1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 03 28 Activated J. Crist/N. Lindsay-Merte Printed copies are uncontrolled Page 1 of 15 Copyright 2003, Ford Global Technologies, Inc. ADHESIVE TAPE, RIVETABLE, THERMAL CURE, STRUCTURAL WSS-M18P18-A 1. S
2、COPE This specification defines the material performance requirements for expanding and non-expanding structural tape adhesives. The tapes may be used on aluminum and steel and are rivetable. They will cure at electrocoat oven temperatures. 2. APPLICATION The specification was released originally fo
3、r materials used to structurally bond body components such as top rails, rear sills, and cross members to floor pans and inners to outers in a wheel house. These adhesive tapes can be used to bond oily, unclean mill finish and pretreated aluminum sheet and oily, unclean steel for body-in-white appli
4、cations. The use of pretreated aluminum sheet or galvanized steel provides optimal adhesion performance for long term durability. Optimal adhesion strengths are achieved with adhesive bondlines of 0.25 mm. The materials are cured in the electrocoat oven. The Manufacturing Properties and Engineering
5、Performance requirements defined in this specification are based on laboratory sample testing and define the minimum acceptance criteria for adhesive performance. The function and design requirements for the application are defined by the Sub-system Design Specification (SDS), key life test requirem
6、ents, or vehicle program requirements. Prior to use, the adhesive must be evaluated under the production parameters. The choice of substrates, stamping lubricants, stamping plant processing conditions, assembly plant processing conditions and specific design application may affect adhesive performan
7、ce. Compliance with this specification does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production
8、 Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATION WSS-M18P18-A Page 2 of 15 Copyright 2003, Ford Global Technologies, Inc. 3.2 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stamping lubricants and adhesive. The mate
9、rial system was oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may affect adhesive performance. If any of these parameters are changed, the adhesive performance must be vali
10、dated using the new parameters. 3.3 DIMENSIONS Cross sections/dimensions for tape shall be specified on the engineering drawing. 3.4 MATERIAL PROPERTIES 3.4.1 Weight Per Volume +/- 0.1 (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.1 kg/L, based on the recorded weight of their
11、 original approved production sample. Reference para 4.1. 3.4.2 Volatile Organic Compounds (VOC) Content +/- 0.05 kg/L (EPA Method 24, Procedure B) The VOC Content variation for any one supplier shall be +/- 0.05 kg/L, based on the recorded VOC Content of their original approved production sample. R
12、eference para 4.2. 3.4.3 Cure Requirements Report (Define the process cure window for material cure, Report minimum and maximum time at temperature requirements to define performance boundaries) Critical performance characteristics shall include, but are not limited to, the following: Stress Durabil
13、ity, para 3.6.2 Fracture Toughness, para 3.6.4 Fatigue, para 3.6.5 Tensile Properties, para 4.3 ENGINEERING MATERIAL SPECIFICATION WSS-M18P18-A Page 3 of 15 Copyright 2003, Ford Global Technologies, Inc. 3.4.4 Volume Change Not to exceed a 25% (FLTM BV 108-02, material cure difference between para 4
14、.5, min. and max. bake) minimum and maximum bake The volume change variation for any one supplier shall be +/- 10 %, based on the recorded volume change of their original approved production sample. Application specific requirements are stated on the Engineering Drawing and shall be controlled per t
15、he suppliers control plan. 3.4.5 Vertical Expansion Adhesion 90 -100% cohesive (Expandable Materials only) failure to both panels, Report Test Method: Apply a 10.0 x 200 mm strip of tape at production tape thickness to the center of a 100 x 300 mm oily panel per para 4.4. Position a spacer at the mi
16、dpoint of each side of the panel. Place a second oily metal panel on the spacers and secure the assembly with clamps. Bake the assemblies in the horizontal position according to the bake schedule in para 4.5. Allow the assemblies to cool to 23 +/- 2 C and remove the clamps and spacers. Separate the
17、panels in a cleavage manner to fail the bond. Begin with a spacer equal to the tape thickness and repeat test increasing spacer height in multiples of tape thickness until failure mode reaches 60-70% cohesive failure mode on both panels. Report the failure mode for each sample and graphically summar
