1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1988 03 07 CER1-DR157277 Released KB ERR LWMWP 3948-a Page 1 of 7 DEADENER, ASBESTOS FREE MASTIC, EXEMPT SOLVENT, ESB-M5G46-ACORROSION RESISTANT1. SCOPEThe material defined by this specification is an asphalt bas
2、e, asbestosfree, exempt solvent type, sandless deadener with good c orrosion resistanceand im proved low temperature adhesion properties for use over oilyzincro metal and galvanized metal, minimum air dry between application andphosphating.2. APPLICATIONThis specification was released originally as
3、a material for use as aspray- on deadener for galvanized 1987 truck doors utilizing airless sprayequipment.3. REQUIREMENTS3.1 STATISTICAL PROCESSSupplie rs must conform to the requirements of Ford Quality SystemStand ard Q-101. A mutually acceptable Control Plan as describedtherein is required for m
4、aterial/source approval. Appropriatestatist ical tools must be used to analyze process/product data sothat variation in the final product is continuously reduced.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may conduct infrared and/ortherma l analysis of m
5、aterial/parts supplied to this specification.The IR spectra and thermograms established for i nitial approval shallconst itute the reference standard and shall be kept on file at thedesignated material laboratory. All samples sha ll produce IR spectraand thermograms that correspond to the reference
6、standard when testedunder the same conditions.3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on ma terial conditioned ina control led atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under thesame conditions u
7、nless otherwise specified.ENGINEERING MATERIAL SPECIFICATIONESB-M5G46-AWP 3948-b Page 2 of 7 3.4 DRYING CHARACTERISTICS (Stamping and Assembly Plants)Oily t est panels, 300 x 300 mm, are sprayed with deadener to betested and immediately conditioned per each of the following dryingcycles prior to pho
8、spha ting. Individual panels will be required foreach process condition. The following processes are specificrequirements for the subsequent durability and c ompatibility testing.NOTE: Mask all four edges with 25 mm wide tape prior to deadenerapplication and remove tape immediately after spraying.Pr
9、ocess A: 15 mi nutes at R.T. + five (5) hours at - 29 C +15 minutes at R.T.Process B: 15 mi nutes at R.T. + five (5) hours at - 29 C +one (1) hour at R.T.Process C: Six (6) hours at R.T.Process D: Seven (7) days at R.T.3.5 SOLIDS, min 82 %(ASTM D 2834, except heat at 121 +/- 3 Cfor 3 h in a mechanic
10、al convection oven)3.6 WEIGHT PER VOLUME 1.44 - 1.56 Kg/L(ASTM D 816)The weight tolerance for any one supplier shall be +/- .02 Kg/L basedon the recorded weight of the original approved production sample.3.7 VISCOSITY(FLTM BV 3-2, using 69 kPa line pressure with3.2 mm orifice)3.7.1 As Received 20 -
11、40 s3.7.2 Aged, max 50 sWhen stored 45 days or less at a temperature bet ween 18 C and32 C.3.8 SAG, max 12.7 mm3.8.1 30 minutes after applicationENGINEERING MATERIAL SPECIFICATIONESB-M5G46-AWP 3948-b Page 3 of 7 3.8.2 After Process A, B, C, D,(Para 3.4)Test method: Apply 25 mm wide masking tape to l
12、ower edge ofan oily galvanized 300 x 300 mm metal panel. Apply deadenerto a wet film thickness of 2.3 mm. Immediately aftersprayi ng, remove the masking tape and place the panel in avert ical position with the uncoated strip at the bottom.Measure the sag distance of the deadener mass after 30minutes
13、 and after the processes A, B, C, and D. Individualpanels will be required for each process condition.3.9 ADHESION, min 85 % and no lifting(FLTM BV 1-1 modified, FLTM BV 1-2 modified) of material3.9.1 After Process A, B, C, D (Para 3.4)Test Method: The conditioned panels from para 3.4 shall beslamme
14、d 6 times at 23 +/- 2 C. The results afte r slams shallbe reported. See para 5.5, 5.6, and 5.7.3.9.2 After Phosphate Cycle and E-Coat BakeTest Method: The conditioned panels in para 3.4 shall beproce ssed through phosphate cycle, E-coat bath, and E-coatbake. After the E-coat bake, the panels are con
