1、ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date 2000 08 30 PERFORMANCE REQUIREMENTS, ADHESIVE FOR BONDING PLASTIC BUMPERS Action Revi si0 ns Revised Updated A. Cockman ESB-MI 1 P38-B 1. SCOPE This specification defines the performance requirements of an adhesive or adhesiv
2、e system for bonding plastic bumpers. 2. APPLICATION This specification was released originally for adhesives used to structurally bond plastic bumper assem blies. This specification does not describe initial adhesive cure conditions. The procedures for assembly bonding shall be prescribed in accord
3、ance to adhesive manufacturer and part supplier recommendations. Materials meeting this performance specification are identified on the Corporate Approved Source List. Compliance with this performance specification does not guarantee the structural adhesive will function for all potential applicatio
4、ns on a vehicle. The specific design condition should be evaluated by a plant trial or laboratory simulation prior to release of the material. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers
5、 and part producers must conform to the Companys Quality System Requirements. 3.2 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 “C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and
6、 tested under the same conditions unless otherwise specified. Copyright O 2000, Ford Global Technologies, Inc ENGINEERING MATERIAL SPECIFICATION ESB-MI 1 P38-B 3.3 SHEAR ADHESION Subject bonded test assemblies to the following exposures: Normal, min (Condition for 30 min at specified temperature pri
7、or to test) 3.3.1 Test at 23 +/- 2 OC 3.3.2 Test at 88 +/- 1 OC 3.3.3 Test at -29 +/- 1 OC Minimum load specified or substrate breakage 2.4 MPa 1.0 MPa 4.2 MPa 0 Environmental Aged, min 3.3.4 1000 h heat age at 88 +/- 1 OC 2.8 MPa 3.3.5 1000 h humidity at 38 +/- 2 OC and 95 - 100% RH 3.3.6 1000 h wa
8、ter immersion described per FLTM BI 4-1 3.3.7 240 h salt spray described per ASTM B 11 7 2.3 MPa 1.3 MPa 1.7 MPa 3.3.8 10 thermal cycles: 2.9 MPa 4 h at 88 +/- 1 OC, 4 h humidity (38 +/- 2 OC and 95 - 100 % RH), 16 h at -29 +/- 2 OC Test Method: Prepare a minimum of 3 test assemblies per test condit
9、ion as illustrated in Figure 1. Test substrates shall consist of 1 O0 x 25.4 x 3 mm coupons identified in para 5. Bond test coupons and condition at 23 +/- 2 OC until full adhesive cure. Subject test assemblies to the environments listed above. 0 Allow test assemblies to condition 24 h minimum after
10、 environmental exposure before pull test. Conduct shear pull test on a tensile tester at a rate of 13 mm per minute. Report peak load at failure and indicate type of failure mode. Page 2 of 6 Copyright O 2000, Ford Global Technologies, Inc ENGINEERING MATERIAL SPECIFICATION ESB-MI 1 P38-B Figure 1 O
11、VERLAP SHEAR ASSEMBLY 12.7 mm 3.4 CREEP RESISTANCE (ASTM D 1780, prepare three test samples per para 3.3, apply a 4.5 kg dead weight load to test samples and expose to 88 +/- 1 OC for 24 h) 3.5 MANDREL BEND FLEXIBILITY adhesion No Slippage No cracking or loss to substrate Test Method: 0 Apply a 13 m
12、m wide x 3 mm thickness ribbon of adhesive centered lengthwise on two 250 x 50 x 3 mm panels identified in para 5. Condition test panels after bonding at 23 +/- 2 OC until adhesive full cure. Conduct 60 mandrel bend test at 23 +/- 2 OC and -29 +/- 2 OC over a 50 mm diameter mandrel. Substrate is in
13、contact with mandrel during test. 0 Repeat above procedure on test assemblies heat aged at 70 +/- 2 OC for 2 weeks. Page 3 of 6 Copyright O 2000, Ford Global Technologies, Inc ENGINEERING MATERIAL SPECIFICATION ESB-MI 1 P38-B 3.6 COLD SLAM RESISTANCE (FLTM BV 1-2, 10 cycles of 6 slams per cycle at -
14、29 +/- 2 OC, 3 samples minimum) No cracking,adhesion or cohesion failure 0 Prepare test assemblies as illustrated in Figure II. Test substrates shall consist of 100 x250 x 3 mm panels identified in para 5. 0 Condition test assemblies after bonding at 23 +/- 2 OC until adhesive full cure. 0 Mechanica
