1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2009 11 12 N-STATUS Replaced by WSS-M4G177-B4 M. Mehandru, NA 1989 01 18 CTS1-DR406626 Released WP 3948-a Page 1 of 8 SEALER, VINYL BASED - SELF LEVELING - HEAT CURE - ESB-M4G177-B2 PAINTABLE - PUMPABLE - FO
2、R ELECTROCOATED SUBSTRATES NOT TO BE USED FOR NEW DESIGN 1. SCOPE: The material defined by this specification is a lead free vinyl based, self leveling, paintable, heat curing sealer. This specification has been advanced due to the removal of asbestos from the sealer. 2. APPLICATION: This specificat
3、ion was released originally for sealing exterior body seams, such as drip rail to roof ditch, and is intended for use over freshly baked electrocoat primer. Acceptable paintability is achieved with or without primer surfacer on sealer. 3. REQUIREMENTS: 3.1 QUALITY CONTROL Suppliers must conform to t
4、he requirements of Ford Quality System Standard Q-101, with control charts and process data analyzed according to Ford Continuing Process Control and Process Capability Improvement Manual. Additionally, a Control Plan is required for material source approvals. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR T
5、HERMAL ANALYSIS All samples shall produce spectra or thermograms that correspond to the reference standard when tested under the same conditions. The infrared spectra or thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated m
6、aterial laboratory. 3.3 CONDITIONING All test values indicated herein are based on materials conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for 24 h prior to testing and tested under the same controlled conditions. 3.4 SOLIDS, min 96 % (ASTM D 2834, except heat
7、 at 102 +/- 1 C for 3 h in a mechanical convection oven Save sample for next test, para 3.5) ENGINEERING MATERIAL SPECIFICATION ESB-M4G177-B2 WP 3948-b Page 2 of 8 3.5 ASH, max 36 % (Based on the Solids weight) Test Method: . Place the crucible containing the solids residue in a cool muffle furnace.
8、 . Slowly heat to and maintain at 760 +/- 30 C for 1 h . Cool crucible in a desiccator and weigh. 3.6 WEIGHT PER VOLUME 1.35 - 1.55 kg/L (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.02 kg/L, based on the recorded weight of his original approval production sample. 3.7 VISCOSI
9、TY (SAE J 1524, 2.64 mm orifice, 138 kPa) 3.7.1 As Received Viscosity 4 - 30 s (Unagitated - Method “A“) 3.7.2 Aged Viscosity 50 s increase max. (Material aged in closed container from initial for 72 h at 41 +/- 1 C, Unagitated - viscosity Method “A“) Final approval of a specific material viscosity
10、for production shipments shall be made by the affected manufacturing activity. In all cases, the viscosity shall be within specification limits. 3.8 ADHESION Shall not be peeled off in a continuous film. Test Method: . Apply a ribbon of material, 25.4 x 152.4 x 2.032 mm, on two electrocoated panels,
11、 identified per para 6.2. . Subject one test panel to the minimum bake schedule and the other test panel to the maximum bake schedule identified per para 6.3. . Evaluate adhesion by cutting a 25 mm wide strip across the ribbon. Using the tip of a squared spatula, lift the material, then attempt to h
12、and peel material at 90 deg from substrate. . Save test panels for heat stability test, para 3.9, and corrosion resistance test, para 3.10. ENGINEERING MATERIAL SPECIFICATION ESB-M4G177-B2 WP 3948-b Page 3 of 8 3.9 HEAT RESISTANCE TEST No evidence of blistering, cracking, charring, or other deleteri
13、ous effects Test Method: . Examine the test material prepared for Adhesion Test, para 3.8, for any of the above conditions. 3.10 CORROSION RESISTANCE No corrosion or adhesion loss Test Method: . Expose the panels prepared in para 3.8 for 240 h in the salt spray cabinet described per ASTM D 117. . Co
14、ndition the test panels after exposure at 23 +/- 2 C for 24 h. . Evaluate material adhesion as described in para 3.8. Observe for any evidence of corrosion originating directly under material. 3.11 MANDREL BEND TEST No cracking or adhesion failure (FLTM BV 22-1, material bake schedule per para 6.3,
15、heat age test specimen 14 days at 70 +/- 1 C before test) 3.11.1 Test at 23 +/- 2 C 3.12 COMPATIBILITY WITH PRODUCTION PAINTS (SAE J 1800) No tackiness, staining, discoloration, or other deleterious effects on topcoats. 3.12.1 500 h QUV (Equipment described in ASTM G 53) 3.12.2 336 h Heat Age at 70
16、+/- 2 C Test Method: . Prepare six test panels per SAE J 1800, Method No. 1 and Method No. 2, use a primer bake per Schedule I para 6.3.1, and a topcoat bake per Schedule II para 6.3.1. Apply current production paints as identified by the Body and Chassis Product Engineering Office. . Condition pain
17、ted panels at 23 +/- 2 C for 72 h. . Subject one primed panel with topcoat to each exposure listed above. Retain extra panel as control. . After exposure, examine test panels and compare to the control panel. ENGINEERING MATERIAL SPECIFICATION ESB-M4G177-B2 WP 3948-b Page 4 of 8 3.13 REPAINT CRACK R
18、ESISTANCE No cracks Test Method: . Fill the inside cover of six 1 L tin can lids with sealer. . Paint three test panels (lids) per SAE J 1800, Method No. 1 and Method No. 2, use a primer bake per Schedule I, para 6.3.1, and a topcoat bake per Schedule II, para 6.3.1. Apply current production paints
