1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1991 01 31 DE00E00107002086 Revised & Retyped J. Huebner1978 06 12 CF4H-RD567168-21 Metricated & Retyped J. Huebner1966 10 10 F6-2888 ReleasedWP 3948-a Page 1 of 4 VARNISH, MODIFIED POLYESTER “CLASS F“, HI BOND,
2、ESF-M7J35-AELECTRICAL INSULATING1. SCOPEThe material defined by this specification is a modified polyester typeinsulating baking varnish (Class “F“) having high bond s trength at elevatedtemperatures.2. APPLICATIONThis specification was released originally for varnish u sed for coating andimpregnati
3、ng high temperature alternator rotors and stators.3. REQUIREMENTS3.1 SPECIFIC GRAVITY, min 0.975(ASTM D 154 at 23 +/- 2 C)3.2 VISCOSITY 50 - 70 s(FLTM BI 111-01 at 23 +/- 2 C)3.3 FLASH POINT, min 22 C(ASTM D 93)3.4 SOLIDS, min 47 %(ASTM D 115 at 135 +/- 3 C)3.5 STABILITYDip Tank, 3 months min, visco
4、sity increase, max 15 sShelf 6 months min, viscosity increase, max 15 s3.6 QUALITYThe mat erial shall be clear and shall deposit no sediment oncentri fuging and/or standing at existing temperatures and climaticconditions for a minimu m period of 6 months while stored in airtightcontainers.ENGINEERIN
5、G MATERIAL SPECIFICATIONESF-M7J35-AWP 3948-b Page 2 of 4 3.7 CURINGThe material shall completely cure in 60 minutes at 149 C.Test Method: Place 10 g of the material as received in a 64 mmdiameter aluminum evaporation dish and bake for 60 minutes at 149 +/-1 C. Remove from oven, air cool to room temp
6、erature and inspect forinternal tackiness.3.8 CHARACTERISTICS AFTER REDUCTIONThe mat erial shall be capable of being reduced to the properconsistency with Xylol. There shall be no evidence of cloudiness orseparation. When a coil preheated to 79 C is subjected to a singledip in the varnish, the coati
7、ng produced shall completely cover thewinding with a uniform unbroken film thickness. Bare copper wire andin sulated magnet wire shall show a solid heavy coating, free frombloom, lumps, and air pockets.3.9 CHARACTERISTICS AFTER CURINGThe bak ed finish shall be hard, adherent and resistant to bending
8、The finish shall not lo se its physical or insulating properties whensubjected to the long continuous action of heat and electrical stressThe finish shall also b e resistant to the action of alkalies, acids,oils, and moisture that may be present in its applicationenvironment.3.10 HIGH TEMPERATURE R
9、EQUIREMENTS Class 155 C(AIEE 57 twisted pair ESF-M2L27-A, magnet wire)3.11 DURABILITYThere shall be no evide nce of blistering or flaking after completionof the number of hours or cycles required on the Engineering Drawingand/or Engineering Specification.3.12 HELICAL COIL BOND STRENGTH23 +/- 2 C, mi
10、n 20.4 kg149 +/- 3 C 4.6 kgTest Me thod: Place helical coils of #15 gage ESF-M2L16-A22 nylon-acetal insulated copper magnet wire on a 6.4 mm mandrel. Wind eachturn of wire closely to gether under even tension to a coil length of75 mm. Place 12 of the 75 mm coils on a fixture. Dip into the varnishwhi
11、ch has been adjusted to 50 s, #4 Ford Cup. Wi thdraw at rate of 100mm/minute. Dip and bake cycle is listed below:ENGINEERING MATERIAL SPECIFICATIONESF-M7J35-AWP 3948-b Page 3 of 4 5 minutes Dip Invert Coils:10 minutes Drain 5 minutes Dip60 minutes Bake 177 C 10 minutes Drain10 minutes Cool 60 minute
12、s Bake 177 CPlace the samples in a flexural testing type jig such as is availableat Rawsonville Quality Control Laboratory. Apply the load in thecenter of 51 mm span on the coils through a lever system attached tothe heating chamber and testing jig. The load is lead shot pouredinto a pail attached t
13、o the lever. When the testing is performed at149 C, the sample is pl aced into the jig and allowed to stand for 15mi nutes prior to load application to bring sample up to thetemperature.3.13 STATISTICAL PROCESSSupplie rs must conform to the requirements of Ford Quality SystemStand ard Q-101. A mutua
14、lly 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.3.14 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification
15、 must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to making any change in the properties, composition,constr uction, color, processing or labeling of the materialorig inally approved under this specification, whether or not suchchange s affec
16、t 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 Engineeringactivity. Test data, t est samples and a new code identif
17、ication 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, unlessa different suffix (e.g., A2 or A3) is specified on the
18、engineeringdocument for the application.ENGINEERING MATERIAL SPECIFICATIONESF-M7J35-AWP 3948-b Page 4 of 4 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
19、 first obtain an expression 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
20、of the test faci lity, demonstratingful 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. In addition to meeting therequi rements of this specification, the materials will be assessed forsuita bility for intended applications as part of the approval process.Upo n approval, the material will be added to the Engineering MaterialApproved Source List.
