1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1996 10 02 Activated W. Curtiss/D. RuonaWP 3948-a Page 1 of 9 ADHESIVE/HEADLINER REQUIREMENTS FOR BONDED IN WSB-M11P59-AHEADLINER1. SCOPEThis specification defines the adhesive/headliner requirements formaterials
2、 used to bond in headl iners where roof bows have been eliminated.2. APPLICATIONThis specification was released originally for bonding of rigid headlinersto th e roof interior sheet metal. The roof sheet metal can have varyingdegree s of phosphate, electrocoat, body primer, and/or topcoat overspray.
3、The headliner can be comprised of different scrims/substrate composites.This s pecification does not describe individual material properties. Theapplicable material specifications should be referenced for non-performancecharacteristics.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers
4、 and part producers must conform to Quality SystemRequirements, QS-9000. Material specification r equirements are to beused fo r initial qualification of materials. A Control Plan forong oing production verification is required. This plan must bereviewed and approved b y the relevant Ford Materials
5、activity and/orFor d Supplier Technical Assistance (STA) prior to production partssubmission. Appropriate statistical tools must be used to analyzepr ocess/product data and assure consistent processing of thematerials.Part producers using this material in their products, must use Fordapproved materi
6、als and must conform to a process control plan whichhas been approved by STA and/or the relevant Materials Activity.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.T
7、he 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 standard when testedunder the same conditions.
8、ENGINEERING MATERIAL SPECIFICATIONWSB-M11P59-AWP 3948-b Page 2 of 9 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 unde
9、r thesame conditions unless otherwise specified.3.4 PEEL ADHESION, Min 350 N/m width100 % c ohesive failure of adhesive on production painted panels orsubstrate breakage above the specified loads. Exposure Conditions - Bonded Test Assemblies:After material cure, place assembly in 90 degree peel fixt
10、ure.Condition at room temperature for 30 minutes prior to testing at 23+/- 2 C (except where n oted). Report failure mode, initial peel andstrengt h and continued peel strength. Test 5 samples per exposurecondition.3.4.1 24 h at 23 +/- 2 C3.4.2 2 weeks at 90 +/- 2 C3.4.3 2 weeks at 38 +/- 2 C a nd 9
11、8 +/- 2 % relative humidity, non-condensing.3.4.4 Thermal cycle - 5 cyclesOne cycle consists of:4 h at 90 +/- 2 C4 h at 38 +/- 1 C and 98 +/- 2 % relative humidity16 h at - 30 +/- 1 CTest Method:Apply a 10 mm diameter bead of adhesive to a 25 x 380 mmsect ion of headliner substrate. Immediately bond
12、 to thecent er of a 50 x 300 mm metal panel (per para 5.2.2) andcompress to 3 mm bondli ne thickness. (See Figure 1) Removeany exce ss adhesive with a spatula or other suitable tool.After complete material cure, expose the samples to thecon ditions indicated above. After the exposure period,conditio
13、n the samples for 24 h at 23 +/- 2 C (co ndition 3.4.1does not require an additional 24 h). Clamp a 9 0 degree peeltest fixture equipped w ith ball bearing track allowing for acontinuous 90 degree peel angle into the jaw of a tensiletest ing machine. Place the test panel into the fixture.Insert the
14、extended end of the headliner into cr oss head jaw.Initiate jaw separation at the rate of 50 mm/min ute. Continuethe te st until all the headliner has been removed from thepanel. Record the average peel force and mode of failure.ENGINEERING MATERIAL SPECIFICATIONWSB-M11P59-AWP 3948-b Page 3 of 9 FIG
15、URE 13.5 STATIC DEAD WEIGHT No cohesive or adhesive failure onproduction painted panels orheadliner. Substrate breakage isacceptable.3.5.1 24 h at 23 +/- 2 C3.5.2 24 h at - 30 +/- 1 C3.5.3 30 minutes at 120 +/- 2 C (15 h material cure only)3.5.4 2 weeks at 90 +/- 2 C3.5.5 2 weeks at 38 +/- 2 C a nd
16、98 +/- 2 % relative humidity, non-condensing.3.5.6 Thermal cycle - 5 cyclesOne cycle consists of:4 h at 90 +/- 2 C4 h at 38 +/- 1 C and 98 +/- 2 % relative humidity16 h at - 30 +/- 1 CENGINEERING MATERIAL SPECIFICATIONWSB-M11P59-AWP 3948-b Page 4 of 9 Test Method:Use a 50 x 100 mm secti on of headli
17、ner material. Apply 2 18x 18 x 6 mm daubs of adhesive to the back side of theheadliner specimen. (See Figure 2) A template m ay be used toassur e proper dimensions. Place the headliner with theadhes ive side down on a 100 x 300 x 0.89 mm steel panelidentified in para 5.2.2. Use a shim to allow f or
18、a bondlinethickness of 3 mm. Pre ss the specimen onto the metal panel.Remove t he shim. After complete material cure, invert thepanel and suspend a 250 g weight, centrally located from theheadl iner speciman, for the length of time and exposureconditions indicated above. Record failure mode andappro
19、x imate time to failure. Test 3 samples per exposurecondition.FIGURE 23.6 COLD ADHESION No cohesive or adhesive failure onproduction painted panels orheadliner.Exposure Conditions - Bonded Test Assemblies(condition for 120 h at 23 +/- 2 C unless otherwise noted)3.6.1 Test after 15 h cure only3.6.2 H
20、igh t emperature exposure, 120 C for 30 minutes (15 h roomtemperature materials cure only)3.6.3 Normal after 24 h at 23 +/- 2 C3.6.4 Heat aged 2 weeks at 90 +/- CENGINEERING MATERIAL SPECIFICATIONWSB-M11P59-AWP 3948-b Page 5 of 9 3.6.5 Thermal Cycle - 5 cyclesOne cycles consists of:4 h at 90 +/- 2 C
