1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1990 09 07 NL00E10035203005 Released L. Gullen, R. Fekete, H. SchrockWP 3948-a Page 1 of 9 INSULATOR, ELASTOMER BASED, EXTRUDED, PRESSURE ESL-M5G51-ASENSITIVE WITH POLYESTER FILM1. SCOPEThe material defined by th
2、is specification is an extrude d elastomeric basedins ulator material. This material is pressure sensitive and forms animmediate bond to oily galvanized steel at room temperature.2. APPLICATIONThis sp ecification was released originally to insulate heat shields andfuel tank support components on the
3、 underbody. This mate rial can be appliedin trim area or in prefabricate d applications at vendor plants. It may beapp lied over oily galvanized, CRLC steel, zinc rich primer, and plasticsubstrat es. Material is supplied extruded onto a polyester film whichbecomes a permanent component of the part.3
4、. 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 material/source approval. Appropriatestatist ical tools must be used to analyze process/product data sothat v
5、ariation 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 material/parts supplied to this specification.The IR spectra and thermograms established for i nitial approva
6、l 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 standard when testedunder the same conditions.3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated
7、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 unless otherwise specified.ENGINEERING MATERIAL SPECIFICATIONESL-M5G51-AWP 3948-b Page 2 of 9 3.4 DIMENSIONS
8、As specified on engineering drawingand/or in Trim & Sealer Manual 3.5 CONSISTENCY(ASTM D 1321, 300 gtl cone)3.5.1 As receivedat 25 C 5.0 - 6.0 mmat 5 C 1.5 - 2.5 mmat 49 C 7.5 - 9.5 mm3.5.2 Aged, 60 days at 23 Cat 25 C 5.0 - 6.0 mmat 5 C 1.5 - 2.5 mmat 49 C 6.5 - 8.5 mm3.6 SOLIDS, min, by weight 99
9、%(ASTM D 2834, except heat at 102 +/- 3 Cin a mechanical convection oven)3.7 ASH (Based on solids weight, max 40 %Test Method: Place the crucible containing the solids residue in acool muffle furnace. Slowly heat to and maintai n at 760 +/- 30 C for1 h, cool in desiccator and weigh.3.8 SPECIFIC GRAV
10、ITY 1.25 +/- 0.1(ASTM D 297, Hydrostatic Method)3.9 TENSILE STRENGTH, min 0.75 MPaELONGATION, min 2000 %Test Method:. Prepare specimens of the material which are 2 mm x 25 mm x 150 mm. Condition the test specimens for 2 h at 23 C. Place the test specimens in the holders of a device appropriate tomea
11、sure the tensile strength and extensibility of the material. Samples should be placed so that the jaws of tensile tester are 25mm apart at the beginning of the test. Run the test at a rate of extension of 500 mm per minute. Extend the material until the material fails by breaking ortearing. Compute
12、the tensile strength by dividing the load in Newtons at thetime of failure by the cross-sectional area of the specimen. Compute the elongation by measuring the displacement between thejaws in mm at the time of failure. Subtract 25 mm from thisdisplacement and divide by 25 mm. Express this ratio as a
13、 percent.ENGINEERING MATERIAL SPECIFICATIONESL-M5G51-AWP 3948-b Page 3 of 9 3.10 PEEL STRENGTH3.10.1 180 degree peel, on 3 mil polyester,127 mm/minuteInitial 500 N/m7 days at 70 C 1500 N/m7 days salt spray, 38 C 800 N/m7 days 100 % R.H., 37 C 800 N/mTest Method:. Prepare test specimens by extruding
14、a 2 mm x 35 mm sectionof material onto a .075 x 55 mm strip of polyester film.The material should be extruded so that it runs down thecenter of the film. Cut these extruded parts to a length of 125 mm. Condition the samples so extruded for 7 days at 23 C. Manually peel back the material from the pol
15、yester to adistance of 75 mm from one end. Place the polyester in one jaw of the peel tester and thematerial in the other jaw. The polyester shou ld be held inthe jaw at a point approximately 12 mm from where thepolyester and material are joined. The mater ial should beput in the jaw at a point appr
16、oximately 25 mm from wherethe polyester and material meet. The peel tester should be started and the maximum valueobtained while peeling 25 mm of material or the maximumvalue obtained before the material break from the polyesterfilm shall be recorded. Compute the peel strength by dividing the maximu
