1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2009 10 14 A2- INACTIVE A- N-STATUS Replaced by global strategy B. Witkowski, NA 1996 03 06 Revised Updated and retyped W. Scholz 1975 01 09 Released SM/ET0859 TP WP 3948-a Page 1 of 7 SEALER, WELDABLE, EXPAND
2、ING, HEAT CURING SK-M4G9508-A POLYACRYLIC ESTER NOT TO BE USED FOR NEW DESIGN SEALER, WELDABLE, HEAT CURING, BUTYL RUBBER INACTIVE SK-M4G9508-A2 1. SCOPE The materials defined by these specifications are spot weldable, heat curing sealers based on polyacrylic ester or butyl rubber. 2. APPLICATION Th
3、ese materials were released originally for materials used for sealing spot weld seams e.g. sealing of side panel to wheel arch (SK-M4G9508-A) and sealing of floor pan (SK-M4G9508-A2) or as specified on Engineering drawing and is applied to oiled surfaces in body assembly. 3. REQUIREMENTS 3.1 QUALITY
4、 SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for initial qualification of materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and a
5、pproved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to analyze process/product data and assure consistent processing of the materials. Part producers using this material in th
6、eir products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of m
7、aterial/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference
8、 standard when tested under the same conditions. ENGINEERING MATERIAL SPECIFICATION SK-M4G9508-A SK-M4G9508-A2 WP 3948-b Page 2 of 7 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relativ
9、e humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 COLUR Black 3.5 SOLIDS, min SK-M4G9508-A: 85 % (FLTM BV 150-10) SK-M4G9508-A2: 98 % 3.6 ASH, max 45 % (FLTM BV 150-10) 3.7 FLASH POINT 56 C (ASTM D 56) 3.8 DENSITY AT 20 C 1.0 to 1
10、.6 kg/l (ASTM D 1475) 3.9 VISCOSITY AT 20 C (FLTM BV 103-1, line pressure 0.392 MN/m2, nozzle diameter 2 mm) If the finished part does not allow the preparation of specimens, the supplier is required to provide, together with the Initial Sample Report, specimens of same material and equivalent manuf
11、acture used for the finished part. Samples for control and routine checks shall be submitted assured by Quality Control. 3.9.1 As Received SK-M4G9508-A: 70 - 200 s SK-M4G9508-A2: 200 - 600 s 3.9.2 After Ageing SK-M4G9508-A: max 200 s SK-M4G9508-A2: max 600 s 3.10 FLOW RATE max 3 mm (FLTM BV 153-1, M
12、ethod A, except oiled panels according to FLTM BZ 150-11, “Normal Grade“) 3.11 COLD RESISTANCE AFTER AGEING No loss of adhesion or chipping. Test Method: 1. Apply 250 x 30 x 3 mm ribbons of test material in the middle of 300 x 100 x 0.8 - 0.9 mm test panels prepared according to FLTM BZ 150-11, “Nor
13、mal Grade“. ENGINEERING MATERIAL SPECIFICATION SK-M4G9508-A SK-M4G9508-A2 WP 3948-b Page 3 of 7 2. Expose separately test assemblies according to FLTM BV 150-5, Table 1: a) minimum curing cycle b) maximum curing cycle 3. Expose test assemblies in a mechanically convected air-drying oven at 80 +/- 2
14、C for two weeks. 4. After cooling to 23 +/- 2 C expose test assemblies and bending fixture (see FLTM BV 153-4, except 100 mm mandrel) in a cold box at - 30 +/- 1 C for 4 h. 5. While still in the cold box bend test assemblies within 2 s around the 100 mm mandrel through an angle of 90 degrees. 3.12 F
15、LAMMABILITY AND CORROSION (FLTM BV 159-2, Method A. Immediately after welding separate the welded parts using a test fixture according to FLTM BV 159-1, Figure 4. Examine after 48 h at 23 +/- 2 C.) No burning, no corrosion. 3.13 CORROSION RESISTANCE The material shall protect the test panel from cor
16、rosion. No corrosion or blistering at the borderline sealer/EC/steel. Test Method: 1. Test panel preparation according to FLTM BV 159-2, Method A. 2. After 2 h at 23 +/- 2 C wash, phosphate and electrocoat test assemblies under normal production conditions. 3. Expose separately test assemblies accor
17、ding to FLTM BV 150-5, Table 1. a) minimum curing cycle b) maximum curing cycle 4. After 24 h at 23 +/- 2 C expose test assemblies to a salt spray fog according to ASTM B 117 for 240 h. 5. Separate welded assemblies using a test fixture according to FLTM BV 159-1, Figure 4 and examine. ENGINEERING M
18、ATERIAL SPECIFICATION SK-M4G9508-A SK-M4G9508-A2 WP 3948-b Page 4 of 7 3.14 WASH RESISTANCE No wash-off of sealer, no deformation of sealer surface permitted. Test Method: 1. Apply two 250 x 30 x 3 mm ribbons of test material in the middle and 50 mm apart from each other to a 300 x 100 x 0.8 - 0.9 m