18、ize the data. 3.5 MANUFACTURING PROPERTIES 3.5.1 Differential Scanning Calorimetry (20 +/- 1 mg sample size, 10 C/min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) Onset of reaction, min 80 C Glass Transition Temperature Report ENGINEERING MATERIAL SPECIFICATION
19、 WSS-M18P18-A Page 4 of 15 Copyright 2003, Ford Global Technologies, Inc. 3.5.2 Uncured Adhesion The uncured material shall not peel at the edges or fall off the panel. Test Method: Prepare four panels for each substrate per para 4.4. Cut four 10.0 x 200 mm strips at production tape thickness and ap
20、ply to four 100 x 300 mm panels prepared for each substrate per para 4.4. Pass a 2.2 kg roller over samples per ASTM D1000. Invert two panels immediately after material application and condition for 72 h at 40 C. Observe for peeling or lifting of adhesive from panel or slump or sag. Stand the remain
21、ing two panels vertically immediately after material application and condition for 72 h at 40 C. Observe for peeling or lifting of material from panel or slump or sag. 3.5.3 Release Paper Adherence and Removal The release paper must remain attached to the adhesive during shipment and handling. It mu
22、st be easily removed from the adhesive/polymer without part distortion or paper tear at ambient plant conditions (7 to 38 C). Final approval for the release paper may be part and plant specific. Release paper information shall be noted in the supplier control plan. 3.5.4 Sag Resistance (FLTM BV 118-
23、01, 10.0 x 200 mm strips at production tape thickness, substrates per para 5.4, condition for 24 h at 40 C, oven schedule per para 5.5, one panel each bake) Horizontal No measurable movement Vertical No measurable movement Inverted No loss of material ENGINEERING MATERIAL SPECIFICATION WSS-M18P18-A
24、Page 5 of 15 Copyright 2003, Ford Global Technologies, Inc. 3.5.5 Slump Resistance, max 3 mm Assembly aged 30 days at 50 +/- 1 C Test Assembly: Two 25 x 100 mm coupons, prepared per para 4.4, with two 38 x 12 x 3 mm spacers. The spacers are placed at each end of one of the coupons, and sufficient ad
25、hesive is applied between the spacers to fill the gap. The second coupon is placed on top of the adhesive and spacers (Figure 1). Clamp the assembly with spring clips at each end. Remove excess adhesive from all exterior edges with a spatula. Test Method: Prepare 3 assemblies per substrate. Subject
26、one assembly per substrate to exposures. After exposure, condition assemblies at 23 +/- 2 C for 24 hours, then bake at minimum bake per para 5.5. Determine the slump by measuring adhesive loss from the bottom of the assembly. Photograph and record observations of any adhesive loss after exposure and
27、 after bake. Repeat the above procedures for maximum bake per para 4.5. 3.5.6 Bridging, max 3 mm (SAE J243 ADS-9, Section 3.3, Method D, nonflow fixture, substrates per para 5.4, photograph after exposure and after material cure bake conditions per para 4.5) Assembly aged 30 days at 50 +/- 1 C 3.5.7
28、 Wash Resistance No measurable movement, displacement or wash-off. 3.5.7.1 Jaguar Production (JNS 30.03.24) ENGINEERING MATERIAL SPECIFICATION WSS-M18P18-A Page 6 of 15 Copyright 2003, Ford Global Technologies, Inc. 3.5.7.2 North American Production (FLTM BV 116-03, Method B, 10.0 x 200.0 mm at prod
29、uction tape thickness, substrates per para 4.4) 3.5.7.3 European Production (Concurrence Required) Test Method: Prepare a 300 x 100 x 1.0 mm test panel with lubricants as directed by Materials. Apply a 250 x 10 mm strip at production tape thickness to the panel. Condition for 2 h at 23 +/- 2 C. Wash
30、, phosphate and electrocoat the test panel under current process conditions. 3.5.8 Electrocoat Compatibility (FLTM BV 119-01, use current production paints as identified by Material Engineering, substrates per para 5.4) Shall not contaminate electrocoat primer bath or cause electrocoat film irregula
31、rities. 3.5.9 Rivetability The adhesive shall not cause excess quilting as defined in Figure 2, nor cause a break through of the sheet metal or buckling of the rivet. Original approval was based on laboratory/plant trials using hydraulic/electric and manual/robotic parameters. New applications shall
32、 be validated using the intended production parameters Test Method: Perform rivet tests using methods typical of the production application, e.g. hydraulic/electric; manual/robotic. Using 1.0 x 100 x 400 mm aluminum coupons construct an assembly as defined in Figure 3. A strip of adhesive tape at pr
33、oduction thickness/width shall be applied 9.5 mm from edge of lower coupon prior to mating with the top coupon. Use rivet and type as specified by the application. After riveting, cure adhesive per para 4.4. ENGINEERING MATERIAL SPECIFICATION WSS-M18P18-A Page 7 of 15 Copyright 2003, Ford Global Tec
