1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 08 19 Activated J. Crist Printed copies are uncontrolled Page 1 of 17 Copyright 2002, Ford Global Technologies, Inc. STRUCTURAL PERFORMANCE, CAVITY REINFORCING WSS-M99P33-A ENGINEERED PARTS, HEAT CURING
2、 1. SCOPE This specification defines the adhesive/polymer material performance requirements for cavity reinforcing heat curing, engineered parts applied in the body shop. These parts are used to improve localized joint stiffness and torsional rigidity. 2. APPLICATION The specification was originally
3、 released for the adhesive/polymer in engineered parts applied to oily metal in the body shop and cured in the electrocoat oven. The parts are used to improve localized joint stiffness and torsional rigidity in applications such as window frame, pillar to roof, pillar to rocker, rocker and rail sect
4、ions. These engineered parts are not intended to be used for skin panel stiffening or oil canning. Special consideration is required when evaluating the use of these engineered parts in crash or crush sensitive locations. Sensitivity studies should be conducted since the material properties can chan
5、ge with temperature and environmental aging. The engineered parts are supplied with an adhesive/polymer as a drop-in part or attached to a carrier. The adhesive/polymer on drop-in parts may be supplied in a pressure sensitive/tacky version or non-tacky version with attachments. On parts supplied wit
6、h a carrier, the carrier may be a thin metal foil, metal backing plate, nylon or other specified carrier material. The adhesive/polymer cures at electrocoat oven temperatures. Material cure is critical to long term material performance. It is recommended that time/temperature data packs be placed on
7、 a vehicle in the intended locations to determine the time at temperature requirements for a given application prior to release. The on-vehicle material time at electrocoat oven temperatures must fall within the cure window for the approved material. After release, periodic follow-up time/temperatur
8、e checks are recommended to insure cure performance is maintained. The Manufacturing Properties and Engineering Performance requirements defined in this specification is based on laboratory sample testing and defines the minimum acceptance criteria for adhesive/polymer material performance. The func
9、tion and design requirements for the engineered part are defined by the component SDS (Sub-system Design Specification), key life test requirements, or vehicle program requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 2 of 17 Copyright 2002, Ford Global Technologies, Inc. Prior to u
10、se, the engineered part must be evaluated under the intended application processing parameters. The choice of substrates, stamping lubricants, stamping and assembly plant processing conditions and specific design application may affect engineered part performance. Compliance with this specification
11、does not guarantee the engineered part 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 Materials (WSS-M99P1111-A). 3.2
12、 SYSTEM COMPATIBILITY Initial material approval was based on a specific material system which included the substrate, stamping lubricants and adhesive/polymer. The originally approved material system was oven cured using specific production process parameters. The choice of substrates, stamping lubr
13、icants, stamping and assembly plant processing conditions and specific design application may affect adhesive/polymer/engineered part performance. If any of these parameters are changed, the material performance must be validated using the new parameters. 3.3 ENGINEERED PART The dimensions and const
14、ruction of the engineered part, adhesive/polymer plus attachments or carrier if required, shall be specified on the engineering drawing. Each part shall meet the specification requirements under the time/temperature cure conditions for each body application site. On-vehicle time/temperature oven cha
15、rts shall be provided for each application site. Test data for the paragraphs listed below shall be submitted for each new part prior to release. Surrogate part testing for similar parts may be accepted, if concurred upon by the responsible Supplier Technical Assistance Activity. 3.3.1 Phosphate Was
16、h Resistance 3.3.2 Uncured Adhesion 3.3.3 Adhesion Test 3.3.4 Adhesion Bake Test ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 3 of 17 Copyright 2002, Ford Global Technologies, Inc. 3.3.5 Adhesion to the carrier / Attachment 3.3.6 Release Paper Adherence and Removal 3.3.7 30 Cycles APGE (Part
17、 shall no evidence of undercutting between the material and carrier or attachment. Material shall be firmly anchored to the carrier or attachment.) 3.4 MATERIAL PROPERTIES 3.4.1 Density Report (ISO 845/ASTM D 3574, Test A, interior density) The density variation for any one supplier shall be +/- 10
