1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 04 02 Revised See Summary of Revisions M. Mehandru, FNA 2006 10 27 Activated M. Mehandru Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 9 SEALER, VINYL, LOW DENSITY, EXTRUDABLE, SPRAYABLE WSS-M4G25
2、2-E2 ABRASION RESISTANT, NON-PAINTABLE 1. SCOPE The material defined by this specification is a vinyl based, extrudable, sprayable, sag resistant, abrasion resistant, non-paintable, heat cured sealer. 2. APPLICATION This specification was released originally as an interior seam sealer and underbody
3、stone chip resistance material. The material will not have good appearance when top-coated and therefore should be used only on non-paintable surfaces. This material can be sealer gun extruded and spray applied to body electrocoat primed surfaces. Recommended material cure schedules are specified in
4、 para 5.3. A 0.50 mm wet film thickness is recommended for abrasion resistance. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Comp
5、anys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 SOLIDS, min 95% (ASTM D 2834, except heat at 102 +/- 1 C for 3 h in a mechanical convectional oven. Save sample for next test, para 3.3) 3.3 ASH (Based on solids weight), (ISO 3491, Method A, 760 +/- 30 C) The ash content tole
6、rance for any one supplier shall be +/- 5% based on the recorded ash content for their originally approved production sample. See paragraph 4.4. 3.4 WEIGHT PER VOLUME .87 kg/L, max (ASTM D 816) .93 kg/L sprayed max The weight per volume shall be measured after the material has undergone airless spra
7、ying. Spray the sealer at a 300 mm distance thru a -.79 mm/60 tip at 20 MPa onto a clean steel panel. Measure the density of sprayed sealer with a pycnometer. The weight tolerance for any one supplier shall be +/- 0.06 kg/L, based on the recorded weight of his original approved production sample See
8、 paragraph 4.5. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 9 3.5 VISCOSITY (SAE J1524, VIS-2, 1.32 mm orifice, 280 kPa) Final approval of a specific material viscosity for production shipments shall be made
9、by the affected manufacturing activity. In all cases, the viscosity shall be within process limits as identified on the material control plan. The viscosity tolerance for any one supplier shall be +/- 10%, based on the recorded viscosity of the original approved production sample. 3.5.1 As Received
10、Viscosity +/- 10% (Unagitated - Method “A“) 3.5.2 Aged Viscosity original +50% (Material aged in closed container for increase 72 h at 40 +/- 1 C, Unagitated - Method “A“) 3.6 BRIDGING, max 6.4 mm Test Method: Apply a 13 mm diameter material bead over the 6.4 mm diameter holes shown in sketch below.
11、 Condition the test fixture with material bead for 15 minutes at 23 +/- 2 C, then bake fixture at the minimum bake schedule per para 4.3. Measure the amount of material sag through hole. BRIDGING TEST FIXTURE ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 Printed copies are uncontrolled Copyright 2
12、009, Ford Global Technologies, LLC Page 3 of 9 3.7 SAG RESISTANCE 3.7.1 Horizontal, max 6.4 mm 3.7.2 Vertical, max 6.4 mm 3.7.3 Inverted No loss of material Test Method: Apply a 3 x 30 x 200 mm ribbon of material along the center line of three electrocoated panels prepared per para 4.2 Scribe panels
13、 to mark the initial material location. Position the panels with the material in the attitude above for 1 h. Immediately after conditioning, place panels in an oven to cure material at the minimum bake schedule per para 4.3. Maintain panels in the specified attitude during baking and cooling. Allow
14、the panel to cool to 23 +/- 2 C. Determine the sag by measuring the material movement below the scribe mark. 3.8 ADHESION Shall not be peeled off in a continuous film at any thickness. Test Method: Apply 6.4 - 0 mm tapered material ribbon on two electrocoated panels prepared per para 4.2. See sketch
15、 below. Subject one test panel, to the minimum bake schedule and the other test panel to the maximum bake schedule identified per para 4.3. Condition panels after baking at 23 +/- 2 C for 1 h minimum. Evaluate adhesion by cutting a 25 mm wide strip across the tapered ribbon. Using the tip of a squar
