1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 12 10 Revised Para 3.0 inserted ; Para 3.1, 3.2, 3.3, 3.9, 3.10, 4 deleted 2002 05 06 Activated T. Muller, S. Ward, J. Crist, J. Hughes Printed copies are uncontrolled Page 1 of 16 Copyright 2002, Ford
2、Global Technologies, Inc. AFTERMARKET ADHESIVE, WELDABLE, RIVETABLE, AIR DRY, WSS-M2G410-A2 STRUCTURAL, ALUMINUM 1. SCOPE The materials defined by this specification are pumpable, two component, air dry curing, weldable, or rivetable structural adhesives for aluminum. 2. APPLICATION This specificati
3、on is released for materials used to structurally bond body components such as: top rails, quarter panels, roofs, rear sills, and cross members to floor pans and inners to outers in a wheel house. These adhesives can be used to bond E-coated service parts including pretreated aluminum sheet, casting
4、s, and extrusions during warranty and after collision damage repairs. Aftermarket repairs may or may not require the use of a pretreatment to provide optimal characteristics. Bond line spacers are required components to maintain bond line thickness during the service repair process. These materials
5、are to be room temperature cured or can be force cured using temperatures no higher than 140 F/60 C panel temperature in the field. The Manufacturing Properties and Engineering Performance requirements defined in this specification are based on laboratory sample testing and define the minimum accept
6、ance criteria for adhesive performance. The pass /fail test criteria for these products will be raised within three years of specification release to raise/improve the durability of currently available products. The function and design requirements for the Sub-system Design Specification (SDS) defin
7、es the application, key life test requirements, or vehicle program requirements. Prior to use, the adhesive must be evaluated using parameters listed in this specification. The choice of substrates types, and specific design application may affect adhesive performance. Compliance with this specifica
8、tion does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must con
9、form to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A2 Page 2 of 16 Copyright 2002, Ford Global Technologies, Inc. 3.4 SYSTEM COMPATIBILITY Initial adhesive approval is based on a specific material system, which includes
10、 the substrate, E-coat and adhesive. Substrate choice, service part processing conditions may affect adhesive performance. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. 3.5 MATERIAL PROPERTIES 3.5.1 Cure Requirements Air Dry & Force Cure
11、 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 Durability, para 3.7.2 Fracture Toughness, para 3.
12、7.4 Fatigue, para 3.7.5 Tensile Properties, para 3.7.7 3.5.2 Expansion No porosity or expansion Substrates per Para 5.1, cure per Para 5.2, one panel for each substrate and cure) Extrude a 13 x 200 mm adhesive bead onto a 100 x 300 mm panel. Room temperature cure. Place the test panel in an air-circ
13、ulating oven and bake at 140 F / 60 C for 40 minutes oven time. After bake, condition test panel at 23 +/- 2 C for 1 h min. Cut the panel length wise through the center of the adhesive. Examine the adhesive for any voids, porosity or expansion caused by entrapped air or internal gassing. 3.6 MANUFAC
14、TURING PROPERTIES 3.6.1 Rheology (SAE J1524, Brookfield Viscosity measurement. Report production material batch/lot number and identify Brookfield model used, including spindle and speed used. Submit plot for viscosity vs. temperature. Initial (as received) Test at Room temperature application Test
15、over range 140 F/60 C to 170 F/76 at increments of 10 F ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A2 Page 3 of 16 Copyright 2002, Ford Global Technologies, Inc. Aged (age then test at 23 C and room temperature application) 7 days at 40 +/- 1 C 90 days at 32 +/- 1 C The rheology variation for any
16、 one supplier shall be +/- 50%, based on the recorded rheology of the original approved production sample. The flow curves established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce flow curves t
17、hat correspond to the reference standard when tested under the same conditions. Final approval of material rheology for service stock production shipments shall be made by the affected activity. In all cases, the rheology shall be within the limits as identified on the material control plan. 3.6.2 P
18、umpability/Dispense Capability Report Materials being considered for approval to this specification shall be evaluated for processing capability using existing aftermarket methodologies. The pumpability/dispensing capability report must be approved by the affected service activity operation. Cartrid