17、m forcerecorded in Newtons, by the width in mm of the materialsection.3.10.2 90 degree peel on galvanized,127 mm/minuteInitial 500 N/m14 days at 70 C 1200 N/m14 days, salt spray, at 38 C 700 N/m14 days, 100 % R.H., at 37 C 700 N/m Test Method:. Prepare material test specimens which are 2 mm x 22 mm
18、x100 mm. Condition the test specimens for 24 h at 23 CENGINEERING MATERIAL SPECIFICATIONESL-M5G51-AWP 3948-b Page 4 of 9 . Prepare 4 panels of galvanized steel which are 0.80 x 100x 150 mm. Clean the surface by wiping with mineral spiritsand allowing 10 minutes to dry. Apply 3 strips of the material
19、 to be tested t o each of thefour panels. The length of the strips should be placedalong the length of the panel (see illustration 1). Immediately cover each panel with a piece of release paperand pass a roller over each panel 6 times. The rollershould weigh 5 Kg. When passed over the specimens no f
20、orceshould be applied do wnward except the mass of the roller. After subjecting each panel to the specified environmentalconditions, allow the panels to be conditione d for 24 h at23 C. Using a chisel nose spatula, manually peel back a 50 mmstrip of material from each specimen on the panel. Place th
21、e panel in a fixture which will hold it firmly. Place the peeled back material in the jaw of the peeltester to a depth of 25 mm. Peel the material ba ck at a 90 deg angle to the panel andat a rate of 125 mm per minute. Record the maximum value obtained in Newtons while 25 mmis being peeled from the
22、panel or the maximum valueobtained before the material breaks. Compute the peel strength by dividing the value recordedby the width of the specimen in mm.3.10.3 Inverted Peel(on oily galvanized)distance, max7 days at 23 C 30 mm7 days at 70 C 50 mmpeel strength, min7 days at 23 C 800 N/m 7 days at 70
23、 C 3000 N/m Test Method:. Prepare specimens as in para 3.10.1. Cut the samples to a length of 250 mm. Prepare 6 panels of galvanized. These panels should beoily. They should be 0.80 x 100 x 300 mm. Apply one sample to each of the panels. The pressuresensitive side should be applied to the panel.ENGI
24、NEERING MATERIAL SPECIFICATIONESL-M5G51-AWP 3948-b Page 5 of 9 . After applying the sample, it should be affix ed by rollingeach sample no more than 6 passes with a 5 Kg roller. After fixturing, peel back 25 mm in length fr om one end ofeach strip. While h olding it away from the metal, invertthe pa
25、nel so that the sample is facing downward. (SeeIllustration 2). Place the panel in a fixture which will keep it invertedfor the time and condition specified. It must be positionedso that the sample has no support underneath it nor anyobstruction to prevent its falling or peeling. At the conclusion o
26、f the test, measure the distance in mmwhich the material has peeled back from the originalposition. Then perform a 90 deg peel test according to para3.10.2 recording the maximum value obtained d uring a 50 mmlong peel.3.11 FORCE TO COMPRESS, minInitial 1750 N50 cycles 1500 NTest Method:. Prepare sam
27、ples of material which are 4 x 25 x 100 mm. Apply apolyester film .075 x 25 x 100 mm to each sample. Place each of these samples on a galvanized s teel panel 0.80 x 100x 150 mm. Apply samples with the pressure sensitive side downagainst the panel. Prepare a steel loading assembly of approximately 6
28、mm thick steel.The assembly should be 25 x 100 mm. Place this steel loading assembly on top of the sample to betested. Put this into a compression testing device capable ofapplying a force of at least 2240 N. Bring the compression testing device down to where it just makescontact with the sample. Co
29、mpress the sample a distance of no more tha n 1 mm at the rate of125 mm/minutes. Record the value in Newtons obtained on the first compression. Repeat the compression cycle 49 times in a period of 10 minutes.Record the maximum v alue obtained on the compression phase of the50th cycle.ENGINEERING MAT
30、ERIAL SPECIFICATIONESL-M5G51-AWP 3948-b Page 6 of 9 3.12 COMPRESSION RECOVERY, minThickness Recovery,14 days at 23 C 95 %24 hours at 54 C 90 %24 hours at 70 C 50 %Test Method:. Prepare material samples in accordance with para 3.10.1. Place the samples with the pressure sensitive side down ongalvaniz
