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1、 WORLDWIDE ENGINEERING STANDARDS Material Specification Paint GMW3011 Phosphating Generic Qualifications 1 Scope This specification details the general material performance, compatibility, and processing information requirements for international corporate approval of zinc phosphate conversion coati
2、ngs. 1.1 Material Description. Materials qualified to this standard shall meet the performance shown in Table 1. Additional testing and any exceptions to the requirements detailed herein are noted in the appendix. Suppliers must demonstrate the technology as being production capable to reduce undue
3、risk prior to release in a production facility. Any material development issues, such as chemical or performance values that fall outside of specified ranges, must be discussed with the appropriate material engineer for resolution. Material must successfully complete a production trial in a target f
4、acility prior to release for other facilities. 1.2 Typical Applications This specification applies to zinc phosphate conversion coating materials that are intended for use on automotive vehicles and space frames. These coatings must provide a crystalline, corrosion resistant, paint adhesion promotin
5、g surface to bare Cold Rolled Steel (CRS), Electrogalvanized coated steel (EG), Zinc-Nickel coated steel (ZnNi), Hot Dip Galvanized coated steel (HDG), Galvannealed (Zinc-Iron-Alloy - ZnFe) and Aluminum substrates (Al). 1.3 Remarks. In the event of any conflict between the English and domestic langu
6、age regarding this document, the English language will take precedence. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM B117 DIN 50942 2.2 GM Standards/Specifications. 9984032 GM9733P 9984090 GME R-0-6 GM438
7、9M GME 60268 GM4466P GME 60401 GM6185M GME 60411 GM6201M GMN3824TP GM9071P GMW2 GM9102P GMW8 GM9163P GMW11 GM9508P GMW3001 GM9540P GMW3059 GM9613P 2.3 Additional References. G.M. Paint Facility Process Specifications Surface Coatings Process Control Relationships Manual ITDC Process Specifications 3
8、 Requirements 3.1 Chemical Fingerprint. GM may conduct analyses of the materials supplied to this specification. Analyses may also be performed on representative panels. The analyses established for initial approval shall constitute a reference standard and shall be part of the submission package. I
9、nformation on the technologys ingredient formulation ranges and key manufacturing control characteristics must be provided as part of the submission package. If a product change is proposed that is outside the technology formulation limits, the responsible engineer must be notified. All ingredient r
10、anges, key manufacturing control limits, and certificate of analysis ranges must pass standard gage repeatability & reproducibility study. Copyright 2003 General Motors Corporation All Rights Reserved December 2003 Originating Department: North American Engineering Standards Page 1 of 5 GMW3011 GM W
11、ORLDWIDE ENGINEERING STANDARDS Copyright 2003 General Motors Corporation All Rights Reserved Page 2 of 5 December 2003 3.1.3 Delivery Documentation. The supplier shall be responsible for submitting a certificate of analysis with each batch of material arriving at a plant. This document shall be prep
12、ared and provide data in accordance with the requirements detailed in GM 4389M. 3.1.4 Physical Requirements 3.1.4.1 Product Information. The engineer responsible for technical qualification shall be contacted prior to test initiation. A product data sheet, product composition and all related product
13、 processing information must be submitted for review at that time. 3.1.4.2 Mini-Submissions. Some approvals will require mini submissions when only minor changes are made to previously approved phosphate materials. Tests may be added or deleted according to the type and amount of material modificati
14、ons. These shall be determined prior to testing by agreement between the supplier and responsible engineers. 3.1.4.3 Panel Preparation. The specific number and substrate combinations to be evaluated are shown in Table 1. A maximum profilometer roughness of 0.8 to 1.6 microns is allowed on the test s
15、ubstrates. Initial test panel roughness must be recorded prior to any coating applications. 3.1.4.4 Test Substrates. Table 1 outlines the test substrates and durability requirements. Following are the requirements for the test panels: Thickness: 0.75 to 0.90 mm Materials: Cold Rolled Steel (CRS) Ele
16、ctrogalvanized Steel (EG) Zinc-Nickel (ZnNi) Hot Dip Galvanized Steel (HDG) Galvannealed (Zinc-Iron-Alloy - ZnFe) Aluminium (Al) Type Old New CRS SAE 1008 or ST 1405 GMW-2-M-STS EG GM6201M or QS 1010ZZ GMW11-M-STS ZnNi QS 101ZN GMW11-M-STS HDG GM6185M GMW8-M-STS ZnFe GM6185M GMW8-M-STS Al AA6111 AA6
