1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 08 03 N-STATUS No replacement named; Inserted 3.0; Deleted 3.1, 3.1.1, 3.1.2, 3.1.3, 3.1.4, 3.1.5, 3.1.6 & 4 B. Witkowski 1988 08 25 CDR1-WN182519-1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 5
2、 SEALER, ELASTOMER, WELDABLE, HOT APPLY, NON EXPANDABLE ESB-M4G305-A NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a pumpable, weldable, non-expanding, highly wash resistant, hot apply, elastomer sealant. 2. APPLICATION This specification was released originall
3、y for material used for sealing the down standing flange of the door opening panel and the front floor side inner, thereby preventing wind noise and dust from entering the “rocker panel“ area. This material can be applied to lightly oiled CRLC and galvanized steel surfaces. The material should be ap
4、plied hot at a temperature of 120 C - 134 C utilizing a positive displacement pump. Maximum temperature overrun not to exceed 177 C. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material
5、suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 FUNCTIONAL PERFORMANCE REQUIREMENTS 3.2.1 Adhesion, Cold Impact No cracking or adhesion failure. Test Method: Apply a ribbon of sealant material 1.5 x 25 x 200 mm to two 0.8
6、9 x 300 x 300 mm oily steel panels. Bake one panel to each cure schedule per paragraph 5.3. Position panels in a horizontal attitude during material bake. After bake, condition panels at 23 +/- 2 C for 1 hour minimum. Condition the panels in a mechanical convection oven at 70 +/- 2 C for 7 days. Con
7、dition the panels at 23 +/- 2 C for 1 hour. Place panels in the slamming apparatus (FLTM BV 101-02) at -29 +/- 2 C for 3 hours. Each panel shall be slammed a total of 10 times. 3.2.2 Adhesion, Hot Applied The material shall adhere when hot applied to an oily steel surface. 3.2.3 Bridging, Sag, maxim
8、um 6 mm Test Method: Apply a 9.5 x 150 mm length of bead over the holes in the bridging fixture. Prepare two assemblies and condition at 23 +/- 2 C for 1 hour. Subject one assembly to each oven schedule per paragraph 5.3. ENGINEERING MATERIAL SPECIFICATIONESB-M4G305-A Printed copies are uncontrolled
9、 Copyright 2007, Ford Global Technologies, LLC Page 2 of 5 3.2.4 Corrosion Resistance 500 hour Salt Spray (ASTM B 117, use “Paint Test (Quality“ PTQ steel panels) 3.2.4.1 Unassembled Less than 1.5 mm of corrosion undercut on CRLC steel surface and less than 10 mm for galvanized steel surface. Loss o
10、f adhesion shall not be 3 mm more than corrosion limit. Test Method: Apply a 1.5 x 25 x 200 mm ribbon of sealant to two 0.89 x 100 x 300 mm oily test panels of each substrate material. Subject one panel of each substrate material to each oven schedule per paragraph 5.3. Allow assembly to cool to roo
11、m temperature, then expose to 500 hours salt spray. After exposure, condition panels at 23 +/- 2 C for 24 hours minimum. Remove sealant with a spatula and clean residue with a suitable solvent. No loss of adhesion of sealant to panel when removing. Examine the metal surface for any evidence of corro
12、sion. 3.2.4.2 Welded Assembly Adhesion and Corrosion limits same as for unassembled panel except that areas where weld expulsion has caused loss of sealant shall be discounted. Test Method: Apply a 6 mm diameter bead of sealant 12 mm from the edge of two 0.89 x 50 x 3 00 mm oily test panels of each
13、substrate material. Form a sandwich 25 mm wide with the material by overlapping with another similar panel, and weld 6 times at 50 mm intervals through the material starting 25 mm from end of panel. Subject one panel of each substrate to each oven schedule, then allow to cool to room temperature. Su
14、bject to 500 hours salt spray. After exposure, condition assembly at 23 +/- 2 C for 24 hours minimum. Disassemble and remove sealant material. Examine the sealed surfaces for evidence of corrosion and loss of adhesion. 3.2.5 Electrocoat Compatibility Shall not contaminate (FLTM BV 119-01, use curren
15、t electrocoat primer production paints as identified bath or cause by the Body Materials Engineering electrocoat film Office.) irregularities. ENGINEERING MATERIAL SPECIFICATIONESB-M4G305-A Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 5 3.2.6 Oven Exposure
16、Characteristics No evidence of cracking, charring, embrittlement, loss of adhesion to oily metal, etching of metal surface, or loss of flexibility. Test Method: Apply a 1.5 x 25 x 200 mm ribbon of sealant to two 0.89 x 00 x 300 mm oily test panels of each substrate material. After oven exposure per
17、paragraph 5.3, condition panels at 23 +/- 2 C for 4 hours minimum. Evaluate adhesion by inserting the tip of a sharp knife under the end of the material strip. Grasp the tab and attempt to peel at 180 angle. Observe for any indication that the material fails to adhere, or is brittle or friable. 3.2.