18、%, based on the recorded density of their original approved production sample. Reference para 4.3. 3.4.2 Volume Change Report (FLTM BV 108-02, material cure per para 4.2) The volume change variation for any one supplier shall be +/- 25 %, based on the recorded volume change of their original approve
19、d production sample. Reference para 4.4. 3.4.3 Volatile Organic Compounds (VOC) Content Report (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. 3.4.4 Cure Requirements R
20、eport (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: Volume change, para 3.4.2 Compressive modulus, para 3.6.1
21、Shear adhesion, para 3.6.2 ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 4 of 17 Copyright 2002, Ford Global Technologies, Inc. 3.4.5 Differential Scanning Calorimetry Report (20 +/- 1 mg sample size, 10 C/min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve)
22、 Report onset of reaction 3.5 MANUFACTURING PROPERTIES 3.5.1 Phosphate Wash Resistance Pressure Sensitive/Tacky Materials - No measurable movement, dissolution, displacement or evidence of material wash off or lifting from panel. Non-tacky Materials - No measurable dissolution or evidence of materia
23、l wash off. Constructed Parts - No measurable movement, dissolution, displacement or evidence of material wash off from carrier, if present. Attachment, if present, shall not be dislodged or displaced. 3.5.1.1 North American Production (FLTM BV 116-01, Methods B, substrates per para 4.1) Panel Prepa
24、ration: Cut a 100 x 150 x 4 mm strip of the material and apply a 300 x 300 mm panels prepared for each substrate per para 4.1. For pressure sensitive or tacky materials, pass a 2.2 kg roller over samples per ASTM D 1000. For non-tacky materials, attach material to the 300 x 300 mm panels using pin a
25、ttachments in each of the four corners of the adhesive/polymer strip. Condition at 23 +/- 2 C for 1 hour prior to performing wash test. For constructed parts, fixture part and perform test. ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 5 of 17 Copyright 2002, Ford Global Technologies, Inc. 3.
26、5.1.2 European Production Test Method: Prepare a test panel (300 X 100 X 0.8 - 0.9 mm) according to FLTM BZ 250-11 oiling grade Normal. Apply a ribbon of test material (250 x 30 x 5 mm) to the panel. Condition for 2 h at 23 +/- 2 C. Wash, phosphate and electrocoat the test panel under current proces
27、s conditions. 3.5.2 Electrocoat Compatibility Must Pass (FLTM BV 119-01, use current production paints as identified by Materials Engineering) Shall not contaminate electrocoat primer bath or cause electrocoat film irregularities. 3.5.3 Uncured Adhesion Pressure Sensitive/Tacky Materials - The uncur
28、ed material shall not peel at the edges or fall off the panel. Non-tacky Materials - The uncured material shall not slump or sag between attachments or flow off the carrier. Constructed Parts - The uncured materials shall not slump, sag, peel or fall off the carrier, if present. An attachment, if pr
29、esent, shall not be dislodged or displaced. Test Method: Prepare four panels for each substrate per para 4.1. Cut four 100 x 150 x 4 mm strips of the material and apply to four 300 x 300 mm panels prepared for each substrate per para 4.1. For pressure sensitive or tacky materials, pass a 2.2 kg roll
30、er over samples per ASTM D1000. ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 6 of 17 Copyright 2002, Ford Global Technologies, Inc. For non-tacky materials, attach material to the 300 x 300 mm panels using pin attachments in each of the four corners of the adhesive / polymer strip. Invert tw
31、o panels immediately after material application and condition for 72 h at 40 C. Observe for peeling or lifting of adhesive/polymer from panel or slump or sag between attachments, as appropriate. Save panels for Adhesion Bake Test, para 3.5.4 Stand the remaining two panels vertically immediately afte
32、r material application and condition for 72 h at 40 C. Observe for peeling or lifting of material from panel or slump or sag between attachments, as appropriate. Save panels for Adhesion Bake Test, para 3.5.4. For constructed parts, fixture and condition for 72 h at 40 C. Observe for slump, sag, pee
33、l or materials separation from the carrier, if present. Observe for any change to the attachment, if present. Save parts for Adhesion Bake Test, para 3.5.4 3.5.4 Adhesion Bake Test Pressure Sensitive/Tacky Materials - The material must not peel at the edges or fall off the panel in the bake oven. No
34、n-tacky Materials - The material shall not slump or sag between attachments or flow off the carrier in the bake oven. For constructed parts - The material shall not slump, sag, peel at the edges or separate from the carrier, if present. An attachment, if present, shall not be dislodged or displaced.