16、e spatula, lift the material at both the thin and thick film edges then attempt to had peel material at 90 from substrate. Save test panels for Heat Stability Test, para 3.9 and Corrosion Resistance Test, para 3.10. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 Printed copies are uncontrolled Copy
17、right 2009, Ford Global Technologies, LLC Page 4 of 9 3.9 HEAT RESISTANCE TEST No evidence of blistering, cracking, charring or other deleterious effects Test Method: Examine the maximum bake panel prepared for Adhesion Test, para 3.8, for any of the above conditions. 3.10 CORROSION RESISTANCE TEST
18、No corrosion or adhesion loss 3.10.1 Option 1 (FLTM BI 123-03, 30 cycles for North America, 50 cycles for Europe) Or 3.10.2 Option 2 (CETP 00.00-L-467, 6 weeks) Note: Report the test method used. 3.11 MANDREL BEND TEST No cracking or (FLTM BV 122-01, material bake schedule adhesion failure per para
19、5.3, heat age test specimen 14 days at 70 +/- 1 C before test) 3.11.1 Test at 23 +/- 2 C 3.11.2 Test at -20 +/- 1 C 3.12 CRACK RESISTANCE, min 5,000 cycles (FLTM BV 115-01, except bake an additional set of panels for 15 minutes at 135 +/- 1 C for normal and aged test, use substrate identified per pa
20、ra 4.2) ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 9 3.13 COMPATIBILITY WITH PRODUCTION PAINTS No color transfer of the topcoat from the sealer to other objects. Test Method: 3.13.1 Prepare test panels per F
21、LTM BV 153-08, Procedure “A“, but with the following modifications: Spray a 7 micrometer (top of panel) to 25 micrometer (bottom of panel) body primer film wedge wet-on-wet over the sealer and bake for 8 minutes at 135 +/- 1 C metal temperature. Spray a 7 micrometer (top of panel) to 25 micrometer (
22、bottom of panel) topcoat film wedge and bake for 10 minutes at 130 +/- 1 C metal temperature. Apply current production paint as identified by the B&CE Materials and Corrosion Protection Engineering Office. 3.13.2 Condition the test panels for 1 h at 23 +/- 2 C. 3.13.3 With moderate pressure, rub the
23、 painted sealer with a white cotton cloth. No paint shall transfer onto the cloth. Min Bake Max Bake Exposure Exposure 3.14 SHEAR ADHESION, min 310 N 800 N (SAE J1523, substrate per para 4.2, 3 mm bondline thickness, 6.54 cm overlap, test at a crosshead speed of 25 mm per min, material bake schedule
24、s per para 4.3) 3.14.1 As received material 3.14.2 Aged material (Material aged in closed container for 72 h at 41 +/- 1 C) 3.15 HARDNESS, DUROMETER “A“ (ASTM D 2240) The hardness tolerance for any one supplier shall be +/- 5 points, based on the original approved production sample. Test Method: App
25、ly enough material into a container (such as an ointment tin) to give a 6 mm thickness slab. Bake material at 135 +/- 1 C for 30 minutes. Condition test sample at 23 +/- 2 C for 4 h, then check instantaneous material hardness. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 Printed copies are uncont
26、rolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 9 3.16 ABRASIVE None Test Method: Dilute a 1 g sample of the material with 1 g of M14J167 special spirits or equivalent, and mix thoroughly. Rub a portion of the diluted material 100 times between 2 pieces of flat, clean plate glass. The
27、 appearance of scratches on the glass plate shall be considered failure. 3.17 SPRAYABILITY Shall be suitable for use in the airless spray equipment designated by the Paint Operation Activity. 3.18 UNDERBODY STONE ABRASION (SAE J400, for North America only) Less than 5% average material loss per test
28、 area per panel and less than 5 average rust point per test panel after 72 h. Test Method: Spray apply sealer to a dry film thickness of 0.5 mm to five 100 x 300 x 0.8 mm electrocoated panels. Bake the panels according to the minimum bake schedule per para 4.3. Subject the bottom portion of the pane
29、ls to 4.75 L of stones total, 0.475 L at a time. Use 7 gauge aluminum backing plate. Manually remove (without rubbing or abrading) all loose and/or blistered materials. Report percentage of material lost (per panel and average over all panels). Ignore any material loss within 5 mm of panel edge. Aft
30、er abrasion testing is completed, condition the panels in an environmental chamber. Use 10 cycles of APGE testing per FLTM BI 023-03: Remove the panels and carefully scrape off remaining sealer with spatula. Record the number of rust spots per panel. Report the average number of rust spots over the
