1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Release/Revision1986 05 30 CDQ1-DR536616 Released E.R.R. L.W.M.WP 3948-a Page 1 of 11SEALER, HOT MELT - PREFORMED - PRESSURE SENSITIVE - ESB-M4G256-BPAINTABLE1. SCOPE:The material defined by this specification is a
2、n extruded pressuresensitive butyl rubber base hot melt sealer.This material is suitable for use on interior and exterior class No. 2surfaces, and will present an acceptable appearance for such areas whenpainted.2. APPLICATION:This specification was released originally for materials used to sealhori
3、zontal and vertical weld joints, such as the upper back panel toquarter panel in the deck lid trough. The material must be applied overelectrocoat or spray primer.Compliance with the performance requirements of this specification doesnot guarantee the hot melt sealer will function for all similar fu
4、nctionson a vehicle. The specific design condition should be evaluated by aplant trial or laboratory simulation prior to release of the material.3. REQUIREMENTS:3.1 QUALITY CONTROLSuppliers must conform to the requirements of Ford Quality SystemStandard Q-101, with control charts and process data an
5、alyzedaccording to Ford Continuing Process Control and Process CapabilityImprovement Manual. Additionally, a Control Plan is required formaterial source approvals.3.2 CONDITIONINGAll test values indicated herein are based on material conditionedin a controlled atmosphere of 23 +/- 2 C and 50 +/- 5%
6、relativehumidity for 24 h prior to testing and tested under the samecontrolled conditions.ENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 2 of 113.3 INFRARED SPECTROPHOTOMETRYFord Motor Company, at its option, may conduct infrared analysis ofmaterial/parts supplied to this specification
7、. The spectraestablished for initial approval shall constitute the referencestandard and shall be kept on file at Ford. All samples shallproduce spectrographs that correspond to the referenced standardwhen tested under the same conditions as those specified on themaster spectra.3.4 DIMENSIONS As spe
8、cified on the engineeringdrawing and/or trim and sealermanual3.5 CONSISTENCY, mm(ASTM D 1321, 100 g Total Load)3.5.1 As received 0.5 - 2.532 Aged, 72 h at 49 C 0.5 - 2.53.6 ASH, %, max 60(Based on Solids Weight)Test Method: Place the crucible containing the solids residue in acool muffle furnace. Sl
9、owly heat to and maintain at 760 +/- 30 Cfor 1 h, cool in desiccator, and weigh.3.7 SPECIFIC GRAVITY 1.0 - 1.23.8 SOLIDS, %, min 98(ASTM D 2834, except heat at 102 +/- 3 Cfor 3 h in a mechanical convection oven)3.9 MANDREL BEND TEST No cracking or adhesion failure(FLTM BN 22-1, material bakeschedule
10、 per para 6.3, heat age testspecimen 14 days at 70 +/- 1 Cbefore test)3.9.1 Test at 23 +/- 2 C3.9.2 Test at -29 +/- 1 CENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 3 of 113.10 FLOW CHARACTERISTICS, mm3.10.1 Minimum Bake Exposure 1.0 - 3.03.10.2 Maximum Bake Exposure 1.0 - 3.0Test Met
11、hod:. Two 0.8 x 100 x 150 mm eletrocoated panels are to beused for determining flow properties. Panels coated withelectrocoat paint described per para 6.2 may be used fortesting. Apply a 1.5 x 25 x 125 mm ribbon of material on twoelectrocoated panels. See sketch below. To assureuniform material cont
12、act, roll the material ribbon witha 2.0 kg roller (ASTM D 1000) using one forward andbackward stroke. Scribe each panel to mark the original materiallocation. Position test panels at 53 +/- 2 attitudeand condition 1 h at 23 +/- 2 C. See sketch. It is recommended that a metal panel rack, manufactured
13、by Atlas Electric Devices Corp. - Chicago, Ill., ModelNo. 19-1323-00, or equivalent, be used to maintain thetest panels at the 53 +/- 2 attitude during flowevaluation tests. Maintain the test panels at a 53 +/- 2 angle andcure one panel at the minimum bake schedule per para6.3. Subject the remaining
14、 test panel to the maximumbake schedule per para 6.3. Allow panels to cool at a 53 +/- 2 attitude for 1 hat 23 +/- 2 C. Determine flow by measuring the distance the materialhas moved below the scribe marks. After flow test, thematerial shall appear as a continuous uninterruptedfilm, any sealer separ
15、ation will constitute a failure.ENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 4 of 11FLOW TEST3.11 ADHESIONShall not be removable in a continuous coherent film when subjectedto the following environments:3.11.1 Normal, 24 h at 23 +/- 2 C3.11.2 Salt Spray, 500 h(ASTM B 117)3.11.3 Therm
