Ford FLTM BI 157-06 High-Performance Stone Impact Resistance Test

The “Ford FLTM BI 157-06 High-Performance Stone Impact Resistance Test” standard, developed by Ford Motor Company (Ford), describes a test method used to evaluate how well automotive coatings (paint systems and similar surface coatings) resist stone impact and gravel impact under high-speed conditions.

The primary purpose of the Ford FLTM BI 157-06 standard is to measure the following:

• Resistance of painted exterior surfaces to stone impact.
• Durability of multi-layer coating systems (primer, base coat, clear coat)
• Susceptibility to cracking, peeling, or loss of coating.
• Overall surface protection performance under real driving conditions.

This test method simulates what happens when vehicles are exposed to the following:

• gravel roads
• High-speed highway driving
• Impact of road debris

This standard uses a controlled multi-impact or gravel bombardment system (commonly referred to as a gravel gauge or multi-sand tester). Generally, the testing process follows these steps:

• A coated test panel is prepared (metal or plastic substrate).
• The panel is subjected to high-speed impacts of standardized particles (gravel or cooled cast iron medium).
• The following parameters are carefully checked:
  • Air pressure
  • Impact angle
  • Exposure time
  • Particle size / material
• After testing, the surface is assessed for damage. The assessment is done using a visual rating scale based on the following:
  • Number and size of cracks
  • Degree of coating removal
  • Damage depth (down to the primer or substrate)
  • Overall view compared to reference panels

This new grading scale feature of the Ford FLTM BI 157-06 standard means that results are standardized, allowing different suppliers and laboratories to consistently compare performance.

This standard is widely used in the automotive industry in the following areas:

• Vehicle body exterior panels
• Bumpers and front panels
• Side mirrors and trim pieces
• Rims and wheel arch areas
• Coated plastic and metal components

The Ford FLTM BI 157-06 standard is generally used in conjunction with, or is compatible with, the following standards:

• ISO 20567-1: Multiple impact stone chip test
• SAE J400: Stone impact resistance rating
• Original equipment manufacturer standards (Renault, PSA, VW equivalents)

The Ford FLTM BI 157-06 standard is important because it helps ensure that automotive coating systems can withstand stone and gravel impacts encountered during normal vehicle use. Exterior paint damage is not just a cosmetic issue; it can also affect long-term durability and corrosion protection. Here are the key reasons why this standard is considered important:

• It preserves the vehicle's appearance: Vehicles are constantly exposed to the following:
  • The road is gravel.
  • Kum
  • Loose stones
  • Construction debris

These materials can strike painted surfaces at high speeds, causing scratches and surface damage. This standard helps manufacturers maintain the vehicle's appearance for its lifespan by evaluating a coating's resistance to such impacts.

• Prevents corrosion: When a piece of stone penetrates the paint system and exposes the metal substrate,
  • Moisture can reach the metal surface.
  • Corrosion may begin.
  • Rust can spread under surrounding coatings.

This standard verifies stone chip resistance, helping to ensure that coating systems continue to protect vehicle bodies against corrosion.

• The coating system increases durability: Modern automotive paint systems consist of multiple layers:
  • Electroplating (E-coating)
  • Astar
  • Base layer
  • Transparent coating

This standard evaluates how well these layers work together under impact conditions. Poor adhesion between layers can lead to peeling or delamination after stone impacts.

• It supports material and coating development: Paint suppliers and automotive manufacturers use this test for the following purposes:
  • Comparing new coating technologies.
  • Optimizing paint formulations
  • Improving coating flexibility and adhesion.
  • Verifying environmentally friendly coating systems.

This helps encourage continuous improvements in vehicle surface protection.

• Supplier quality is ensured: Ford requires suppliers to meet specific performance requirements. This standard provides a standardized method for evaluating:
  • Paint systems
  • Coated components
  • Surface treatments

Using a common testing method ensures consistent quality across different suppliers and production sites.

• Reduces warranty costs: Poor stone chip resistance can lead to:
  • Customer complaints
  • Early corrosion
  • Repainting or repair
  • Warranty claims

Tests conducted according to this standard help identify weaknesses in vehicles before they go into production, reducing long-term costs.

• It simulates real-world driving conditions: This standard reproduces impact damage that occurs under the following circumstances:
  • Highway driving
  • Winter driving on sandy roads
  • Using gravel roads
  • Land use

This allows for a realistic assessment of coating performance, rather than relying solely on laboratory adhesion or hardness tests.

• It supports customer satisfaction: Consumers expect their car paint to remain attractive and protective for many years. High stone chip resistance contributes to this.
  • Better long-term outlook
  • Improved corrosion resistance
  • Higher perceived vehicle quality.
  • Increased customer confidence in the product.

In short, the Ford FLTM BI 157-06 standard is a critical automotive paint durability test that simulates stone chip damage on vehicle surfaces. This standard ensures that coatings used on Ford vehicles can withstand harsh road conditions, protect underlying materials from corrosion, and maintain long-term appearance quality.

This standard is important because it verifies the resistance of automotive coatings to stone chip damage under harsh service conditions, and helps protect vehicle appearance, prevent corrosion, increase coating durability, ensure supplier quality, and improve customer satisfaction. In short, it plays a significant role in overall vehicle durability and quality assurance programs.

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 157-06 standard.