17、1111 Al AA6016 AA6016 Other aluminum alloys such as AA 5754, AA 5182, AA 5083 and/or others may be requested for testing as needed. These alloys should be included as part of the plant specific testing. 3.1.4.5 Sample Size. The number of samples for each test shall be 3, unless the responsible engin
18、eer and the supplier agree on a different number for specific tests, prior to the start of testing. All substrates, pretreatments, and coating layers shall be fully identified with source, product code, batch number, bake description and film build. 3.1.4.6 Conditioning. When testing over fully laye
19、red panels, the samples shall be subject to an aging period of at least 72 h at room temperature following the bake cycle. 3.1.4.7 Storage Requirements. The materials approved to this specification must be stable for 360 days, at () +5 to +35 degrees C, as defined by the ability to pass all initial
20、test requirements after 360 days storage in the application facility (i.e. assembly plant). If there is any disagreement with these requirements the supplier must contact the responsible engineer. 3.2 Physical Requirements 3.2.1 Appearance. Upon visual inspection (without magnification), the phospha
21、te coating on samples shall be smooth and uniform prior to the application of subsequent layers. 3.2.2 Phosphate Crystal Size. The phosphate crystal morphology shall exhibit a maximum, predominant, crystal size of 25 microns. Voids or streaking are not permitted. However, primary body and body metal
22、 components are to target crystal sizes in the range of 2 to 10 microns. -,-,- GM WORLDWIDE ENGINEERING STANDARDS GMW3011 Copyright 2003 General Motors Corporation All Rights Reserved Page 3 of 5 December 2003 3.2.3 Phosphate Coating Weight The phosphate coating weight is to be determined using GM97
23、33P or EN ISO 3892 and DIN 50942. These coating weight requirements are substrate dependent and must comply with the limits shown in the following table. Substrate Coating g / m2 Coating mg / ft2 Cold Rolled Steel 2.0 - 5.0 180 - 460 Electrogalvanized 1.5 - 5.0 140 - 460 Zinc Nickel 1.5 - 5.0 140 -
24、460 Hot Dip Galvanized 1.5 - 5.0 140 - 460 Galvannealed 1.5 - 5.0 140 - 460 Aluminum 1.5 - 4.0 140- 370 Road Test Options Testing can be performed on test panels that are attached to the exterior of a vehicle on Road Schedule, or on full vehicles processed with the phosphate material being qualified
25、. The decision regarding panel or full vehicle testing shall be agreed upon by the responsible engineer and the supplier prior to initial testing. Option 1: Road testing can be performed at the Milford Proving Ground, Milford MI., USA, 5 phases (test years) are to be achieved by running (5) GMN3824T
26、P Road Schedules. Option 2:The European equivalent Proving Ground road test can be performed at the Dudenhofen Test Centre Facilities, Germany: Road Schedule GME R- 0-6, 40 cycles If full durability vehicle testing is done, perforation corrosion life estimates should be made following the cosmetic c
27、orrosion cycle testing (reference for option 1 and 2). 3.2.4 Additional Requirements 3.2.4.1 Passivation Material. All test panels have to be prepared with an approved non-chrome passivation material. The responsible engineer and the supplier shall agree upon the selection of the passivation materia
28、l. 3.2.4.2 Panel Preparation. The decision regarding the required paint system of the panels (Elpo, Primer, Topcoat) shall be agreed upon the responsible engineer and the supplier prior to initial testing. 3.3 Performance Requirements 3.3.1 Accelerated Corrosion Testing. Proving Ground Road and Lab
29、Tests must be performed to achieve the equivalent of 5 years of cosmetic corrosion exposure minimum. Creep is to be evaluated using GM 9102P (max. peak to max. peak) Lab testing to meet the requirements for GM 9540P, 40 cycles. 3.3.2 Outdoor Exposure Testing Prior to Outdoor exposure testing, Initia
30、l Tape Adhesion per GM 9071P- Method A or GME 60401 must be performed Outdoor exposure testing is to be performed per GM 9163P or GME 60411 requirements. Results to be evaluated after six months (visual only) and one year of exposure. Creep back shall be measured zero to max. peak on the left side o
31、f the scribe, plus zero to max. peak right side of the scribe.“ Record in total mm of creep (Reference GM 9102P). After exposure, panels shall undergo deionized water immersion (GM 4466P) for 72 h 55 C, or GME 60410 for 48 h 63 C followed by tape adhesion test GM 9071P, Method A or GME 60401. The re
32、sponsible engineer and supplier must agree upon the specific details of this requirement prior to the initiation of testing. 3.3.3 Physical Requirements 3.3.3.1 Chip Resistance. Two methods of chip resistance are to be performed: GM 9508P, Method A and GME 60268 B/C. The results must meet the specif