31、5 panels. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7 of 9 3.19 ABRASION RESISTANCE (ASTM D 968 for Europe only) There shall be no exposed metal area showing after 300 L gravel impact. No loss of adhesion on and
32、 around the area of stone impact. Panel Preparation: Test panels of 300 x 100 mm (prepared according to FLTM BI 120-01) shall be coated with the material under test in such a manner (airless) that after curing a dry coating thickness of 0.5 - 0.65 mm is obtained. After 10 minutes at 23 +/- 2 C cure
33、test specimens separately according to FLTM BV 150-05 for the individual region a) min curing cycle b) max curing cycle Condition for 2 h at 23 +/- 2 C and expose in mechanical convection oven maintained at 70 +/- 2 C for 120 h. Test Method: After conditioning for 24 h at 23 +/- 2 C, determine the a
34、brasion resistance according to ASTM D 968, except I.D. of tube 25 mm and at a gravel throughput rate of 30 - 40 liters/h. For each specimen a 5 L volume of fresh gravel shall be used. Check for abrasion resistance and loss of adhesion after 300 L gravel impact. Continue abrasion test until exposure
35、 of metal area and again check for loss of adhesion. Gravel: Type “GABBRO“ grain size 5 - 8 mm Possible Supply Source: ODENWAELDER HARTSTEIN INDUSTRIE GMBH Lise-Meitner-Str. 35 D 63457 Hanau 3.20 ODOR, max Rating 3 (FLTM BO 131-03, for interior application only) North American only SAE J 1351 3.21 F
36、OGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 and 16 hrs.) Fog Number, number 70, min Any fog film present shall be examined for the formation of droplets or coalescence into a clear film. Such conditions, if present, shall be cause for rejection. Uncured and
37、cured samples shall be tested. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 8 of 9 3.22 STORAGE STABILITY (From date of receipt at Ford Motor Company) The material shall be stored at temperatures below 40 C away fr
38、om all sources of heat and sunlight. Heat greatly accelerates aging. Under these storage conditions, the shelf life of the material shall be 4 months. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature prior to application. Adequate conditioning
39、 permits the material to obtain its optimum application properties. Material may not be used after the expiration date unless the supplier has given written documentation to Materials Engineering and the affected Manufacturing Plant that the material conforms to requirements outlined in the material
40、 control plan. The supplier shall also indicate in the letter the number of additional days the material will be usable. 3.23 FUNCTIONAL APPROVAL Materials being evaluated for initial specification shall be subjected to a production trial. Functional trial results should be available to Design and M
41、aterials 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 MECHANICAL CONVECTION OVEN The mechanical oven(s) used to cure the material shall be cap
42、able of obtaining 205 C metal temperature on body steel (0.8 - 0.9 mm thickness) within 8-10 minutes. 4.2 SUBSTRATES Nominal panel dimensions are 0.8 x 100 x 300 mm. Electrocoat primed steel panel: Use current production paints as identified by the Paint Engineering. 4.3 MATERIAL CURE SCHEDULES 4.3.
43、1 Minimum (includes two bakes): First Bake: 8 minutes at 135 +/- 1 C metal temperature Second Bake: 8 minutes at 120 +/- 1 C metal temperature plus 3 minutes at 130 +/- 1 C metal temperature 4.3.2 Maximum : 20 minutes at 177 +/- 1 C metal temperature ENGINEERING MATERIAL SPECIFICATIONWSS-M4G252-E2 P
44、rinted copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 9 of 9 4.4 ASH 40% 4.5 WEIGHT PER VOLUME, Typical 0.87 kg/L max (Refer to para 3.4) 0.93 kg/L sprayed max 4.6 COLOR Gray or as specified by B&AGO Paint Operation Activity 4.7 VOLATILE ORGANIC CONTENT, max ppm 1500 4.8
45、ALCANE RESTRICTION (European use and for interior applied materials only) (VDA 278 (Thermodesorption) The supplied material shall not contain Alcanes (n-Aliphates as C10H22 thru C16H34) based on VOC test method and requirements. 5. SUMMARY OF REVISIONS 2009 04 02 1. Revised Numbering 2. Revised Ash. 3. Revised Weight per volume 4. Updated Corrosion Resistance Test 5. Updated Underbody Stone Abrasion 6. Added Abrasion Resistance for Europe 6. Updated Odor 7. Revised Storage Stability. 8. Updated General Information with Ash and Wt per volume
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