35、 The cured material shall be firmly anchored to the carrier or attachment. Neither the carrier nor the attachment shall show an evidence of distortion or degradation. Test Method: Cure the panels per para 4.2, maintaining the inverted or vertical positions in the oven. Observe panels for peeling, li
36、fting, slump, sag or flow. ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 7 of 17 Copyright 2002, Ford Global Technologies, Inc. Save panels for Cold Slam, para 3.6.3 For constructed parts, fixture and cure the parts for 30 minutes at 180 C. Observe for material slump, sag, peel at the edges o
37、r separation from the carrier, if present. Observe for any change to the attachment location, if present. Verify that the material is firmly anchored to the carrier or attachment. Evaluate the carrier and attachment for any evidence of distortion or degradation. 3.5.5 Adhesion to the Carrier / Attac
38、hments (Materials with a carrier or attachments only) Flexible Carrier - The adhesive polymer shall not delaminate or crack when folded 180 degrees upon itself. The carrier shall not contain any loose fibers or slivers nor crack. Rigid Carrier - The adhesive/polymer shall not delaminate from the car
39、rier during shipment, storage, application and processing under plant conditions. Attachments - The attachments shall not pull or fall out of the adhesive/polymer during shipment, storage, application and processing under plant conditions. 3.5.6 Release Paper Adherence and Removal Pressure Sensitive
40、/Tacky Materials only) The release paper must remain attached to the adhesive / polymer surface during shipment and handling. It must 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
41、 part and plant specific. Release paper information shall be noted in the supplier control plan. 3.5.7 Odor 3.5.7.1 Odor (North American Production) Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.5.7.2 Odor (European Producti
42、on), Rating 2 max. (FLTM BO 131-01, cured material per 3.3) ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 8 of 17 Copyright 2002, Ford Global Technologies, Inc. 3.5.8 Uncured Flammability (ISO 3795/SAE J369) Burn Rate, max 100 mm/min Uncured material shall not ignite, out gas or burn under ty
43、pical plant processing conditions such a exposure to weld flash or high heat exposure from nearby welding operations. 3.5.9 Storage Stability 3 Months Heat and moisture will accelerate aging. The materials shall be stored in sealed packages (if so recommended by the supplier) away from all sources o
44、f heat and moisture. The shelf life of the material shall be 3 months from date of manufacture when stored at temperatures below 32 C. Ambient plant conditions may fluctuate between 15 C and 38 C. Materials shall be evaluated for local plants conditions to determine plant specific requirements for t
45、emperatures in excess of 32 C. Deviations from the shelf life requirement shall be identified and concurred upon by the plant and noted in the supplier control plan. When materials are stored at temperatures below 23 C, they shall be conditioned at room temperature for a minimum of 24 hours prior to
46、 application. Application properties are optimized with adequate conditioning of the material. Critical performance characteristics to evaluate for shelf life stability shall include, but are not limited to, the following: Volume change, para 3.4.2 Uncured Adhesion, para 3.5.3 Adhesion Bake Test, pa
47、ra 3.5.4 Release Paper Adherence and Removal, para 3.5.5 Adhesion to the Carrier / Attachments, para 3.5.6 Compressive modulus, para 3.6.1 Lap shear adhesion, para 3.6.2 ENGINEERING MATERIAL SPECIFICATION WSS-M99P33-A Page 9 of 17 Copyright 2002, Ford Global Technologies, Inc. 3.6 ENGINEERING REQUIR
48、EMENTS 3.6.1 Elastic Compression Modulus, ECOMP, MPa (ASTM D 1621, cylindrical test samples, diameter 30 +/- 5 mm, height 2 x diameter, material cure per para 4.2, record up to a minimum of 25 % over yield point, report compressive modulus, compressive yield point, report uncured sample volume and w
49、eight, report cured sample weight prior to and after environmental exposure, cured sample density and cured sample dimensions, submit stress-strain curve, measure exact sample dimensions for each samples and save for 3.8.6 Dimensional Stability) Sample preparation: Insert uncured material into an aluminum cylindrical tube lined with release paper with an inside diameter of 30 +/- 5 mm. Sample volume to be determine by minimum expansion assumption used for engineering part design. Cure material per para 4.2 using two thermocouple probes to
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