or anti-chip primer surfacer are
required to meet the requirements of this specification.

3.2.4 Repairs, In-Department and Pre-delivery

Repaired areas must meet the requirements of this specification. All repair materials and
processes used should be approved by the affected Product Materials Activity. Maximum
film thickness and/or number of repairs for repaired parts will be specified in the mutually
agreed control plan and conform to the requirements in Para 3.3. All repairs must be with
the identical color to the original finish unless approved by Materials Engineering.
st
3 in department repairs = 1 run part + 2 in line repairs

For 2-Component systems the recoats must be applied within manufacturer recommended
timeframe as noted on their Technical Data Sheets.

3.2.5 Finished Parts

Testing must be conducted on actual production parts. Where part dimensions limit
equipment access, representative panels run through the production processes may be
substituted for production parts. If regrind is used, testing at the maximum loading level is
required and must meet the specification requirement.

These panels shall be processed together with parts and shall be representative of the
parts with respect to substrate, phosphate coating, primer thickness, sanding, Paint
thickness, and processing.

When panels are used as a substitute, this must be clearly reported on the PSW or the
laboratory test report.

3.2.6 Aging

Test specimens prepared for investigations according to this specification must be aged at
least 72 hours at 23 +/- 2 C (preferred) or 16 hours at 45 +/- 1 C prior to testing.

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 ENGINEERING MATERIAL SPECIFICATION

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3.2.7 Process/Product Validation Test Requirements as listed in Table 1.

This table is for only approved paint technologies as shown on Ford Approved
Source List, otherwise full WSS-M2P180-D specification testing is required.

Design Verification Testing (DV or pre-DV) is done on plaques by the paint supplier and is
covered in the applicable paint material specification.

Product/Process Validation Testing (PV) is done on production painted parts as defined in

Table 1.

3.2.8 Cure Profile

A temperature part profile curve (Time/Temp) from the production process for the part
must be included in the PPAP.

3.3 FILM PROPERTIES

3.3.1 Color
(FLTM BI 109-01 Visual Assessment,
SAE J1545, Three-Angle CMC)

Shall match the Master Approved Sample color panel or the

initial sample as approved by Design Center.

3.3.2 Gloss Report

(FLTM BI 110-01, ASTM D 523)

Shall match the Master Approved Sample color panel or the

initial sample as approved by Design Center.

Gloss 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
L: 60 Glossmeter 0.5 - 2.0
N: 60 Glossmeter 1.8 - 2.4
R: 60 Glossmeter 1.2 1.6

3.3.3 Film Thickness As defined in

(FLTM BI 117-01, Metallic Substrates, PELT or equivalent, paragraph 3.2.3
ASTM B 487, Non-Metallic Substrates, PELT or equivalent)

All areas of the component visible after assembly must be evaluated/tested, including
flanges, parting lines, styling lines and grooves. Film thickness must meet paragraph 3.2.3
unless mutually agreed upon by Materials Engineering and noted MCDCC.

3.3.4 Film Thickness 350 m max

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

There shall be no more than 3 in-department repairs as defined in paragraph 3.2.4.

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3.4 RESISTANCE PROPERTIES

3.4.1 Paint Adhesion, (See Table 1, Note 6) Grade 2 max

(FLTM BI 106-01, Method B for flat area &
Method E for curved/radius areas, carbide tip scribe for Metal &
Thermoset resins and knife blade for all other, note method used on test data)

All areas of the component visible after assembly must be evaluated/tested, including
flanges, parting lines, areas subject to post-mould treatment, styling lines and grooves.

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

3.4.2 Water Resistance No blistering, dulling,

(FLTM BI 104-01, 240h, scribe per 3.4.1) softening, and/or any
other film failure.

After exposure, adhesion shall be tested and meet Para 3.4.1 within 30 minutes after
removal from water.

