Number: Name: Organic Coating Performance Requirements for DDC, HDEP, MBE, and MTUDD Components and Engines. Source: MATERIALS ENGINEERING, Jeremy Dean Latest Revision Date: 04/01/2007 Previous Revision Date: 5/9/1996 Approved: Sang Soon Koh Approved: Curtis Glowzinski Approved: Chris Ellswood Approved: Rob Rehnlund Approved: Timothy Schafer Approved: Dan Theriault Approved: Joerg Sieverding Approved: Chris Kafura I. Purpose/Scope: This specification addresses the performance and appearance of coatings used for coating incoming engine components and finished engines. It does not address the requirements for applying the paint, EPA concerns, safety and hazard requirements, or the chemical makeup of the paints used. II. Surface Preparation: All engines require washing with a soap that degreases, resists rust and has a residue that is compatible with our paint adhesion requirements. It must be thorough enough to guarantee good adhesion. Parts to be painted that are not on the engine as it is assembled and tested must be clean and free of all oils, dirt, rust and any residue that may also impair adhesion of the paint. Only parts that are delivered pre-masked may by-pass this requirement. The engine is to be masked as directed by engineering. During masking, it is imperative that no dirt, oil or foreign material be introduced to the surfaces that are to be painted. Machined surfaces of incoming components must be masked before coating, unless otherwise directed by Engineering. III. Requirements: The following determines the performance and appearance of the coatings. Different coating categories have different requirements for tests and the values determined by those tests are detailed in the Table 1. Coatings and coated parts must not exhibit visible in-homogeneities including, but not limited to, runs, drips, sags, spots, changes in gloss or pigmentation, etc. Note: Coatings used for evaluation can be submitted by the coating manufacturer, or prepared in-plant under production conditions. Pre-coated parts will be evaluated individually where possible. When coated panels are used for tests, match as many variables as possible be to the end-use process. Variations in coating thickness greater than 0.018 mm (0.7 mil) on panels will not be tested. 1 of 6
Salt Spray: All coatings must be tested against a salt spray as described in ASTM B117 for the proper time period (see Table 1). The coating to be tested must have an X scribed through it to the base material. Evaluate per ASTM D1654. Humidity: All coatings must be tested against humidity as described by ASTM D2247 for the proper time period (table 1). Evaluate per ASTM D1654. Tape adhesion testing (see below) shall be performed after a 10 minute recovery period. Fuel-Oil Resistance: All coatings must be submerged in No. 2 diesel fuel for 24 hours at 25 C (72 F) and exhibit no permanent changes (blistering, bubbling, etc.). Adhesion: Adhesion is to be tested according to ASTM D3359, Method B. Adhesion requirements are listed in the Table 1. Temperature Resistance: All coatings are to be held at 93 C (200 F) for 2 hours and must exhibit no permanent changes (blistering, bubbling, etc.). The coating must resist imprinting by a thumbnail while at this temperature. Freeze/ Thaw Resistance: All coatings must be able to withstand being held at -7 C (20 F) for 24 hours to the humidity chamber as described in ASTM D2247 for 24 hours without permanent changes (blistering, bubbling, etc.). Color Match: Pigmented coatings must match the color chips (or CIE tristimulus values) supplied by DDC with a CIELAB E of less than 1 under the following three standard illuminants (See ASTM E308): Daylight (D65 or D75), Afternoon/Sunset (A) and Cool White Fluorescent (F2, F7 or F11). The CIELAB E is described in ASTM D3134 and its referenced standards. If there is a difference noticeable to the naked eye, the CIELAB E is greater than 1. It is considered acceptable to compare colors with the standards by eye, but in a dispute, the CIELAB E will be measured as the refereeing metric. Gloss: Coatings with a gloss requirement are to meet those described in the table as tested at 60 by the test described in ASTM D523. (The unit for specular gloss is also called degrees, not to be confused with the degrees of an angle.) Hiding Power: Pigmented coatings must obscure the substrate completely at the minimum thickness described in the table. Marks on the substrate that are visible to the naked eye are not obscured. The after-market touch-up paint requirement is designed to force the applicator to achieve a minimum thickness so that corrosion protection is achieved. Full hiding for this paint must not occur before 2 mils of touch-up paint are applied. *Note: In-house touch-up paint will follow the requirements for and be treated as top coat paint. Thickness: Thickness requirements are listed in Table 1. Measurements are taken using a nondestructive device used in accordance with the manufacturer s operating instructions and properly calibrated. Metallographic preparation of a representative cross-section for measurement in a calibrated microscope is also acceptable. Dry Times: Required minimum dry times are listed in Table 1. This specification considers a coating dry when it is ready to accept a new coat (either a second coat or a different paint that is compatible with the dried paint). Cure Times: Required minimum cure times are listed in Table 1. Cured coatings are to be tested by the ASTM D5402 method using the appropriate solvent (listed in Table 1). Five wipes with a lint-free wipe should not change the gloss on the surface of the paint more than 20 degrees (units of gloss) from the original gloss when measured at a 60 angle. A second, empirical measure of cure is the amount of coatings removed by the cloth. Fully cured coatings will not leave any paint on the wiping cloth. 2 of 6
