1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 09 30 N-STATUS Replaced by WSB-M2G388-A B. Witkowski, NA 2004 11 19 Activated J. Crist Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 9 ADHESIVE, WELDABLE, EXPANDABLE, THERMAL CURE, WSS-M2G411-A ST
2、RUCTURAL, STEEL NOT TO BE USED FOR NEW DESIGN 1. SCOPE The materials defined by this specification are pumpable, one component, thermal curing, weldable, expandable structural adhesives for steel. 2. APPLICATION This specification was released originally for materials used to structurally bond body
3、components such as top rails, rear sills, and cross members to floor pans and inners to outers in a wheel house. This adhesive can be used to bond oily, unclean cold rolled and galvanized steel for body-in white applications. Optimal adhesion strengths and bond durabilities are achieved with adhesiv
4、e bondlines of 0.25 mm and the use of galvanized steel. The material is cured in the electrocoat oven. The Manufacturing Properties and Engineering Performance requirements defined in this specification are based on laboratory sample testing and define the minimum acceptance criteria for adhesive pe
5、rformance. The function and design requirements for the application are defined by the Sub-system Design Specification (SDS), key life test requirements, or vehicle program requirements. Prior to use, the adhesive must be evaluated under the production parameters. The choice of substrates, stamping
6、lubricants, stamping plant processing conditions, assembly plant processing conditions and specific design application may affect adhesive performance. Compliance with this specification does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.1 ST
7、ANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, st
8、amping lubricants and adhesive. The material 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 change
9、d, the adhesive performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 9 3.3 MATERIAL PROPERTIES 3.3.1 Weight Per Volume Report (ASTM D 816) The weight tolerance fo
10、r any one supplier shall be +/- 0.02 kg/L, based on the recorded weight of their original approved production sample. Reference para 4.1. 3.3.2 Volatile Organic Compounds (VOC) Content Report (EPA Method 24, Procedure B) The VOC Content variation for any one supplier shall be +/- 0.01 kg/L, based on
11、 the recorded VOC Content of their original approved production sample. Reference para 4.2. 3.3.3 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 characteris
12、tics shall include, but are not limited to, the following: Shear Strength, para 3.5.1.1 Fracture Toughness, para 3.5.4 Volume Expansion, para 3.5.5 Vertical Expansion Adhesion, para 3.5.6 Tensile Properties, para 3.5.8 3.4 MANUFACTURING PROPERTIES 3.4.1 Rheology (SAE J1524, rotational rheometer with
13、 40 mm diameter parallel plates, 500 micron gap, 50 Pa/sec ramp, stress controlled rheometers use stress range 0 - 3500 Pa, strain controlled rheometers use strain range 0 - 100 sec-1, evaluate material to highest stress or strain as the formulation will allow, report material batch/lot number, iden
14、tify rheometer make and model, for each test condition report yield stress and submit plots for shear stress vs shear rate, submit plot for viscosity vs temperature at mid-range shear rate). Initial (as received) Test at 23 +/- 1 C Test over range 10 to 50 C at increments of 10 C Aged (age then test
15、 at 23 C and application temperature) 7 days at 40 +/- 1 C 90 days at 32 +/- 1 C ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 9 The rheology variation for any one supplier shall be +/- 10%, based on the recorde
16、d 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 that correspond to the reference standard when tested
17、 under the same conditions. Final approval of material rheology for production shipments shall be made by the affected manufacturing activity. In all cases, the rheology shall be within the limits as identified on the material control plan. 3.4.2 Differential Scanning Calorimetry (20 +/- 1 mg sample
