ENGINEERING MATERIAL SPECIFICATION

Material Name

Specification Number

PRIMER, WATERBORNE CATIONIC ELECTROCOAT,

LEAD-FREE, HIGH THROW POWER, EDGE
CORROSION RESISTANT, INITIAL FILL

WSS-M64J39-A1

MAKEUP FEED, WATERBORNE CATIONIC

ELECTROCOAT, LEAD-FREE, HIGH THROW
POWER, EDGE CORROSION RESISTANT, RESIN

WSS-M64J39-A2

MAKEUP FEED, WATERBORNE CATIONIC

ELECTROCOAT, LEAD-FREE HIGH THROW POWER,
EDGE CORROSION RESISTANT, PIGMENT

WSS-M64J39-A3

FLOW CONTROL ADDITIVE

WSS-M64J39-A4

MAKEUP FEED, WATERBORNE CATIONIC

ELECTROCOAT, LEAD-FREE, HIGH THROW POWER,
EDGE CORROSION RESISTANT, PRE-BLEND

WSS-M64J39-A5

1.

SCOPE
The materials defined by these specifications are the basic components
for lead-free, high-throw power, high-edge corrosion resistant cathodic
electrocoat primer.

2.

APPLICATION
These specifications were released originally for a paint system when
properly electrodeposited on vehicle bodies, sheet metal components or
small parts will provide good corrosion resistance, adhesion and enamel
appearance properties. These materials together make a paint system that
is lead-free with high-throw power and high-edge corrosion resistance.
WSS-M64J39-A1:

This material is the initial fill material and

represents
the
electrocoat
bath
during
production.

WSS-M64J39-A2:

This material is makeup feed material used to

replenish
the
resins
of
the
initial
fill
electrocoat bath.

Date

1998 03 24

WP 3948-a

Action

Activated

Changes

N. Chamberlain

G. Schuh
Page 1 of 7

ENGINEERING MATERIAL SPECIFICATION

3.

WSS-M64J39-A1-A5

WSS-M64J39-A3:

This material is makeup feed material used to

replenish the pigments of the initial fill
electrocoat bath.

WSS-M64J39-A4:

This material is makeup feed material used to

correct poor flow characteristics of the primer
which may develop when the bath ages.
This
additive is used only as recommended by the
supplier following ultrafiltrate purge or when
discontinuous operation of an electrocoat tank
results in evaporation of bath volatiles.

WSS-M64J39-A5:

This material is a pre-blended makeup feed

material used to replenish the resins and
pigments of the initial fill electrocoat bath.
The ratio of resin to pigment shall be agreed
upon by the supplier, the affected assembly
plant, Global Paint Engineering and Production
Purchasing prior to delivery of the material to
the assembly plant.

REQUIREMENTS
3.1

QUALITY SYSTEM REQUIREMENTS

Material suppliers and part producers must conform to Quality
System Requirements, QS-9000. Material specification requirements
are to be used for initial qualification of materials. A Control
Plan for ongoing production verification is required.
This plan
must be reviewed and approved by the relevant Ford Materials
activity and/or Ford Supplier Technical Assistance (STA) prior to
production parts submission. Appropriate statistical tools must be
used to analyze process/product data and assure consistent
processing of the materials.
Part producers using this material in their products, must use Ford
approved materials and must conform to a process control plan which
has been approved by STA and/or the relevant Materials Activity.

3.2

INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS

Ford Motor Company, at its option, may conduct infrared and/or
thermal analysis of material/parts supplied to this specification.
The IR spectra and thermograms established for initial approval
shall constitute the reference standard and shall be kept on file
at the designated material laboratory. All samples shall produce IR
spectra and thermograms that correspond to the reference standard
when tested under the same conditions.

WP 3948-b

Page 2 of 7

ENGINEERING MATERIAL SPECIFICATION

3.3

WSS-M64J39-A1-A5

CONDITIONING AND TEST CONDITIONS

All test values indicated herein are based on material conditioned
in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative
humidity for not less than 24 h prior to testing and tested under
the same conditions unless otherwise specified.

3.4

COMPOSITION
3.4.1

Density, kg/L at 25 C
(ASTM D 1475)

Initial Sample
+/- 0.05 %

3.4.2

Non-volatile, weight %
(FLTM BI 102-01)

Initial Sample
+/- 0.05 %

3.4.3

Weight Loss, max

(FLTM BI 120-15)

Initial Sample
+/- 0.05 %

Measure weight loss after 10 minutes at 182 +/- 2 C metal

temperature bake cycle.
3.4.4

Solvent Emissions, max

(ASTM D 3960)

0.096 kg/L of
wet paint

This requirement is as determined by the United States

Environmental Protection Agency Reference Method #24 but is
only applicable to materials used in the USA.
3.5

STABILITY
3.5.1

Pumping Stability, min

(FLTM BI 120-04)

21 days

After 21 day min agitation, the bath prepared from the

initial fill or feed materials shall meet all requirements
of the specification.
3.5.2

Storage Stability, min

2 months

During a storage of 2 months between 5 and 32 C temperature

the material as supplied shall not settle or cake.
3.6

PREPARATION OF TEST PANELS

Coating System I
- Electrocoat Only
Coating System II - Electrocoat and Primer Surfacer
Coating System III - Total Paint System

WP 3948-b

Page 3 of 7

ENGINEERING MATERIAL SPECIFICATION

3.6.1

WSS-M64J39-A1-A5

Substrates
Auto body steel, aluminum, pre-coated or electroplated zinc
or zinc alloy coated steel and zinc die casting or as
specified on Engineering documents.

