1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Released1994 12 06 Revised and Retyped, was 7 pages1987 07 20 SM/ER1101 TC ReleasedWP 3948-a Page 1 of 6 EXPANDED PVC ACOUSTIC UNDERBODY COATING ESD-M5G43-A1. SCOPEThe ma terial defined by this specification is a s
2、olvent free, heat curingpoly vinylchloride or other plastics based material with good abrasion,corrosion and heat resistance.2 APPLICATIONThis material was originally re leased for visible and non-visible areas ofthe underbody, wheel houses and rocker panel. The mater ial is applied ontodry electroc
3、oat using airless spray equipment. After cu ring, visible areasare su bsequently painted with normal production enamel, exterior quality,or before spray primer curing a re painted wet in wet with black, low glosssynthetic baking enamel.3. REQUIREMENTS3.1 STATISTICAL PROCESSSupplie rs must conform to
4、 the requirements of Ford Quality SystemStand ard Q-101. A mutually acceptable Control Plan as describedtherein is required for material/source approval. Appropriatestatist ical tools must be used to analyze process/product data sothat variation in the final product is continuously reduced.3.2 INFRA
5、RED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may conduct infrared and/ortherma l analysis of material/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
6、file at thedesignated material laboratory. All samples sha ll produce IR spectraand thermograms that correspond to the reference 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 atmos
7、phere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under thesame conditions unless otherwise specified.ENGINEERING MATERIAL SPECIFICATIONESD-M5G43-AWP 3948-b Page 2 of 6 3.4 COLOR Da rk grey or as specified on theEngineering drawing3.5 SOLIDS, min
8、96 %(FLTM EU-BV 50-10)3.6 ASH, max 35 %(FLTM EU-BV 50-10)3.7 FLASH POINT Over 90 C(ASTM D 56)3.8 DENSITY at 20 C 1.3 - 1.6 Mg/m3The d ensity tolerance for any one supplier shall be +/- 0.05 Mg/m3ba sed on the recorded density of the original approved sample, asdetermined per ASTM D 1475.3.9 VISCOSIT
9、Y at 20 C 0.275 MN/m2(FLTM EU-BV 3-1) Line Pressure Nozzle Dia: 2 mm3.9.1 As Received 3 - 20 s3.9.2 After Ageing, max 70 s(336 h at 30 +/- 2 C)Note: Final approval of a specific viscosity of material forproduction shipments sh all be made by affected ManufacturingDivi sion. In all cases, however, th
10、e viscosity shall bewithin the limits specified above and the materi al shall meetall requirements of this specification (Control SampleLaboratory Report).3.10 ABRASION RESISTANCE3.10.1 There shall be no exposed metal area showing aft er 370 litresgravel impact. No loss of adhesion on and aroun d th
11、e area ofstone impact.Test Method: Prepare the test panels as follows:1) Test panels of 300 x 100 mm (prepared according to FLTMEU-BI 2 0-1) shall be coated to produce a minimum drythick ness of 1.1 mm and shall be stoved for the minimumand maximum cycle times as quoted in FLTM EU-BV 50-5,table 2.2)
12、 After conditioning for 24 hours at 23 +/- 2 C determinethe a brasion resistance according to ASTM D 968, exceptI.D. of tube 25 mm and at a gravel through put rate of30 - 40 litres/hour. For each specimen 5 litres offresh gravel shall be used.ENGINEERING MATERIAL SPECIFICATIONESD-M5G43-AWP 3948-b Pa
13、ge 3 of 6 GRAVEL: Type “GABBRO“ grain size 5 - 8 mmSUPPLY SOURCE: ODENWALDER HARTSTEIN INDUSTRIE GMBHErbacher Strasse 62D-6101 Rossdorf3.11 CORROSION RESISTANCEThe material shall protect the test panel from corrosion for a saltspray exposure period of 500 hours. It shall show no expansion,flaking or
14、 loss of abrasion resistance. No loss of adhesion on andaround the area of stone impact.Test Method:1) Prepare test specimens in accordance with the test methoddescr ibed in clause 3.10.1. Panels shall be coated to produce aminimum d ry thickness of 1.1 mm and shall be stoved for theminimum a nd max
15、imum cycle times as quoted in FLTM EU-BV 50-5,Table 2.2) After con ditioning for 24 hours at 23 +/- 2 C, expose for 500hours to a salt spray fog according to ASTM B 117.3) Deter mine abrasion resistance as specified under clause 3.10 andexamine test panel for evidenc e of corrosion. Disregard the ar
16、ea10 mm from the edges.3.12 FLOW RATE, max 15 mm(FLTM EU-BV 51-3, 300 x 300 mm test panelsprepared according to clause 3.10.1. except wetfilm thickness of material under test should be chosen to give a nominal 2.0 mm thick coating after stoving)3.13 RESISTANCE TO DRIPPINGThe material must not fall o
17、ff or show evidence of dripping.Test Method:1) Pre pare 300 x 300 mm test panel according to method in clause3.10.1.2) After conditioning for 5 minut es at 23 +/- 2 C place specimens inan inverted position in a mechanical convection oven an d stove for15 minutes at 180 C.3.14 COLD ADHESION at - 40 C
18、 No flaking, no loss of adhesion(FLTM EU-BV 51-1, specimens preparationaccording to clause 3.10.1. Test Load A300 x 300 x 0.9 +/- 0.05 mm panels)ENGINEERING MATERIAL SPECIFICATIONESD-M5G43-AWP 3948-b Page 4 of 6 3.15 ADHESIONThe m aterial at all ranges of coating thickness must not be peeledoff in a
