1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 02 08 Revised Revised 2, 3.4.1, 3.4.5.2, 3.4.8, 3.4.9, 3.5, 3.6, 3.7.1.6, 3.7.2 Inserted 3.10, 3.11, 5.2, 5.3 Deleted 3.4.6 Para 3.1, 3.2, 3.3, 3.10, 3.11, 4 deleted W. Janitschke1995 01 10 Released EP00E10452964000 W. Scholz Printed copi
2、es are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 6 ADHESIVE, EPOXY, FOR METAL REINFORCEMENT, WSK-M2G384-A1 ADFOSY SPRAYABLE, HEAT CURING, ADFOSY 1. SCOPE The material defined by this specification is an ADFOSY sprayable, one component, solvent free, heat curing adhesive ba
3、sed on epoxy resin. 2. APPLICATION This specification was released originally for material used to reinforce and stiffen sheet metal body panels. The materials are applicable on oiled surfaces with acceptable oil film weights (European applications limit the oil/pre-lubricant film weight to max 3 g/
4、m, see para. 3.10). Note: Care must be taken to ensure that the local oil film weight in the area of the adhesive/sealer application does not exceed the critical limit. Monitoring of the film thickness, adequate storage of the part and/or cleaning of the surface prior to sealer/adhesive application
5、is necessary to avoid critical film thickness values, which would then cause malfunction of the sealer/adhesive 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M9
6、9P1111-A). 3.4 UNCURED MATERIAL PROPERTIES 3.4.1 Color Black 3.4.2 Solids, min 98% (FLTM BV 150-10) 3.4.3 Ash, max 42% (FLTM BV 150-10) 3.4.4 Density at 23 C 1.43 +/- 0.05 kg/L (ASTM D 1475) 3.4.5 Viscosity at 23 C (Rotational rheometer, i.e. Bohlin CS, plate/plate configuration 20 mm dia., 1 mm gap
7、, shear stress 2500 Pa) ENGINEERING MATERIAL SPECIFICATIONWSK-M2G384-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 6 3.4.5.1 Bingham yield stress 350 - 450 Pa 3.4.5.2 Viscosity as received 200 - 300 Pas 3.4.5.3 Viscosity after ageing, max 400 Pas (7 d at
8、40 +/- 2 C) 3.4.7 Test for Abrasive Content No scratches Test Method: Rub a portion of the material 100 times between two pieces of flat, clean plate glass. The appearance of scratches on the glass plate will be considered failure. 3.4.8 Resistance to Phosphate Wash No evidence of material wash off
9、or displacement due to precleaning or phosphating process. Test Method: . Test panels of 300 x 300 x 0.8 mm (prepared according to paragraph 3.10) shall be coated with material under test in the middle of an area 150 x 150 mm in such a manner (ADFOSY) that after curing a dry coating thickness of 1.0
10、 mm is obtained. . Position the panel horizontally and maintain a spray of water at a temperature of 55 +/- 2 C using a jet spray (Spraying System Co., Nozzle No. 1/2 GG-25 Full Jet) at 200 kPa. Direct the spray at a distance of 250 mm for 1 minute. 3.4.9 Electrocoat Compatibility Shall not contamin
11、ate electrocoat (FLTM BV 119-01, oiled panels primer bath or cause electrocoat according to paragraph 3.10) film irregularities 3.5 FLOW RATE No flow permitted (FLTM BV 153-01, Method A, with following exceptions) Test Method: Prepare panels according to paragraph 3.10. Apply a bead of 8 mm diameter
12、 and bake 30 minutes at 110 +/- 2 C. 3.6 WETTING (FLTM BV 153-08, Method A) The paint film (paint materials shall be noted in the Initial Sample Report of the adhesive, see also para 5.4) shall cover the sealer with a continuous film. ENGINEERING MATERIAL SPECIFICATIONWSK-M2G384-A1 Printed copies ar
13、e uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 6 3.7 CURED MATERIAL PROPERTIES 3.7.1 Flexural Strength, min Condition for 30 minutes at 23 +/- 2 C prior to test. 3.7.1.1 Test at 23 +/- 2 C 50 N 3.7.1.2 Test at 90 +/- 2 C 30 N After Environmental Ageing condition for 24 h at 2
14、3 +/- 2 C after exposure, then test at 23 +/- 2 C. 3.7.1.3 14 days heat age at 90 +/- 2 C 50 N 3.7.1.4 500 h humidity at 38 +/- 2 C 50 N and 95 - 100 R.H. 3.7.1.5 Environmental Cycling 50 N 8 cycles of the following sequence and then stored for 1 h at 23 +/- 2 C. After 4 cycles, specimens are to be
15、stored at 23 +/- 2 C for 72 h before running remaining 4 cycles. One cycle consists of: 16 h humidity (38 +/- 2 C and 95 - 100% R.H.) 4 h at -40 +/- 2 C 4 h at 90 +/- 2 C 3.7.1.6 72 h at 40 +/- 2 C 50 N (Adhesive storage only prior to bonding) Test Method: . Spray material (ADFOSY) under test to a 2
16、5 x 150 mm panel (prepared according to paragraph 3.10) in such a manner that after curing a dry coating thickness of 1.0 mm is obtained. . Cure test samples according to BV 150-05, Table 2, minimum and maximum cycle. . After exposure to each above mentioned test condition, place test samples in the
17、 fixture shown in Figure 1. . Conduct flexural strength test at a crosshead rate of 5 mm/minute. . Record the peak load value. A minimum of 3 samples per test condition shall be evaluated. ENGINEERING MATERIAL SPECIFICATIONWSK-M2G384-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Tec
18、hnologies, LLC Page 4 of 6 3.7.2 Corrosion Resistance No corrosion or blistering at the border line sealer/EC/steel The material shall protect the test panel from corrosion. Test Method: (a) Prepare test assemblies according to FLTM BV 159-02, Method A (exception: test panel preparation according to
19、 para. 3.10). Material thickness 1.0 - 1.2 mm. (b) After 2 h at 23 +/- 2 C wash, phosphate and electrocoat test assemblies under defined process conditions according to UC 800. (c) Expose test assemblies according to FLTM BV 150-05, Table 2, min curing cycle and max curing cycle (d1) For Cold Rolled