33、ied requirements shown in Table 1, and be at least equivalent to the control 4 Manufacturing Process Not applicable. 5 Rules and Regulations 5.1 All materials supplied to this specification must comply with the requirements of GMW3001, Rules and Regulations for Material Specifications. 5.2 All mater
34、ials supplied to this specification must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts. 5.3 Legal Regulations. For use of this material, the valid laws and other regulations and -,-,- GMW3011 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2003 General Motors C
35、orporation All Rights Reserved Page 4 of 5 December 2003 recommendations in the country of usage must be followed. 5.4 Inspection and Rejection. All shipments of materials or parts under contract or purchase order manufactured to this specification shall be equivalent in every respect to the initial
36、 samples approved by engineering. There shall be no changes in formulation or manufacturing process permitted without prior notification and approval by engineering. Lack of notification by the supplier constitutes grounds for rejection of any shipment. While samples may be taken from incoming shipm
37、ents and checked for conformance to this specification, the supplier shall accept the responsibility for incoming shipments meeting this specification without dependence upon purchasers inspection. 5.5 Initial Source Approval. No shipments shall be made by any supplier, until representative producti
38、on samples have been approved by Materials Engineering as meeting the requirements of this specification. Refer to GM Supplier Development General PPAP Procedure for the method used to determine the materials / manufacturing Key Control Characteristics (KCCs). 5.6. Safety Data Sheets. A completed co
39、py of the Safety Data Sheet must be submitted with any new shipment or when composition changes in Safety Data Sheets have occurred. 6 Approved Sources Engineering qualification of an approved source is required for this specification. Only sources listed in the GM Materials File (i.e., MATSPC) unde
40、r this specification number have been qualified by engineering as meeting the requirements of this specification for use in North America. For other GM locations, the responsible engineering group should be contacted to obtain the approved source in that individual country. 7 Coding System This mate
41、rial specification shall be referenced in other documents, drawings, VTS, CTS, etc. as follows: Material per GMW3011 8 Release and Revisions 8.1 Release. This material specification originated as a draft by NAO Paint and Opel ITDC ME Paint in November 1996 8.2 Revision. Rev Approval Date Description
42、 (Organization) A FEB 2003 Complete revision and reformat. (NAO Paint, ITDC ME Paint, GMVO Paint and Polymers, GM Brazil, GM Holden, Isuzu Motors Ltd) -,-,- GM WORLDWIDE ENGINEERING STANDARDS GMW3011 Copyright 2003 General Motors Corporation All Rights Reserved Page 5 of 6 December 2003 Table 1: Req
43、uired Testing and Performance Test Requirement Miscellaneous Items Initial Tape Adhesion GM 9071P or GME 60401 Adhesion: 95% or GT 1 max. See B below Accelerated Corrosion: GM 9540P, 40 cycles CRS 6 mm max. EG, ZnNi, HDG, ZnFe & Al: 3 mm max. See A & B below Outdoor Exposure: GM 9163P or GME 60411 A
44、dhesion: GM 9071P or GME 60401 after DI Water Immersion GM 4466P or GME 60410 Corrosion: Equivalent or better than the control. CRS 6 mm max. EG, ZnNi, HDG, ZnFe & Al: 3 mm max. Adhesion: 95% or GT 1 max. See B below Water Immersion: GM 4466P: 72 h 55 C GME 60410: 48 h 63 C Chip Resistance: GM 9508P
45、, Method A and GME 60268 B/C GM9508P: 6 Rating Minimum GME 60268: 8 Rating Minimum See A & C below See C below Proving Grounds: NAO R-15-116 (GMN3824TP) or GME R-0-6 CRS 6 mm max. EG, ZnNi, HDG, ZnFe & Al: 3 mm max. (All equivalent to or better than the control) See A & B below Note 1: An equivalent
46、 number of control panels are to be run for each designated test. A: Test 3 phosphate & Elpo coated only panels using CRS, EG, HDG, Al, ZnNi, ZnFe & Al substrates. B: Test 3 fully layered panels using CRS, EG, HDG, Al, ZnNi & ZnFe (white only). C: Test 3 fully layered panels using CRS, EG, HDG, Al,
47、ZnNi & ZnFe x 3 colors (white, red & black). Note 2: Panel types and associated layering systems have been chosen with the intent to simulate the actual field use of each particular substrate. GMW3011 GM WORLDWIDE ENGINEERING STANDARDS Appendix A Items shown in this appendix will be included in the specification during the next full update. They are to be included, at this time, in any generic approval testing. Copyright 2003 General Motors Corporation All Rights Reserved Page 6 of 6 December 2003 -,-,-
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