ES805-07012

Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 1 of 9 Standard Performance Requirements & Test Standards for Components General Finishes: Cosmetic & Structural Printed copy is Uncontrolled. Always refer to the Controlled H-D electronic database for official document. Site: PDC Dept: 805 Materials and Processes Number: ES805-07012 Legacy Number : GES07012 Document Revision History Version: Page(s) Revision By: Date: Description of Change A --- Sue Jokela 3/26/02 New Release 1 All Sue Jokela 3/15/03 Document conversion; deleted information not associated with Engineering performance. Document Custodian: Materials and Processes Engineering Dept 805 Dept 805 Technical Services Position: Current Engineer Assigned: Date: Sr Materials Engineer Sue Jokela 3/31/03 Chief Engineer Rod Riek 3/31/03 References ASTM Standards ASTM B117 Practice for Operating Salt Spray (Fog) Apparatus ASTM D 523 Test Method for Specular Gloss ASTM D 1729 Practice for Visual Evaluation of Color Differences of Opaque Materials ASTM D3363 Test Method for Film Hardness by Pencil Test ASTM D3359 Test Method for Measuring Adhesion by Tape Test ASTM G53 Practice for Operating Light- and Water-Exposure Apparatus for Exposure of Nonmetallic Materials ASTM D4587 Conducting Tests on Paint and Related Coatings and Materials (using ASTM G53) HD Engineering Standard ES805-07011 Performance Requirements and Test Procedures for Painted Components Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 2 of 9 Purpose: The purpose of this document is to describe and define the test procedures, performance requirements, data reporting format, and level of testing required for validation of specific application processes, materials, and supplier sources for the category of Generally Finished Components. This category typically includes components which do not use paint or plating as their primary finish. Finishes of this type include anodized, color anodized, molded in color polymers, colored/tanned natural materials, plating for decorative purposes only (ex. Gold), or other materials not covered in a specific performance standard. ü These are minimum requirements set up to ensure the performance of general exterior finishes for the very demanding structural and cosmetic requirements of a Harley Davidson component during the life of a motorcycle. ü This typically would apply to a Class A or B surface, as well as any surface protected for structural intentions (ex. An anodized aluminum wheel). ü This process and product validation is particularly critical when the finish is completely new to Harley Davidson. Scope: This standard specifies the tests required for the validation of products, supplier sources, and processes. This specifically includes the total production content of the component. Cloisonnés, medallions, or other external graphics are expected to perform to the same level as the base component. (Additional testing may be required based upon the construction of said graphic.) ü Validation is inclusive of finish materials and construction, application process, and specific substrate. Validation will occur prior to FPE or Production Shipments. ü The Tier 1 supplier is responsible for completing the test protocol and supplying the completed test data, for validation, PPAP, and periodic quality control verification. ü Although finishes and their associated manufacturing processes will vary significantly, this general battery of testing has been found to consistently determine the long term commercial viability of the finish. ü This performance standard is intended to hold jurisdiction over finishes where more specific or appropriate standards do not currently exist. (i.e. for paint, chrome plating, etc.) ü Successful completion of this standard is required for the qualification of supplier sources, processes, and process changes for general finishes used by Harley-Davidson Motor Co. ü In the case of developmental or other critical finishes, internal HD Materials lab personnel should oversee validation performance testing. Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 3 of 9 Term Definition Developmental Process An unproven process which has not been previously used as a production process by HD or other similar user. Production Process A proven process which has been previously validated by HD or other similar user. Test Flow 1 Sequential test flow to determine basic production viability of a specific coating formulation and specific application process. This includes: Dry adhesion on a scribed sample, humidity, adhesion, corrosion, and then adhesion/creep resistance. Validation (1) (per HD CPPDM) Testing to ensure that product conforms to defined user needs and / or requirements. Validation follows successful verification and is normally performed on the final product under defined operating conditions. Multiple validations may be performed if there are different intended uses. Definitions: Validation (2) (as applied to this standard) Full Engineering Standard (ES) testing is required to approve a developmental process or product to be upgraded to an approved production intent process or product. Levels of Validation: All developmental processes or products require full validation testing as defined in this standard. New processes, applications, material suppliers, and facilities must be validated through testing prior to approval for use in the manufacture of parts for Harley-Davidson Motor Co. This specifically includes significant changes to a previously validated supply chain. For finishes in which color is inherently combined within the finish itself, the definition of substrate is inclusive of color. This would specifically apply to molded-in-color or color anodizing processes for instance. Substrates must meet the performance requirements as shown on the part drawing. Validation is inclusive of the specific combination of coating formula, application process and specific type of substrate. (ex. 5 Die cast A356-T6 parts, painted with 1 paint formula, by 1 specific painter only requires 1 validation) For engineered plastic substrates, the definition of substrate is inclusive of color. Validation testing must occur in advance of production or FPE shipment. IMPORTANT: The entire validation sequence for class A, B, or other critical components is a minimum of 1 year of Continuous Test Time. · IF appearance or function could be significantly affected by UV exposure. · This is inclusive of all Class A or B components with their total production content (graphics, cloisonnés, medallions, etc). · HD airbox and fender finishes, finishes critical to the nature of the design, or new to Harley-Davidson vehicles. · This would specifically include polymeric or other materials where UV exposure may compromise their structural integrity. · This can be reduced to 30 or 60 days for one cycle of testing if the materials are metallic, not colored. IMPORTANT: The entire validation sequence for class C, D, or non-critical components is a minimum of 30 days of Continuous Test Time. Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 4 of 9 Testing Requirements for Process and Product Validation Validation Of: Supplier Source Process Substrate: METAL PLASTIC METAL PLASTIC PERFORMANCE TEST (*) each production lot (+) each PPAP lot (R) Required performance test. Must pass specified test (E) Evaluation. Must be appropriate for the application. Appearance *+ R R R R Thickness *+ R R R R Adhesion *+ R R R R Humidity + for plastic substrates R R R R Corrosion + for metal substrates R N/A R N/A Test Flow 1 *+ R R R R UV Resistance UV Chamber Lab Test N/A R R R R UV Resistance 1 Year FL or AZ Exposure N/A R R R R Staining N/A E E E E Cold Cracking N/A R R R R Heat Durability/Resistance + R R R R Gravel Chip N/A E E E E Cleaning Products N/A E E E E The specific tests required for validation are listed in the table below, "Testing Requirements for Process and Product Validation". Additional testing specific to the type of coating, construction, or combination of finishes may be required. Where practical, coating performance will be validated on the actual components intended for production use. Note: New colors are typically considered new coatings for the purposes of validation. Validation of highly developmental products should occur on test panels prior to using actual components. This allows for specific validation of the developmental aspects while minimizing spent resources. Statistical Sample Size Validation Tests: Important: It is NOT physically possible to perform validation testing unless 5 - 10 components (depending upon size) are supplied to the testing facility. A sample size of 1 is NOT recommended and will NOT be accepted by Harley-Davidson. It is a good practice to obtain samples from at least 2 separate production intent lots – particularly for high risk projects. Approved Testing Facilities: The supplier of parts (Tier 1) is responsible for providing proof of successful performance of the specific combination of substrate, coating and process. The supplier may use the services of an independent testing laboratory, provided that the laboratory is nationally accredited (ex. A2LA) or is part of an ISO9000 approved facility. It is strongly recommended that the lab accreditation or approval be obtained PRIOR to the commencement of any testing. Test results from unaccredited laboratories will NOT be accepted. Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 5 of 9 Testing Procedures and Performance Requirements Overview: The Following Tests Are to Be Performed as Listed Below: · These tests should be performed on a statistically appropriate sample size. · Testing should be performed on untested components or panels. · In the case of layered constructions, the majority of the samples allocated should be subjected to “Test Flow 1”. · “Test Flow 1” requires 5 days of continuous test time to complete. · If samples do not pass “Test Flow 1”, it is not typically cost or time effective to perform any additional testing of that lot of samples. · This standard does not suppose to address all of the safety issues associated with its use. The safety is the responsibility of the user. · Additional testing may be required at the discretion of a Materials and Processes or Quality Department representative, based upon performance criteria for specific components. · The appearance will be approved by the appropriate Styling or Engineering representative. · Fitness for use, as approved by Styling, determines the appropriate appearance. · Untested samples should have their appearance attributes rated using the following test methods utilizing the appropriate ASTM standard identified below as appropriate for colored finishes. This data is intended to establish a baseline of comparison only. · All results must be reported. Color: ASTM D 1729 Appearance: Gloss: ASTM D 523 Thickness and Construction: · Thickness and layer construction will be determined and controlled by the supplier. The finish must pass the performance tests, cosmetic requirements, and dimensional requirements as specified by Harley-Davidson. The supplier will provide documentation, which defines the expected range of thickness for each layer of the coating at location sites designated by the supplier. These range(s) and site(s) will be used for future reference by Harley-Davidson and the supplier, to assure process control and suitability for service. · Any change to the construction, or intended thickness, must be validated by testing to this specification. · For initial validation of a new process, the supplier shall submit test evidence that the part, at its minimum and maximum expected plating thickness, passes the performance and fit requirements in this Harley-Davidson specification. · Destructive or Nondestructive methods are acceptable. The definitive test for thickness and construction is the ASTM B487 cross section, mount and polish then analyze using a microscope. Other methods are needed to determine and document layers of more complex constructions. Test Flow 1: This Applies to All Layered Coatings: Dry adhesion on a scribed sample, humidity, adhesion, corrosion followed by adhesion and creep resistance. (Corrosion is unnecessary for polymer or nonmetallic constructions) Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 6 of 9 This Applies to All Layered Coatings: · Test per ASTM D3359 Test Method A using a pressure sensitive tape as prescribed by ASTM. · A standard 