31、ed panels 0.80 x 100 x 150 mm. Measure the thicknes s of the sample to an accuracy of +/- .05 mm. Place a metal block measuring 50 x 50 x 50 mm and weighing no lessthan .9 Kg on top of the samples. Run the test for the time and at the temperature specified. Remove the block and condition the samples
32、 for 1 hr at 23 C. Measure the thickness of the sample where the block has beenpositioned on the sample. Measure to an accuracy of +/- .05 mm.Record value. Divide the thickness after test by the original thickness of thesample and report as a percentage.3.13 ELASTIC RECOVERY, max 160 mmat max 60 sec
33、Test Method:. Prepare a sample of material 2 x 35 x 152 mm (152 +/- 1 mm). Lay sample on a piec e of release paper 150 mm wide x 380 mm long. Hold the sample down on one end and stretch the other end out inno more than 5 seconds to a length of no less than 300 mm. Immediately release the sample and
34、allow it to recover its originallength while laying on the release paper. At 60 seconds from t he time of release of the sample, measure thelength in mm. Record this value.3.14 COLD FLEXIBILITY No cracking,(24 h at - 40 C) splitting orbreakingA 2 x 35 x 150 mm sampl e, conditioned for 24 h at - 40 C
35、 is bent 180degrees over a 175 mm mandril, with mastic side down, in no more than5 seconds.ENGINEERING MATERIAL SPECIFICATIONESL-M5G51-AWP 3948-b Page 7 of 9 3.15 STORAGE STABILITYThe material shall be stored at temperatures bel ow 54 C. Under thesestorage conditions, the minimum shelf life of the m
36、aterial shall be6 months. When these materials are stored at tem peratures below 23 C,they shall be conditioned at room temperature prior to application.3.16 FUNCTIONAL APPROVALMaterials being evaluat ed for initial approval to this specificationshall be subjected to a production trial. Functional t
37、rial resultssho uld be available to design and material engineering prior tomaterial approval and release.3.17 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manufa ctured parts shall bespecified on the Engineering drawing, Engineerin g parts specificationand/or performance specifi
38、cations. All critical areas with respect tothese properties shall be clearly designated on the engineeringdrawing.3.19 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to ma
39、king 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 affect the materials ability to meet the specificationrequir ements, the Supplier shall notify Purchasing, Toxicology
40、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 identification areto be submitted with the request.Substance restrictions imposed by law, regulations or Ford, apply tot
41、he 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 engineeringdocument for the application.4. APPROVAL OF MATERIALSMat erials defined by this specification must hav
42、e prior approval by theresponsible Materials Engineeri ng activity. Suppliers desiring approval ofthe ir materials shall first obtain an expression of interest from theaffec ted Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials En
43、gineeringactivity its own laboratory rep ort to the specification (test results, notnominal values), the material designation and code number, and testspecim ens for Ford evaluation. Upon approval, the material will be addedto the Engineering Material Approved Source List.ENGINEERING MATERIAL SPECIF
44、ICATIONESL-M5G51-AWP 3948-b Page 8 of 9 5. GENERAL INFORMATIONThe information below is provided for clarification and assistance inmeeting the requirements to the specification.5.1 MECHANICAL CONVECTION OVENThe mechanical oven(s) used to test the material shall be capable ofobtaining 205 C metal tem
45、perature on body steel (0.8 - 0.9 mmthickness) within 8 - 10 minutes.5.2 SUBSTRATESNominal panel dimensions are 0.8 x 100 x 300 mminjection molded specimen)5.2.1 Gal vanized steel (WSB-M1A250-C3): Surface precoated withM-99C47 -A Mineral Oil at an application of approx 0.2cm3/ft2.ENGINEERING MATERIAL SPECIFICATIONESL-M5G51-AWP 3948-b Page 9 of 9 ILLUSTRATIONS
