1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 03 27 N-STATUS To N-Status per South Americas request; Inserted 3.0; Deleted 3.19 such as wheel house assemblies to quarter panels and floor part extensions to quarter panels. 3. REQUIEM5ENTK 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATER
2、IALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 COLOR Gray or as specified on the engineering drawing and/or the Trim and Sealer manual. 3.2 VISCOSITY (FLTM BV 103-01, 60 psi (414 kP r e) 3.2.1 As Received 2
3、5 - 70 s 3.2.2 Aged, max 100 s (72 h at 45 +/- 2 C) 3.3 SOLIDS, min 97% (ASTM D 2834, except heat at 100 +/- 2 C for 3h in a mechanical convection oven) 3.4 WEIGHT PER VOLUME (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.2 lb/gal (0.02 kg/L) based on the recorded weight of hi
4、s original approved production sample. (See para 5.2.) ENGINEERING MATERIAL SPECIFICATIONESB-M4G161-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 7 3.5 ADHESION, 100% Cohesive Failure, min 200 lb (890 N) Test Method: Apply the material to the face of the s
5、tandard adhesion button describe in ASTM D 429. Place the companion adhesion plate over the adhesive face, inserting the spacer pin to provide 1/8 in (3.2 mm) controlled adhesive mass over the 2 in2(12.9 cm2) area. Remove the excess material from the edges of the adhesive fixture with a spatula or o
6、ther suitable means. Air dry 15 min and not more than 30 min at 23 +/- C. Cure the assembly in a mechanical convection oven to achieve a metal temperature of 135 +/- 3 C for 8 min. Cool the specimens to 23 +/- 2 C for 4 h minimum and not more than 24 h. Determine the adhesion in a tensile tester ope
7、rated at the rate of 1 in (25 mm)/min. A minimum of 3 adhesion buttons shall be used to establish the average adhesion value. 3.6 VOLUME EXPANSION 30 - 60% Test Method: Apply a semicircular bead of material 5/16 in (8 mm) radius down the center of a 4 x 1 x 0.036 - 0.042 in (100 x 25 x 0.91 - 1.07 m
8、m) (20 gauge CRLC) steel panel. Cut off the bead on both ends to provide the required 2 in (50 mm) length, and specifically to eliminate “necking“ in the test bead. Determine the normal volume by water displacement. Cure the specimens in a mechanical convection oven to achieve a metal temperature of
9、 135 + 3 C for 8 min. Specimens are to be cured in a horizontal position centrally located and protected from direct air flow. To insure the proper cure schedule, place the test samples on a 12 x 12 x 0.035 in (300 x 300 x 0.89 mm) CRLC steel panel while in the oven. Cool the specimens to 23 + 20 C
10、and determine the volume of the expanded material. Calculate the volume increase as percentage of the original volume as follows: V2- VIx 100 Percent Volume Expansion = V1- VCWhere VCVolume of steel coupon 1Volume of original material and coupon V2Volume of coupon and material after cure Repeat abov
11、e procedure except cure at a metal temperature of 205 + 3 C for 20 min. 3.7 WATER ABSORPTION, max Method “A“ (normal, as expanded) 2% Method “B“ (skin - cut through) 3% Test Method: Weigh an aluminum coupon 4 x 1 x 0.030 in (100 x 25 x 0.76 mm) to the nearest milligram. Apply a semicircular bead of
12、material 5/16 in (8 mm) radius down the center of the aluminum coupon. Cut off the bead on both ends (to eliminate “necking“) leaving a 2 in (50 mm) specimen. Bake the specimen in a mechanical convection oven to achieve a metal temperature of 135 + 3 C for 8 min. Specimens are to be cured in a horiz
13、ontal position, centrally located and protected from direct air flow. ENGINEERING MATERIAL SPECIFICATIONESB-M4G161-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 7 To insure the proper cure schedule, place the test samples on a 12 x 12 x 0.035 in (300 x 300
14、 x 0.89 mm) CRLC steel panel while in the oven. Cool this specimen to 23 + 20 C and weigh. Totally immerse the sample in water at 23 + 2 C for 22 h (Method “A“). Method “B“; prior to immersing the sample in water, cut 2 intersecting lines approximately 1 in (25 mm) in length through the natural surf
15、ace skin of the expanded bead. Remove the specimen from the water and lightly blot with a high absorbing paper towel, as rapidly as possible. Weigh the specimen, calculate and express the increase in weight as percent water absorption as follows: W3- W2Percent Water Absorption x 100 W2 W1Where W1Wei
