1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Release/Revision1991 09 02 EP00E01089488000 Released W.Scholz;J.Schult;W.Curtiss;E.RezendesWP 3948-a Page 1 of 6 PERFORMANCE REQUIREMENTS, ADHESIVE FOR BONDING WSB-M11P38-CPLASTIC BUMPERS1. SCOPEThis s pecification
2、 defines the performance requirements of an adhesive oradhesive system for bonding plastic bumpers.2. APPLICATIONTh is specification was released originally for adhesives used tostructurally bond plastic bumper assemblies.This specification does not describe initial adhesive cu re conditions. Thepro
3、cedures for assembly bonding shall be prescribed in accordance toadhesive manufacturer and part supplier recommendations.Mate rials meeting this performance specification are identified on theCorporate Approved Source List.Compl iance with this performance specification does not guarantee thestr uct
4、ural adhesive will function for all potential applications on ave hicle. The specific design condition should be evaluated by a planttrial or laboratory simulation prior to release of the material.3. REQUIREMENTS3.1 STATISTICAL PROCESSSupplie rs must conform to the requirements of Ford Quality Syste
5、mStand ard Q-101. A mutually acceptable Control Plan as describedtherein is required for material/source approval. Appropriatestatist ical tools must be used to analyze process/product data sothat variation in the final product is continuously reduced.3.2 CONDITIONING AND TEST CONDITIONSAll test val
6、ues indicated herein are based on ma terial conditioned ina control led atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under thesame conditions unless otherwise specified.ENGINEERING MATERIAL SPECIFICATIONWSB-M11P38-CWP 3948-b Page 2 of 6
7、3.3 SHEAR ADHESION Minimum load specified orsubstrate breakageSubject bonded test assemblies to the following exposures:. Normal, min(Condition for 30 minutes at specifiedtemperature prior to test)3.3.1 Test at 23 +/- 2 C 2.4 MPa3.3.2 Test at 88 +/- 2 C 1.0 MPa3.3.3 Test at - 29 +/- 2 C 4.2 MPa. Env
8、ironmental Aged, min3.3.4 1000 h Heat Age at 88 +/- 2 C 2.8 MPa3.3.5 1000 h Humidity at 38 +/- 2 C and 2.3 MPa95 - 100 % R.H.3.3.6 1000 h Water Immersion described 1.3 MPaper FLTM BI 104-013.3.7 240 h Salt Spray 1.7 MPa(ASTM B 117)3.3.8 10 Thermal Cycles: 2.9 MPa4 h at 8 8 +/- 2 C, 4 h humidity (38
9、+/- 2 C and 95 - 100 %R.H.), 16 h at - 29 +/- 2 C.Test Method:. Prepar e a minimum of 3 test assemblies per test condition asillustrated in Figure 1. Te st substrates shall consist of 100 x 25.4 x 3 mm couponsidentified in para 5. Bond test coupons and condition at 23 +/- 2 C until full adhesivecure
10、. Subject test assemblies to the environments listed above. Allow test assemblies to condition 24 h minimum after environmentalexposure before pull test. Conduct shear pull test on a tensile tester at a rate of 13 mm perminute. Report peak load at failure and indicate type of failure mode.ENGINEERIN
11、G MATERIAL SPECIFICATIONWSB-M11P38-CWP 3948-b Page 3 of 6 3.4 CREEP RESISTANCE No Slippage(ASTM D 1780, prepare three test samples perpara 3.3, apply a 4.5 kg dead weight load totest samples and expose to 88 +/- 2 C for 24 h)3.5 MANDREL BEND FLEXIBILITY No cracking oradhesion loss tosubstrateTest Me
12、thod:. Apply a 13 mm wide x 3 mm thickness ribbon of adhesive centeredlengthwise on two 250 x 50 x 3 mm panels identified in para 5. Condition test panels after bonding at 23 +/- 2 C until adhesivefull cure. Conduct 60 mandrel bend test at 23 +/- 2 C and - 29 +/- 2 C overa 50 mm d iameter mandrel. S
13、ubstrate is in contact with mandrelduring test. Repeat above proce dure on test assemblies heat aged at 70 +/- 2 Cfor 2 weeks.3.6 COLD SLAM RESISTANCE No cracking,(FLTM BV 101-02, 10 cycles of 6 slams per adhesion orcycle at - 29 +/- 2 C, 3 samples minimum) cohesion failure. Prepare test assemblies
14、as illustrated in Figure 2. Test substratesshall consist of 100 x 250 x 3 mm panels identified in para 5. Condition test assemblies after bonding at 23 +/- 2 C untiladhesive full cure. Mechanically attac h bonded test assembly to a 300 x 300 x 0.76 mmCRS base panel. Centrally locate test assembly on
15、 base panel. Conduct test as outlined per FLTM BV 101-02 following steps 9, 10,and 11. Position panel in slam fixture with test assembly facinginward. Subject each test assembly to 10 cycles of 6 slams percycle at - 29 +/- 2 C.3.7 REVERSE IMPACT PLAQUE TEST Test plaques shall exhi bit no less(FLTM B