19、m test panel, prepared according to FLTM BZ 150-11, “Normal Grade“. 2. After conditioning for 2 h at 23 +/- 2 C expose test assemblies in horizontal position to a water jet of 50 +/- 5 C using a nozzle no. 1/2 GG-Full Jet (Spraying System Co.) and a pressure of 200 kN/m2. The distance between the no
20、zzle and test material shall be 300 mm. The water jet shall be applied between the beads for 1 minute. 3.15 WASH AND PHOSPHATING SOLUTION RESISTANCE 3.15.1 Non-Cured Material No evidence of dissolution or lifting from panel. Test Method: 1. Apply 250 x 40 x 0.1 - 0.2 mm ribbons of test material to 2
21、50 x 60 mm oiled test panels, prepared according to FLTM BZ 150-11, “Normal Grade“. 2. After 2 h at 23 +/- 2 C wash and phosphate test assemblies under normal production conditions. 3.15.2 Cured Material No loss of adhesion or chipping. Test Method: 1. Test specimens as prepared and tested under cla
22、use 3.15.1 shall be exposed for 20 minutes in a mechanically convected air-drying oven at 100 +/- 2 C and subsequently subjected to maximum curing cycle according to FLTM BV 150-5, Table 1, Phase 1 and 2. 2. After cooling to 23 +/- 2 C expose test assemblies and bending fixture (see FLTM BV 153-4, M
23、ethod A, except 100 mm mandrel) in a cold box at - 30 +/- 1 C for 4 h. 3. While still in the cold box bend test assemblies within 2 s around the 100 mm mandrel through an angle of 90 degrees. ENGINEERING MATERIAL SPECIFICATION SK-M4G9508-A SK-M4G9508-A2 WP 3948-b Page 5 of 7 3.16 WETTING (FLTM BV 15
24、3-8, Method A) The enamel shall form a continuous film over the visible edges of sealing strip. Discoloration or staining permitted. 3.17 TENSILE ADHESION min 10 N/cm2 (FLTM BV 154-3, Method A, Type 1, x = 3 mm, heat curing after 10 minutes at 23 +/- 2 C, test at 23 +/- 2 C) 3.18 WATER ABSORPTION ma
25、x 8 % (FLTM BV 153-7) 3.19 VOLUME EXPANSION SK-M4G9508-A: 25 - 55 % SK-M4G9508-A2: max 25 % Test Method: 1. Determine the volume V1 of clean 150 x 25 mm test panels. 2. Apply test strips of 8 mm in diameter and 100 mm in length (see sketch in FLTM BV 153-7) and determine volume V2. 3. Expose test as
26、semblies separately according to FLTM BV 150-5, Table 1: a) minimum curing cycle b) maximum curing cycle, phase 1 and 2 4. After cooling to 23 +/- 2 C determine volume V3. Note: Determine volumes by water displacement. The volume increase in % of the original volume shall be determined as follows: V
27、3 - V2 Volume Expansion in % = - x 100 V2 - V1 Where: V1 = Volume of test panel V2 = Volume of test panel and sealing strip V3 = Volume of test panel and sealing strip after curing ENGINEERING MATERIAL SPECIFICATION SK-M4G9508-A SK-M4G9508-A2 WP 3948-b Page 6 of 7 3.20 STRUCTURE AFTER CURING The mat
28、erial shall form a closed skin after heat curing. The inner cell structure shall be fine without large voids. Test Method: 1. Preparation of test assemblies according to clause 3.19, para 1 to 3. 2. After cooling to 23 +/- 2 C test specimens are cut through and examined visually. 3.21 SHORE HARDNESS
29、 “A“ 20 - 75 Test Method: Apply enough material to a test panel 300 x 60 mm prepared according to FLTM BZ 150-11 “Normal Grade“ and scrape to a dimension of 30 x 5 mm. Condition for 10 minutes at 23 +/- 2 C and expose to a mechanical convected air-drying oven to a temperature of 165 +/- 2 C for 30 m
30、inutes. Condition for 4 h at 23 +/- 2 C and check the shore hardness according to ASTM D 2240. 3.22 QUALITY The material shall be of uniform quality, free from foreign materials and properties detrimental to normal production use. 3.23 SUPPLIERS RESPONSIBILITY All materials supplied to this specific
31、ation must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes
32、 affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code
33、 identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Materials Specification WSS-M99P9999-A1. ENGINEERING MATERIAL SPECIFICATION SK-M4G9508-A SK
34、-M4G9508-A2 WP 3948-b Page 7 of 7 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Des
35、ign and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requi
36、rements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended process
37、es and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 STORAGE STABILITY (From date of receipt at FMC) Minimum 6 months when stored between 5 C and 28 C.