3.4.3 Condensing Humidity Resistance Rating 4-5 min

(FLTM BI 104-02, Method A, 240h
AATCC Evaluation Procedure 1/ISO 105-A02)

Alternative Methods (Must be agreed upon by Materials Engineering)

3.4.3.1 Humidity Resistance 168hr at 85C & 90%R.H. Rating 4-5 min

3.4.3.2 Humidity Resistance 240hr at 85C & 90%R.H. Report

After exposure, adhesion shall be tested and met Para 3.4.1 within 60 minutes after
exposure. No blistering, dulling, softening, and/or any other film failure.

3.4.4 Corrosion Resistance

3.4.4.1 All Metallic Substrates Applications

(CETP 00.00-L-467, 9 weeks except scribe as
in FLTM BI 169-01, ASTM D 610)

Spot/General/Pinpoint Corrosion Grade 6 max

Visible cut edges No obvious corrosion

Scribe Creep, width 6 mm max with no one

measurement more
than 3 mm.

3.4.4.2 Additional testing for Bright Machined and Polished, Clear Coated Surfaces
(Wheel Ornament, Badge, SAE J2635, No Scribe, 672 h)

No Filiform corrosion or white corrosion on any visible part of the component.

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 ENGINEERING MATERIAL SPECIFICATION

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3.4.5 Fluid Spotting Resistance

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

Test Fluids:
Body and Exterior Trim. Rating 4-5 min

For Wheel Trim and Ornaments, include

Wheel Cleaner (Motorcraft P/N ZC-37-A) Rating 4-5 min
tire sealant (TMK Kit, P/N 4G7Z-19L523-AA. Rating 4-5 min
Brake Fluid (DOT 3 or DOT 4) Report Rating

No color dulling, surface distortion or permanent softening permitted.

After exposure, adhesion testing performance must be met per Para. 3.4.1 within 60 minutes
after exposure.

3.4.6 Acid Resistance (Not for Wheel Trim/Ornamentation) Equal or better than
(FLTM BI 113-01 except at 60 C and current production
80 C for 30 minutes) material

The following solutions shall be tested on candidate materials:

3.4.6.1 Sulfuric acid (H2SO4) adjusted to pH of 2

3.4.6.2 Phosphoric acid (H3PO4), 0.5%
3.4.6.3 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 to 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.

3.4.7 Mar Resistance (A& B Gloss Materials) 70% Gloss retention

(FLTM BI 161-01) No visual Mar at
all angles

3.4.8 Scratch Resistance

3.4.8.1 A & B Gloss Materials Fracture Load >8.0 Nm

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

3.4.8.2 C - J Gloss Materials

(FLTM BO 162-01)

Requirement at 2N load

Scratch: Rating 2 max

(No color Change
at any angle)

Marring: Rating 2 max

Requirement at 7N load

Whitening Rating 1 max

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 ENGINEERING MATERIAL SPECIFICATION

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3.4.9 Chip Resistance

3.4.9.1 Grit Blast, Split Shot Rating 4 min

(FLTM BI 157-06)

3.4.9.2 Stone Chip, 1.4 L

(SAE J400, -20 C +/- 2 & 23 +/- 2 C)

Tested topcoat systems will include:

First run panel Rating 5B or 97%

Paint retention. No
chips > 3mm dia.

First run plus three in-line repairs Rating 3B or 93%

(apply 2K repairs, 7 days after Paint retention.
prior application, as defined in 3.2.4) No chips > 3mm 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 (Atlas VIEEW software

or equivalent).

3.4.10 Environmental Cycling, Total of 15 cycles Rating 4-5 min

(FLTM BQ 104-07, Procedure 1 or 10,
AATCC Evaluation Procedure 1/ISO 105-A02)

No evidence of cracks, no blistering, no change in appearance or other failure

when compared with original material approval.

After exposure, adhesion testing performance must be met per Para. 3.4.1 within
60 minutes after exposure.

Note: For procedure 1 test pieces shall be maintained at 38 C+/-2 C and 95-
98% R.H. during any weekend break in cycling

3.4.11 High Performance Adhesion (See Table 1, Note 6)

All areas of the component visible after assembly must be evaluated/tested,

including flanges, parting lines, areas subject to post-mould treatment, styling
lines and grooves.