Documentation: Documentation of the following is required for PPAP approval of painted parts: Salt spray tests, Fuel-Oil Resistance, Adhesion, Thickness, Cure Time and MSDS of the coating. No lead, chrome, cadmium, zinc or other toxic materials will be accepted. If the painted part fails one of the other tests listed in the table, the part can be rejected at any time and re-accepted pending the documentation for all the tests. Once a paint system is approved, no aspect may be altered without re-approval. Paints to be applied in-house must have a symbol number (see DDC 90K218) with approvals by Environmental Engineering, Materials Engineering and Purchasing departments. Paints to be applied in-house must meet any and all applicable K-specifications pertinent to the area they will be applied in. Compatibility: All coatings are required to be compatible, and perform adequately with the current coatings that will be applied to them, or they will be applied over. When two coatings are found incompatible, DDC personnel will determine which coating remains accepted. All coatings are required to be compatible and perform adequately with the material that becomes the substrate onto which it is applied. All coatings are required to withstand the cleaners and chemicals that are to be used on the painted surfaces. When cleaners and chemicals are used for this purpose, the compounds will be supplied for tests upon request. Coatings on parts that receive subsequent machining must behave acceptably in those machining operations (coolant compatible, no chipping, peeling, discoloration, softening, etc.). No paint chip generated during machining may be larger than twice the largest dimension of the metal chips generated during machining. Chipping on the edges of machined parts may not extend below 0.25 mm (10 mil) from the machined edge. Coatings will not show any detrimental signs of change when subjected to casting impregnation per DDC spec 91K15. Coatings supplied for application at DDC will be compatible with the equipment and processes used to apply and handle them. The paints shall remain stable with normal handling during their residence in the system used for handling the paints. 3 of 6
Classes of Coatings: The classes of finishes are as follows: A168 Water based coatings typically used to coat fully assembled off-highway engines (and ship loose components). A336 Premium coatings typically used to coat fully assembled marine engines (and ship loose components). C168 Water based coating normally used to coat fully assembled on-highway engines. P101 Normally used for incoming as-cast engine components (non-ecoat). P102 Normally used for incoming smooth parts, tubes, brackets, etc. (non-ecoat). P103 Normally used for incoming components requiring cathodic e-coat. T104 After Market touch-up paints normally used on fully assembled engines. 4 of 6
TEST DESCRIPTION Salt Spray ASTM B117 Humidity ASTM D2247 Fuel Oil Resistance Adhesion ASTM D3359 Temperature Resistance Freeze/Thaw Resistance Color Match ASTM D3134 Gloss ASTM D523 Hiding Power A168 A336 C168 P101 P102 P103 T104 168 hrs Note 1,5 336 hrs Note 1, 3, 4 Note 1, 2,4 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 3B 4B/5B 3B/4B 3B 4B 3B/4B 3B/4B Note 6 Note 6 Note 6 Note 7 Note 7 Note 6 Note 6 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 ΔE <1 ΔE <1 ΔE <1 ΔE <1 ΔE <1 ΔE <1 ΔE <1 > 75 > 90 >75 Note 8 >75 >75 >75 >90 @0.02 mm (0.8 mil) @0.013 (0.5 mil) >0.05 mm (>2.0 mil) Thickness 0.05-0.01mm 0.05-0.01mm 0.025-0.1mm (1-4 mil) 0.05-0.125mm Before packing 0.04-0.10mm (1.5-4 mil) 0.02-0.04mm (0.8-1.5 mil) N/A 0.05-0.01mm 45 min Dry Time 45 min Note 9 45 min 15 min @ 50 C Before packing Cure Time 7 days 7days 7 days Before Before Before 7 days ASTM D5402 Note 10 Note 10 Note 10 Packing packing packing Note 10 Note 10 Note 10 Note 10 *The values listed in this table may be superseded by blueprint requirements when specified.* Notes: 1. No evidence of blistering, bubbling, peeling, softening, discolorization or other permanent changes. 2. Maximum allowable creep back is 3 mm. 3. Maximum allowable creep back is 1 mm. 4. No more than 10% of the surface (exclusive of scribes and exceeding 3 mm of sharp edges). 5. No change in adhesion per ASTM D3359 is permissible. 6. The first number refers to adhesion to an as-cast surface; the second number refers to a machined surface. 7. Adhesion measurements are to be taken on the predominant surface. 8. Gloss of clear coat must be >90. 9. Primer must be able to accept top coat in 15 minutes. 10. An appropriate solvent must be used for the type of coating used. Please contact your paint vendor for suggested solvent. 5 of 6
Record of Change 11/96 Title Changed from Paint Requirements for Series 60 Engine and Components to Pre-Coating of Engine Components and finish Coating After Assembly Necessary changes to accommodate alternative product and coating processes were carried out. 07/98 Revised powder coat application (E-2) Revised characteristics of base coat (G-2, 3 & 7) Revised paint thickness criteria in test panel preparation. (H1) Revised test parameters (H2-3) Revised characteristics of clear coat. (I-1, 2) 07/99 Revised paint thickness criteria in base coat preparation. (F2) Added addition characteristic of base coat. (F3) Revised salt spray (corrosion) (H-2, 3). Revised characteristics of base coat (F-1, 4) Revised Base Coat Designations (E-2) 3/02 Re-written for clarity. Revised to include applicable specifications. Expanded to include Marine applications, e-coat and specific characteristics that have become apparent since the last revision. Title changed to Organic Coatings for Engine Parts and Engines. 4/07 Re-written for clarity. Expanded to include HDEP and MBE 900 applications. Title changed to Organic Coating Performance Requirements for DDC, HDEP, MBE, and MTUDD Components and Engines 6 of 6