ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev 04 2012 07 31 Revised Para 1, 3.5, 3.10, 5.8 revised. 5.9 added. A. Toennessen, D Jordan NA 2004 03 17 Revised Para 2 revised B. Curtiss 1996 02 15 Activated K. Thurgood Controlled document at www.MATS.ford.com Copyright © 2012, Ford Global Technologies, LLC Page 1 of 10 COATINGS, STEEL SHEET WSS-M1P94-A 1. SCOPE This specification defines the requirements for coil coatings on steel sheet. These coatings comprise 4 categories: . Zinc Based Metallic (i.e. Zinc, Zinc/Iron, Zinc/Nickel and other Zinc/Alloy) . Other Metallic (i.e. Nickel, Tin) . Organic (i.e. Zinc Rich Primer) . Phosphate (Upon request from the Stamping Plant to the responsible Materials Engineering Activity, there is the option of using prephosphated material to aid formability). Such coatings shall be specified in conjunction with the appropriate base steel sheet. The currently released base steel specifications are: Specifications released for regional use (prior to 2012): WSS-M1A183-D WSB-M1A215-E1/F1 WSD-M1A333-A1/A2/A3/A4 WSS-M1A338-A1 WSS-M1A341-A1/A2/A3/A4/A5/A6/A7/A8/A9/A10/A11/A12 WSS-M1A344-A1/A2 WSS-M1A345-A1/A2/A3/A4 WSS-M1A346-A1/A2/A3/A4/A5/A6 WSS-M1A347-A1/A2/A3/A4/A5/A6 WSS-M1A348-A1/A2/A3/A4/A5/A6/A7/A8/A9 Specifications released for global use (2012 and later): WSS-M1A365-A11/A12/A13/A14/A15 WSS-M1A367-A11/A12/A21/A22/A23/A33/A34/A35/A36/A37/A38 WSS-M1A368-A13/A14/A81/A82/A83/A84/A91/A92 2. APPLICATION This specification was released originally for material used for automobile body and chassis parts requiring good corrosion resistance. The category of Other Metallic Coatings was incorporated originally for fuel systems parts requiring good corrosion resistance. Note: Good quality paintability depends upon the critical factors of chemical cleanliness and crystalline integrity of the phosphate coating. Accordingly, prudence should be exercised when considering a pre-phosphate coating on exterior facing surfaces e.g. skin panels. Note: The presence of a coating will influence the properties of the final coated product, compared to the uncoated base steel sheet. Note: Rinses used during the coating process must be hexavalent chromium free. ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 2 of 10 3. REQUIREMENTS 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 FORMABILITY The formability paragraph of the appropriate Base Steel Sheet material specification shall apply. 3.3 WELDABILITY The weldability paragraph of the appropriate Base Steel Sheet material specification shall apply, except in the case of WSD-M1A333-A1/A2/A3/A4 and zinc based metallic coatings; also WSD-M1A333-A1/A2/A3/A4 and zinc rich primer, when FLTM BA 113-01 shall apply. 3.4 PAINTABILITY The paintability para of the appropriate Base Steel Sheet material specification shall apply. 3.5 COATING: ZINC BASED METALLIC 3.5.1 Coating Mass (ASTM A 90) Standard Range Coating Mass Coating Mass Per Side g/m 2 Designation Single Spot min/max* Hot Dipped** Electrolytic** 00 NA 0 20 20/50 20/30 30 30/60 30/45 40 40/70 40/55 45 45/75 45/60 50 50/80 50/70 55 55/85 55/75 60 60/90 60/80 70 70/100 70/90 98 100/130 100/130 In some instances, coatings that are produced to tighter coating mass ranges than shown above may be available. These shall be designated as 'Restricted Coating' (Symbol 'C') and shall be detailed on the appropriate Engineering Drawing as follows: Restricted Range Coating Mass Coating Mass Per Side g/m 2 Designation Single Spot min/max* Hot Dipped** Electrolytic** 50 50/70 50/65 55 55/75 55/70 60 60/80 60/75 70 70/90 98 100/130 ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 3 of 10 *ASTM A 90 should be suitably modified to allow coating mass determinations on individual sides. **Where these tolerances cannot be met, exceptions must be approved by the responsible activity. Differentially coated products and higher strength coated products generally have greater coating mass ranges than those stated. 