3.4.11.1 Thermal Shock

(FLTM BI 107-05)

For Exterior Badging, 0.125 cm max

For all other Applications, Rating 19 min

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 ENGINEERING MATERIAL SPECIFICATION

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Alternate Method:
2
3.4.11.2 Resistance Against High Pressure Cleaner 2 mm max
(FLTM BO 160-04, Method B & Method C)

For Method B 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.

For Method C prior to test run Split Shot per FLTM BI 157-06 (1st
shot only) then run test at 23C. No X-Scribe.

The test method must be noted in initial submission package

3.4.12 Heat Resistance Rating 4-5 min

(7 days at 80 +/-2 C, AATCC Evaluation < 25% Gloss Loss
Procedure 1/ISO 105-A02)

Return to room temperature before evaluation.

After exposure, adhesion testing performance must be met per Para. 3.4.1 within
60 minutes after exposure.

3.5 RESISTANCE TO EXTERIOR WEATHERING

3.5.1 Accelerated Weathering

ASTM D7869 SAE J2527

(preferred) Boro/Boro
New Color Approved
2250 hours 3000 hours
Technology

New Paint
3750 hours 6000 hours
Technology

3.5.1.1 Color Change Rating 4 min

(AATCC Evaluation Procedure 1/
ISO 105-A02, prior to 3.5.1.4)

Wiping with wet clean cloth allowed no polishing allowed

3.5.1.2 Gloss Change (A & B gloss only) 25% max

(FLTM BI 110-01, prior to 3.5.1.4)

3.5.1.3 Adhesion, X-Scribe < 10% loss

(Evaluation procedure per FLTM BI 104-01) (Figure 8)

No Peeling, delamination, blistering, cracking, or crazing.

3.5.1.4 Adhesion after Water Immersion < 10% loss

(FLTM BI 104-01, 24hr immersion) (Figure 8)

No Peeling, delamination, blistering, cracking, or crazing.

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3.5.2 Outdoor Weathering 1 & 2 year submission

(SAE J 1976, Procedure A) required for new
technology only

3.5.2.1 Color Change Rating 4 min

(AATCC Evaluation Procedure 1/
ISO 105-A02, prior to 3.5.2.4)

3.5.2.2 Gloss Change (A & B Gloss only) 25% max

(FLTM BI 110-01, prior to 3.5.2.4)

3.5.2.3 Adhesion, X-Scribe < 10% loss

(Evaluation procedure per FLTM BI 104-01) (Figure 8)

No Peeling, delamination, blistering, cracking, or crazing.

3.5.2.4 Adhesion after Water Immersion < 10% loss

(FLTM BI 104-01, 24hr immersion) (Figure 8)

No Peeling, delamination, blistering, cracking, or crazing.

3.6 PROCESS WINDOW

The applicator will determine their process (Bake Time/Temperature & DFT) is within the process
window/limitations of the paint technology being used to assure compliance to the specification
requirements. A temperature part profile curve (Time/Temp) from the production process for the
part must be included in the PPAP.

3.7 CONTROL PLANS and PFMEA's

The suppliers Control Plan must include but is not limited to the following Information:

1) Film Thickness,once per shift/color

2) Cure, para 3.2.8 once per shift/color
3) Color & Gloss, para 3.3.1 & .2 once per shift/color
4) Initial Adhesion, para 3.4.1 once per shift/color

Note: These are considered to be mandatory control tests unless otherwise agreed by
Materials Engineering.

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 HARDNESS
(ASTM D1474)

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

Properly cured paint finish shall be hard enough to dry sand easily with 360 grit paper without
gumminess or severe scratching.

