Ford FLTM BI 009-05 Bending Test for Coating Adhesion

The “Ford FLTM BI 009-05 Bending Test for Coating Adhesion” standard, developed by Ford Motor Company (Ford), describes a test method used to evaluate the ability of a coating system to remain firmly adhered to a substrate when subjected to bending deformation. This standard is primarily applied to painted or coated automotive components and metal panels to assess coating flexibility and adhesion under mechanical stress.

Automotive coatings undergo numerous forming and bending processes during production, including the following:

• Stamping
• Folding and hemming
• Edge shaping
• Assembly operations
• Vehicle service deformation

A coating that adheres well to a flat surface may crack, peel, or separate into layers when the substrate is bent. The Ford FLTM BI 009-05 standard was developed to determine whether a coating system can withstand this type of deformation without loss of adhesion.

In principle, this test involves bending a coated sample along a specific angle or radius and then examining the coating for the following characteristics:

• Cracking
• Exfoliation
• Peeling
• Layer separation
• Loss of adhesion

The severity of coating damage is visually assessed and compared to the acceptance criteria defined in Ford material specifications.

In general, the testing process follows these steps:

• Preparation of coated test panels.
• Conditioning of the samples under the specified laboratory conditions.
• Bending the panel around a mandrel or a defined radius.
• Visual inspection of the bent area.
• Recording any coating defects.
• Comparing the results with Ford's acceptance requirements.

The materials generally evaluated with this test are as follows:

• Electro-coated steel panels
• Primed metal substrates
• Painted body panels
• Decorative coatings
• Protective coating systems
• Coated aluminum components

This testing method is particularly useful for materials that undergo shaping processes in vehicle manufacturing.

Bending tests can reveal various coating weaknesses. The identified failure modes are as follows:

• Cracking: The coating breaks during bending.
• Peeling: The separation of the coating from the substrate.
• Layer separation: Separation between coating layers.
• Flaking: Shedding; small pieces of coating separating.
• Edge failure: Veneer damage concentrated at the bending edges.

These defects may indicate insufficient coating flexibility, inadequate surface preparation, or inadequate adhesion between the coating layers and the substrate.

Ford uses the bending-adhesion test to evaluate the quality of the following products:

• Body paint systems
• Lower body coverings
• Trim panels
• Exterior decorative coatings
• Supplier of coating materials.
• New paint formulations

This method helps ensure that coatings maintain their performance throughout the manufacturing and vehicle lifespan.

The Ford FLTM BI 009-05 standard is typically used in conjunction with the following other Ford coating evaluation methods:

• Ford FLTM BI 105-0: Tapered mandrel test
• Ford FLTM BI 106-01: Coating adhesion test
• Ford FLTM BI 107-05: Thermal shock test for adhesion.
• Ford FLTM BI 108-01: Impact test for painted panels.

These tests, together, evaluate coating performance under varying mechanical and environmental stresses.

The Ford FLTM BI 009-05 standard is required because automotive coatings must maintain their adhesion and integrity as metal parts are bent, shaped, assembled, and used throughout the life of a vehicle. A coating that performs well on a flat panel may fail when subjected to deformation, leading to cosmetic and durability issues. This standard is considered important for the following reasons:

• It simulates real production conditions: In vehicle production, coated metal components undergo numerous forming processes, including:
  • Stamping
  • Bending
  • Fold
  • Folding
  • Assembly compatibility

These processes apply significant stress to the coating. This standard evaluates whether the coating can withstand these stresses without cracking or peeling.

• Prevents paint and coating failures: This testing method helps identify coating systems that may exhibit the following problems:
  • Cracking
  • Exfoliation
  • Peeling
  • Layer separation
  • Loss of adhesion

Identifying these issues during material qualification prevents costly production and field failures.

• It provides corrosion protection: Automotive coatings act as a barrier against moisture, road salts, and environmental pollutants. If a coating cracks during bending,
  • Bare metal may be exposed.
  • Corrosion may begin in the damaged areas.
  • Long-term durability may be compromised.

The bending test ensures that protective coatings remain intact after deformation.

• It ensures coating flexibility: Different coating formulations have different levels of flexibility. This standard confirms the following:
  • The liners remain adhesive during shaping.
  • Paint systems do not become fragile.
  • Multilayer coating systems work as a whole.

This is particularly important for modern high-strength steels and aluminum components, which may be subjected to significant forming stresses.

• Supports supplier quality control: Ford trusts suppliers for coated materials and painted components. This standard ensures:
  • A uniform evaluation method
  • Consistent acceptance criteria
  • Comparable results between suppliers and production sites.

This ensures that all materials meet the same performance expectations.

• This confirms long-term durability: Vehicle components continue to be subjected to stresses after production for the following reasons:
  • Vibration
  • Thermal expansion and contraction
  • Small blows
  • Structural flexing during vehicle operation.

A coating that passes the bending test is more likely to maintain its adhesion and appearance for the entire service life of the vehicle.

In short, this standard helps reduce costs and improve vehicle quality by identifying weak coating systems before production.

In summary, the Ford FLTM BI 009-05 standard is a specialized coating performance test used to evaluate adhesion retention during bending. By simulating deformation that occurs during manufacturing and service, this standard helps ensure that automotive coatings remain robust, durable, and protective throughout the vehicle's lifespan. Its role in coating qualification forms a key component of Ford's overall paint and corrosion prevention testing program.

For many years, our organization, with its competent and experienced staff, has been understanding the needs of its customers, providing the advanced testing services they require, and assisting them in the establishment, implementation, and improvement of management systems. Within this framework, we also provide testing services compliant with the Ford FLTM BI 009-05 standard.