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Chrysler Group LLC Document Number: MS-PB-60-2 Material Standard Date Published: 2009-10-01 Category Code: G-2 Change Level: M EASL Requirement: Yes
Restricted: No
PAINT – PRIMER - CATHODIC EPOXY ELECTROCOAT – COMPONENTS***
1.0 GENERAL
1.1 Purpose
This standard presents the requirements of a cathodic epoxy electrocoat for use on steel, coated steel, aluminum, magnesium and zinc components. Examples of such components are chassis components, engine cradles, frames, or interior/exterior metallic add-on components. These components may have zinc or zinc-iron alloy metallic coatings. This material when applied in accordance with PS-7232 is suitable as a finish coat on chassis parts where ultraviolet light (UV) durability/stability is not required. This finish can also be used in a multi-layer system (i.e. electrocoat with powder topcoat) when corrosion resistance and UV stability or other performance characteristics are required. Approved multi-layer systems can found in the Engineering Approved Source List (EASL) of MS-PZ-1-1, MS-PZ-2-1, MS-PZ-3-1, MS-PZ-4-1, or MS-PZ-5-1. Processing requirements, including film build, can be found PS-7232.
1.2 Coverage of this Standard
A. This standard covers the requirements of cathodic epoxy electrocoats, as specified in this standard, for
use in accordance with PS-7232. Pretreatment shall be according to PS-508. Depending on the part configuration and extent of welding, the pretreatment may include an acid pickle step after the cleaning stages to remove weld smut and to adequately clean both interior and exterior surfaces of Cold Rolled Steel (CRS) and Hot Rolled Steel (HRS) assemblies. For a determination of when acid pickling is required refer to PS-508. An acid pickle cannot be used with aluminum, magnesium, galvanized, galvanneal, or any zinc coated metal.
B. This standard also covers the requirements of high edge coverage, cathodic epoxy electrocoats, as
specified in this standard, for use in accordance with PS-7232. Pretreatment shall be according to PS-508. Approved standard and high edge coverage electrocoats are listed in the attached EASL. When designating the type of electrocoat on a part print, standard or high edge should be specified (i.e.
standard electrocoat, MS-PB-60-2S or high edge electrocoat, MS-PB-60-2H).
Suppliers must also meet PF-7051, “PART SUPPLIER – PAINT CONTINUOUS CONFORMANCE TEST REQUIREMENTS – INCLUDING PPAP AND PSO”. Significant material or process changes must follow the Chrysler Forever Requirements outlined in PF-7051.
NOTE: As of July 1, 2002 coatings containing lead, and as of January 1, 2007 coatings containing hexavalent chrome will no longer be available for purchase. Coatings containing these chemicals will be removed from the Approved Source List of this standard at these times. This is to comply with the European End-of-Life Scrap Vehicle Directive.
2.0 MATERIAL CHARACTERISTICS
The supplier is given latitude in the selection of raw materials and processes of manufacture, provided the product meets all the requirements listed in Section 2.0, 3.0 and 4.0 of this standard. Products approved as high edge electrocoats must also meet the requirements listed in Section 5.0 of this standard.
Reference the approved supplier's product data sheets for the characteristics of the electrocoat bath components (resin/emulsion and pigment paste), including: weight % non-volatile (WNV), volume % non-volatile (VNV), weight per gallon (WPG), viscosity, pH, pigment/binder ratio (P/B), conductivity, and volatile organic content (VOC) for each material. Additional material characteristics are listed in Table 1.
TABLE 1: MATERIAL CHARACTERISTICS REQUIREMENTS
TEST METHOD REQUIREMENTS
Shelf Stability ASTM-D-1200 The maximum permissible increase in viscosity of the wet
sample is 15 seconds unless otherwise specified.
Oven Stability ASTM-D-1200 16h@140 F. No hard settling and maximum permissible
increase in viscosity of the wet sample is 15 seconds unless
otherwise specified.
Grind Fineness Fineness of pigment paste as measured on the Hegman
Fineness of Grind Gauge North Standard, shall be 7.0 or
less unless otherwise specified.