19、ge sizes for materials will be 50 ml. and 225 ml. No extreme measures will be accepted to improve pumpability of the materials. Results shall be made available to Materials Engineering prior to material approval and release. 3.6.3 Sag Resistance (FLTM BV 118-01, lab caulking gun applied 5 mm diamete
20、r bead, substrates per para 5.1, condition for 24 h at 140 F/60 C, oven schedule per para 5.2, one panel each bake) Horizontal No measurable movement Vertical No measurable movement Inverted No loss of material 3.6.4 Slump Resistance, max 3 mm Assembly aged 30 days at 50 +/- 1 C Test Assembly: Two 2
21、5 x 100 mm coupons, prepared per para 5.1, with two 38 x 12 x 3 mm spacers. The spacers are placed at each end of one of the coupons, and sufficient adhesive 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
22、with spring clips at each end. Remove excess adhesive from all exterior edges with a spatula. Test Method: Prepare three assemblies per substrate and subject to exposure After exposure, condition assemblies at 23 +/- 2 C for 24 hours, then bake at minimum bake per para 5.2. ENGINEERING MATERIAL SPEC
23、IFICATION WSS-M2G410-A2 Page 4 of 16 Copyright 2002, Ford Global Technologies, Inc. Determine the slump by measuring adhesive loss from the bottom of the assembly. Photograph and record observations of any adhesive loss after exposure and force curing. Repeat the above procedures for maximum force c
24、uring per Para 5.2. 3.6.5 Bridging, max 3 mm (SAE J243 ADS-9, Section 3.3, Method D, non-flow fixture, substrates per Para 5.1, photograph after exposure and after material cure, force curing conditions per Para 5.2) Assembly aged 30 days at 50 +/- 1 C 3.6.6 Paint Material Compatibility Use current
25、Ford Approved Refinish paints as identified by FCSD, substrates per Para 5.1) Shall not contaminate primer, basecoat, or cause any paint film irregularities. 3.6.7 Rivetability The adhesive shall not cause excess quilting as defined in Figure 2, nor cause a break through of the sheet metal or buckli
26、ng of the rivet. Approval is based on laboratory and service facility trials using commercially available air powered and hand manual operated riveting equipment. Test Method: Perform rivet tests using methods typical of the service repair application, e.g. air powered or hand manual. Using 1.0 x 10
27、0 x 400 mm aluminum coupons construct an assembly as defined in Figure 3. A 3 mm bead of adhesive 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 5.2. Examine the assembl
28、y. Cross section the assembly through the rivet. FCSD and Design Engineering must approve a rivetability report. Results shall be made available to RPP Materials Engineering prior to material approval and release. 3.6.8 Odor Shall be free from objectionable odors as determined by the FCSD, both as r
29、eceived and after curing. No lingering odor is allowed after full 8 hr cure time has evolved. 3.6.9 Material Consistency Shall be a smooth homogenous mixture, free from entrapped air, foreign materials and any properties detrimental to normal service repair procedures. ENGINEERING MATERIAL SPECIFICA
30、TION WSS-M2G410-A2 Page 5 of 16 Copyright 2002, Ford Global Technologies, Inc. 3.6.10 Storage Stability Report as required 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 12 months from date of m
31、anufacture when stored below 27 C. 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 repair facility conditions may fluctuate betw
32、een 7 C (or 15) and 38 C. Materials shall be evaluated for local extreme conditions to determine facility specific requirements in excess of 27 C. Critical performance characteristics to evaluate for and pass for shelf life stability shall include, but are not limited to, the following: Rheology, Pa
33、ra 3.6.1 Sag Resistance, Para 3.6.3 Slump Resistance, Para 3.6.4 Rivetability, Para 3.6.7 Stress Durability, Para 3.7.2 Fracture Toughness, Para 3.7.4 Fatigue, Para 3.7.5 Tensile Properties, para 3.7.7 3.6.11 Color Each component should be distinctly different in color. The mixed adhesive should be
34、a significantly different color than each component indicating correctly mixed and in-process curing product and shall meet manufacturing process control requirements. Final approval of material color for service stock shipments shall be made by the affected activity. The material color for any one
35、supplier shall not visually deviate from the originally approved production sample. 3.6.12 Creep Resistance, min (ASTM D 1780, substrates per para 5.1 0.25 mm adhesive bondline thickness, 13 mm bond overlap, accelerated heat per para 5.1 or cure per para 5.2, condition at 23 +/- 2 C for 72 h, before
36、 testing. Room Temperature No creep w/dead load weight of5 kg ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A2 Page 6 of 16 Copyright 2002, Ford Global Technologies, Inc. 3.7 ENGINEERING REQUIREMENTS 3.7.1 Adhesion Strength, Not to exceed more than 20% reduction of strength after aging or exposure.
