1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Release No. Release/Revision 2014 10 17 N Status No replacement L. Sinclair, NA 1986 05 30 CDQ1-DR536616 Revised was ESB-M4G256-A2 E. Rezendes LWM 1984 12 06 CE01-AF527299 WP 3948-a Page 1 of 10 SEALER, HOT MELT - PREFORMED
2、- NON TACK - ESB-M4G256-B2 PAINTABLE NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is an extruded ethylene vinyl acetate base hot melt sealer with a non tack surface. This material is suitable for use on interior and exterior Class No. 2 surfaces, and will present
3、 an acceptable apprearance, for such areas when painted. 2. APPLICATION This specification was released originally for material used to seal horizontal and vertical weld joints, such as the upper back panel to quarter panel in the deck lid trough. The material must be applied over electrocoat or spr
4、ay primer. Compliance with the performance requirements of this specification does not guarantee the hot melt sealers will function for all similar functions on a vehicle. The specific design condition should be evaluated by a plant trial or laboratory simulation prior to release of the material. 3.
5、 REQUIREMENTS: 3.1 QUALITY CONTROL Suppliers must conform to the 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 mate
6、rial source approvals. 3.2 CONDITIONING All test values indicated herein are based on material conditioned in a controlled tmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for 24 h prior to testing and tested under the same controlled conditions. 3.3 INFRARED SPECTROPHOTOMETRY Ford Motor Com
7、pany, at its option, may conduct infrared analysis of material/parts supplied to this specification. The spectra established for initial approval shall constitute the reference standard and shall be kept on file at Ford. All samples shall produce spectrographs that correspond to the referenced stand
8、ard when tested under the same conditions as those specified on the master spectra. ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 2 of 10 3.4 DIMENSIONS As specified on the engineering drawing and/or trim and sealer manual 3.5 CONSISTENCY, mm (ASTM D 1321, 100 g Total Load 3.5.1 As
9、 received 0.5 - 2.5 3.5.2 Aged, 72 h at 49 C 0.5 - 2.5 3.6 ASH, %, max 60 (Based on Solids Weight) Test Method: Place the crucible containing the solids residue in a cool muffle furnace. Slowly heat to and maintain at 760 +/- 30 C for 1 h, cool in desiccator, and weigh. 3.7 SPECIFIC GRAVITY 1.0 - 1.
10、2 3.8 SOLIDS, %, min 98 (ASTM D 2834, except heat at 102 +/- 3 C for 3 h in a mechanical convection oven) 3.9 MANDREL BEND TEST No cracking or adhesion failure (FLTM BV 22-1, material bake schedule per para 6.3, heat age test specimen 14 days at 70 +/- 1 C before test) 3.9.1 Test at 23 +/- 2 C 3.9.2
11、 Test at -29 +/- 1 C 3.10 FLOW CHARACTERISTICS, mm 3.10.1 Minimum Bake Exposure 1.0 - 3.0 3.10.2 Maximum Bake Exposure 1.0 - 3.0 Test Method: . Two 0.8 x 100 x 150 mm electrocoated panels are to be used for determining flow properties. Panels coated with electrocoat paint described per para 6.2 may
12、be used for testing. . Apply a 1.5 x 25 x 125 mm ribbon of material on two electrocoated panels. See sketch below. To assure uniform material contact, roll the material ribbon with a 2.0 kg roller (ASTM D 1000) using one forward and backward stroke. ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 W
13、P 3948-b Page 3 of 10 . Scribe each panel to mark the original material location. Position test panels at 53 +/- 2 attitude and condition 1 h at 23 +/- 2 C. See sketch. . It is recommended that a metal panel rack, manufactured by Atlas Electric Devices Corp. - Chicago, Ill., Model No. 19-1323-00, or
14、 equivalent, be used to maintain the test panels at the 53 +/- 2 C attitude during flow evaluation tests. . Maintain the test panels at a 53 +/- 2 C angle and cure one panel at the minimum bake schedule per para 6.3. Subject the remaining test panel to the maximum bake schedule per para 6.3. . Allow
15、 panels to cool at a 53 +/- 2C attitude for 1 h at 23 +/- 2 C. . Determine flow by measuring the distance the material has moved below the scribe marks. After flow test, the material shall appear as a continuous uninterrupted film; any sealer separation will constitute a failure. FLOW TEST 3.11 ADHE
16、SION Shall not be removable in a continuous coherent film when subjected to the following environments: 3.11.1 Normal, 24 h at 23 +/- 2 C 3.11.2 Salt Spray, 500 h (ASTM B 117) 3.11.3 Thermal 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
17、 +/- 1 C and 95 - 100 % R.H. . 4 h at 83 +/- 2 C . 4 h at -29 +/- 1 C ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 4 of 10 Sample Preparation: For each adhesion test exposure noted above, prepare samples as follows: . Apply a 1.5 x 25 x 200 mm ribbon of material along the centerli
18、ne of two 0.8 x 100 x 300 mm panels. Use a 2 kg roller, as described in para 3.10 to assure uniform material contact with panel. . Subject one panel of each substrate to the minimum bake schedule, and the other panel to the maximum bake schedule described per para 6.3. Panels are to be in a flat att
19、itude during bake cycle. . Condition panels at 23 +/- 2C for 1 h minimum in a flat position. Test Method: . Subject test panels to exposures noted. . Condition panels at 23 +/- 2C for a minimum of 2 h prior to evaluating adhesion. . Evaluate sealer adhesion to each test panel by making two parallel
20、cuts across ribbon of material. Cuts should be through to metal and 25 mm apart. Check adhesion by inserting the tip of a squared spatula under the edge of the 25 mm wide section of material, and then attempt to hand peel sealer at a 90C angle to panel. Material should fail cohesively rather than de
21、laminating cleanly from substrate surface. 3.12 LOW TEMPERATURE RESISTANCE No cracking or adhesion failure Test Method: . Prepare and cure two test panels of each substrate using procedure described in para 3.11. . After minimum and maximum bake schedules, condition samples at 23 +/- 2 C for 1 h min