16、al Cycle (5 Times). 4 h at 83 +/- 2 C. 4 h at 38 +/- 1 C and 95-100% R.H. 16 h at -29 +/- 1 C. 4 h at 38 +/- 1 C and 95-100% R.H. 4 h at 83 +/- 2 C. 4 h at -29 +/- 1 CENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 5 of 11Sample Preparation: For each adhesion test exposureindicated abov
17、e, prepare samples as follows:. Apply a 1.5 x 25 x 200 mm ribbon of material along thecenter line of two 0.8 x 100 x 300 mm panels. Use a 2 kgroller, as described in para 3.10 to assure uniformmaterial contact with panel. Subject one panel of each substrate to the minimum bakeschedule, and the other
18、 panel to the maximum bakeschedule described per para 6.3. Panels are to be in aflat attitude during bake cycle. Condition panels at 23 +/- 2 C for 1 h minimum in a flatposition.Test Method:. Subject test panels to exposures noted. Condition panels at 23 +/- 2 C for a minimum of 2 hprior to evaluati
19、ng adhesion. Evaluate sealer adhesion to each test panel by makingtwo parallel cuts across ribbon of material. Cutsshould be through to metal and 25 mm apart. Checkadhesion by inserting the tip of a squared spatula underthe edge of the 25 mm wide section of material, and thenattempt to hand peel sea
20、ler at a 90 angle to panel.Material should fail cohesively rather than delaminatingcleanly from substrate surface.3.12 LOW TEMPERATURE RESISTANCE No cracking or adhesion failureTest Method:. Prepare and cure two test panels of each substrate usingprocedure described in para 3.11. After minimum and m
21、aximum bake schedules, condition samples at23 +/- 2 C for 1 h minimum. Expose all test panels for 7 days at 70 +/- 2 C. After heat exposure, condition panels at 23 +/- 2 C for 1 hminimum. Attach each test panel along the bottom edge of a 0.8 x 300 x300 mm CRLC steel panel with pop-rivets or sheet me
22、tal screws.The long side of test panel should align with bottom edge of 300x 300 mm panel.ENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 6 of 113.13 BRIDGlNGTest Method:. Prepare two test fixtures using 0.8 x 100 x 300 mm electrocoatedpanels prepared per para 6.2 as shown in Figure 2.F
23、IGURE 2BRIDGING TEST FIXTURE PREPARATION. Apply a 1.5 x 25 x 200 mm ribbon of material to each testfixture as shown in Figure 3.ENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 7 of 11FIGURE 3SEALER APPLICATION. Cure one test fixture at a minimum bake schedule per para 6.3.1.Subject the
24、second test fixture to the maximum bake schedule perpara 6.3.1. Allow test fixtures to cool for 1 h at 23 +/- 2 C.Inspection Test Method:. Inspect test fixtures to insure that material has satisfactorilybridged raised portion of panel as shown in Figure 2, Section B.Any evidence of tearing will cons
25、titute a failure. Material has satisfactorily bridged metal-to-metal portion ofthe panel as shown in Figure 2, Section A. Any evidence ofgapping will constitute a failure.ENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 8 of 11. Place assembled panels and cold slam apparatus described in
26、 FLTMBN 1-2 in a cold box and condition at -29 +/- 1 C for a minimumof 4 h. Individually mount 300 x 300 mm panels on the slam apparatuswith the test material bottom facing away from fixture. Slam 10times at -29 +/- 1 C.3.14 COMPATIBILITY WITH PRODUCTION PAINTSThis material shall be compatible with
27、all current production paintsystems.No tackiness, porosity, cracking or other deleterious effects ontop coats are permissible, unless they are within acceptableappearance standards established for Class No. 2 surfaces.3.14.1 240 h Weatherometer Exposure(Equipment described in FLTM BO 1-1)3.14.2 96 h
28、 Dry Ultraviolet Light Source(Equipment described in FLTM BV 7-2)Test Method:Evaluate current production spray primers and top coatpaint systems as identified by the Body and ChassisEngineering Office. Three 0.8 x 100 x 300 mm panels of each substratedescribed in para 6.3 are to be prepared for each
29、 topcoat system evaluated. Apply material ribbon “A“ (1.5 x 25 x 125 mm) on centerline of substrate panels as shown in Figure 4. Use 2 kgroller as described in para 3.10.2. Apply appropriate spray primer to entire surface ofpanels per ESB-M2P4. Cure primer 10 minutes at 149 +/-1 C metal temperature.
