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1、m 9006379 0004564 284 GENERAL MOTORS ENGINEERING STANDARDS I Materials and Processes - Paint I FORMABLE AUTOMOTIVE COATING - EXTERIOR 9984145 1 SCOPE. This specification covers the performance and qualification requirements for a decorative, adhesive backed film which can be vacuum formed over vario
2、us plastic or metallic substrates. The film is suitable for use on exterior automotive body panels and parts. The composite film consists of a plastic carrier film suitably primed or treated to accept a decorative topcoat on the face and adhesive on the back. After forming, the finished part must me
3、et Corporate goals for appearance and durability. Unless specifically tested and qualified for use on flexible substrates, the film is intended for use on rigid or semirigid substrates only. The film, before and after forming and bonding, must meet all the requirements of GM4367M unless otherwise in
4、dicated. 2 REFERENCED STANDARDS. GM4348M GM907 IP GM43SOM GM95OOP GM4364M GM9501P GM4367M GM9508P GM4465P GM9534P GM4466P GM9799P ASTM D903 ASTM D1186 ASTM D1308 ASTM D3359 3 REQUIREMENTS. 3.1 Material Requirements. The following requiremmts refer to the laminate material itself, prior to any formin
5、g and bonding operations to produce the finished part. operations to produce the finished part. 3.1.1 Shipment And Storage. The laminate shall be shipped in rolls or flat sheets with a protective liner on the adhesive side. The material shall be free of any dirt or contaminants which would affect fi
6、nished part quality and must be suitably protected from contamination during shipment. The supplier must establish shelf life limitations and storage requirements including, but not limited to, time, temperature, relative humidity and storage techniques. 3.1.2 Appearance. The appearance rquiremmts f
7、or the unformed material which are necessary to meet finished part appearance specifications shall be determined during work- ability trials and made part of this material specification. 3.1.3 Thickness. The nominal thickness of each layer of the laminate shall be established during qualification an
8、d held within commercial tolerance on subsequent lots. All perfor- mance requirements must be met within this thickness range. 3.1.4 Ultraviolet Transmission (GM9534P). The laminate, at the maximum strain level designated in 3.2.3, must be opaque to UV transmission to the underlying part. Opacity is
9、 defined as 0% transmission at a wavelength of 350 nm. In addition, the top layer of the laminate must be sufficimtly opaque to prevmt any deterioration of underlying layers of the laminate. 3.1.5 Odor And Smoke Characteristics (GM9799P). Initial- ly and during processing the material must not emit
10、noxious odors or smoke. The supplier must provide information regarding any special ventilation requirements while process- ing. 3.2 Performance Requirements. These requirements shall be met on all surfaces of the part designated to be covered with the formable laminate. The finished product must ma
11、intain the same test performance and durability levels established during qualification testing. Except where specifically indicat- ed, the face coating surface of the laminate shall meet all the performance requirements set forth in GM4367M. For quali- fication and quality control, some performance
12、 requirements may be measured on the unformed laminate, either free or bonded to a flat test substrate. Full qualification requires testing of laminate which has been thermoformed to agreed strain levels and bonded to a represmtative test substrate. The maximum strain capability of the laminate shal
13、l be deter- mined at qualification and will be used to establish part design standards. The thetmoformed laminate must meet all performance requirements when tested as a component of the finished part. Once qualified, routine testing of film or parts may be covered by GM43SOM. 3.2.1 Qualification. P
14、rior to production use, the material shall have been previously tested and qualified as capable of meeting all the performance qualities specified herein. Docu- mentation covering all performance properties and test results must be provided in a form acceptable to the General Motors Engineering acti
15、vity to which the material has been submit- ted. General qualification procedures are described below and testing shall be per test methods indicated. After qualification no significant changes which might affect finished perfor- mance may be made to the material without notification and assessment
16、to determine if additional testing is required. Initial qualification testing is performed using colors which represent the typical range of pigment loading. After technol- ogy qualification, all additional colors must be tested per Annual Color Test Program requirements. 3.2.1-l General. The Engine