18、7 Pumpability Plant Equipment Simulation: Pumpability of material shall be determined prior to plant use by evaluating its pumpability in simulating the plant system. (Refer to: Paragraph 5.5 Application Parameters, Equipment). 3.2.8 Sag Resistance, maximum 6 mm (FLTM BV 118-01, with oily steel subs
19、trate and oven schedules, FLTM BV 118-01 (modified) for a horizontal configuration.) Material bead 4.5 x 152 mm is hot applied and conditioned 23 +/- 2 C for 1 hour prior to oven exposures. 3.2.9 Storage Stability The material shall be stored at temperatures below 41 C away from all sources of heat
20、and sunlight. Under these storage conditions, the shelf life of the material shall be 6 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
21、 properties. 3.2.10 Wash Resistance No evidence of material wash off or any displacement due to precleaning, phosphatizing solution in flow phosphate tanks or electrocoat tanks. 3.2.10.1 Laboratory - FLTM BV 116-01, Method B 3.2.10.2 Laboratory testing using the following parameters: Water temperatu
22、res of 65.5 +/- 2 C (150 +/- 3 F), Vee Jet H1/4U8050 nozzle (Spray Systems Company) of equivalent, spray pressure of 45 +/- 2 psi, distance between nozzle exit and test panel of 230 mm, and exposure time of 1 minute. ENGINEERING MATERIAL SPECIFICATIONESB-M4G305-A Printed copies are uncontrolled Copy
23、right 2007, Ford Global Technologies, LLC Page 4 of 5 3.2.10.3 Plant Trial: 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
24、including laboratory evaluation for wash resistance. 3.2.11 Weld Acceptance Must Pass (Shunt Method, 76.2 mm (3.0“) shunt) 3.2.12 Weld Flammability Test Less than 5% of the welds shall (FLTM BV 114-01) exhibit flame and shall be self- extinguishing within 30 seconds. 3.3 MATERIAL PHYSICAL AND CHEMIC
25、AL PROPERTY REQUIREMENTS A new supplier being evaluated for initial approval to the specification shall be subject to reporting their materials specific values in conformance with the Quality Control and Suppliers Responsibility requirements of paragraphs 3.1.4 and 3.1.5. This is a mandatory quality
26、 control requirement for the approved supplier. Variations in 3.3 are allowed for initial submissions from a new supplier provided the new supplier meets all other requirements of 3.1 and 3.2. When a new suppliers material becomes approved, quality control values for paragraphs 3.3.1 through 3.3.4 w
27、ill be established from the initial submission values and will then be a mandatory requirement. 3.3.1 Flash Point, minimum 205 C (ASTM D 1310, Tag Open Cup) 3.3.2 Penetration, CONE 25 C 45 - 65 (ASTM D 217, 150 grams total weight) Initial and after material is aged for 72 hours at 45 +/- 2 C 3.3.3 P
28、ress Flow, Hot 18 +/- 5 seconds 120 C (FLTM BV 103-01, Modified) 8 +/- 5 seconds 135 C Test Method: Transfer sample of flowmeter cup. Insert a plunger into flowmeter cup, on top of material. Place assembly into forced air oven with temperature set at desired test temperature. Measure temperature wit
29、h a thermometer. Upon reaching the desired temperature, remove assembly from oven and attach to test apparatus. Perform press-flow test within 1 minute after removal of the flowmeter cup from the oven. Test samples using the following fixed standards: 20 gram sample, 60 psi pressure, 2.64 mm (0.104“
30、) diameter orifice. 3.3.4 Specific Gravity 1.15 +/- 0.1 (ASTM D 297, Hydrostatic Method) 5. GENERAL INFORMATION: The information given below is provided for clarification and assistance in meeting the requirements of this specification. ENGINEERING MATERIAL SPECIFICATIONESB-M4G305-A Printed copies a
31、re uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 5 5.1 MECHANICAL CONVECTION OVEN The mechanical convection oven(s) used to cure the material shall be capable of obtaining 205 C metal temperature on body steel (0.89 mm) within 8 - 10 min. 5.2 SUBSTRATES 5.2.1 CRLC Steel 0.89 m
32、m thickness-surface precoated with M99C47-A Mineral Oil at an application of approximately 2.2 cm/m production steel. 5.2.2 Galvanized Steel 0.89 mm thickness-surface precoated with M99C47-A Mineral Oil at an application of approximately 2.2 cm/m production steel and/or ESB-M1A250-A3. 5.3 OVEN TEMPE
33、RATURE SCHEDULES 5.3.1 Minimum: 171 C metal temperature for 8 minutes. 5.3.2 Maximum: 205 C metal temperature for 30 minutes. 5.4 COLOR AND APPEARANCE Tan solid at room temperatures Or as specified by B&AGO or B&CE. 5.5 APPLICATION PARAMETERS Equipment . Mastic extrusion pump with heated platen (Dru
34、m follower plate) to provide melt down and temperature controls for barrel changeover and continuous operation. Air driven reciprocating (piston) type having a pumping ratio of 30:1 minimum, or a gear type with equivalent output capacity. . Heated material headers, hoses and guns with temperature co
35、ntrols to provide heat for start-up and continuous operation. Equipment should be turned off when not in use. Material: . Material application temperature of 120 - 134 C Maximum temperature overrun not to exceed 177 C. . Material may be applied in bed or ribbon as indicated by Sealing Engineering requirements typically 5 - 9.5 mm diameter bead or 1.5 x 9.5 mm ribbon. . No contamination should occur in the material in open containers.