15、lly attach bonded test assembly to a 300 x 300 x 0.76 mm CRS base panel. Centrally locate test assembly on base panel. Conduct test as outlined per FLTM BN 1-2 following steps 9, IO, and 11. Position panel in slam fixture with test assembly facing inward. Subject each test assembly to 10 cycles of 6
16、 slams per cycle at -29 +/- 2 OC. 0 Figure II COLD SLAM TEST ASSEMBLY bead 0.13 rnrn inboard from V test assembly edge 10Ox250mm Centrally locate and mechanically attach test assembly to base panel Page 4 of 6 Copyright Q 2000, Ford Global Technologies, Inc ENGINEERING MATERIAL SPECIFICATION ESB-MI
17、1 P38-B 3.7 REVERSE IMPACT PLAQUE TEST Test plaques shall exhibit no less than (FLTM BO 17-2) 80% of the impact resistance of the control plaques and failure mode must be ductile. Test Method: 0 Impact test samples must be injection molded 127 mm x 127 mm or 101.6 mm x 101.6 mm plaques with smooth s
18、urfaces and 2.54 mm thick. Prepare five test samples with adhesive applied to one side, 1.02 mm thick, covering at least a 76.2 mm diameter area in center of plaque. Subject the five test plaques and the five control plaques to bake cycle below: 30 min 77 OC (oven temp) 30 min room temp 30 min 77 OC
19、 (oven temp) Adhesive must be fully cured. Condition panels at test temperature for at least 2.5 h prior to impact testing. Reverse impact plaques (adhesive side out) at 15 mph and a temperature of -29 OC +/- 2 oc. 3.8 IN-PLANT PROCESS COMPATIBILITY No evidence of adhesion loss or other deleterious
20、effects on adhesive bond quality Test Method: Prepare three test samples as shown in Figure I, para 3.3. Bond coupons and condition at 23 +/- 2 OC for 1 h. Simulate implant process conditions by exposing test assemblies to deionized water immersion at 75 +/- 2 OC for 30 min. then heat at 82 +/- 2 OC
21、 for 1 h. Allow test assemblies to return to 23 +/- 2 OC for 24 h. Conduct shear pull test on a tensile tester at a rate of 25 mm per minute. Report peak load at failure and indicate type of failure mode. Shear adhesion values must be comparable to results obtained per para 3.3.1 Page 5 of 6 Copyrig
22、ht O 2000, Ford Global Technologies, Inc ENGINEERING MATERIAL SPECIFICATION ESB-MI 1 P38-B 3.9 3.10 3.1 1 BUMPER PERFORMANCE REQUIREMENTS Parts assembled with adhesive shall meet all performance requirements specified on engineering drawing. In addition, bumper assemblies shall be exposed to environ
23、mental conditions from section 3.3 as recommended by Body and Chassis Engineering Materials Engineering. These bumpers will be impact tested and evaluated for approval by PPE, Design, and Materials Engineering. The tested bumpers shall yield satisfactory failure modes. FUNCTIONAL APPROVAL Materials
24、being evaluated for initial approval to this specification shall be subjected to a production trial. Functional trial results should be available to Design and Materials Engineering prior to material approval and release. SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be
25、equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall
26、notify the affected Purchasing, and Materials Engineering activities (with reasons) of the proposed changes. Upon notification of the Company, further instructions will be provided. Note: Suppliers should be prepared to provide test data and samples demonstrating compliance to this specification, if
27、 requested. Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in Restricted Substance Management Standard WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS This specification is intended to define the perfo
28、rmance and/or properties of finished parts or systems of combined materials. An Engineering Material Approved Source listing is not applicable for this specification. Product Engineering materials referenced in this document and/or the affected engineering drawing, which require prior Engineering ap
29、proval, are shown in the Engineering Material Approved Source List under the specification cited. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. SUBSTRATES: ESB-M4D442-A3 or as specified on engineering drawing. Page 6 of 6 Copyright O 2000, Ford Global Technologies, Inc