30、 Allow panels to cool to 23 +/- 2 C and apply materialribbon “B“ (1.5 x 25 x 125 mm) as shown in Figure 4.Roll with 2 kg roller per para 3.10.2, taking care toavoid roller contact with first ribbon applied. Apply appropriate top coat paint to entire test panelsurface per ESB-M2P4. Cure top coat 8 mi
31、n at 120 +/- 1 Cmetal temperature plus a peak of 3 min at 130 +/- 1 Cmetal temperature.ENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 9 of 11. Subject one panel of each top coat system to exposuresper para 3.14.1 and 3.14.2. Retain remaining panel ascontrol. After exposures are complet
32、ed, examine test panels andcompare to control panel.3.15 PACKAGINGThe material shall be supplied in sealed packages and materialblocking is not permitted during container shipping or storage.3.16 UNCURED ADHESION AND RELEASE PAPER REMOVALMaterial shall adhere when hand applied to substrate panelsdes
33、cribed in para 6.2. The release paper shall be removed withoutcausing the uncured material to release from the primer surface.3.17 STORAGE STABILITYThe material shall be stored at temperature below 41 C away fromall sources of heat and sunlight. Heat greatly accelerates aging.Under these storage con
34、ditions, the minimum shelf life of thematerial shall be 6 months. When these materials are stored attemperatures below 23 C, they shall be conditioned at roomtemperature 24 h prior to application. Adequate conditioningpermits the material to obtain its optimum application properties.4. FUNCTIONAL AP
35、PROVAL:Materials being evaluated for initial approval to this specificationshall be subjected to a production trial. Functional trial resultsshould be available to Design and Materials Engineering prior to materialapproval and release.4.1 SUPPLIERS RESPONSIBILITYAll materials supplied to this specif
36、ication must be equivalent inall characteristics to the material upon which approval wasoriginally granted.Prior to making any change in the properties, composition,construction, color, processing or labeling of the materialoriginally approved under this specification, whether or not suchchanges aff
37、ect the materials ability to meet the specificationrequirements, the Supplier shall notify Purchasing, Toxicology, andthe affected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Test data, test samples and a new code identi
38、ficationare to be submitted with the request.Substance restrictions imposed by law, regulations or Ford apply tothe materials addressed by this document. The restrictions aredefined in Engineering Material Specification WSS-M99P9999-A1,unless a different suffix (e.g., A2 or A3) is specified on theen
39、gineering document for the application.ENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 10 of 115. APPROVAL OF MATERIALS:Materials defined by this specification must have prior approval by theresponsible Materials Engineering activity. Suppliers desiring approvalof their materials shall
40、first obtain an expression of interest from theaffected Purchasing, Design, and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity its own laboratory report to the specification (test results,not nominal values), the material designat
41、ion and code number and testspecimens for Ford evaluation. Upon approval, the material will be addedto the Engineering Material Approved Source List.6. GENERAL INFORMATION:The material data included herein is for information only and is not arequirement for the supplier.6.1 MECHANICAL CONVECTION OVE
42、NThe mechanical oven(s) used to cure the material shall be capableof obtaining 205 C metal temperature on body steel (0.8-0.9 mmthickness) within 8-10 min.6.2 SUBSTRATESNominal panel dimension are 0.8 x 100 x 300 mm.Electrocoat primed steel panel: Prepared per ESB-M2P4 performancespecification. Use
43、current production paints as identified by theBody and Chassis Electrical Product Engineering Office.6.3 MATERIAL CURE SCHEDULES6.3.1 Minimum (Includes two bakes):Bake Schedule I 10 min at 149 +/- 1 Cmetal temperatureBake Schedule II 8 min at 120 +/- 1 Cmetal temperatureplus3 min at 130 +/- 1 Cmetal temperature6.3.2 Maximum: 20 min at 177 +/- 1 Cmetal temperature6.4 COLOR Gray or as specified by B&AGOPaint Operation ActivityENGINEERING MATERIAL SPECIFICATIONESB-M4G256-BWP 3948-b Page 11 of 11FIGURE 4PAINT COMPATIBILITY