20、 Steel: After 24 h at 23 +/- 2 C expose test assemblies to a salt spray fog according to ASTM B 117 for 480 h. For North America Only, for Cold Rolled Steel, replace (d1) above with the following test- 30 APGE Cycles, report after 10, 20, 30 cycles. (d2) For Precoated Steel: After 34 h at 23 C +/- 2
21、 C expose test assemblies to a Scab Corrosion Test (FLTM BI 123-01) for 50 cycles. (e) Separate welded assemblies using a test fixture according to FLTM BV 159-01, Fig. 4 and examine. 3.7.3 Cold Adhesion No flaking, no loss of adhesion (FLTM BV 151-01, -40 C, load “A“, except curing according to FLT
22、M BV 150- 05, Table 2, minimum and maximum cycle, 10 cycles of 6 slams. 3.9 QUALITY The material shall be of uniform quality, free from foreign material and properties detrimental to normal production use. It shall not cause excessive soiling of handlers in normal production use. 3.10 OIL COMPATIBIL
23、ITY & REFERENCE OIL (FOR EUROPE) All materials released to this specification must be applicable to oiled surfaces, including corrosion protection oil, wash oils, pre-lubricants, draw oils, hotmelts etc. The approved products for use in Ford of Europe or the European brands are listed in the applica
24、ble approved source list (contact materials engineering for details). The supplier must confirm the compatibility of the adhesive/sealer material to these specific coating materials in the appropriate lab tests listed in para 3 and - prior to vehicle production - in a line trial in cooperation with
25、Ford manufacturing engineering. The lab test panels (see para 3.10.1) must be oiled with maximum permissible oil film thickness. Reference oil for adhesive performance comparison is Fuchs Anticorit 4107S Attention: New compatibility tests are necessary if the oil grade of the affected part is change
26、d! Nominal oil film weight is 1 - 1.5 g/m ENGINEERING MATERIAL SPECIFICATIONWSK-M2G384-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 6 The maximum permissible oil weight for full adhesive performance is 3 g/m Note: All necessary actions must be taken to p
27、revent any local oil film weight exceeding 3 g/m in the area of adhesive/sealer application. Critical areas are the lowest positions of parts during transport/storage, e.g. door hem flanges or other oil trapping areas. Unacceptable oil collection will require appropriate storage geometries (critical
28、 areas turned to top) or in-process cleaning operations prior to sealer/adhesive application. 3.10.1 Oiling-Method of Lab Test Panels 3.10.1.1 Test-Panel Cleaning Clean the test-panel with the lint-free cloth soaked with the solvent n-hexane. Rinse both sides of the test panel with n-hexane until no
29、 process traces remain on the surface. Allow to dry at ambient-temperature until the n-hexane has completely evaporated. 3.10.1.2 Oiling the Test-Panel Small panels (Tensil-, Shear-, Peel-Adhesion): Immediately after air drying, immerse the panel in a 250 ml glass beaker, filled up to 200 ml with a
30、mixture of 10% n-hexane/90% reference oil. Prevent evaporation losses by covering the glass beaker with aluminum foil as airtight as possible. After immersion for 1 minute, remove the panel from the glass beaker. Allow the panel to drain in a vertical position at ambient temperature. Other panels (f
31、.ex. Hardness): The cleaned panel should be warmed up for a short time in a heat cabin (for better oil-distribution). Apply some drops of oil on the panel and distribute them even over the panel with a lint-free cloth. Check the oil-weight. 3.10.1.3 Checking of Oil Coating/Weight A test panel prepar
32、ed as per 3.10.1.1 is weighed on an analytic scale with a precision of 0,001 g. After oiling weigh again. The oil coating in g/m is derived from the weight difference in relation with the panel-dimensions. If the oil-weight deviates approx. +/- 0.3 g/m from the specified oil-weight, the panel can be
33、 used. Otherwise oil again or re-adjust the above mixture. 3.11 LINE TRIAL Materials being evaluated for approval to this specification shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made
34、 available to Materials Engineering prior to material approval and release. ENGINEERING MATERIAL SPECIFICATIONWSK-M2G384-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 6 of 6 5. GENERAL INFORMATION The information given below is provided for clarification and a
35、ssistance in meeting the requirements of this specification. 5.1 SUBSTRATES Cold rolled steel as specified on engineering drawing with panel thickness of 0.8 mm unless otherwise specified. Note: If any other steel, i.e., procoated with Zn, Zn/Ni, Duplex, galvanealed, etc. gets relevant for manufactu
36、ring, the adhesive has to be tested according to this specification on these substrates. Use current production paints as identified by the appropriate Materials Engineering Activity. 5.2 OPEN ASSEMBLY TIME As specified by (At the required operation temperature) the supplier Open assembly time is th
37、e maximum time interval from initial application of the adhesive to the completion of the part assembly for bonding. 5.3 STORAGE STABILITY (From date of receipt at Ford Motor Company) The material must be stable for 3 month during storage in unopened drums out of direct sunlight at temperatures between 5 C and 32 C. 5.4 MATERIAL REFERENCE All related materials used for approval of adhesives according to this specification, e.g. paint materials or metallic substrates, shall be noted in the Initial Sample Report of the adhesive. FIGURE 1: FLEXURAL STRENGTH TEST FIXTURE
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