17、ering Group responsible for coordinating the material development must always be con- tacted prior to the preparation of panels and initiation of tests to determine the exact test program requirements. All data submitted by the vendor must be dated and signed by an authorized representative stating
18、that testing was done in accordance with this specification. 3.2.1.2 Test Panel Preparation. Testing of the laminate technology will be conducted with a minimum of white nonmetallic and light blue metallic colors. Additional colors, the substrate and its cleaning and pretreatment, and the need for r
19、eplicate samples to be tested will be agreed upon prior to the start of testing. All substrates, pretreatments, primers and laminates must be fully identified as to source, product code and batch numbers. 3.2.1.2.1 Testing may be conducted on the free, unformed and unbonded laminate (FREE), unformed
20、 laminate bonded to a flat test substrate (BOND), or thermoformed laminate MARCH 1990 PAGE 1 9984145 Copyright General Motors North America Provided by IHS under license with GM Licensee=IHS Employees/1111111001, User=Japan, IHS Not for Resale, 06/23/2008 22:53:45 MDTNo reproduction or networking pe
21、rmitted without license from IHS -,-,- m 900b379 0004565 IILO 1 GENERAL MOTORS ENGINEERING STANDARDS 1 Materials and Processes - Paint 1 FORMABLE AUTOMOTIVE COATING - EXTERIOR 9984145 bonded to the test substrate (FORM). Unless specifically indicated, all requiremmts must be met with formed and bond
22、ed laminate (FORM). However, initial screen testing should always be performed on the unformed laminate to determine if the laminate layers themselves are capable of withstanding the environmental test conditions. 3.2.1.2.2 The nominal thermoforming temperature and cycle time that the laminate will
23、be at elevated temperature shall be established prior to preparing test panels. Panels must then be prepared within the nominal minimum operating window as follows: Normal (N) - Nominal temperature and cycle time. High heat (H) - Nominal temperature plus 14 C at twice the nominal cycle time. Low hea
24、t (L) - Nominal temperature less 14C at the nominal cycle time. 3.2.1.2.3 For qualification, the thermoforming time and temperature conditions to be tested for each product require- ment below are indicated. If no condition is indicated, normal temperature and time is assumed. Qualification test pan
25、els shall be made of the designated substrate, approximately 100 x 300 mm in size. The laminate shall be thermofotmed and bonded to the panel in a mold designed to give a strain gradient for the laminate of essentially zero at one end of the panel to the maximum designated strain at the other end. E
26、dges should be trimmed flush using anticipated production methods. Unless otherwise indicated for specific tests, three 50 mm cuts perpendicular to the strain gradient line shall be made with a sharp razor, through the laminate to the substrate at points representing 25, SO and 75% of the maximum st
27、rain. 3.2.2 Appearance (N) (H) (L). The laminate, after forming and bonding shall be smooth and uniform, and free of any defects detrimental to appearance or durability. The finished surface must meet all the requirements set forth in GM4364M. Coatings Surface Appearance Specifications and GM4348M.
28、Appearance Specifications For Applied Parts. Color shall be per approved Master Standards. Hiding shall be such that there is no discernible difference between areas of maximum and minimum strain. Ability to meet these specifi- cations shall be determined during processibihty and produc- tion trials
29、. 3.2.3 Film Thickness (ASTM D1186). During qualification, the maximum strain at which the laminate meets all perfor- mance rquiremmts is established. The resulting thickness of each layer after forming to the maximum strain shall be determined and becomes the minimum thickness require- ments on fin
30、ished parts. 3.2.4 Hardness, Mar Resistance and Adequacy of Cure (N) (H) (L). Mar resistance shall be at least equivalent to currently approved materials. The absolute hardness value is specific to each material and color and is secondary to toughness as a measure of mar resistance and polishability
31、. The supplier must provide the expected hardness for each color prior to the start of production. 3.2.5 Adhesion (N) (Ii) (L). Initially, and following environ- mental exposure where indicated, adhesion of each layer to other layers of the laminate and adhesion of the laminate to properly cleaned a
32、nd prepared substrates shall meet the following requirements. There must be no lifting and creep- back at edges. Scribes for tape adhesion shall be cut through to at least the adhesive layer. Cuts for peel adhesion must be to substra:e. 3.2.5.1 Cross Cut (X-Scribe) Tape Adhesion (GM9071P). Minimum 9
33、 rating per pictorial standards. 3.2.5.2 Cross Hatch Tape Adhesion (ASDM D3359). Mini- mum 99% adhesion. 3.2.5.3 180” Peel Adhesion (laminate to substrate) (ASTM D903). Minimum 13 N/cm. 3.2.6 Moisture Resistance (N) (H) (L). There shall be no color change, blistering, milking or other change in appe