3.6.2

Substrate Condition
Clean the surface by an automated process to ensure the
absence
of
oil
or
alkaline
residues,
fingerprints,
corrosion, dirt, moisture, and other foreign materials.

3.6.3

Coating Material
3.6.3.1

Zinc Phosphate (All Panels)

Zinc phosphate coating per WSS-M3P1-D for cold
rolled steel, pre-coated, electroplated zinc or
zinc alloy coated steel and zinc die castings.
Aluminum when processed alone should use chromium
oxide coating per WSK-M6P2-B.
If steel and
aluminum parts are processed concurrently, apply
zinc phosphate per WSS-M3P1-D. Do not exceed the
aluminum tolerance of the process.
Steel and
aluminum parts are to meet all requirements of
both WSS-M3P1-D and this specification.

3.6.3.2

Cathodic Electrocoat (Coating System I)

Ford Engineering approved current production
materials or material under evaluation.
Film
thickness requirements are based on current
production requirements or direction of materials
engineer. Baking requirements are 10 minutes at
165, 175 and 200 C metal temperature.

3.6.3.3

Electrocoat and Primer Surfacer

(Coating System II)
Ford Engineering
materials.

3.6.3.4

current

production

Total Paint System (Coating System III)

Ford Engineering
materials.

WP 3948-b

approved

approved

current

production

Page 4 of 7

ENGINEERING MATERIAL SPECIFICATION

3.7

WSS-M64J39-A1-A5

APPEARANCE
3.7.1
3.7.2

Color
(FLTM BI 109-01)

Initial Sample

Leveling
3.7.2.1

Smoothness
The surface of the electrocoat primer shall be
smooth without any structure and not more than a
min of orange peel when applied and baked as
required in Coating System I.

3.7.2.2

Gloss
(FLTM BI 110-01)

Initial Sample
+/- 5 %

Use a 60 deg glossmeter for gloss measurements.

3.7.3

Holdout
Apply the enamel color coat over unsanded electrocoat
primer. Failure is evidence of dulling or change in image
clarity compared to current approved production electrocoat
enamel (Coating System III).

3.8

RESISTANCE PROPERTIES
The material defined by this
requirements of WSS-M2P182-A.

3.9

specification

must

meet

the

MATERIAL COMPATIBILITY
The material must be compatible with all related materials, for
example, electrocoats, sealers, and adhesives. The supplier of this
material shall keep abreast of changes in technology of related
materials which may affect the compatibility and performance of
this product.
The supplier shall notify the appropriate Ford
Product
Materials
Engineering
Office
in
writing
when
incompatibility is anticipated.

3.10 SUPPLIER'S RESPONSIBILITY

All materials supplied to this specification must be equivalent in
all characteristics to the material upon which approval was
originally granted.

WP 3948-b

Page 5 of 7

ENGINEERING MATERIAL SPECIFICATION

WSS-M64J39-A1-A5

Prior to making any change in the properties, composition,

construction, color, processing or labeling of the material
originally approved under this specification, whether or not such
changes affect the material's ability to meet the specification
requirements, the Supplier shall notify Purchasing, Toxicology and
the affected Materials Engineering activity of the proposed changes
and obtain the written approval of the Materials Engineering
activity. Test data, test samples and a new code identification are
to be submitted with the request.
Substance restrictions imposed by law, regulations or Ford, apply
to the materials addressed by this document. The regulations are
defined in Engineering Materials Specification WSS-M99P9999-A1.
4.

APPROVAL OF MATERIALS
Materials defined by this specification must have prior approval by the
responsible Materials Engineering activity. Suppliers desiring approval
of their materials shall first obtain an expression of interest from the
affected Purchasing, Design and Materials Engineering activity.
Upon
request, the Supplier shall submit to the affected Materials Engineering
activity a completed copy of their laboratory test reports, signed by a
qualified
and
authorized
representative
of
the
test
facility,
demonstrating full compliance with all the requirements of this
specification
(test
results,
not
nominal
values),
the
material
designation and code number, and test specimens for Ford evaluation.
Ford's engineering approval of a material will be based on its
performance to this specification and on an assessment of suitability
for intended processes and/or applications. Upon approval, the material
will be added to the Engineering Material Approved Source List.

5.

GENERAL INFORMATION
The information given below is provided for clarification and assistance
in meeting the requirements of this specification.
The corrosion resistance required in this specification is the basis of
corrosion protection of vehicle body steel. Test Panels and parts which
meet
this
specification
will
also
conform
with
the
corrosion
requirements of WSS-M2P180-A.
5.1

Panel Information
5.1.1

Standard Steel Panels

Standard steel panels are laboratory quality mild coal
rolled steel available clean or zinc phosphated. Qualified
coil stock is available from Advanced Coating Technologies,
Inc.*
OR

WP 3948-b

Page 6 of 7

ENGINEERING MATERIAL SPECIFICATION

WSS-M64J39-A1-A5

Use panels prepared in accordance with Ford Manufacturing

Standard U-MA001-8001.
5.1.2

Electrogalvanized Steel

50 - 80 g/m2

Qualified coil stock is available from Advanced Coating

Technologies, Inc.*
OR
Use panels complying with relevant grades of WSB-M1A250-C3
and WSB-M1A311-B2.
5.1.3

Aluminum Panels
Aluminum panels (AA6111) can
Coating Technologies, Inc.*

5.2

be

obtained

from

Advanced

Panel Preparation
Panels can be prepared and or tested at:
* Advanced Coating Technologies, Inc.
PO Box 735
273 Industrial Dr.
Hillsdale, Michigan 49242
(517) 439-1485

WP 3948-b

Page 7 of 7