1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2001 07 02 Revised Updated A. Cockman 1989 09 17 C9S1-DR356228 Released E. Rezendes Printed copies are uncontrolled Page 1 of 11 SEALER, INJECTION MOLDED OR EXTRUDED ESB-M4G300-B POLYOLEFIN - HEAT EXPANDING
2、- HIGH TEMPERATURE CURE - LOW EXPANSION 1. SCOPE The material defined by this specification is an injection molded or extruded uncured ethylene vinyl acetate base sealer which expands when exposed to heat. It can be used only in plants with electrocoat paint systems. 2. APPLICATION This specificatio
3、n was originally released for material used to isolate body side strainers, sealers fuel fillers, and roof bows from exterior sheet metal panels. The material is normally stapled, heat staked, or snapped in position, and is used on oily galvanized and CRLC steel surfaces. Recommended cure schedules
4、are 8 min at 171 C metal temperature minimum, and 30 minutes at emperature maximum. Compliance with this material specification does not guarantee the expandable sealer will function for all potential applications on a vehicle. The specific design condition should be evaluated by a plant trial or la
5、boratory 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 and part producers must conform to the Companys Quality System Requirements. 3.2 INFRARE
6、D SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference stand
7、ard when tested under the same conditions. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-B Page 2 of 11 Copyright 2001, Ford Global Technologies, Inc. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and
8、50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 DIMENSIONS As specified on engineering drawing and/or in trim uncured material thickness per para 5.4, bondline thickness after cure 1.8 - 3.3 mm, substrates per
9、para 5.2, material cure temperature per para 5.3. Prepare five samples per exposure per bake schedule. After curing, condition coupons for 24 h at 23 +/- 2 C. Prior to beginning exposure tests. Test Method: Subject test assemblies to exposures noted. After completing exposure, the test specimens sha
10、ll be conditioned at a 23 +/- 2 C for a minimum of 2 h and a maximum of 3 h prior to testing on a tensile machine at a jaw separation rate of 25 mm/min. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-B Page 4 of 11 Copyright 2001, Ford Global Technologies, Inc. 3.10 CORROSION RESISTANCE, min 500 h (A
11、STM B 117) 3.10.1 CRCL Steel - Oiled Surface rust within 7.0 mm of the perimeter of the cured sealer is permissible after disassembly of test assemblies. Test Method: Prepare four test assemblies as shown in Fig. 2A. Cure two samples at each of the bake schedules indicated in para 5.3. Condition sam
12、ples 24 h at 23 +/- 2 C. Remove clamps and subject the four cured assemblies to 500 h salt spray per ASTM B 117. After exposure, disassemble panels and examine metal surfaces under sealer for evidence of corrosion. Surface corrosion shall not extend more than 7.0 mm inside of sealer perimeter. 3.10.
13、2 CRCL Steel Electrocoated There shall be no evidence of corrosion under the sealer on either panel surface. Test Method: Prepare four test assemblies as shown in Fig. 2B. Electrocoat four assemblies in a production paint system or equivalent laboratory batch tank. Electrocoating to be conducted wit
14、h the assistance of qualified Ford paint personnel. Note: When electrocoating in a production facility, oiled CRLC steel test assemblies are to be processed through the phosphate system. If samples are electrocated in a batch tank, Parker 40 panels should be used to construct the test assemblies. Cu
15、re two samples at each of the bake schedules indicated in para 5.3. Electrocoated assemblies to be cured in a vertical position with the 150 mm long side parallel to bottom of oven. After curing, remove clamps and condition 24 h at 23 +/- 2 C. Subject cured assemblies to 500 h salt spray per ASTM B
16、117. After exposure, disassemble panels and examine metal surfaces under sealer for corrosion. There shall be no evidence of corrosion beneath the sealer on either steel panel. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-B Page 5 of 11 Copyright 2001, Ford Global Technologies, Inc. 3.11 LOW TEMPER
17、ATURE RESISTANCE There shall be no evidence of adhesive or cohesive failure after the test assemblies have accumulated 100 cold slams at -29 +/- 1 C. Test Method: Prepare two test samples as shown in Fig. 3. Cure on sample at each of the bake schedules indicated in para 5.3. Cure samples in a horizo
18、ntal position. Condition samples at 23 +/- 2 C for a minimum of 24 h. Place two test assemblies and cold slam apparatus described in FLTM BV 1-2 in a cold box and condition at -29 +/- 1 C for a minimum of 4 h. Individually mount panels on the cold slam apparatus with bonded 100 x 300 mm panel at bot
19、tom side facing away from fixture. Slam 10 times per FLTM BV 1-2 at -29 +/- 1 C. Remove two test panels from cold box and condition at 23 +/- 2 h a minimum of 1 h. Return two panels to cold box and condition 4 h minimum at -29 +/- 1 C and slam 10 times. Repeat this sequence until 100 cold slams have
20、 accumulated. Condition at 23 +/- 2 C for 1 h minimum and disassemble samples. Examination of samples shall indicate no adhesive or cohesive failure of the sealer. 3.12 SAG RESISTANCE, max 3.0 mm Test Method: Provide a 12.7 mm diameter hole in the center of four oily CRLC steel panels with nominal d
21、imension of 100 x 150 x 0.8 - 0.9 mm. Place a 50 x 50 x 2.3 - 2.8 mm piece of uncured sealer material on each panel with sealer centered over hole. Support the panels on opposite sides and bake in a horizontal position. Cure two samples at each of the bake schedules indicated in para 5.3. Remove fro