21、4 h at 38 +/- 1 C and 98 +/- 2 % relative humidity,non-condensing16 h at - 30 +/- 1 CTest Method:SAE J243, ADS-2, Method A modified as follows: Apply three10 mm diameter beads of adhesive to the back side of a 150 x150 mm section of headliner. The beads shall be spaced byapproximately 50 mm and the
22、ends shall be approx imately 13 mmfro m the edge of the headliner. (See Figure 2) Bond thehea dliner specimen to the center of a 300 x 300 x 0.89 mmsteel panel per para 5. 2.2. Use appropriate shims to obtain3 mm bondline thickness. Completely cure the sam ples prior toen vironmental exposure unless
23、 otherwise specified. Exposethree samples of each paint finish listed in para 5.2.2 tothe above environmental conditions. Position panel insl amming fixture with headliner facing inward. Perform 10cycles of 10 slams/cycl e at - 30 C with a 10 minute dwell at- 30 C bet ween cycles. Inspect for loss o
24、f adhesion andreport percentages of failure and type of failur e. Also noteany degradation in headliner substrate. Test 3 a ssemblies perexposure condition.FIGURE3ENGINEERING MATERIAL SPECIFICATIONWSB-M11P59-AWP 3948-b Page 6 of 9 3.7 ACOUSTICSHeadliner assemblies must be evaluated and approved by t
25、he affectedNoise, Vibration and Ha rshness group of Vehicle Development prior tofinal approval to this specification. Acoustical materials employedin this assembly shall also meet the acoustical requirements asdesignated in their individual engineering material specifications.3.8 SIMULATED IN-CAR EN
26、VIRONMENTAL AGINGHeadliner Sag 13 mm maxEdge Gap Deformation 3.5 mm maxShall not show any delamination, loss of embossed definition,excessive deformation, or any objectionable surface imperfections.Test Method:Install a complete headliner using production as sembly techniques, inan approved test buc
27、k or vehicle, representative of intendedproduction dimensions. Expose the vehicle (with windows open) or testbuck to the following environmental cycle:6 h at 85 +/- 2 C and 98 +/- 5 % relative humidity6 h at - 35 +/- 2 C12 h at 85 +/- 2 C6 h at - 35 +/- 2 C6 h at 85 +/- 2 C and 98 +/- 5 % relative h
28、umidityAfter completion of cycle, buck must sit at least 8 h before takingmeasurements.Sag Measurements (Figure 4)Location 1 - Above driver and front seat passengerLocation 2 - Center of headlinerLocation 3 - Above rear seat passenger, right and leftMe asurements can be done by punching through the
29、headliner to thesheet metal. Measure before and after cycle at locations marked withX on Figure 4. (Note: Measurements shall be tak en by the same personfor consistency.) Edge Deformation (Figure 5)Measu rements shall be taken every 150 mm along unsupported edges(i.e. f ront and rear windows, side w
30、indows without mouldings).Measurements in the dow nward direction (Z) and in/out direction (X),must be taken as close to the edge of the headliner as possible. ENGINEERING MATERIAL SPECIFICATIONWSB-M11P59-AWP 3948-b Page 7 of 9 FIGURE 4Figure 53.9 FUNCTIONAL APPROVALMaterials being evaluated for app
31、roval to this s pecification shall besubject ed to a production trial. Functional trial results must beapproved by the affected assembly operation and Design Engineering.Results shall be made available to Materials Engineering prior tomaterial approval and release.ENGINEERING MATERIAL SPECIFICATIONW
32、SB-M11P59-AWP 3948-b Page 8 of 9 3.10 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manufa ctured parts shall bespecified on the Engineering drawing, Engineerin g parts specificationand/or performance specification. All critical areas with respect tothese properties shall be clear
33、ly designated on the engineeringdrawing.3.11 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, composition,constr uction, color, proce
34、ssing 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 activity of the proposed changesand
35、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. The restrictions aredefined in En
36、gineering Materials Specification WSS-M99P9999-A1.4. 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 first obtain an expression of interest from theaffec ted
37、 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, demonstratingful l compliance with
38、 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 anassessment of suitability for int
39、ended processes and/or applications. Uponapprov al, the material will be added to the Engineering Material ApprovedSource List.ENGINEERING MATERIAL SPECIFICATIONWSB-M11P59-AWP 3948-b Page 9 of 9 5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting
40、the requirements of this specification.5.1 MECHANICAL CONVECTION OVENThe mechanical convection oven(s) used to cure the sealers shall becapable of obtaining 205 +/- 3 C metal temperatu re on body steel gagethickness in 10 minutes.5.2 SUBSTRATESThe substrates listed s hall be used in all tests requir
41、ing headlinerand metal panels, unless otherwise noted.5.2.1 He adliner: Current production headliner as identified byMaterials Engineering.5.2.2 St eel: WSB-M1A250-C3 60G60GEL Steel panel coated with thefollowing paints: (See Note). Bare steel (no coating, clean). Phosphate only. Phosphate + E-Coat
42、Primer. Phosphate + E-Coat primer + Taupe primer “Overspray“ +BC/CC “Overspray“ NOTE: When qualifying a new headliner substrate, test only E-coatedpanels.5.2.3 PaintsPho sphate, electrocoat, primed, and topcoat steel panels:Prepare per ESB-M2P4 pe rformance specification. Use currentproduction paints as id entified by the responsible MaterialsEngineering Activity.