34、hnologies, Inc. Examine the assembly. Cross section the assembly through the rivet. A rivetability report must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. 3.5.10 Odor Shall be
35、free from objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.5.11 Storage Stability Heat greatly accelerates aging. The material shall be stored in closed containers away from all sources of heat. The shelf life of the material shall be 3 months fr
36、om date of manufacture when stored below 32C. When materials are stored at temperatures below 23 C, they shall be conditioned at room temperature 24 hours prior to application. Application properties are optimized with adequate conditioning of the material. Ambient plant conditions may fluctuate bet
37、ween 7C and 38 C. Materials shall be evaluated for local plant conditions to determine plant specific requirements in excess of 32 C. Critical performance characteristics to evaluate for shelf life stability shall include, but are limited to, the following: Volume Change, para 3.4.4 Vertical Expansi
38、on Adhesion, para 3.4.5 Uncured Adhesion, para 3.5.2 Release Paper Adherence and Removal, para 3.5.3 Sag Resistance, para 3.5.4 Slump Resistance, para 3.5.5 Bridging, para 3.5.6 Rivetability, para 3.5.9 Stress Durability, para 3.6.2 Fracture Toughness, para 3.6.4 Fatigue, para 3.6.5 Tensile Properti
39、es, para 4.3 ENGINEERING MATERIAL SPECIFICATION WSS-M18P18-A Page 8 of 15 Copyright 2003, Ford Global Technologies, Inc. 3.6 ENGINEERING REQUIREMENTS 3.6.1 Adhesion Strength, min 12.0 MPa, not to exceed more than 30% reduction of strength after aging or exposure. (SAE J1523, substrates per para 4.4,
40、 at production tape thickness, maintain with a spacer equal to the tape thickness, 13 mm length overlap, 13 mm/min pull rate, oven cure per para 4.5) 3.6.1.1 Normal (Condition for 30 minutes at specified temperature prior to test) Test at 23 +/- 2 C Test at 80 +/- 2 C Test at -40 +/- 2 C 3.6.1.2 Exp
41、osed (Condition at 23 +/- 2 C for 1 h, subject to environmental cycle, oven cure per para 5.5, test at 23 C) Environmental cycle: - 40 +/- 1 C for 7 days PLUS 38 +/- 1 C for 98 +/- 2 % RH for 7 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for 1 day 3.6.1.3 Aged (Condition at 23 +/- 2 C for 24 h a
42、fter exposure, test at 23 +/- 2 C) 10 Thermal Cycles One Cycle: 90 +/- 1 C for 4 h PLUS 38 +/- 1 C and 98 +/- 2 % RH for 4 h PLUS - 40 +/- 1 C for 16 h 10 Moisture Intrusion Cycles ENGINEERING MATERIAL SPECIFICATION WSS-M18P18-A Page 9 of 15 Copyright 2003, Ford Global Technologies, Inc. One Cycle:
43、16 h at 38 +/- 2 C and 95 +/-5 % condensing RH 4 h at -40 +/- 2 C 4 h at 80 +/- 2 C Samples are to be conditioned at 23 +/- 2 C and 50 +/- 5% RH over weekends and holidays. Time between conditions shall not exceed 5 minutes. 30 APGE Cycles (FLTM BI 123-01, modified cycle, substrates per para 5.4, ov
44、en cure per para 5.5, report after 10, 20 and 30 cycles) One APGE cycle: 15 min salt water immersion(5 % salt solution), plus 1 h and 45 min drip dry at RT 22 h at 50 +/- 2 C and 90 +/- 5% RH Samples are to remain in the 50 +/- 2 C and 90 % +/- 5 % environment over the weekends and holidays. 3.6.2 S
45、tress Durability, min (FLTM BV 101-07, substrates per para 4.4, all coupons from one manufacturers lot, report thickness for each coupon and substrate yield strength for manufacturers lot, oven cure para 4.5, two fixtures, cyclic corrosion exposure, report data per test method) All samples at a spec
46、ified load shall meet the minimum amount of cycles at 10, 20, 30, and 40 % of failure load established for unexposed samples tested at 23 C per para 3.6.1. 10 +/- 1 % 75 cycles 20 +/- 1 % 60 cycles 30 +/- 1 % 45 cycles 40 +/- 1 % 30 cycles 3.6.3 Peel Resistance (ASTM D 1876, at production tape thick
47、ness, 76.2 mm overlap, 127 mm/min pull rate, substrates per para 4.4, oven cure per para 4.5, condition for 30 minutes at specified temperature prior to test) Test at 23 +/- 2 C 125 N/25 mm min Test at 80 +/- 2 C 125 N/25 mm min Test at - 40 +/- 2 C Report ENGINEERING MATERIAL SPECIFICATION WSS-M18P
48、18-A Page 10 of 15 Copyright 2003, Ford Global Technologies, Inc. 3.6.4 Fracture Toughness (FLTM BU 121-01, at production tape thickness, substrates per para 4.4, oven cure per para 4.5, condition at specified temperature 30 minutes prior to test, 2 m/s impact velocity, Report A, h and n for the cha
49、racterized metal, report R1 and R2 for each coupon assembly) Test at 23 +/- 2 C 0.5 kJ/m2min Test at 80 +/- 2 C 0.5 kJ/m2min Test at - 40 +/- 2 C Report 3.6.5 Fatigue Values shall be above the minimum in Figure 4. Test Method: Prepare 36 lap shear coupons as prepared per para 3.6.1, substrates per para 4.4, oven cure per para 4.5. Condition at 23 +/- 2 C for 2 h. Refer to para 3.6.1 Shear Adhesion testing at 23 C
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