34、ar- ance after exposure to the tests below (maximum 10 minutes recovery). There shall be no discernible opening of the cuts made perpendicular to the strain line. Adhesion shall be per 3.25. 3.2.6.1 Condmsing humidity (GM4465P) shall be 96 h at 100% RH, 38 C. 3.2.6.2 Water immersion (GM4466P) shall
35、be 96 h. 3.2.7 Gravelometer (GM9508P, Method A) (N) (I-I) (L) shall have a minimum rating of 7. 3.2.8 Fuel Resistance (N) (L). During the exposure tests below, there shall be no color change, loss of adhesion, crazing, softening or other detrimental efIect. There should be no significant opening of
36、the cuts made perpendicular to the strain line or lifting at any edge. Peel adhesion shall be per 3.2.5.3. Tests shall be performed using synthetic gasoline (45% toluol, 55% naphtha) and synthetic gasohol (40% toluol. 50% naphtha, 10% ethanol). 3.2.8.1 Immersion test (ASTM D1308) shall be 4 cycles o
37、f 2 minutes rmmerston and 24 h dry off, followed by 96 h humidity exposure per 3.2.6. 3.2.8.2 Dip test (GM9SOlP) shall be 25 cycles of 10s immersion and 20 s dry off at room temperature. Film should also be evaluated at 10 and 20 cycles. 3.2.8.3 Puddle Test (GM9SOOP). 3.2.9 Repairability. Unless oth
38、erwise indicated for specific applications, a repair system must be provided for the coating 9984145 PAGE 2 MARCH 1990 Copyright General Motors North America Provided by IHS under license with GM Licensee=IHS Employees/1111111001, User=Japan, IHS Not for Resale, 06/23/2008 22:53:45 MDTNo reproductio
39、n or networking permitted without license from IHS -,-,- GENERAL MOTORS ENGINEERING STANDARDS I Materials and Processes - Paint I FORMABLE AUTOMOTIVE COATING - EXTERIOR 9984145 and tested and qualified concurrently with the coating qualification. The repair system shall meet all the perfor- mance re
40、quirements of the original coating. Procedures for use of in-plant and field repair systems must be provided. The repair system may be evaluated alone for durability but it must also be evaluated in actual repairs with the formabie coating for appearance and durability. . 32.10 Heat Age (N) (L) (H).
41、 Following exposure to the elevated temperature tests below, there shall be no change in appearance, shrinkage, softening, lifting at edges or other deleterious effects. There shall be no significant enlargement or appearance change in the cuts made perpendicular to the strain line. There shall be n
42、o reduction in adhesion, tested per 3.2.5, or embrittlement, tested per 3.2.7. 3.2.10.1 250 h at 80 C. 3.2.10.2 30 minutes at 93 C. 3.3 Processability Requirements. The coating must be capa- ble of being bonded to applicable substrates by vacuum forming under processing conditions available in Gener
43、al Motors plants, yielding a finished part which meets ail performance requirements herein. Basic production bonding feasibility must be established as part of material qualifica- tion. The following processing information will be used to establish equipment requirements and process controls. The su
44、pplier must provide recommendations for optimun vacuum forming temperature, limits for time at forming temperature and maximum strain (elongation) limits. Charts must be provided showing the relationship of these process variables to each appearance and durability requirement herein. A composite of
45、all such charts shall be used to define the operating window for processing the formable coating. Any precautions for material storage, handling or limits for processing must be provided. 3.4 Production qualification And Plant Tryout. After com- pletion of basic durability testing and determination
46、of optimum process parameters, production feasibility will be established by processing parts under actual plant conditions. Additional colors may also need to be tested for workability at this point. Materials meeting all appearance, durability and processability requirements may be placed on the C
47、orporate approved source list for this specification. However, the coating is part of the total pan construction and must be evaluated for compatibility with other associated materials and the plant process. Approved materials are thus not interchangeable until compatibility is proven. Additional du
48、rability screening may be required if plant conditions vary significantly from qualification test conditions. The following are typical plant materials and processes which must be evaluated: primers, other decorative coatings, plant specific plastic substrates and primers, underbody deadeners and pl
49、ant specific adhesive systems. The specific plant process and finished part must be evaluated for MVSS glass bonding requirements if fixed glass is to be bonded to the formable coating. 4 INITIAL SOURCE APPROVAL. No shipment shall be made by any supplier until representative initial production samples have been approved by engineering as meeting the requirements of this specification. 4.1 Completed copies of the GM Material Safety Data Sheet and Critical Materials Register (available from the engineer- ing depa