3.0 OPERATING PERFORMANCE (Bath Characteristics)
Reference the approved supplier's operational manuals for the characteristics of the electrocoat bath, including: weight % non-volatile (WNV), volume % non-volatile (VNV), pH, pigment/binder ratio (P/B), conductivity, maximum operating temperature, recommended feed ratio and volatile organic content (VOC). The bath material, when used at the recommended parameters, shall meet the requirements listed in Table 2.
TABLE 2: OPERATING PERFORMANCE REQUIREMENTS
TEST REQUIREMENTS
Bath Stability The material, after use in an operational tank for three months, shall exhibit
appearance and performance characteristics comparable to the original material fill. Throw Power The material shall exhibit throw power equivalent to or better than the currently
supplied material or the Chrysler Laboratory Standard.
Crater Resistance The material shall exhibit crater resistance equivalent to the Chrysler Laboratory Standard as measured by both soak and coat and sandwich testing with all relevant
mill oils, drawing compounds, and fogging oils. A description of these tests is
outlined in Chrysler Laboratory Procedures LP-463CB-12-02 and LP-463CB-12-04. Cure Curve A cure curve shall be established using solvent resistance as the performance
criteria on cold rolled steel, including 10 through 20 minutes metal temperatures. Bath Performance The following attributes shall be determined and should meet the existing standard for each supplier, as agreed to by Chrysler Engineering:
- Columbic Yield
- Rupture Voltage
- Horizontal Settling
- UF Requirements (to maintain specified conductivity)
- UF Flux Rate
- Pinholing Tendency
- Odor
4.0 PERFORMANCE REQUIREMENTS OF THE MATERIAL
The criteria for acceptable performance shall be as stated in Table 3. The Chrysler Laboratory Standard is defined as any currently approved material on the applicable EASL. Test panels of Cold Rolled Steel, Hot Rolled Steel, Galvanized, Galvanneal, and Aluminum substrates prepared in accordance with this
standard (electrocoat only unless otherwise specified) and PS-7232 shall be subjected to the tests listed in Table 3. The criteria for acceptable performance, for chassis and underhood applications, shall be as defined in MS-PZ-3-1.
4.1 Test Panel Preparation
A. Unless otherwise specified, test panels measuring 100 X 300 mm (4 X 12 in.) shall be used. The
panels shall be chemically surface treated in accordance with PS-508.
B. Electrocoat panels per Chrysler Laboratory Procedure LP-463PB-21-01 to a dry film thickness of 15.0
– 20.0 µm (0.6 – 0.8 mil.). The panels shall be cured for 20 minutes at 177 C (350 F), or as
recommended by the electrocoat supplier. If parts are being used for testing, film build requirements can be found in PS-7232.
4.2 Testing
TABLE 3: PERFORMANCE TESTS
TEST
METHOD REQUIREMENTS
Smoothness/Appearance
Profilometer, Rank Taylor Hobson Surtronic 3profilometer or equivalent
Smoothness of the electrocoat surface should be 12 µ-inches or less. Initial Adhesion ASTM-D-3359-A. No less than 4A. Humidity ASTM-D-1735, ASTM-D-3359-B, 240 hours. Cut 250 mm (10 in.) long X-scribe in panel before test, and tape
pull per ASTM-D-3359-A, adhesion rating no less than 4A.
Cycle Crack – Method IV LP-463PB-22-01 for 15 cycles, Method IV. The panels shall exhibit no cracking, blistering, loss of adhesion, or
other detrimental effect.
Deionized Water Soak Tape pull per ASTM-D-3359-B, 240 hours.
The panels shall be cross hatched in a 10 x 10 grid pattern, tape
pulled and immersed in Deionized water, at 60 C (140 F). Panels
shall be removed, blotted dry, and tape pulled. An additional 10 x 10 grid shall be scribed in an adjacent area and tape pulled. The test panels shall exhibit no blistering, loss of adhesion, or
delamination in excess of Chrysler Laboratory Standard panels. Solvent Wipe
LP-463PB-31-01, Method J, MIBK and Acetone, 20 Double Rubs
There shall be no marring, whitening, or loss of gloss. There also shall be no softening or resistance to the rubbing which would indicate lack of cure.