3.5.2 Coating Composition (Electrolytic) Unless an alloy coating is chosen, the primary deposit shall be Zinc. Electrolytic Zinc/Nickel shall contain 10.5 - 13.5% Nickel. Electrolytic Zinc/Iron shall contain 12 - 18% Iron. The frequency of testing and the analytical method shall form part of the control plan. 3.5.3 Coating Composition (Hot Dipped) Unless an alloy coating is chosen, the primary deposit shall be Zinc. The frequency of testing and the analytical method shall form part of the control plan (see also para 4.3). 3.5.4 Supplementary Coatings Unless otherwise stated (see para 3.7 and 3.8), no supplementary coatings (other than a company approved mill oil (rust preventative oil) or prelube) are permitted. 3.5.5 Coating Adhesion (ASTM A 924M/ASTM A 591) Coated steel shall conform to the coating bend test requirements of ASTM A 924M for hot dipped and ASTM A 591 for electrolytic coated products. The frequency of testing shall form part of the control plan. 3.5.5.1 Coating Bend Test (ASTM A 924M/ASTM A591) Coated Steel shall conform to the coating bend test requirements of ASTM A 924M for hot dipped and ASTM A 591 for electrolytic coated products. The frequency of testing shall form part of the control plan. 3.5.5.2 Adhesive Shear Test (SAE J1523 or ISO 4587) For All Coating Types At a frequency to be negotiated with Materials Engineering (as part of the Source Approval Process) and incorporated into the control plan, the following: When tested according to SAE J1523 or ISO 4587 (0.8 mm. thickness specimen; additional bonding thickness of 0.25 mm.) using a high strength structural epoxy adhesive such as WSB-M2G388-A (1k) or WSB-M2G373-A (2k), the coating (ie. zinc or zinc/alloy) shall remain adherent to the steel substrate up to a minimum shear strength requirement of 8 MPa. The supplier shall have the option to seek or decline approval to paragraph 3.5.5.2. If approval to paragraph 3.5.5.2 is declined, no material shall be supplied for adhesive bonding applications, as defined ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 4 of 10 by the relevant Engineering Drawings. The entry on the ASL (Approved Source List) shall reflect this. For relevant Engineering Drawings, component engineers are recommended not to specify a minimum shear strength requirement lower than 8 MPa. 3.5.6 Coating Wraparound and Edge Condition For one side coated products, traces of coating are allowed on the uncoated side of the sheet from the edges to 15 mm from coil edges. No coating is allowed on the remainder of the uncoated side. The amount of coating on the strip edge shall be no greater than the maximum stipulated in para 3.5.1 and of sufficient adhesion to prevent flaking during the manufacturing process. 3.5.7 Coating Appearance For hot dipped products, the coating shall be minimum spangle and when viewed at 1X the individual zinc crystals shall be no longer than 5 mm across the maximum dimension. The need for a final temper mill reduction to control surface appearance or formability is to be negotiated between the manufacturing activity and the coater. 3.6 COATING: OTHER METALLIC 3.6.1 Tin 3.6.1.1 Coating Mass (ASTM A 630) Coating Mass Coating Mass Per Side g/m 2 Designation Single Spot min/max* Hot Dipped Electrolytic 20 20/50 20/35 35 35/65 35/50 50 50/80 50/65 65 65/95 65/80 *ASTM A 630 should be suitably modified to allow coating mass determinations on individual sides in SI units. ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 5 of 10 3.6.2 Nickel 3.6.2.1 Coating Mass (ASTM B 530) (with a multiplication factor of 8.90) Coating Mass Coating Mass Per Side g/m 2 Designation Electrolytic 25 25/40 35 35/50 45 45/60 3.6.3 Coating Bend Test (ASTM B 571) No peeling or flaking of the coating is permitted. 3.6.4 Edge Condition Single side coatings are not anticipated. The amount of coating on the strip edge shall be no greater than the maximum stipulated in para 3.6.1.1 and 3.6.2.1 and of sufficient adhesion to prevent flaking during the manufacturing process. 3.6.5 Coating Appearance The coating shall have a workmanlike appearance and shall not have defects of a nature or degree for the grade and quality ordered that will be detrimental to the fabrication of the finished part. The need for a final temper mill reduction to control surface appearance or formability is to be negotiated between the manufacturing activity and the coater. 3.7 COATING: ORGANIC - ZINC RICH PRIMER 3.7.1 Base Material Between the appropriate Base Steel Sheet and the Zinc Rich Primer layer shall be a Zinc Based Metallic layer, usually Electrolytic Zinc/Nickel. 3.7.2 Pretreatment Layer A conductive Inorganic/Zinc Dust complex shall be used to give a satisfactory bond between the Zinc Based Metallic (usually Electrolytic Zinc/Nickel) layer and the Conductive Organic layer. 3.7.2.1 Coating Weight (as Cr), g/m 2 0.38 + 0.10 - 0.05 3.7.3 Conductive Organic Layer This shall comprise an Epoxide Binder (Epoxy Resin) modified with Zinc Particles. The control plan referred to in para 3.1 shall address conductive organic layer composition and consistency of electrical conductivity. ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 6 of 10 3.7.3.1 Coating Thickness, Micrometers 9 + 2.5 - 1.5 (ISO 2808) 3.7.4 Coating Appearance The coating shall have a workmanlike appearance and shall not have defects of a nature or degree for the grade and quality ordered that will be detrimental to the fabrication of the finished part. 3.7.5 Coating Bend Test (ASTM B 571) No peeling, flaking or interlayer separation of the coating is permitted. 3.8 COATING: TRI-CATIONIC PHOSPHATE 3.8.1 Base Material Between the appropriate Base Steel Sheet and the Phosphate layer shall be a Zinc Based Metallic layer, usually Electrolytic Zinc or Hot Dipped Zinc/Iron. 3.8.2 Phosphate Layer When approved by the responsible Materials Engineering Activity, a suitable Tri- Cationic (Zinc/Nickel/Manganese) Automotive Quality Phosphate shall be used. This section shall constitute part of the control plan (see para 3.1). Such phosphating shall not be detrimental to any other para, particularly 3.4. Attention is also drawn to para 3.2. 3.8.2.1 Coating Weight g/m 2 1.5 +/- 0.3 (FLTM AQ 101-01) 3.9 COIL COATED FINAL PRODUCT IDENTIFICATION Unless an alternative method is agreed upon by the coated steel supplier and Manufacturing activity, the coil coated final product shall be identified as follows: This information shall be marked on the more heavily coated side of a one-sided or differentially coated product and on the unexposed side of equally coated products for exposed surfaces and shall be repeated at 1 meter intervals. . Steel Company Name and Location . Coater's Name (if different from above) . Date Coated 3.10 COATING DESIGNATION In addition to the base steel sheet specification, engineering drawings shall show a coating designation which identifies the coating mass of each side, the coating composition of each side and the method of coating (Electrolytic and/or Hot Dipped) as follows: . 1st and 2nd characters: The coating mass designation of one side (the unexposed side or heavier coated side). ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 7 of 10 . 3rd character: The coating composition of the unexposed side or heavier coated side where G = Zinc, A = Zinc/Iron, N = Zinc/Nickel, T = Tin, K = Nickel and X = other than G, A, N, T or K. . 4th and 5th characters: The coating mass designation of the opposite side (the exposed side or lighter coated side). . 6th character: The coating composition of the opposite side where G = Zinc, A = Zinc/Iron, N = Zinc/Nickel, T = Tin, K = Nickel and X = Other than G, A, N, T or K. 7th and 8th characters: Specifications released for regional use (prior to 2012): HD: Hot dip galvanized (continuous strip, used for galvanized and galvannealed type) EL: Electrolytic deposition (continuous strip) Specifications released for global use (2012 and later): GI: Hot dip galvanized (continuous strip) GA: Hot dip galvannealed (continuous strip) EG: Electrolytic deposition (continuous strip) UC: Uncoated 9th character: (used to mark “restricted” zinc coatings only) C = Restricted Coating Mass 10th character: P = (Pre-) Phosphate NOTE: See paragraph 4.8 for drawing callout examples. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact
[email protected] for questions concerning Engineering Material Specifications. 4.1 DOCUMENT ORIGIN This document was modified in 1999 and subsequently, as a collaborative effort between Ford Motor Company, Mazda (Mazda Motor Corporation) and Jaguar (Jaguar Cars), part of PAG (PAG is Premier Automotive Group). 4.2 ENGINEERING SOURCE APPROVAL BY FORD The Engineering Approved sources for coatings will be listed against the appropriate Base Steel Sheet Engineering Material Specifications. 4.3 INITIAL SUPPLIER APPROVAL BY FORD For initial approval, the supplier should furnish the following information for each coating designation/coating line combination. . A plan detailing how each requirements of para 3 will be controlled on a continuing production basis. ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 8 of 10 . Test results from a typical production sample for the requirements outlined in para 3. . Test results from typical production samples for paintability requirements outlined in para 3.4. . Typical coating chemical analysis. For products coated by Hot Dipping, coating composition should be determined by analysis of samples taken from the molten bath. For Electrodeposited coatings, composition should be as deposited. . Coating mass histogram including mean and standard deviation values. Data should consist of a minimum of 500 mass measurements randomly taken from each side of a minimum of 20 coils while the process is operating in statistical control. Upon approval, the material will be added to the Engineering Material Approved Source List (see para 4.2). 4.4 COATING COMPOSITION (HOT DIPPED) Hot Dipped Zinc and Hot Dipped Zinc/Iron usually contain Aluminum to aid adhesion of the coating to the base steel. The proportion of Aluminum in the coating varies with coating thickness but rarely exceeds 1%. Additionally, Hot Dipped Zinc/Iron usually contains 8 - 12% Iron. 4.5 COATING THICKNESS If it is desired to estimate the thickness of the coating from the coating mass, the following factors (per side) shall be used: . Zinc (Hot Dipped or Electrolytic) 7.14 g/m 2 = 1 micron . Zinc/Nickel (Electrolytic) 7.35 g/m 2 = 1 micron . Zinc/Iron (Electrolytic) 7.25 g/m 2 = 1 micron . Zinc/Iron (Hot Dipped) 7.21 g/m 2 = 1 micron . Tin 7.30 g/m 2 = 1 micron . Nickel 8.90 g/m 2 = 1 micron (Note: 1 micron = 1 micrometer = 0.001 mm) 4.6 CROSS REFERENCE OF SPECIFICATIONS (Note: For Mazda guidance only) Cross Reference of Japanese Sources (for Mazda only) (In conjunction with Ford/Mazda Joint Programs for Common Platforms only) Mass Coating MES a) b) JFS c) 50 50G50G-HD M-45/45 35/35 50 50G50G-HD P-30/30 ----- 55 55A55A-HD M-65/65 55/55 55 55A55A-HD P-30/30 ----- 50 50G50G-EL M-55/55 45/45 50 50G50G-EL P-30/30 ----- 50 50G50G-EL Z-60/60 51/51 Notes: 'M' means Hot Dipped Galvannealed Coating. 