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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)

Target
(Average to be Achieved)
Color Lincoln
Ford Production Production Minimiums
Horizontal/Vertical Horizontal/Vertical Horizontal/Vertical

Light Metallic (L15 > 90) 57 / 44 62 / 49 50 / 37

Medium Metallic (L15 50-89) 60 / 47 65 / 52 53 / 40
Dark Metallics (L15 < 50) 62 / 49 67 / 54 55 / 42
Light Solids (L15 > 75) 62 / 49 67 / 54 55 / 42
Medium Solids (L15 30-75) 65 / 52 70 / 57 58 / 45
Dark Solids (L15 < 30) 67 / 54 72 / 59 60 / 47
Note: These ranges are for information only

4.4 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.

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5. SUMMARY OF REVISIONS

2017 05 03
3.4.5 Changed wheel trim brake fluid requirement to report only

2016 02 17 3.1 Removed WSS-M99P1111-A and added applicable requirements to

this specification.
3.2.4 Added 2-component recoat statement
3.4.4 Renumbered and reworded for clarity. Updated FLTM number.
3.5 Reworded to Global Nomenclature & A/B Gloss note
3.7 Added Note

2014 03 03 3.2.3 Update film builds added 3-layer systems

3.3.2 Added R Gloss
3.4.1 Added Knife
3.4.2 Changed after removal time from 20 to 30 minutes align with FLTM
3.4.5 Changed ZC-37 to ZC-37-A and 4G7V-19L523-AB to 4G7Z-19L523-AA
3.4.8.2 Added Whitening requirement
3.4.11.2 Updated method C added 23C and no X-scribe
3.5.1 Added AST D 7869 updated adhesion testing for clarification
3.7 Added
4.3 Updated to new ranges
Added test time after exposure in paragraphs 3.4.3, 3.4.5, 3.4.10, and 3.4.12
Updated Table 1 colors needed in Column 2

2012 10 18 Removed Gloss from paragraphs 3.4.3 & 3.4.10

Updated Wavescan Values per current requirements 4.3

2011 03 04 Added aluminum badges to 3.4.4.2

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Table 1 - Approval Test Requirements for Process/Product Validation (see Note 5)

Column Number 2 3 4 5
New Part/New
New Change In New Color Color approved
paint technology
Sample Applicator Approved
(signed MCDCC),
size per Facility or Paint System , Approved Paint
approved
color NonApproved Primer, or Technology applicator and
Applicator Substrate substrate
(Note 6)
White, Light
Colors 5 Key* Metallic, Tri- New 5 Key*
coat

3.3 Film Properties 3 X X X X

3.4.1 Adhesion 3 X X X X
(6 locations, (6 locations, (6 locations, (6 locations, Note
Note 7) Note 7) Note 7) 7)
3.4.2 Water Resist 3 X X X
3.4.3 Humidity Resist 1 X X
3.4.4 Corrosion 1 X X (if applicable)
3.4.5 Fluid Spot 1 X**
3.4.6 Resistance to 1 X**
Acid Spotting.
3.4.7 Mar Resist. 1 X**
3.4.8 Scratch Resist. 1 X**
3.4.9 Chip Resistance, 1 X** X** X**
(3.4.9.1 or .2)
st
1 run
Chip Resistance, 1 X** X** X**
(3.4.9.1 or .2)
Repair
3.4.10 Environ. 1 X X
Cycling
3.4.11 High Perf. 3 X X X X
Adhesion (6 locations, (6 locations, (6 locations, (6 locations, Note
Note 7) Note 7) Note 7) 7)
3.4.12 Heat resist. 3 X X
3.5.1 Resistance to 1 X** X** X**(Note 4)
Exterior Weathering

* White, Light Metallic, Dark Metallic, Tri-Coat and Tinted Clear

** Plaques may be substituted but must be prepared in the production process

Note 4: Weathering test can be waived by Materials Engineering with appropriate supporting data

Note 5: This table is only for approved paint technologies as shown on Ford Approved Source List otherwise full
WSS-M2P180-D specification testing is required.

Note 6: The Film Properties, Initial Adhesion and High Performance Adhesion shall also be performed on areas of
post mold operations as agreed upon by Design and/or Materials Engineering.

Note 7: These locations must include edges/radius/parting line for at least 3 locations

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