15、d itioned at 23+/- 2 C for 1 hour. Then the panels shall be sla mmed 36 timesat 23 +/- 2 C. The results after the slams shall be reported.The tested panels shall be used in para 3.9.3. See para 5.5,5.6, 5.7.3.9.3 Cold SlamTest panels from para 3 .9.2 are conditioned for 4 hours at -29 C +/- 1 C and
16、slamme d per FLTM BV 1-1, para 9 through 12.The r esults after each cycle (max 6 cycles) shall bereported. See para 5.5, 5.6, 5.7.3.9.4 Cold Slam with Excess OilTest Method: Mask 6 galvanized steel panels, as per para 3.3,and oil as per para 5.6.3. Spray 3 panels with deadener at2.3 mm and an additi
17、onal 3 panels with 1.15 mm. Remove thetape and a ir dry for 48 hours at 23 +/- 2 C and 50 +/- 5 %R.H. Process the panel s through the phosphate cycle, E-coatbath , and E-coat bake. Condition the panels at R.T. for 6hours, then test the panels cold adhesion per p ara 3.9.3 andreport results.ENGINEERI
18、NG MATERIAL SPECIFICATIONESB-M5G46-AWP 3948-b Page 4 of 7 3.10 INVERTED BAKE RETENTION No loss ofmaterial3.10.1 Oily Galvanized Metal at 2.3 mm Wet FilmDry four (4) sets of pa nels per process procedures A-D as inpara 3.4.Test Method: 300 x 300 mm oily galvanized metal panels shallhave a 25 mm wide
19、masking tape applied to all four edgesleaving 250 x 250 mm ce nter section open. Spray deadener onthe panels at the specified thickness, immediate ly remove themasking tape from all edges, and place the panel s in racks inan inverted position. The panels are air dried per para 3.4and baked at 176 de
20、g +/- 2 C for 30 minutes in the sameinverted position. Examine each panel for materi al retention.3.11 COMPATIBILITY WITH CATHODIC ELECTROCOAT No craters(FLTM BV 19-1, Part A and modified Part B)Part B direct contamination test shall be conducted from deadenermaterial scraped from panels after Proce
21、ss A and B in para 3.4.3.12 COMPATIBILITY WITH PHOSPHATE WASH CYCLE No wash offTest Method: 100 x 300 mm oily galvanized metal panels shall have a25 mm wide masking tape applied to top and botto m edges of the panel,leaving 100 x 250 mm section open. Spray deadener to be tested onthree sets of panel
22、s at the specified thickness, immediately removethe masking tape, air dry per section 3.4, process B, C, and D, andsubject panels to the phosphatizing cycle. Examine the panels forwash off.3.13 DAMPING LOSS FACTOR, min(ASTM E 756 at 200 Hz, 15 C increments for 0 Cto 45 C, average of five bars)Temper
23、ature Min Loss Factor0 C 0.0515 C 0.0430 C 0.0445 C 0.03Test Conditions:. 320 x 20 x 0.8 mm clean cold rolled steel Oberst bar. Oberst bar damped one side only. Apply deadener to Oberst bars and air dry for 24 hours before bake. 40 mm root length undamped, 280 mm free length damped. Material air dri
24、ed weight 2.44 kg/m2. Expose air dried material at 180 C for 30 minutes. Report composite bar loss factor onlyENGINEERING MATERIAL SPECIFICATIONESB-M5G46-AWP 3948-b Page 5 of 7 No te: Report the value interpolated by intersecting the 200 Hzfre quency line and the straight line connecting the loss fa
25、ctorvalues for the resonances directly on either side of 200 Hz.3.14 DRY RATEShall be free from tackiness and firm to the touch.Test Method: A test panel shall be sprayed as d escribed in para 3.8,allowed to air dry at 23 +/- 2 C for 3 h, and subjected to a fingerpressure test. Following the finger
26、pressure tes t, the panel shall beslammed once in the Ford cold slamming fixture as described in FLTMBV 1-1 at 23 +/- 2 C, and shall show no material separation.3.15 The volatile portion shall not be photochemicall y reactive as definedbelow:The photochemically reactive solvent is any solv ent with
27、an aggregateof more than 20 % of its total volume composed of the chemicalcompo unds classified below or which exceeds any of the followingindividual percentage composition limitations referred to the totalvolume of solvent:. A combination of hydrocarbons, alcohols, aldehydes, esters, orketones havi
28、ng an olefinic or cycloolefinic type of unsaturation- 5 %. A combination of aro matic compounds with eight (8) or more carbonatoms to the molecule, except ethylbezene - 8 %. A combination of eth ylbenene, ketones having branched hydrocarbonstructures, trichloroethylene, or toluene - 20 %.3.16 SPECIF