'P' & 'Z' mean Electrolytic Coating. ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 9 of 10 a) In MES (and JFS), the coating mass is defined as the value of the Triple Spot Test (see also para 3.5.1). Additionally, MES specifies the nominal (as opposed to the minimum) coating mass (see also para 3.5.1). b) Prior to choosing the coating type, it is necessary to investigate the principal selection criteria i.e. corrosion resistance and performance, the ability of the component(s) to be successfully manufactured; also cost considerations. c) JFS specifies the minimum coating mass (see also para 3.5.1). Pertinent MES Standards are MM 108, MM 109 & MM 119. Pertinent JFS Standards are A 3011 & A 3021. 4.7 REFERENCE DOCUMENTS WSS-M1A183-D ASTM A 90 WSB-M1A215-E1/F1 ASTM A 591 WSD-M1A333-A1/A2/A3/A4 ASTM A 630 WSS-M1A338-A ASTM A 924M WSS-M1A341-A1/A2/A3/A4/A5/A6/A7/A8/A9/A10/A11/A12 ASTM B 530 FLTM BA 113-01 ASTM B 571 FLTM AQ 101-01 ISO 2808 JFS A 3011 MES MM 108 JFS A 3021 MES MM 109 WSS-M1A344-A1/A2 MES MM 119 WSS-M1A345-A1/A2/A3/A4 WSS-M1A346-A1/A2/A3/A4/A5/A6 WSS-M1A347-A1/A2/A3/A4/A5/A6 WSS-M1A348-A1/A2/A3/A4/A5/A6/A7/A8/A9 WSS-M99P1111-A WSS-M1A365-A11/A12/A13/A14/A15 WSS-M1A367-A11/A12/A21/A22/A23/A33/A34/A35/A36/A37/A38 WSS-M1A368-A13/A14/A81/A82/A83/A84/A91/A92 4.8 METHOD OF SPECIFYING The specification on the Engineering Drawing shall include the Base Steel Sheet, the Coating(s), and, if applicable, the Surface Quality. Zinc Coatings e.g. Steel, Sheet, Bake Hardenable, 210 MPa minimum as received yield strength, coated with double sided Hot Dipped Zinc for a visible exterior body panel, would be specified thus: . Steel to WSS-M1A341-A4, Coated to WSS-M1P94-A: 50G50G-HD, Class 1 . Steel to WSS-M1A367-A22, Coated to WSS-M1P94-A: 50G50G-GI. Class 1 e.g. Steel, Sheet, Cold Rolled, Low Carbon, coated with double sided Electrolytic or Hot Dipped Zinc for a non-visible structural part, would be specified thus: . Steel to WSD-M1A333-A2, Coated to WSS-M1P94-A: 50G50G-EL/HD, Class 3 ENGINEERING MATERIAL SPECIFICATION WSS-M1P94-A Copyright © 2012, Ford Global Technologies, LLC Page 10 of 10 e.g. Steel, Sheet, Cold Rolled, Low Carbon, coated with double sided Hot Dipped Zinc for a non-visible structural part, would be specified thus: . Steel to WSD-M1A333-A2, Coated to WSS-M1P94-A: 50G50G-HD, Class 3 . Steel to WSS-M1A365-A12, Coated to WSS-M1P94-A: 50G50G-GI, Class 3 Other Metallic Coatings: e.g. Steel, Sheet, Cold Rolled, Low Carbon, coated with double sided Electrolytic Tin, would be specified thus: . Steel to WSD-M1A345-A2, Coated to WSS-M1P94-A: 50T50T-EL, Class 3 . Steel to WSS-M1A365-A12, Coated to WSS-M1P94-A: 50T50T-EG, Class 3 e.g. Steel, Sheet, Cold Rolled, Low Carbon, coated with double sided Electrolytic Nickel, would be specified thus: . Steel to WSD-M1A333-A2, Coated to WSS-M1P94-A: 25K25K-EL, Class 3 . Steel to WSD-M1A365-A12, Coated to WSS-M1P94-A: 25K25K-EG, Class 3 5. SUMMARY OF REVISIONS 2012 07 31 - Added global steel specifications to paragraph 1 - Clarified standard and restricted coating weight ranges in paragraph 3.5.1 - Added new hot dip and electrolytic nomenclature for global steel specifications in para 3.10 - Updated reference documents in paragraph 4.7 and clarified examples in paragraph 4.8 - Added Summary of Revisions and renumbered. 2003 07 31 Revised Para 3.0 inserted; Para 3.1, 3.11, 4 deleted