Fluid Resistance
LP-463PB-31-01
Gasoline (MS-7621) – Method B-24 hours, Ethanol – Method B-24 hours, Antifreeze ( MS-9769) – Method A-24 hours, Motor Oil (MS-10797) – Method A-24 hours,888
Transmission Fluid (MS-9602) – Method A-24 hours, Brake Fluid (MS-4574<S>) – Method B-2 hours. After wiping the fluid from the panel, the coating shall exhibit no loss of adhesion, softening, swelling, blistering or other detrimental effects.
Salt Spray
ASTM-B-117,
240 and 360 hours (CRS only).
No loss of adhesion or blistering. Scribe creep ≤ 4 mm (total scribe width, average of 5 readings/scribe)
TEST METHOD REQUIREMENTS
Heat Resistance ASTM B117, 1000 hours Coat panels to a minimum film build per paragraph 4.1B. Scribe
panels with two 220-mm (8 in.) lines in the shape of an X. Place
into a room temperature oven and heat to 204 C (400 F). Let
panels stand at temperature for 48 hours then quench in ice water.
Expose in salt spray for 1000 hours per ASTM B-117. No loss of
adhesion or blistering. Scribe creep ≤ 4 mm (total scribe width,
average of 5 readings/scribe).
Salt Water Soak 240 hours in 5% solution of
sodium chloride in water at 60
degrees C (140 F). After removal from immersion the panels shall be blotted dry and tape pulled per ASTM-D-3359-B. Panels shall exhibit no blistering, loss of adhesion, or delamination in excess of the Chrysler Laboratory Standard.
Cyclic Corrosion Panel sets cured at standard
20 minute electrocoat cure, 14
degrees C (25 degrees F) over
and under the standard cure,
topcoat, then subjected to
testing per SAE-J-2334. Panels from all three sets must comply with the requirements of CS-CORROSION. Acceptable appearance is required after 60 cycles (5 year equivalent) and functionality is required after 120 cycles (10 year equivalent).
Cyclic Corrosion – Low Film Build Panel sets cured at standard
20 minute electrocoat cure, 14
degrees C (25 degrees F) over
and under the standard cure,
topcoat, then subjected to
testing per SAE-J-2334
Cold and hot rolled steel test panels shall be prepared at 10.0 µm
(0.0004 in.) of electrocoat film build. Panels from all three sets
must comply with the requirements of CS-CORROSION.
Acceptable appearance is required after 60 cycles (5 year
equivalent) and functionality is required after 120 cycles (10 year
equivalent).Scribe creep ≤ 7 mm for CRS (total scribe width,
average of 5 readings/scribe).
Protective Throw Power SAE-J-2334, 60 cycles Test panels that have been subjected throw power testing shall be
subjected to 60 cycles of SAE-J-2334. The height of corrosion
protection provided by the electrocoat versus initial throw power on
the interior surface shall meet or exceed the Chrysler Laboratory
Standard.
Volvo Corrosion Topcoated, scribed test panels
shall be exposed to climate
conditions in South Florida at
an angle of 45 degrees. The
exposure shall be 6, 12 and 18
months unless otherwise
specified. The panels shall be
sprayed with a 5% sodium
chloride in water solution, twice
a week. Scribe creep ≤ 4 mm for zinc coated substrates and aluminum, ≤12 mm for CRS (total scribe width, average of 5 readings/scribe).
Shot Resistance SAE-J-400, 90 degree angle of
impact at ambient temperature Test panels shall be exposed to 1200 cc (2.5 pints) of shot impingement at 0.34 MPa (50 psi) and) .48 MPa (70 psi) at opposite ends. The shot shall be SAE standard cast shot, size S-780. Finished panels (ecoat only and with topcoat) must have a rating of 7 or better (Table 4).