18、 size, 5 C/min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) Onset of reaction, min 80 C 3.4.3 Sag Resistance (FLTM BV 118-01, lab calking gun applied 5 mm diameter bead, substrates per para 4.3, condition for 24 h at 40 C, oven schedule per para 4.4, one panel
19、each bake) Horizontal No measurable movement Vertical No measurable movement Inverted No loss of material 3.4.4 Slump Resistance, max 3 mm Assembly aged 30 days at 23 +/- 2 C Assembly aged 30 days at 50 +/- 2 C Test Assembly: Two 25 x 100 mm coupons, prepared per para 4.4, with two 38 x 12 x 3 mm sp
20、acers. 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 with spring clips at each end. Remove excess adhesive from all exteri
21、or edges with a spatula. Test Method: Prepare 3 assemblies per substrate. Subject one assembly per substrate to exposures. After exposure, condition assemblies at 23 +/- 2 C for 24 hours, then bake at minimum bake per para 4.4. Determine the slump by measuring adhesive loss from the bottom of the as
22、sembly. Photograph and record observations of any adhesive loss after exposure or after bake. Repeat the above procedures for maximum bake per para 4.4. ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 9 3.4.5 Brid
23、ging, max 3 mm (SAE J243 ADS-9, Section 3.3, Method D, nonflow fixture, substrates per para 4.3, photograph after exposure and after material cure, bake conditions per para 4.4) Assembly aged 30 days at 23 +/- 2 C Assembly aged 30 days at 50 +/- 1 C 3.4.6 Wash Resistance No measurable movement, disp
24、lacement or wash-off. 3.4.6.1 North American Production (FLTM BV 116-03, 2000 psi) 3.4.7 Electrocoat Compatibility (FLTM BV 119-01, use current production paints as identified by Material Engineering, substrates per para 4.3) Shall not contaminate electrocoat primer bath or cause electrocoat film ir
25、regularities. 3.4.8 Welding Acceptance Test Must Pass (FLTM BV 109-01, 25 coupon assemblies per condition) As prepared (fresh material) Assembly aged 30 days at 23 +/- 2 C Assembly aged 30 days at 40 +/- 2 C 3.4.9 Flammability with Continuous Spot Welding (FLTM BV 140-01, substrates per para 4.3) Du
26、ring welding tests, less than 5% of the welds shall exhibit a flame and all shall be self-extinguishing within 30 s. 3.4.10 Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.4.11 Material Consistency Shall be a smooth homog
27、enous mixture, free from entrapped air, foreign materials and any properties detrimental to normal production operation. ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 9 3.4.12 Storage Stability Heat greatly acce
28、lerates 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 from date of manufacture when stored below 27 C. When materials are stored at temperatures below 23 C, they shall be conditioned at room temperature 24 hou
29、rs prior to application. Application properties are optimized with adequate conditioning of the material. Ambient plant conditions may fluctuate between 15 and 38 C. Materials shall be evaluated for local plant conditions to determine plant specific requirements in excess of 27 C. Critical performan
30、ce characteristics to evaluate for shelf like stability shall include, but are limited to, the following: Rheology, para 3.4.1 Sag Resistance, para 3.4.3 Slump Resistance, para 3.4.4 Weldability, para 3.4.8 Volume Expansion, para 3.5.5 Vertical Expansion Adhesion, para 3.5.6 3.5 ENGINEERING REQUIREM
31、ENTS 3.5.1 Adhesion Strength, min 12.0 MPa, not (SAE J1523, substrates per para 4.3, to exceed more 0.25 mm adhesive bondline thickness, than 20% reduction 13 mm length overlap, 13 mm/min pull rate, aging or exposure. oven cure per para 4.4) 3.5.1.1 Normal (Condition for 30 minutes at specified temp
32、erature prior to test) Test at 23 +/- 2 C Test at 80 +/- 2 C Test at -40 +/- 2 C 3.5.1.2 Exposed (Condition at 23 +/- 2 C for 1 h, subject to environmental cycle, oven cure per para 4.4, 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 +/-
33、 1 C for 7 days PLUS 23 +/- 2 C for 1 day ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 9 3.5.1.3 Aged (Condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2 C) 10 Thermal Cycles One Cycle: 90 +/- 1
34、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: 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 betwe