16、ght of aluminum coupon 2Weight of coupon and sealer after cure cycle W3Weight of coupon and sealer after water immersion. Repeat above procedure except cure at a metal temperature of 205 + 30 C for 20 min. 3.8 BRIDGING Shall not sag through the 1/4 in (6.4 mm) diameter holes more than 1/4 in (6.4 mm
17、) when a 1/2 in (13 mm) diameter bead is positioned and cured on the fixture described below. Air dry the assembly for 15 min at 23 +/- 2 C, then cure in a mechanical convection oven at a metal temperature of 135 +/- 3 C for 8 min. Bridging Test Fixture Conversion in mm 1/4 6.4 3/4 19 1-1/4 32 1-1/2
18、 38 ENGINEERING MATERIAL SPECIFICATIONESB-M4G161-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 7 3.9 SAG, max 3/8 in (9.5 mm) (Horizontal and Vertical) Test Method: Apply 2 semicircular beads of material 5/16 in (8 mm) radius by 8 in (200 mm) in length to
19、a 12 x 12 x 0.035 in (300 x 300 x 0.89 mm) oily metal panel. Position the beads on the panel so that the vertical and horizontal sag can occur when the panel is placed in a vertical position. Cut off the beads on both ends leaving a 6 in (150 mm) specimen and specifically to eliminate any possible “
20、necking“. Air dry in a vertical position for 15 min at 23 +/- 20 C. Cure in a mechanical convection oven at a metal temperature of 135 +/- 3 C for 8 min. (Place the panel perpendicular to the horizontal air stream with the sealer beads facing away from the air source. Protect the panel from direct a
21、ir through the use of a blank panel located between the air source and test assembly 6 - 12 in (150 -300 mm) apart.) Determine sag by measuring from the bottom of the vertical and horizontal beads immediately after application and also after the cure cycle. Repeat above procedure except cure at a me
22、tal temperature of 205 +/- 3 C for 20 min. 3.10 CURE CHARACTERISTICS No evidence of cracking, loss of flexibility or failure to adhere to oily metal. Test Method: Apply two 0.060 x 1 x 10 in (1.52 x 25 x 250 mm) ribbons of sealer equally spaced for balance, on a 12 x 12 x 0.035 in (300 x 300 x 0.89
23、mm) oily steel panel and condition at 23 +/- 2 C for 1 h. Cure in a horizontal position, in a mechanical convection oven to achieve a metal temperature of 135 +/- 3 C for 8 min. This cure schedule simulates the minimum baking schedule and minimum metal temperature requirement for production usage. C
24、ool to 23 +/- 2 C and examine for any of the above conditions. Insert the tip of a sharp knife under the edge of the sealer ribbon and cut a tab 1-1/2 in (38 mm) long. Grasp the tab and attempt to peel at 180 along the 10 in (250 mm) dimension. Observe for any indication that the film falls to adher
25、e, or is brittle or friable. Save panel for Low Temperature Resistance Test (para 3.12). 3.11 HEAT STABILITY No evidence of cracking, charring, embrittlement, loss of adhesion or etching of the metal surface. Test Method: Proceed as outlined in para 3.10, except cure at a metal temperature of 205 +/
26、- 3 C for 20 min. (Simulates production over bake). Save panel for Low Temperature Resistance Test (para 3.12). 3.12 LOWT EMPERATURE RESISTANCE No cracking or adhesion failure (FLTM BV 101-02) Test Method: Condition the panels from para 3.10 and 3.11 in a mechanical convection oven for 7 days at 70
27、+/- 2 C. Cool to 23 + 2 C. Place the panel in the slamming apparatus and condition for 4 h at -30 +/- 2 C. Each panel shall be slammed a total of 10 times. ENGINEERING MATERIAL SPECIFICATIONESB-M4G161-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 5 of 7 3.13 RE
28、SISTANCE TO CORROSION, min 500 h (ASTM B 117) 3.13.1 Welded Assembly No loss of adhesion or blistering of the sealer and no evidence of corrosion on the metal surface when subjected to salt spray. Test Method: Apply two 5/32 in (4 mm) beads of the sealer on the centerline of oily steel panels, 6 x 3
29、 x 0.035 in (150 x 75 x 0.89 mm), as shown in Fig 1 and weld 5 times at 1 in (25 mm) intervals. Cure in a mechanical convection oven to achieve the following: 1 Assembly - 8 min at 135 +/- 3 C metal temperature 1 Assembly - 20 min at 205 +/- 3 C metal temperature. Subject the cured assemblies to 500
30、 h salt spray exposure. After exposure, drill out the welds, remove the sealer, clean the panels with a suitable solvent and examine the sealed surfaces for evidence of corrosion. 3.13.2 Unassembled No loss of adhesion or blistering of the sealer and no evidence of corrosion on the metal surface whe