1" commercially available adhesion tape is required. · Do NOT use tape that is dried or degraded in appearance. A 1-year tape shelf life is typical. · The test sample coating shall be scratched or scribed using a sharp carbide tipped scriber or utility blade. The scribe lines shall penetrate completely through the coating. · Per ASTM, 2 cuts should be made at each test location, about 1.5" in length, which should intersect near their middle. This should be repeated in two other locations on each test panel. For large structures, make sufficient scribes to ensure that the adhesion evaluation is representative of the whole surface or assembly. · The angle of intersection should be approximately 30 - 45 degrees. · A 3" long piece of tape should be placed over the intersection of the cuts and smoothed into place by finger in the area of the incision, then rubbed firmly with the eraser end of a pencil. Within 90 seconds +/- 30 seconds of application, remove the tape in a smooth but rapid motion, pulling the tape back upon itself at as close to an angle of 180° as possible. · Report the number of tests and where the failure occurred (between which layers or to the substrate). ADHESION (Dry Adhesion): Performance Requirements: ü Adhesion performance shall be a minimum rating of 3A, ü 3A = Jagged removal along incisions of no more than 1/16" on either side, and ü A minimum of 3B is required if using method B. This applies to all finishes: · The sample shall be subjected to 100% relative humidity at 125° F. · Metal substrates should be tested for 16 hours, and plastic substrates for 48 hours. If adhesive interfaces require validation of function, 2 cycles if 48 hours is the current baseline. · After completion of the test exposure, remove the sample from the test chamber and immediately dry it with either paper towels or low-pressure (<20 psi) compressed air. · Rate the appearance of the sample within 5 minutes of removal from the chamber. · Test adhesion over the scribes per ASTM D 3359 and instructions above. Humidity Resistance with Adhesion: Performance Requirements: ü Adhesion performance shall be a minimum rating of 3A, ü Evaluate samples within 10 minutes of removing from chamber, and ü No change of appearance, blistering, or corrosion, etc. This applies to all finishes with metallic construction or substrates. · The test shall be conducted according to ASTM B117. · All samples must be tested in their normal position as found on the vehicle. · Critical cosmetic components shall be subjected to 336 hours. This specifically includes the total production intent content, graphics, cloisonnés, medallions, etc. · All other parts shall be subjected to 96 hours. · Test adhesion over the scribes per ASTM D 3359 and instructions above. Corrosion Resistance: Salt Spray, Creep, and Adhesion Performance Requirements: ü Adhesion performance shall be a minimum rating of 2A, ü 2A = Jagged removal along incisions of no more than 1/8" on either side, ü Evaluate samples within 10 minutes of removing from chamber, ü No visible corrosion is permitted on or under the coated surface after the exposure cycle, and ü No change of appearance, blistering, or corrosion, etc. Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 7 of 9 · The test shall be conducted according to ASTM G53. · Perform QUV test per ASTM D 4587 Condition B for 720 hours based upon the usage of a UVA 340 bulb, or equivalent. · Cycle B = 4 hr UV @ 60° C, · Followed by 4 hr CON @ 50° C UV- Condensation Resistance: Performance Requirements: ü After test exposure, the sample shall not exhibit any change in appearance when compared to an untested sample. ü Any change in appearance must be approved by a Styling Representative before use on vehicles or accessories. ü High gloss finishes shall not exhibit visible change, typically less than 10% gloss loss. ü Low gloss finishes shall not exhibit visible change, typically less than 20% gloss loss. · 1 year south Florida or Arizona outdoor exposure for all critical surfaces. · This is inclusive of all Class A or B components, HD tank and fender finishes, finishes critical to the nature of the design or new to Harley-Davidson vehicles. This would specifically include polymeric or other materials where UV exposure may compromise their structural integrity. · Components representing the production intent process are to be exposed on an ASTM compliant test rack at a 45 degree angle. · Performance of this nature is typically inherent to the pigment materials and processes chosen by the manufacturer, and as such, is expected to be supplied by the manufacturer. In the case of developmental or other critical finishes, internal HD Materials lab personnel should oversee validation performance testing. UV Resistance: 1 Year Florida or Arizona Exposure Performance Requirements: ü After test exposure, the sample shall not exhibit any change in appearance when compared to an untested sample. ü Any change in appearance must be approved by a Styling Representative before use on vehicles or accessories. ü High gloss finishes shall not exhibit visible change, typically less than 10% gloss loss. ü Low gloss finishes shall not exhibit visible change, typically less than 20% gloss loss. · A covered spot test (per ASTM) should be performed at a temperature between 90° F - 110° F. · A cotton swatch should be generously dipped in the agents mentioned below, then covered with an appropriate glass or plastic cover, and exposed to 90° F – 110° F for the duration listed below. · The fuel test samples should be positioned under a light or heat source in a well-ventilated area (fume hood or ventilated paint cure oven) for the time specified. · Other appropriate and safe methods may be utilized for the fuel and other agents. Staining Agent Duration 1% Soap or Detergent Solution 4 hours Motor Oil 24 hours Brake Fluid 24 hours (Dot 4 or 5, as appropriate) Resistance To Staining Agents: Fuel (unleaded) 1 hour This is intended to imitate naturally elevated surface temperatures due to sun or heat on a vehicle, splashed with these types of solutions. The component surface temperature should be between 90° F – 110° F. Printed 1/5/2010 10:22 AM Printed Uncontrolled version of ES805-07012Page 8 of 9 Resistance To Stainin