Gravelometer SAE-J-400, 45 and 90 degree
angles of impact, Frozen and
Ambient. Finished panels (ecoat only and with topcoat) must have a rating of 7 or better (Table 4) when impacted with gravel at 0.48 Mpa (70 psi).
Impact ISO-6272-2 There shall be no loss of adhesion of the electrocoat to the metal
panel when impacted initially on the face and reverse surfaces at
2.26 N⋅m (20 in-lbs.) increments up to 1
3.6 N⋅m (120 in-lbs.).
Aged: 10 days at 70 degrees C (158 F) and impacted at Room
Temperature at 9.0 N·m (80 in-lbs.)
Frozen: Age 4 hours at –30 degrees C (-20 F) and impacted cold
at 9.0 N·m.
Test to Failure FMEA/DOE To be outlined by Chrysler Group LLC Materials Engineering and submitter. DOE’s shall include variations in bake, film build and process for all layers. Reprocess should also be assessed. Testing requirements include, but not limited to adhesion, gravel, cycle crack, accelerated weathering, outdoor weathering, and yellowing.
TEST METHOD REQUIREMENTS
Proving Grounds Assessment LP-461H-117, CS-
CORROSION
If requested by Materials Engineer,test panels or parts shall be
exposed to 120 corrosion cycles, underbody, on vehicles at the
Chelsea Proving Grounds, or equivalent. Cosmetic and structural
corrosion shall not exceed requirements outlined in CS-
CORROSION.
TABLE 4: CHIP RATING SCALE
Chip
Size Count Rating SAE
A (<1mm) 1-9 1 9A-7A
A >9
2
6A-0A
B
(1-<3mm) 1-9 3 9B-7B
B 10-24
4 6B
B 25-49
5 5B
B >50
6
4B-0B
C
(3-<6mm) 1-4 7 9C-8C
C 5-9
8
7C
C >10
9
6C-0C
D (6mm+) 1-4 10 9D-8D
D 5-9
11
7D
D >10
12
6D-0D
5.0 ADDITIONAL PERFORMANCE REQUIREMENTS FOR HIGH EDGE COVERAGE COATINGS
5.1 Edge Corrosion Protection
For this test, the ability of the electroprimer to coat and protect a knife-edge will be evaluated.
5.1.1 Test Procedure
A. The knife blades shall be 100 x 200 mm (4.5 x 9.0 in.), 38 degrees.
B. Clean and phosphate 3 knife blades per PS-508 prior to electrocoating.
C. Coat knife-edges to a minimum film build per paragraph 4.1B.
D. Place knife-edges in salt spray for 168 hours per ASTM-B-117. Blades must be positioned 90 degrees
to the horizontal with the sharp edge up and fully exposed.
E. After 168 hours, rinse with deionized water and allow to air dry. Do not wipe the blades.
F. Rust spots shall be counted along the sharp edge using a 30X power-magnifying lens.
G. No more than 5 rust spots on the knife-edge are allowed.
6.0 QUALITY
Refer to CS-9801 for general quality requirements.
7.0 DEFINITIONS/ABBREVIATIONS/ACRONYMS
ASTM - American Society for Testing and Materials
C - Degrees Celsius
CRS - Cold Rolled Steel
CS - Characteristic Standard
EASL - Engineering Approved Source List
F - Degrees Fahrenheit
HAPS - Hazardous Air Pollutants
HRS - Hot Rolled Steel
ISO - International Organization for Standardization
LP - Laboratory Procedure
MIBK - Methyl Isobutyl Ketone
MS - Material Standard
P/B - Pigment to Binder Ratio
PF - Performance Standard
PS - Process Standard
SAE - Society of Automotive Engineers
Ultrafiltrate
UF -
Ultraviolet
UV -
VNV - Volume % Non-volatile
VOC - Volatile Organic Compound
WNV - Weight % Non-volatile
WPG - Weight per Gallon
8.0 GENERAL INFORMATION
Three asterisks “***” after the section/paragraph header denotes single or multiple technical changes to the section/paragraph. Specific technical changes within a section, subsection, table, or figure may be highlighted in yellow.