31、n subjected to salt spray. All test panels used for evaluating this material must be approved “Paint Test Quality“ (PTQ) steel panels. Suppliers submitting samples for approval to this specification should include all identification numbers, etc., that define the origin of these steel panels. Test M
32、ethod: Apply an 0.060 x 2 x 10 in (1.52 x 50 x 250 mm) ribbon of sealer to two 4 x 12 x 0.035 in (100 x 300 x 0.89 Mm) oily steel panels. ENGINEERING MATERIAL SPECIFICATIONESB-M4G161-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 6 of 7 Cure in a mechanical conv
33、ection oven to achieve the following: 1 panel - 8 min at 135 +/- 3 C metal temperature 1 panel - 20 min at 205 +/- 3 C metal temperature With a sharp knife make 2 parallel cuts through to the base metal approximately 1 in (25 mm) apart across the 2 in (50 mm) sealer ribbon. Subject the test panels t
34、o 500 h salt spray exposure. After exposure, evaluate adhesion by cutting a 3/4 in (19 mm) wide tab about 1-1/2 in (38 mm) long in one end of the sealer ribbon. Insert the tip of a sharp knife under the tab, grasp with the thumb and attempt to peel at 900 to 180 along the 10 in (250 mm) dimension. A
35、 90% minimum cohesive failure is required. Remove the sealer from the lower half of the test panel by first scraping off most of the sealer with a spatula, avoiding scratching the metal surface. Remove the remaining layer of sealer with a suitable solvent and examine the metal surface for evidence o
36、f corrosion. 3.14 WELDING ACCEPTANCE TEST (FLTM BV 109-01, except 72 h at 55 +/- 2 C heat exposure not required) The sealer shall be weldable immediately upon application and after 30 days storage at temperatures below 40 +/- 2 C. 3.15 FLAMMABILITY WITH CONTINUOUS SPOT WELDING During the welding tes
37、ts (FLTM BV 114-01) less than 5% of the welds shall exhibit flame and all shall be self-extinguishing within 30 s. 3.16 FLOW PHOSPHATE WASH RESISTANCE No evidence of material wash off or displacement due to precleaning or phosphating solutions in flow phosphate tanks. 3.16.1 Method “A“ (Functional)
38、Materials being evaluated for initial approval to the specification shall be subjected to a production trial in an area intended for use. This trial will be conducted after all other specification requirements have been met including laboratory evaluation for flow phosphate wash resistance (Method “
39、B“). 3.16.2 Method “B“ (Laboratory) Apply two, 3/16 x 2.0 x 10 (4.8 x 50 x 250 mm) ribbons of sealer to a 12 x 12 in (300 x 300 mm) oily steel panel and condition at 23+/- 2 C for 3 h. Maintain a flow of water at a temperature of 50 60 C using a 0.375 in (9.53 mm) inside diameter rubber hose pinched
40、 together to form a flat stream at 20 psi (138 kPa) water pressure. (1 L H 0/20 s). Position the panel horizontally at 10 - 11 in (250 - 275 mm) from the flow tip. The water flow shall be directed at each ribbon for 1 minute. Visually examine the ribbons for material “wash off“ and displacement. ENG
41、INEERING MATERIAL SPECIFICATIONESB-M4G161-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 7 of 7 3.17 QUALITY Shall be a smooth homogeneous mixture free from foreign materials and properties detrimental to normal production operations. 3.18 ABRASIVES None Test Me
42、thod: Dilute a 1 g sample of the material with 1 g of M14J167 special spirits, and mix thoroughly. Rub a portion of the diluted material 100 times between two pieces of flat, clean, plate glass. The appearance of scratches on the glass plate shall be considered failure. 5. GENERAL INFORMATION The in
43、formation given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 STORAGE STABILITY Shall be stored at temperatures below 40 +/- 2 C away from all sources of heat and sunlight. Heat greatly accelerates aging. Under these storage conditions, the
44、 minimum shelf. life of the material shall be 3 months. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature prior to application. Adequate conditioning permits the material to obtain its optimum application properties. 5.2 WEIGHT PER VOLUME 10-12
45、 lb/gal (1.20-1.44 kg/L) 5.3 MILL OIL M99C47-A 5.4 MECHANICAL CONVECTION OVEN The mechanical convection oven(s) used to cure the sealers shall be capable of obtaining a 135 +/- 3 C metal temperature on body steel gage thickness in 7-8 min and 205 +/- 3 C temperature in 8-10 min. Heavier gauge stock such as tensile buttons and welded assemblies will require longer cure periods which must be determined by thermocouple and should be conducted in equally efficient ovens as described above.
