FORD ESB-M4G300-A-2000 SEALER INJECTION MOLDED POLYOLEFIN - HEAT EXPANDING - HIGH TEMPERATURE CURE《高温固化、热膨胀型聚烯径注塑密封剂》.pdf

1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2000 09 20 Revised Updated A. Cockman 1988 05 13 C9S1 - DR182507 Printed copies are uncontrolled Page 1 of 10 Copyright 2000, Ford Global Technologies, Inc. SEALER, INJECTION MOLDED POLYOLEFIN - HEAT EXPANDI

2、NG ESB-M4G300-A HIGH TEMPERATURE CURE 1. SCOPE: The material defined by this specification is an injection molded uncured ethylene vinyl acetate base sealer which expands when exposed to heat. It can be used only in plants with electrocoat paint systems. This material is produced in injection molded

3、 part form. 2. APPLICATION: This specification was released originally for material used to isolate body side strainers, sealing fuel fillers, and roof b ows from exterior sheet metal panels. The material is normally stapled, heat staked, or snapped in position, and is used on oily galvanized and CR

4、LC steel surfaces. Recommended cure schedules are 8 min at 171 C metal temperature minimum, and 30 min at 20 5 C metal temperature maximum. Compliance with the performance requirements of this specification does not guarantee the expandable sealer will function for all potential applications on a ve

5、hicle. The specific design condition should be evaluated by a plant trial or laboratory simulation prior to release of the material. 3. REQUIREMENTS: Material specification requirements are to be used for initial qualification of materials. 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part

6、 producers mu st conform to the Companys Quality System Requirements. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designat ed material laboratory. All sampl

7、es shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material co nditioned in a controlled atmosphere of 23 +/ - 2 C and 50 +/ - 5 % relative hum

8、idity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 DIMENSION As specified on engineering drawings ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 2 of 10 Copyright 2000, Ford Global Technologies, Inc. 3.5 SPECIFIC GRAVITY (uncured

9、material) 0.95 - 1.15 (ASTM D 297, Water Displacement Method) 3.6 HARDNESS, DUROMETER “D“ 30 - 45 (ASTM D 2240, Reading after 15 s, uncured state) 3.7 EXPANSION 300 - 450 % Test Method: . Prepare six test assembli es as shown in Fig. 1. Use 1.0 - 1.1 mm CRLC steel - oiled. . Cure three samples at ea

10、ch of the bake schedules indicated in para 6.3. . Allow samples to cool to 23 +/ - 2 C for 1 h minimum. . Calculate the percent expansion as the relationship between th e maximum expanded thickness of the cured material (dimension “X“ - Fig. 1) and the uncured thickness of the original sample (“T“).

11、 Percent Expansion = X - T x 100 T . Using a hot knife, disassemble test samples by cutting the cured sealer along the sur face of panel “A“ - Fig. 1. The cured sealer shall be resilient to the touch and exhibit a uniform cell structure. 3.8 SHEAR ADHESION STRENGTH, kPa, min The minimum adhesion val

12、ues indicated shall be obtained by all coupons in each exposure group when s ubjected to the following environments: 3.8.1 Normal - 24 h at 23 +/ - 2 C 620 3.8.2 14 days at 83 +/ - 2 C 620 3.8.3 14 days at 38 +/ - 1 C and 95 - 100 % R.H. 620 3.8.4 Salt Pray, 240 h 100 (ASTM B 117) 3.8.5 Thermal Cycl

13、e (5 time s) 620 . 4 h at 83 +/ - 2 C . 4 h at 38 +/ - 1 C and 95 - 100 % R.H. . 16 h at - 29 +/ - 1 C ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 3 of 10 Copyright 2000, Ford Global Technologies, Inc. . 4 h at 38 +/ - 1 C and 95 - 100 % R.H. . 4 h at 83 +/ - 2 C . 16 h at - 29 +/ - 1 C Sam

14、ple Preparation: Reference FLTM BV 1 - 6; uncured material thickness per para 6.4, bondline thickness after cure 1.8 - 3.3 mm, substrates per para 6.2, material cure temperature per para 6.3. Prepare five samples per exposure per bake schedule. After curing, condition coupons for 24 h at 23 +/ - 2 C

15、. Prior to b eginning exposure tests. Test Method: Subject test assemblies to exposures noted. After completing exposure, the test specimens shall be conditioned at 23 +/ - 2 C for a minimum of 2 h and a maximum of 3 h prior to testing on a tensile machine at a jaw separation rate of 25 mm/min. 3.9