37、(SAE J1523, substrates per para 5.1, 0.25 mm adhesive bondline thickness, 13 mm length overlap, 13 mm/min pull rate, force cure 140 F/60 C per para 5.2) Test at 23 +/- 2 C 12 Mpa min Test at 80 +/- 2 C 5 Mpa min Test at -40 +/- 2 C 14 Mpa min 3.7.1.1 Normal . (Condition for 30 minutes at specified t
38、emperature prior to test) Test at 23 +/- 2 C Test at 80 +/- 2 C Test at -40 +/- 2 C 3.7.1.2 Exposed (Condition at 23 +/- 2 C for 1 h, subject to environmental cycle, force cure 140 F/60 C per para 5.2, test at 23 C) Environmental cycle: - 40 +/- 1 C for 7 days PLUS 38 +/- 1 C for 98 +/- 2 % RH for 7
39、 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for 1 day 3.7.1.3 Aged (Condition at 23 +/- 2 C for 24 h after 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 One Cycle: 1
40、6 h at 38 +/- 2 C and 95 +/-5 % condensing RH 4 h at -40 +/- 2 C 4 h at 80 +/- 2 C ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A2 Page 7 of 16 Copyright 2002, Ford Global Technologies, Inc. Samples are to be conditioned at 23 +/- 2 C and 50 +/- 5% RH over weekends and holidays. Time between condit
41、ions shall not exceed 5 minutes. 30 APGE Cycles (FLTM BI 123-01, modified cycle, substrates per para 5.1 force cure 140 F/60 C, per para 5.2, 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
42、90 +/- 5% RH Samples are to remain in the 50 +/- 2 C and 90 % +/- 5 % environment over the weekends and holidays. 3.7.2 Stress Durability, min (FLTM BV 101-07, substrates per para 5.1, all coupons from one manufacturers lot, report thickness for each coupon and substrate yield strength for manufactu
43、rers lot, force cure 140 F/60 C para 5.2, two fixtures, cyclic corrosion exposure, report data per test method) All samples at a specified 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 3.7.1. 10 +/- 1 %
44、35 cycles 20 +/- 1 % 20 cycles 30 +/- 1 % 15 cycles 40 +/- 1 % 10 cycles 3.7.3 Peel Resistance (ASTM D 1876, 0.25 mm adhesive bondline thickness, 76.2 mm overlap, 127 mm/min pull rate, substrates per para 5.1, force cure 140 F/60 C per para 5.2, Condition for 30 minutes at specified temperature prio
45、r to test) Test at 23 +/- 2 C 125 N/25 mm min Test at 80 +/- 2 C 90 Test at -40 +/- 2 C 75 3.7.4 Fracture Toughness (FLTM BU 121-01, 0.25 mm bondline thickness, substrates per para 5.1, oven cure per para 5.2, condition at specified temperature 30 minutes prior to test, 2 m/s impact velocity, Report
46、 A, h and n for the characterized metal, report R1 and R2 for each coupon assembly) Test at 23 +/- 2 C 0.2 kJ/m2min Test at 80 +/- 2 C 0.2 kJ/m2min Test at -40 +/- 2 C 0.2 kJ/m2min ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A2 Page 8 of 16 Copyright 2002, Ford Global Technologies, Inc. 3.7.5 Fati
47、gue Chart Fig 7 Test Method: Prepare 36 lap shear coupons as prepared per Para 3.7.1, substrates per para 5.1, primary substrate only. Accelerated cure per para 5.2. Condition at 23 +/- 2 C for 2 h. Refer to Para 3.7.1 Shear Adhesion testing at 23 C to determine average static peak load failure. Det
48、ermine fatigue resistance in a dynamic tensile testing machine with a sinusoidal cyclic axial load and a frequency of 10 Hz at less than 1E6 cycles and 20 Hz at greater the 1E6 cycles. Maximum tensile loads to range from 20 to 65% of the static peak failure load. Determine fatigue resistance over ra
49、nge at 20, 30, 40, 50, 60, and 65 %, 3 coupons at each load. Minimum tensile load to be 10% of maximum tensile load. Report peak load vs. cycles to failure and description of failure mode. Normal, Test at 23 C 3.7.6 Cold Adhesion (FLTM BV 101-02, Procedure “E“, 0.5 mm material thickness, substrates per para 5.1, oven cure per para 5.2) No adhesion failure or material cracking. 3.7.7 Ten
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