22、imum. . Expose all test panels for 7 days at 70 +/- 2 C. . After heat exposure, condition panels at 23 +/- 2C for 1 h minimum. . Attach each test panel along the bottom edge of a 0.8 x 300 x 300 mm CRLC steel panel with pop-rivets or sheet metal screws. The long side of test panel should align with
23、bottom edge of 300 x 300 mm panel. ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 5 of 10 3.13 BRIDGING Test Method: . Prepare two test fixtures using 0.8 x 100 x 300 mm electrocoated panels prepared per para 6.2 as shown in Figure 2. FIGURE 2 BRIDGING TEST FIXTURE PREPARATION . App
24、ly a 1.5 x 25 x 200 mm ribbon of material to each test fixture as shown in Figure 3. ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 6 of 10 FIGURE 3 SEALER APPLICATION . Cure one test fixture at the minimum bake schedule per para 6.3.1. Subject the second test fixture to the maximum
25、 bake schedule per para 6.3.1. . Allow test fixtures to cool for 1 h at 23 +/- 2 C. Inspection Test Method: . Inspect test fixture to insure that material has satisfactorily bridged raised portion of panel as shown in Figure 2, Section B. Any evidence of tearing will constitute failure. . Material h
26、as satisfactorily bridged metal-to-metal portion of the panel as shown in Figure 2, Section A. Any evidence of gapping will constitute a failure. . Place assembled panels and cold slam apparatus described in FLTM BN 1-2 in a cold box and condition at -29 +/- 1 C for a minimum of 4 h. . Individually
27、mount 300 x 300 mm panels on the slam apparatus with the test material at the bottom facing away from fixture. Slam 10 times at -29 +/- 1 C. ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 7 of 10 3.14 COMPATIBILITY WITH PRODUCTION PAINTS This material shall be compatible with all cu
28、rrent production paint systems. No tackiness, porosity, cracking or other deleterious effects on top coats are permissible, unless they are within acceptable appearance 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
29、h Dry Ultraviolet Light Source (Equipment described in FLTM BV 7-2) Test Method: Evaluate current production spray primers and top coat paint systems as identified by the Body and Chassis Engineering Office. . Three 0.8 x 100 x 300 mm panels of substrate described in para 6.2 are to be prepared for
30、each top coat system evaluated. . Apply material ribbon “A“ (1.5 x 25 x 125 mm) on center line of substrate panels as shown in Figure 4. Use 2 kg roller as described in para 3.10.2. . Apply appropriate spray primer to entire surface of panels per ESB-M2P4. Cure primer 10 minutes at 149 +/- 1 C metal
31、 temperature. . Allow panels to cool to 23 +/- 2 C and apply material ribbon “B“ 91.5 x 25 x 125 mm) as shown in Figure 4. Roll with 2 kg roller per para 3.10.2 taking care to avoid roller contact with first ribbon applied. . Apply appropriate top coat paint to entire test panel surface per ESB-M2P4
32、. Cure top coat 8 min at 120 +/- 1 C metal temperature plus a peak of 3 min at 130 +/- 1 C metal temperature. . Subject one panel of each top coat system to exposures per para 3.14.1 and 3.14.2. Retain remaining panel as control. . After exposures are completed, examine test panels and compare to co
33、ntrol panel. ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 8 of 10 3.15 PACKAGING The material shall be supplied in sealer packages and material blocking is not permitted during container shipping or storage. 3.16 STORAGE STABILITY The material shall be stored at temperatures below
34、 41C away from all sources of heat and sunlight. Heat greatly accelerates aging. Under these storage conditions, the minimum shelf life of the material shall be 6 months. When these materials are stored at temperatures below 23C, they shall be conditioned at room temperature 24 h prior to applicatio
35、n. Adequate conditioning permits the material to obtain its optimum application properties. 4 FUNCTIONAL APPROVAL Materials 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 Engine
36、ering 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 was originally granted. Prior to making any change in the properties, composition, construction, color
37、, 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 shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed cha
38、nges 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 imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are
39、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. ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 9 of 10 5. APPROVAL OF MATERIALS: Materials defined by this specific
40、ation 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 Supplier shall submit to the affect
41、ed 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 Approved Source List. 6. GENERA
42、L INFORMATION: The material data included herein is for information only and is not a requirement for the supplier. 6.1 MECHANICAL CONVECTION OVEN The mechanical oven(s) used to cure the material shall be capable of obtaining 205 C metal temperature on body steel (0.8 - 0.9 mm thickness) within 8 -
43、10 min. 6.2 SUBSTRATES Nominal panel dimensions are 0.8 x 10 x 300 mm. Electrocoat primed steel panel: Prepared per ESB-M2P4 performance specification. Use current production paints as identified by the Body and Chassis Electrical Product Engineering Office. 6.3 MATERIAL CURE SCHEDULES 6.3.1 Minimum
44、 (Includes two bakes): Bake Schedule I 10 min at 149 +/- 1 C metal temperature Bake Schedule II 8 min at 102 +/- 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 6.4 COLOR Gray or as specified by B&AGO Paint Operation Activity ENGINEERING MATERIAL SPECIFICATION ESB-M4G256-B2 WP 3948-b Page 10 of 10 FIGURE 4 PAINT COMPATIBILITY TEST 0.8 x 100 x 300 mm SUBSTRATE PANEL Per para 5.2.1 and 5.2.2.