16、O 117-02) than 80 % of the impact resistanceof the control plaques and failuremode must be ductile.Test Method:. Impact test samples must be injection molded 127 mm x 127 mm or101.6 mm x 101.6 mm plaques with smooth surfaces and 2.54 mm thick. Prepare five test samples with adhesive applied to one s
17、ide, 1.02mm thick , covering at least a 76 mm diameter area in center ofplaque.ENGINEERING MATERIAL SPECIFICATIONWSB-M11P38-CWP 3948-b Page 4 of 6 . Subject the five test plaques and the five control plaques to bakecycle below:30 minutes at 77 C (oven temp)30 minutes at room temp30 minutes at 77 C (
18、oven temp)Adhesive must be fully cured. Condition panels at test temperature for at least 2.5 h prior toimpact testing. R everse impact plaques (adhesive side out) at 15mph and a temperature of - 29 C +/- 2 C.3.8 IN-PLANT PROCESS COMPATIBILITY No evidence of adhesion loss orother deleterious effects
19、 onadhesive bond qualityTest Method:. Prepare three test samples as shown in Figure 1, para 3.3. Bond coupons and condition at 23 +/- 2 C for 1 h. Simulate implantprocess conditions by exposing test assemblies to deionized waterimmersion at 75 +/- 2 C for 30 minutes, then heat at 82 +/- 2 C for1 h.
20、Allow test assemblies to return to 23 +/- 2 C for 24 h. Conduct shear pull test on a tensile tester at a rate of 25 mm perminute. Report peak load at failure and indicate type of failure mode. Shear adhesion values must be comparable to results obtained perpara 3.3.1.3.9 BUMPER PERFORMANCE REQUIREME
21、NTSParts assembled with adhesive shall meet all per formance requirementsspec ified on engineering drawing. In addition, bumper assembliesshall be exposed to environmental conditions from section 3.3 asreco mmended by the Materials Engineering Activity. These bumperswill be impact tested and evaluat
22、ed for approval by the affectedDes ign, and Materials Engineering Activities The tested bumpersshall yield satisfactory failure modes.3.10 FUNCTIONAL APPROVALMaterials being evaluat ed for initial approval to this specificationshall be subjected to a production trial. Functional trial resultsshoul d
23、 be available to Design and Materials Engineering prior tomaterial approval and release.ENGINEERING MATERIAL SPECIFICATIONWSB-M11P38-CWP 3948-b Page 5 of 6 3.12 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which a
24、pproval wasoriginally granted.Pr ior to making any changes in the properties, composition,co nstruction, color, processing, or labeling of the materialorig inally approved under this specification, whether or not suchchange s affect the materials ability to meet the specificationrequirements, the Su
25、pplier shall notify Purchasing, Toxicology, andthe affected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Test data, test samples, and new code identification areto be submitted with the request.Substance restrictions impo
26、sed by law, regulations, or Ford apply tothe materials addressed by this document. The restrictions aredefined in Engineering Material Specification WS S-M99P9999-A1, unlessa different suffix (e.g., A2 or A3) is specified on the engineeringdocument for the application.4. APPROVAL OF MATERIALSMat eri
27、als defined by this specification must have prior approval by theresp onsible Materials Engineering activity. Suppliers desiring approvalof thei r materials shall first obtain an expression of interest from theaffec ted Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier
28、 shall submit to the affected Materials Engineeringactivity a completed copy of their laboratory test reports, signed by aqualified and authorized representative of the test faci lity, demonstratingful l compliance with all the requirements of this specification (testresults, not nominal values), th
29、e material designation a nd code number, andtes t specimens for Ford evaluation. Fords engineering approval of amateri al will be based on its performance to this specification and on anassessment of suitability for i ntended processes and/or applications. Uponapprov al, the material will be added t
30、o the Engineering Material ApprovedSource List.5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting the requirements to the specification.5.1 SUBSTRATES:NAAO: ESB-M4D442-A3 or as specified on engineering drawing.EAO: WSK-M4D762-A or as specified on engineering drawing.ENGINEERING MATERIAL SPECIFICATIONWSB-M11P38-CWP 3948-b Page 6 of 6 Figure 1 OVERLAP SHEAR ASSEMBLY Figure 2 COLD SLAM TEST ASSEMBLY
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