29、IC COMPOSITION3.16.1 Volatile PortionSuppliers shall furnish certification of conformance to para3.15 of this specification to Ford Motor Company Purchasingand/or Quality Control.3.17 STORAGE STABILITYThe material shall not settle or separate within 45 days of transitand storage, to the ext ent as t
30、o cause difficulty in mixing for use.Re commended storage should not exceed 32 C. When stored atte mperatures below 18 C, the material should be allowed to becon ditioned to an ambient temperature between 18 C and 32 C for 48hours prior to use.3.18 FUNCTIONAL APPROVALMat erial being evaluated for in
31、itial approval to the specificationshall be subjected to s tamping and assembly plants production trial.Functional trial result s should be available to Design and MaterialsEngineering prior to material approval and release.ENGINEERING MATERIAL SPECIFICATIONESB-M5G46-AWP 3948-b Page 6 of 7 3.19 SUPP
32、LIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pr ior to making any changes in the properties, composition,constr uction, color, processing or labeling of the materialorig inally app
33、roved under this specification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the Supplier shall notify Purchasing, Toxicology andthe affected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Eng
34、ineeringactivity. Test data, t est samples and a new code identification areto 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 WS S-M99P9999-A1
35、, unlessa dif ferent suffix (e.g, A2 or A3) is specified on the engineeringdocument for the application.4. APPROVAL OF MATERIALSMat erials defined by this specification must have prior approval by theresponsible Materials Engineeri ng activity. Suppliers desiring approval ofthe ir materials shall fi
36、rst obtain an expression of interest from theaffec ted Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity its own laboratory rep ort to the specification (test results, notnomina l values), the material designat
37、ion and code number and testspecim ens for Ford evaluation. Upon approval, the material will be addedto the Engineering Material Approved Source List.5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting the requirements of the specification.5.1 FLA
38、SH POINT Minimum: 10 C(ASTM D 93)5.2 FLAMMABILITY AND/OR TOXICITYThis material represent s a potential fire and/or health hazard. TheManufacturing Engineering Department shall notify both the plantsecurity and the safety units of its presence in the plant to assurethat proper fire and/or health prec
39、autions are p rovided. The locationin which it is used or stored shall be included in the notifications.ENGINEERING MATERIAL SPECIFICATIONESB-M5G46-AWP 3948-b Page 7 of 7 5.3 MATERIAL AND EQUIPMENTThe material identified in this specification shall be suitable foruse with airless spray equipment. Th
40、e material shall be screened andfiltered by the respective suppliers to control maximum particle size(max 0.59 mm screen). The airless spray nozzle orifice shall bedetermined by the Plant Process Engineering Departments.5.4 LABELINGContainers shall be labeled in accordance with requirements of FordM
41、anufacturing Standard ZF 10.5.5 MECHANICAL CONVECTION OVENThe mechanical oven(s) used to cure the material shall be capable ofobtaining 205 C metal temperature on body steel panel 0.89 mm thickwithin 8 - 10 min.5.6 SUBSTRATES5.6.1 Steel-sheet, zinc rich primer coated (ESB-M1A217): 0.035 in(0.89 mm)
42、thickness - surface precoated with M99 C47-A MineralOil or production oil as specified in plant at a n applicationof approximately 0.2 cm3/ft2 (2.2 cm3/m2).5.6.2 St eel-sheet, galvanized (ESB-M1A250B360G00X): Surfaceprec oated with M99C47-A Mineral Oil or production oil asspe cified in plant at an a
43、pplication of approximately 0.2cm3/ft2 (2.2 cm3/m2).5.6.3 Steel-sheet, galvanized (ESB-M1A250B360G00X): Surfaceprec oated with M99C47-A Mineral Oil or production oil asspe cified in plant at an application of approximately 0.4cm3/ft2 (4.4 cm3/m2).5.7 MATERIAL CURE SCHEDULES5.7.1 Minimum: 8 minutes at 171 C metal temperature5.7.2 Maximum: 30 minutes at 205 C metal temperature5.8 DOOR SYSTEM SLAM CLOSE TEST (for initial approval only)(BW-1.03-A10, except 20.337 Joules slam energy and 83,000 cycles at- 29 +/- 1 C)