19、as identified by the Body and Chassis Engineering Product Office. . Expose painted lids to the following paint repair cycles 10 times: 140 +/- 2 C for 17 min oven time 23 +/- 2 C for 20 min . Observe for any evidence of paint/sealer cracking after each cycle. 3.14 SHEAR ADHESION, min (FLTM BV 1-6, s
20、ubstrate per para 6.2, 0.25 mm bondline thickness, material bake schedules per para 6.3) 3.14.1 As Received Material 2.5 MPa 3.15 HARDNESS, DUROMETER “A“ 50 - 75 (ASTM D 2240) Test Method: . Apply enough material into a container (such as an ointment tin) to give a 6.35 mm thickness slab. . Bake mat
21、erial at 149 +/- 1 C for 20 min. . Condition test sample at 23 +/- 2 C for 4 h, then check instantaneous material hardness. 3.16 LOW TEMPERATURE RESISTANCE No cracking or (FLTM BV 1-2) adhesion failure Test Method: . Condition the panels prepared in para 3.12 for 7 days at 70 +/- 1 C. . Place the pa
22、nels in the slamming apparatus and condition for 4 h at -29 C. . The panels shall be slammed a total of 10 times. ENGINEERING MATERIAL SPECIFICATION ESB-M4G177-B2 WP 3948-b Page 5 of 8 3.17 CURED SEALANT PROPERTIES 3.17.1 Normal Tensile Strength, min 2.5 MPa (ASTM D 412, Die “C“, pulled at 300 mm/mi
23、n. Bake per Schedule I & II, para 6. 3.1) Elongation, min 100 % Tear Strength, min 10. 0 N/mm (ASTM D 624, Die “C“, pulled at 500 mm/min) 3 17.2 Aged Tensile Strength, min 2.5 MPa (ASTM D 412, Die “C“, pulled at 300 mm/min. Bake per Schedule I & II, para 6.3.1) Elongation, min 100 % Tear Strength, m
24、in 10.0 N/mm (ASTM D 624, Die “C“, pulled at 500 mm/min) 3.18 FLOW RATE 25 - 500 mm Test Method: . Block the 6.35 mm groove in the flow rate fixture (Fig. 1) 150 mm from the top edge. . Fill the 150 mm upper portion of the groove with material specified in this specification. . Remove the block, all
25、ow material to flow for 30 min then subject the test assembly to bake Schedule I para 6.3.1. . Remove test assembly from heat exposure and measure the total amount of flow. . Final approval of a specific material flow rate for production shipments shall be made by the affected manufacturing activity
26、. In all cases, the flow rate shall be within specification limits. 3.19 ABRASIVE None Test Method: . Dilute a 1 g sample of the material with 1 g of M14J507 Naphtha 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. ENGINEERING MATERIAL SPECIFICATION ESB-M4G177-B2 WP 3948-b Page 6 of 8 3.20 STORAGE STABILITY The material shall be stored at temperatures below 41 C away from all sources of heat and sunlight. Heat greatly accelerates aging. Un
28、der these storage conditions, the 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. 3.2
29、1 MATERIAL CONSISTENCY Shall be a smooth, homogenous mixture free from foreign materials and properties detrimental to normal production operations. Materials must be free from air entrapment. 4. FUNCTIONAL APPROVAL: Materials being evaluated for initial approval to this specification shall be subje
30、cted to a production trial. Functional trial results should be available to Design and Materials Engineering prior to material approval and release. 4.1 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval
31、 was originally granted. Prior to making any changes in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier
32、 shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions impos
33、ed by law, regulations or Ford apply to the materials addressed by this document. The restrictions are defined in Engineering Material specification WSS-M99P9999-A1, unless a different suffix (e.g, A2 or A3) is specified on the engineering document for the application. 5. APPROVAL OF MATERIALS: Mate
34、rials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Suppl
35、ier shall submit to the affected Materials Engineering activity its own laboratory report to the specification (test results, not nominal values), the material designation and code number and test specimens for Ford evaluation. Upon approval, the material will be added to the Engineering Material Ap
36、proved Source List. ENGINEERING MATERIAL SPECIFICATION ESB-M4G177-B2 WP 3948-b Page 7 of 8 6. GENERAL INFORMATION: The material data included herein is for further information. 6.1 MECHANICAL CONVECTION OVEN The mechanical oven(s) used to cure the material shall be capable of obtaining 205 C metal t
37、emperature on body steel (0.89 - 0.9 mm thickness) within 8 - 10 min. 6.2 SUBSTRATES Nominal panel dimensions are 0.8 x 100 x 300 mm. Electrocoat primed steel panel: Prepared per ESB-M2P4 performance specification. Use current production paints as identified by the Body and Chassis Product Engineeri
38、ng Office. 6.3 MATERIAL CURE SCHEDULES 6.3.1 Minimum (includes two bakes): Bake Schedule I 8 min at 135 +/- 1 C metal temperature Bake Schedule II 8 min at 120 +/- 1 C metal temperature plus 3 min at 130 +/- 1 C metal temperature 6.3.2 Maximum: 20 min at 177 +/- 1 C metal temperature ENGINEERING MATERIAL SPECIFICATION ESB-M4G177-B2 WP 3948-b Page 8 of 8
