ENGINEERING MATERIAL SPECIFICATION

PAINT PERFORMANCE, METAL SUBSTRATES, WSS-M2P177-C1

LOW VISIBILITY, 4 WEEK RESISTANCE

PAINT PERFORMANCE, METAL SUBSTRATES, WSS-M2P177-C2

MODERATE VISIBILITY, 6 WEEK RESISTANCE

PAINT PERFORMANCE, METAL SUBSTRATES, WSS-M2P177-C3

HIGH VISIBILITY, 9 WEEK RESISTANCE

1. SCOPE

These specifications define the minimum performance requirements for a protective finish for chassis
and engine components. These parts are generally not top coated at the assembly plant.

2. APPLICATION

These specifications were originally released for chassis and engine components that do not experience
continuous operating temperatures above 121 °C (250 °F) and which receive a minimal amount of direct
ultraviolet exposure. Where temperature exceeds 121 °C, a high temperature paint system should be
considered. In applications where prolonged exposure to UV light is expected, epoxy resins should not
be used.

These specifications are typically used for epoxy based e-coat or powder coatings. These
specifications are not intended to limit the coating to any specific material type or process, but instead
define the performance of the system. Components typically use the following performance levels.

WSS-M2P177-C1 Knuckles, non-visible castings, engine block

WSS-M2P177-C2 Stabilizer bars, control arms, brackets, shocks,
sub-frames, frames, bumper beams
WSS-M2P177-C3 Tow hooks, trailer hitches, fuel system
components

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 SUBSTRATE PROPERTIES

3.2.1 Substrate

As specified on the Engineering Drawing. Except for Chip Resistance, all requirements
of these specifications must be validated with actual production intent components.

Date Action Revisions Rev. 1

2010 05 25 Revised See Summary of Revisions A. Wedepohl, NA

2009 05 21 Activated Replaces WSS-M2P177-B1/B2 A. Wedepohl, NA
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 ENGINEERING MATERIAL SPECIFICATION

WSS-M2P177-C1/C2/C3

3.2.2 Metal Preparation

The surface to be coated must be free from oil, alkaline residues, rust, dirt, moisture
and other foreign materials. A preliminary shot blasting or pickling operation is required
on castings, forgings, and scaled steel.

A zinc phosphate pretreatment per WSS-M3P36-A1 is recommended for electrocoated

or powder coated components.

3.3 FILM PROPERTIES

3.3.1 Color

Black or as specified on the engineering drawing.

3.3.2 Initial Hardness

The finish shall be sufficiently cured at the time of packing to withstand normal handling
and shipping without damage.

3.3.3 Adhesion
(ASTM D3359)

Method A, X-cut Tape Test 4A or better

Method B, Cross-Cut Tape Test 4B or better

Available surface area and contour of the component determines which method to use.
If both methods are suitable, then Method B is preferred. When using Method A, a
minimum of three X-cuts per part is required to increase sampling area.

3.3.4 Film Thickness, min

(FLTM BI 117-01, ASTM B 487)

Coating thickness must be sufficient to meet all the performance requirements of these
specifications. Minimum coating thickness must be listed on the print and should be
based on production intent parts. The type of coating shall also be referenced on the
print.

Example: E-coat per WSS-M2P177-C1, 20 µm min

3.4 RESISTANCE PROPERTIES

3.4.1 Chip Resistance 5BA max

(SAE J400, Method C, Method II) (less than 49 chips
Chip size < 3 mm)

Test shall be conducted on production intent components or on panels. The test panel
must have the same substrate i.e. cold rolled/hot rolled steel, cast iron, wrought/cast
aluminum and be painted on the same system as the production intent component.

or (FLTM BI 157-06) 6 min

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 ENGINEERING MATERIAL SPECIFICATION

WSS-M2P177-C1/C2/C3

3.4.2 Laboratory Accelerated Cyclic Corrosion Test

(CETP 00.00-L-467, ASTM D610)

WSS-M2P177-C1 4weeks Grade 6 or better

WSS-M2P177-C2 6 weeks Grade 6 or better
WSS-M2P177-C3 9 weeks Grade 6 or better

The part must be rated no worse than Grade 6 as defined by ASTM D 610. Parts
with sharp edges, recessed areas, rough surfaces, or welds may have reduced
corrosion resistance at these locations. Final judgment of corrosion performance
should be based on visibility of the parts as observed from the rear, engine
compartment, or in the wheel wells of the vehicle as described by in Total Vehicle
Corrosion Resistance requirement 18-0040.

3.4.3 Water Resistance, min

(FLTM BI 104-01, ASTM D714)

Immerse samples 240 hours. Allow paint film to recover 1 h at room temperature after
immersion before evaluating.

No softening, rust, dulling, color change and/or loss of adhesion. Blistering shall not
exceed size 8, few per ASTM D 714. Adhesion shall meet the requirements in sec.
3.3.3

3.4.4 Fluid Resistance

(FLTM BI 168-01, Method A
Gasoline, Diesel, Coolant, Engine Oil)

The finish shall not blister or show more than slight softening or dulling. Adhesion shall
meet the requirements in sec. 3.3.3.

4. GENERAL INFORMATION

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

4.1 SURFACE PREPARATION

For initial DV or PV evaluations, descaled parts may be rated according to ASTM D 2200
method B. The SSPC BSP rating achieved on the design intent parts should appear in the
control plan to indicate the level of cleaning.

Example: Descale cleaning level SSPC BSP 10 or better.

4.2 GLOSS
(FLTM BI 110-01)

The recommended gloss level for chassis components visible with "wheels on ground" is 30 to
80 at 60° angle.

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 ENGINEERING MATERIAL SPECIFICATION

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4.3 RECOMMENDED TESTING REQUIREMENTS FOR DESIGN VALIDATION, PRODUCTION

VALIDATION, AND SREA.

Paint performance is a function of material selection, surface preparation, and paint application.
For established coatings and coating lines, this may permit a reduced test schedule to validate
compliance to this specification. Use the following table to determine the recommend test plan
depending on the situation.

Table 1

New
Coating Established Coating
Material
New Paint
All Line Existing Paint Line (Applicator)
Applicators (No Ford
History)
Existing New Part Switching New Process
part for a Known Part/Same Change
different Paints on materials
application same part
Test Requirements
Example A Example B Example C Example D Example E Example F
3.3.3 Adhesion X X X X X
3.3.4 Film Thickness X X X X X
3.4.1 Chip Resistance X X X1 Contact
3.4.2 Laboratory Materials
1
Accelerated Cyclic X X X Engineering
Corrosion
3.4.3 Water
X X X X
Resistance
3.4.4 Fluid Resistance X

Example A. A new coating is developed by a paint manufacture for automotive applications

Example B. Painter goes out of business. New painter uses the same paint, but has never painted parts for
Ford.
Example C. Tier 2 painter for stabilizer bars is asked to coat brackets on the same paint line.
Example D. Sub frame supplier is switching from standard e-coat to high edge e-coat on their in-house paint
line. Both e-coats are widely used at Ford.
Example E. Control arm supplier is painting the first run of PPAP parts for the new model program on the paint
line that supports current model.
Example F. The level of testing is highly dependant on what is changing. Contact Materials Engineering.
1
Potential use of surrogate data

Note: This specification cannot prove out parts or coatings that involve changes in vehicle environment such as
increased stone chipping or increased temperature. These changes may require vehicle testing, consult
SDS/ARL requirements.

5. SUMMARY OF REVISIONS

2010 05 25
Replaced DV PV test table with recommended test table with examples.
Cyclic corrosion changed from 3 to 4 weeks and 12 to 9 weeks for correlation to R-343.

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