Certain important information relative to this standard has been included in separate standards. To assure the processes submitted meet all of Chrysler requirements, it is mandatory that the requirements in the following standards be met.
CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability
Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by
<S> and <E> which correspond to Safety and Emission Shields respectively. When applicable, the Chrysler mandated requirements are designated by <D> which correspond to the Diamond symbol and by <A> for Appearance related objectives, respectively.
For specific information on this document, please refer to the contact person shown in the "Publication Information" Section of this document. For general information on obtaining Engineering Standards and Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
engstds@.
9.0 REFERENCES
Chrysler Standards Chrysler Standards
ASTM
Standards SAE
Standards ISO
Standards
CS-9003 MS-7621 B-117 J-400 6272-2 CS-9800 MS-9602 D-1200 J-2334 CS-9801 MS-10797 D-1735 CS-CORROSION MS-PZ-1-1 D-3359 LP-461H-117 MS-PZ-2-1 LP-463CB-12-02 MS-PZ-3-1 LP-463CB-12-04 MS-PZ-4-1 LP-463PB-21-01 MS-PZ-5-1 LP-463PB-22-01 PF-7051 LP-463PB-31-01 PS-508 MS-4574<S> PS-7232 MS-9769 Quality and Reliability Documents
ISO/TS-16949 “Quality Management System” Other Documents
10.0 ENGINEERING APPROVED SOURCE LIST
TABLE 5: ENGINEERING APPROVED SOURCE LIST
Materials covered by this standard shall only be purchased from the source(s) listed in this table.
SUPPLIER
SUPPLIER CODE H – HIGH EDGE ELECTROCOATS (formerly MS-PB-60-2A and MS-PB-60-2D) S – STANDARD
ELECTROCOATS
(formerly MS-PB-60-2B and
MS-PB-60-2C)
U32KD325B U32KD325B BASF Corporation 2601 Telegraph Road. Southfield, MI 48034-2442 30985 U32KD525 (HAP’s-free) U32KD525 (HAP’s-free) CorMax VI EP Black Cormax III Cormax VI Cormax VI EP
DuPont Automotive 950 Stephenson Highway Troy, MI 48098 69237 Cormax VI Black (HAP’s-free) EC-3000 (same as KCC ED2800)
Hangzhou Unires Chemical Industry Co., Ltd. No. 5 Ning’an Road
Xioashan Economic and Technological Development Zone
Hangzhou, China --- --- EED-060/EEB-068G Kansai Paint Inc. 5455 Corporate Drive Suite 205
Troy, MI 48098
--- --- Elecron HG-10LF Nippon Paint America (NPA Coatings) 11110 Berea Road Cleveland, OH 44102 --- --- Powernics® NB601 Framecoat I Framecoat I Framecoat II PPG Industries, Ind. Automotive Finishes 5875 New King Court Troy, MI 48007 72371M Framecoat II Powercron 590-534 (HAP’s-free)
TABLE 5: ENGINEERING APPROVED SOURCE LIST
Materials covered by this standard shall only be purchased from the source(s) listed in this table.
SUPPLIER SUPPLIER
CODE
H – HIGH EDGE
ELECTROCOATS
(formerly MS-PB-60-2A and
MS-PB-60-2D)
S – STANDARD
ELECTROCOATS
(formerly MS-PB-60-2B and
MS-PB-60-2C)
Powercron CR665-CP415,
Powercron 8000
Powercron 6000CX
VectroGard 850E VectroGard 850
Valspar Corporation
1101 3rd Street South
P.O. Box 1461
Minneapolis, MN 55440
--- VectroGard 900 VectroGard 900
11.0 PUBLICATION INFORMATION
Contact/Phone Number: Adam L. Stals, (248) 576-7423
Alternate Contact/Phone Number: John Hess, (248) 576-7461
Department Name & Department Number: Body Materials Engineering, Dept. 5830
Date Standard Originally Published: 2002-02-23
Date Published: 2009-10-01
Change Notice:
Description of Change:
- Complete revision.
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