16、CORROSION RESISTANCE, min 500 h (ASTM B 117) 3.9.1 CRLC Steel - Oiled Surface rust within 7.0 mm of the perimeter of the cured sealer is permissible after disassembly of test assemblies. Test Method: . Prepare f our test assemblies as shown in Fig. 2 A. . Cure two samples at each of the bake schedul

17、es indicated in para 6.3. . Condition samples 24 h at 23 +/ - 2 C. . Remove clamps and subject the four cured assemblies to 500 h salt spray per ASTM B 117. . A fter exposure, disassemble panels and examine metal surfaces under sealer for evidence of corrosion. Surface corrosion shall not extend mor

18、e than 7.0 mm inside of sealer perimeter . 3.9.2 CRLC Steel - Electrocoated There shall be no evidence of corrosion under the sealer on either panel surface. Test Method: . Prepare four test assemblies as shown in Fig. 2 B. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 4 of 10 Copyright 2000,

19、 Ford Global Technologies, Inc. . Electrocoat four assemblies in a production paint system or equivalent laboratory batch tank. Electrocoating to be conducted with the assi stance of qualified Ford paint personnel. Note: When electrocoating in a production facility, oiled CRLC steel test assemblies

20、are to be processed through the phosphate system. If samples are electrocoated in a batch tank, Parker 40 panels should be used to construct the test assemblies. . Cure two samples at each of the bake schedules indicated in para 6.3. Electrocoated assemblies to be cured in a vertical position with t

21、he 150 mm long side parallel to bottom of oven. . After curing, remove clamps a nd condition 24 h at 23 +/ - 2 C. Subject cured assemblies to 500 h salt spray per ASTM B 117. . After exposure, disassemble panels and examine metal surfaces under sealer for corrosion. There shall be no evidence of cor

22、rosion beneath the sealer on eit her steel panel. 3.10 LOW TEMPERATURE RESISTANCE There shall be no evidence of adhesive or cohesive failure after the test assemblies have accumulated 100 cold slams at - 29 +/ - 1 C. Test Method: . Prepare two test samples as shown in Fig. 3. . Cure o n sample at ea

23、ch of the bake schedules indicated in para 6.3. Cure samples in a horizontal position. . Condition samples at 23 +/ - 2 C for a minimum of 24 h. . Place two test assemblies and cold slam apparatus described in FLTM BV 1 - 2 in a cold box and condition at - 29 +/ - 1 C. . Individually mount panels on

24、 the cold slam apparatus with bonded 100 x 300 mm panel at bottom side facing away from fixture. Slam 10 times per FLTM BV 1 - 2 at - 29 +/ - 1 C. . Remove two test panels from cold box and conditi on at 23 +/ - 2 h a minimum of 1 h. Return two panels to cold box and condition 4 h minimum at - 29 +/

25、 - 1 C and slam 10 times. Repeat this sequence until 100 cold slams have accumulated. . Condition at 23 +/ - 2 C for1 h minimum and disassemble samples. Examination of samples shall indicate no adhesive or cohesive failure of the sealer. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 5 of 10 C

26、opyright 2000, Ford Global Technologies, Inc. 3.11 SAG RESISTANCE, max 3.0 mm Test Method: . Provide a 12.7 mm diameter hold in the center of four oily CRLC steel panels with nominal dimension of 100 x 150 x 0.8 - 0.9 mm. . Place a 50 x 50 x 2.3 - 2.8 mm piece of uncured sealer material on each pane

27、l with sealer centered over hole. . Support the panels on opposite sides and bake in a horizontal position. Cure two samples at each of the bake schedules indica ted in para 6.3. . Remove from oven and condition 1 h minimum at 23 +/ - 2 C. From the under surface of the panel measure the distance the

28、 material has sagged through the hole. 3.12 FUEL RESISTANCE After a controlled immersion in ASTM Type “B“ fuel or diesel fuel and recovery at 23 +/ - 2 C, the minimum adhesion value for overlap shear samples shall be 350 kPa. Test Method: . Prepare overlap shear test samples as described in 3.7. Tes

29、t five samples from each cure schedule in ASTM type “B“ fuel, and five from each schedule in diesel fuel. . Immerse total bonded area of all samples in each type of fuel. . NOTE: Because of precise time constraints for immersion, recovery and tensile period, store samples in a panel rack in testing,

30、 it is recommended each fuel type be tested separately. Vessels containing fuel should be maintained at 23 +/ - 2 C. All fuel work should be conducted in a laboratory hood. Samples to be immersed for 2 h + 5 min, - 0 min. . Remove samples from fuel immersion and condi tion 4 h at 23 +/ - 2 C. During