19、 coherent film.Test Method:1) Coa t 300 x 100 mm test panels, prepared according to FLTM EU-BI 20-1 in such a manner (airless) that after the minimum andmaxim um cycle times as quoted in FLTM EU-BV 50-5, Table 2, a drycoating thickness of nominally 2.0 mm beginning at one edge of thetest panel and t
20、apering to zero at the other is obtained.2) After 24 hours at 23 +/- 2 C make two cuts through the coatingalong the 300 mm length of the test panel and 30 mm apart and tryto peel off coating starting at the edge with the lowest filmthickness.3.16 STAININGNo staining or other deleterious effects to p
21、roduction enamels. Test Me thod: Condition panels prepared as in clause 3.10.1. for24 hours at room temperature.Mask one hal f of the test panels and expose for 200 hours in theFluorescent and Sunlamp Cabinet (FLTM EU-BU 52-2). For examinationcompare the exposed and unexposed area of the test specim
22、en.3.17 PAINT ADHESION TO THE UNDERBODY COATING(FLTM BI 106-1, Method B, Specimens preparationaccording to 3.10.1)No chipping, no flaking, no loss of adhesion.3.18 VOLUME EXPANSION, min 25 %Test Method:1) Determin e the volume V1 of the test panel, see fig. 1, preparedin accor dance with FLTM EU-BV
23、50-11, oiling grade “normal“, bywater displacement.2) Apply test material in the gro ove of the test panel, scrape flushwith the adjoining surfaces and determine volume V2.3) Expo se test specimens in a mechanical convection oven to theminimum curing cycle. The test specimens are to be cured in ahor
24、izont al position and protected from direct air flow. Afterheat curing and cooling to room temperature determine volume V3.ENGINEERING MATERIAL SPECIFICATIONESD-M5G43-AWP 3948-b Page 5 of 6 4) The volume increase in % of the original volume shall bedetermined as follows:V3 - V2% Volume Expansion - x
25、 100V2 - V1Where: V1 - Volume of the test panelV2 - Volu me of the test panel and underbodycoatingV3 - Vo lume of the test panel and material aftercure.3.19 SOUND LOSS FACTORDecay Rate, min 15 dB/sThe Dec ay Rate of the coated steel panel (coated in a dry filmthickne ss of 2.5 mm) shall be determine
26、d according to FLTM EU-BV 60-2. Th e uncoated test panel used for the test shall have adecay rate between 0.5 - 0.8 dB/s.3.20 ABRASIVES The material shall contain no abrasive agentsTest Method: Dilute a one gram sample of material with one gramspecial white spirit (1 50/200) and mix thoroughly. Rub
27、a portion ofthe dil uted material 100 times between two pieces of flat, cleanplate glass. The appea rance of scratches on the glass plate will beconsidered failure.3.21 SPRAYABILITYThe material shall be a smooth homogeneous mixtu re, free from foreignmaterial and suitable for use in airless spray eq
28、uipment.3.22 HEALTH HAZARDS AND ODORThe material must not contain any ingredients (matter) which, undernormal production conditions could lead to health hazards such asskin ra sh or irritation (dermatitis), irritation of the mucousmembranes, difficulties in breathing, etc.The materials shall be free
29、 from objectionable o dors both as receivedand after storage.3.23 QUALITYThe material shall be of uniform quality free from foreign materialand pro perties detrimental to normal production use. It shall notca use excessive soiling of handlers in normal production use. Itmust not separate while in st
30、orage.ENGINEERING MATERIAL SPECIFICATIONESD-M5G43-AWP 3948-b Page 6 of 6 3.24 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to making any change in the properties, compos
31、ition,constr uction, color, processing or labeling of the materialorig inally approved 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 act
32、ivity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. 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.
33、The restrictions aredefined in Engineering Materials Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSMat erials defined by this specification must have prior approval by theresp onsible Materials Engineering activity. Suppliers desiring approvalof thei r materials shall first obtain an express
34、ion of interest from theaffec ted Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity a completed copy of their laboratory test reports, signed by aqualified and authorized representative of the test faci lity, d
35、emonstratingful l compliance with all the requirements of this specification (testresults, not nominal values), the material designation a nd code number, andtes t specimens for Ford evaluation. Fords engineering approval of amateri al will be based on its performance to this specification and on an
36、assessment of suitability for intended processes and/or applications. Uponapprov al, the material will be added to the Engineering Material ApprovedSource List.5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting the requirements of this specificat
37、ion.5.1 STORAGE STABILITY(From date of receipt at Ford Motor Company)Minimum of 6 months when stored between 5 C to 20 C.5.2 COMPATIBILITYAny ot her underbody coating, applied to the production materialESD-M5G43-A as an additional coating either for the purpose of repairor for other reasons (front wheel arch and under body) must be checkedfor compatibility with ESD-M5G43-A.