35、en conditions shall not exceed 5 minutes. 30 APGE Cycles (FLTM BI 123-01, modified cycle, substrates per para 4.3, oven cure per para 4.4, 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 +
36、/- 5% RH Samples are to remain in the 50 +/- 2 C and 90% +/- 5% environment over the weekends and holidays. 3.5.2 Stress Durability, min (FLTM BV 101-07, substrates per para 4.3, all coupons from one manufacturers lot, report thickness for each coupon and substrate yield strength for manufacturers l
37、ot, oven cure para 4.4, 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, and 40% of failure load established for unexposed samples tested at 23 C per para 3.5.1. 10 +/- 1% 22 cycles 20 +/- 1% 15 c
38、ycles 40 +/- 1% 10 cycles ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7 of 9 3.5.3 Peel Resistance (ASTM D 1876, 0.25 mm adhesive bondline thickness, 76.2 mm overlap, 127 mm/min pull rate, substrates per para 4.3,
39、oven cure per para 4.4, condition for 30 minutes at specified temperature prior to test) Test at 23 +/- 2 C 50 N/25 mm min Test at 80 +/- 2 C 50 N/25 mm min Test at -40 +/- 2 C 50 N/25 mm min 3.5.4 Fracture Toughness (FLTM BU 121-01, 0.25 mm bondline thickness, substrates per para 4.3, oven cure per
40、 para 4.4, condition at specified temperature 30 minutes prior to test, 2 m/s impact velocity, Report A, h and n for the characterized metal, report R1 and R2 for each coupon assembly) Test at 23 +/- 2 C 0.30 kJ/m2min 3.5.5 Volume Expansion, range 65 - 115% (FLTM BV 108-02, material cure para 4.4, m
41、in. and max. bake) 3.5.6 Vertical Expansion Adhesion 90 -100% cohesive failure to both panels Test Method: Apply a 5 x 200 mm bead of adhesive to the center of a 0.9x 100 x 300 mm oily panel per para 4.3. Position a 5.5 mm spacer at the midpoint of each side of the panel. Place a second oily metal p
42、anel on the spacers and secure the assembly with clamps. Bake the assemblies in the horizontal position according to the bake schedule in para 4.4. Allow the assemblies to cool to 23 +/- 2 C and remove the clamps and spacers. Separate the panels in a cleavage manner to fail the bond. Report the fail
43、ure mode. 3.5.7 Cold Adhesion (FLTM BV 101-02, Procedure “E“, 0.5 mm material thickness, substrates per para 4.3, oven cure per para 4.4) No adhesion failure or material cracking. ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies,
44、 LLC Page 8 of 9 3.5.8 Tensile Properties (ASTM D 638, 3 +/- 0.5 mm thick, cure adhesive on release paper between 3 mm aluminum panels, oven cure per para 4.4, material temperature shall be determined by inserting a thermocouple probe into the material, Type I specimen, W=10 +/- 0.5 mm, G=50 +/- 0.5
45、 mm, condition at 23 +/- 2 C for 24 h, test at 23 +/- 2 C, 5 mm/min pull rate, use extensometer or strain gage, test at -40, 23, 50 and 80 +/- 2 C) Modulus of elasticity, min 0.6 GPa Elongation at break, min 1.0% Poissons Ratio 0.10 - 0.48 Actual material properties are temperature and formulation d
46、ependent. Results are on file with Materials Engineering. 3.6 FUNCTIONAL APPROVAL 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
47、be made available to Materials Engineering prior to material approval and release. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 WEIGHT PER VOLUME, TYPICAL AS RECEIVED 1.1 1.3 kg/L 4.2 VOC CONTEN
48、T, TYPICAL AS RECEIVED 0.01 kg/L 4.3 SUBSTRATES Materials being evaluated for approval to this specification shall be tested with typical lubricants and at applications levels as specified by Materials Engineering. WSD-M1A333-A2, nominal 0.8 mm thickness, clean, bare, unpolished WSD-M1A333-A2, nomin
49、al 0.8 mm thickness, coated per WSS-M1P94-A to coating weight 60G60G-EL, 60G60G-HD clean, unpolished 4.4 MATERIAL CURE SCHEDULES (FLTM BV 150-05, use table for appropriate regional vehicle assembly site, cure material per material application “Prior to Electrocoat“, min and max bake, condition at 23 +/- 2 C for 1 h min. prior to testing) ENGINEERING MATERIAL SPECIFICATIONWSS-M2G411-A Printed copies are uncontrolled Copyrig
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