22、m oven and condition 1 h minimum at 23 +/- 2 C. From the under surface of the panel measure the distance the material has sagged through the hole. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-B Page 6 of 11 Copyright 2001, Ford Global Technologies, Inc. 3.13 FUEL RESISTANCE After a controlled immer
23、sion in ASTM #F146 fuel or diesel fuel and recovery at 23 +/- 2 C, the minimum adhesion value for overlap shear samples shall be 475 kPa. Test Method: Prepare overlap shear test samples as described in 3.7. Test five samples from each cure schedule in ASTM #F146 fuel, and five from each schedule in
24、diesel fuel. Immerse total bonded area of all samples in each type of fuel. NOTE: Because of precise time constraints for immersion, recovery and tensile testing, it is recommended each fuel type be tested separately. Vessels containing fuel should be maintained at 23 +/- 2 C. All fuel work should b
25、e conducted in a laboratory hood. Samples to be immersed for 2 h + 5 minute, -0 minute. Remove samples from fuel immersion and condition 4 h at 23 +/- 2 C. During conditioning period, store samples in a panel rack in a closed area to minimize evaporative action. After conditioning period, test sampl
26、es immediately on a tensile test machine at a jaw separation rate of 25 mm/minute. The 10 samples should be tested within 15 minutes of completing conditioning. 3.14 WASH RESISTANCE No wash off (FLTM BV 16-1, Method “A“, 1.5 mm material thickness) 3.15 ELECTROCOAT COMPATIBILITY Shall not contaminate
27、 (FLTM BV 19-1, Cathodic) electrocoat primer bath or cause electrocoat film irregularities 3.16 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 60 Formation of clear film, droplets or crystals is cause for rejection. ENGINEERING MATE
28、RIAL SPECIFICATION ESB-M4G300-B Page 7 of 11 Copyright 2001, Ford Global Technologies, Inc. 3.17 STORAGE STABILITY The material shall be stored at temperatures below 41 C, away from all sources of heat. Heat greatly accelerates aging. Under these conditions, the minimum shelf life of the material sh
29、all be six months. When this material is stored at temperatures below 23 C, it shall be conditioned at room temperature prior to application. 3.18 FUNCTIONAL APPROVAL Materials being evaluated for initial approval to this specification shall be subjected to a production trial. Functional trial resul
30、ts should be available to Design and Materials Engineering prior to material approval and release. 3.19 ADDITIONAL REQUIREMENTS Additional requirements for material and/or manufactured parts may be specified on the Engineering drawing, Engineering parts specification, performance specification, Syst
31、em Design Specification (SDS) and/or Component Design Specification (CDS). 3.20 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 changes to the material orig
32、inally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify the affected Purchasing, and Materials Engineering activities (with reasons) of the proposed changes. Upon notification of the Company,
33、 further instructions will be provided. Note: Suppliers should be prepared to provide test data and samples demonstrating compliance to this specification, if requested. Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restri
34、ctions are identified in Restricted Substance Management Standard WSS-M99P9999-A1. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-B Page 8 of 11 Copyright 2001, Ford Global Technologies, Inc. 4. APPROVAL OF MATERIALS Materials defined by this specification for direct supply to the Company must have p
35、rior approval. Certain materials subcontracted by part suppliers may also require prior approval. These include materials critical to the Companys business for regulatory, safety, environmental or compatibility requirements or contractual agreements. Suppliers desiring approval of their materials sh
36、all first obtain an expression of interest from Purchasing, Design or Materials Engineering activity. Upon request, the Supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance wit
37、h all the requirements of this specification. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 MECHANICAL CONVECTION OVEN The mechanical oven(s) used to cure the material shall be capable of obtaini
38、ng 204 C metal temperature on body steel (0.89 mm thickness) within 8-10 minutes. 5.2 SUBSTRATES 5.2.1 CRLC steel meeting ESB-M1A250-A: Nominal 0.81 mm thickness - Surface precoated with M-14B90A-B(F) stamping lubricant at an application of approximately 0.013 mm wet film thickness. 5.2.2 Steel-shee
39、t zinc rich primer coated meeting ESB-M1A217-B: Nominal 0.81 mm thickness - Surface precoated with M-14B90A-B(F) stamping lubricant at an application of approximately 0.013 mm wet film thickness. 5.2.3 Galvanized steel meeting ESB-MA250-A3: Nominal 0.81 mm thickness - Surface precoated with M-14B90A
40、-B(F) stamping lubricant at an application of approximately 0.013 mm wet film thickness. 5.3 PROCESS BAKE SCHEDULES 5.3.1 Minimum: 171 C for 8 minutes metal temperature 5.3.2 Maximum: 204 C for 30 minutes metal temperature 5.4 TEST MATERIAL THICKNESS Sample material submitted for evaluation to the s
41、pecification shall be 2.3-2.8 mm. ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-B Page 9 of 11 Copyright 2001, Ford Global Technologies, Inc. FIGURE 1 - EXPANSION TEST A. TEST ASSEMBLY BEFORE CURE (1.0 1.1 mm CRLC STEEL-OILED) B. TEST ASSEMBLY AFTER CURE ENGINEERING MATERIAL SPECIFICATION ESB-M4G300
42、-B Page 10 of 11 Copyright 2001, Ford Global Technologies, Inc. FIGURE 2 CORROSION RESISTANCE A. CRLC STEEL - OILED B. CRLC STEEL PHOSPHATE AND ELECTROCOATED ENGINEERING MATERIAL SPECIFICATION ESB-M4G300-B Page 11 of 11 Copyright 2001, Ford Global Technologies, Inc. FIGURE 3 LOW TEMPERATURE RESISTANCE