31、 conditioning a closed area to minimize evaporative action. . After conditioning period, test samples immediately on a tensile test machine at a jaw separation rate of 25 mm/min. The 10 samples should be tested within 15 m inutes of completing conditioning. 3.13 WASH RESISTANCE No wash off (FLTM BV

32、16 - 1, Method “A“, 1.5 mm material thickness) 3.14 ELECTROCOAT COMPATIBILITY Shall not contaminate electrocoat (FLTM BV 19 - 1, Cathodic primer bath or cause electrocoat El ectrocoat Primer ESB - M64J23 film irregularities ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 6 of 10 Copyright 2000,

33、 Ford Global Technologies, Inc. 3.15 FOGGING (SAE J 1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 60 % Formation of clear film, droplets or crystals is cause for rejecti on. 3.16 STORAGE STABILITY The material shall be stored at temperatures bel

34、ow 41 C, away from all sources of heat. Heat greatly accelerates aging. Under these conditions, the minimum shelf life of the material shall be six months. When this material i s stored at temperatures below 23 C, it shall be conditioned at room temperature prior to application. 3.17 FUNCTIONAL APPR

35、OVAL Materials being evaluated for initial approval to this specification shall be subjected to a production trial. Functional tr ial results should be available to Design and Materials Engineering prior to material approval and release. 3.18 SUPPLIERS RESPONSIBILITY All materials supplied to this s

36、pecification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements

37、, the Supplier shall notify the affe cted Purchasing, and Materials Engineering activities (with reasons) of the proposed changes. Upon notification of the Company, further instructions will be provided. Note: Suppliers should be prepared to provide test data and samples demonstrating comp liance to

38、 this specification, if requested. Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in Restricted Substance Management Standard WSS - M99P9999 - A1. 4. APPROVAL OF MATERIALS Materials defined by th

39、is specification for direct supply to the Company must have prior approval. Certain materials subcontracted by part suppliers may also require prior approval. These include materials critical to the C ompanys business for regulatory, safety, environmental or compatibility requirements or contractual

40、 agreements. Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Materials Engineering a ctivity. Upon request, the Supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized represe

41、ntative of the test facility, demonstrating full compliance with all the requirements of this specification. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 7 of 10 Copyright 2000, Ford Global Technologies, Inc. 5. GENERAL INFORMATION The information given below is provided for clarification an

42、d assistance in meeting the requirements of this specification. 5.1 MECHANICAL CONVECTION OVEN The mechanical oven(s) used to cure the material shall be capable of obtain ing 240 C metal temperature on body steel (0.89 mm thickness) within 8 - 10 min. 5.2 SUBSTRATES 5.2.1 CRLC steel meeting ESB - M1

43、A250 - A: Nominal 0.81 mm thickness - surface precoated with M - 14B90A - B(F) stamping lubricant at an application of approximately 0.013 mm wet film thickness. 5.2.2 Steel - sheet zinc rich primer coated meeting ESB - M1A217 - B: Nominal 0.81 mm thickness - Surface precoated with M - 14B90A - B(F)

44、 stamping lubricant at an application of approximately 0.013 mm wet film thickness. 5.2.3 Galva nized steel meeting ESB - M1A250 - A3: Nominal 0.81 mm thickness - surface precoated with M - 14B90A - B(F) stamping lubricant at an application of approximately 0.013 mm wet film thickness. 5.3 PROCESS B

45、AKE SCHEDULES 5.3.1 Minimum: 171 C for 8 min metal tempe rature 5.3.2 Maximum: 204 C for 30 min metal temperature 5.4 TEST MATERIAL THICKNESS Sample material submitted for evaluation to the specification shall be 2.3 - 2.8 mm. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 8 of 10 Copyright 20

46、00, Ford Global Technologies, Inc. FIGURE 1 EXPANSION TEST A. TEST ASSEMBLY BEFORE CURE (1.0 1.1 mm CRLC STEEL OILED) B. TEST ASSEMBLY AFTER CURE ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 9 of 10 Copyright 2000, Ford Global Technologies, Inc. FIGURE 2 CORROSION RESISTANCE A. CRLC STEEL - OILED B. CRLC STEEL PHOSPHATE AND ELECTROCOATED ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-A Page 10 of 10 Copyright 2000, Ford Global Technologies, Inc. FIGURE 3 LOW TEMPERATURE RESISTANCE