1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 07 28 N-STATUS Replaced by WSS-M11P64-A1/A2/A3 M. Mehandru 2002 09 16 Revised Updated and Renumbered 1995 05 16 Activated H. Kon, E.R.R. Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 7 ADHESIVE, H
2、IGH STRENGTH, HEAT CURING, EXPANDABLE, EPOXY/ WSB-M2G281-D2 GLASS FIBER LAMINATE, METAL REINFORCEMENT NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a heat curing, epoxy/fiberglass laminate, supplied in die cut form with a release paper backing. The epoxy layer
3、is formulated to expand 100% during electrocoat oven bake. 2. APPLICATION This specification was released originally for material used to reinforce and stiffen sheet metal body panels. This material can be applied to oily cold rolled steel and galvanized steel surfaces. Recommended material cure sch
4、edules are 171 C metal temperature for 10 minutes minimum and 205 C metal temperature for 30 minutes maximum. Cured material properties vary with epoxy fiberglass material thickness. Refer to para 4.4 for additional information. 3. REQUIREMENTS Material specification requirements are to be used for
5、initial qualification of materials. Test must be conducted on material having an original epoxy/fiberglass material thickness of 1.5 +/- 0.1 mm. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production
6、Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPATIBILITY Initial laminate approval was based on a specific material system which included the substrate, stamping lubricants and laminate. The originally approved material system was oven cured using specific production process parameters. Substrate choice
7、, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may affect laminate performance. If any of these parameters are changed, the laminate performance must be validated using the new parameters. 3.3 FIBERGLASS CLOTH REQUIREMENTS Thickness of cloth, wea
8、ve, and breaking strengths in warp and fill directions must be such that all requirements of this specification are met. See para 4.5 for additional information. ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D2 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 7
9、3.4 EPOXY POLYMER REQUIREMENTS 3.4.1 Specific Gravity 0.8 - 1.0 (ASTM D 792) 3.4.2 Volume Expansion, % 90 - 110 (FLTM BV 108-02, material cure per para 4.3) 3.5 UNCURED LAMINATE MATERIAL PROPERTIES 3.5.1 Construction Construction must consist of woven fiberglass cloth onto an epoxy adhesive film bac
10、ked with release paper. There must not be any loose glass fibers after the die cut operation. 3.5.2 Thickness, uncured As specified on (ASTM D 461, 85 g load, Engineering Drawing 25 mm diameter foot, total fiberglass and adhesive) 3.6 UNCURED LAMINATE PERFORMANCE REQUIREMENTS 3.6.1 Formability The m
11、aterial must not delaminate or crack when folded 180 upon itself. 3.6.2 Tack Adhesion Test The laminate must not peel at the edges or fall off panel. Test method: Apply a 100 x 150 mm adhesive laminate strip on a 150 x 300 mm panel. Prepare four panels for each substrate per para 4.2. Pass a 2.2 kg
12、roller over samples per ASTM D 1000. Invert two panels immediately after laminate application and condition at 23 +/- 2 C for 1 h. Observe for peeling or lifting of laminate from panel. Save panels for Inverted Bake Test, para 3.7.2. Stand the remaining two panels vertically immediately after lamina
13、te application and condition at 23 +/- 2 C for 1 h. Observe for peeling, sliding or slumping of laminate from panel. Save panels for Vertical Bake Test, para 3.7.3. 3.6.3 Phosphate Wash Resistance (FLTM BV 116-01, Method “A“ preparation specified below) Sample preparation: 1) Identify the cutting di
14、rection for the fiberglass cloth - Cut 25 x 150 mm specimens of adhesive laminate in warp and fill directions. - For specification testing, cut all laminate specimens in the grain direction producing the highest mean Peak Loads 2) Lubricant application - Using appropriate method, apply the designate
15、d lubricant at the specified amount to substrates described in para 4.2. - Allow coupon to sit undisturbed in horizontal position for at least 1 hour prior to use. 3) Preparing bonded assembly - Apply a 25 x 150 mm adhesive laminate specimen cut in a specified direction to a 25 x 150 mm panel prepar
16、ed in Step 2. - Pass a 2.2 kg roller per ASTM D 1000 over sample within 15 minutes of patch application. - Condition at 23 +/- 2 C and 50 +/- 5% RH for 1 h prior to oven cure per para 4.3. 4) Reporting data - Record load at 2 mm deflection and peak load in Newtons. - Report average load and sample s
17、tandard deviation. Normal ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D2 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 7 (Condition for 30 min at specified temperature prior to test.) Load at 2 mm Peak Deflection Load 3.7.1.1 Test at 23 +/- 2 C 150 220 3.7.
18、1.2 Test at 90 +/- 1 C 75 150 3.7.1.3 Environmentally Aged Assemblies (Condition for 24 h at 23 +/- 2 C and 50 +/- 5% RH after exposure, then test at 23 +/- 2 C) Material must meet Flexural Strength Requirement (para 3.7.1.1) after each of the following environmental exposures: 14 days heat age at 9
19、0 +/- 1 C 500 h humidity at 38 +/- 2 C and 98 +/- 2% RH 10 thermal cycles One cycle: 90 +/- 2 C for 4 h PLUS 40 +/- 2 C and 98 +/- 2% RH for 4 h PLUS -30 +/- 2 C for 16 h 500 h salt spray (ASTM B 117) 3.7.1.4 Adhesive storage prior to bonding. (Expose material in sealed packages. Condition at 23 +/-
20、 2 C for 24 h prior to testing). 72 h at 40 +/- 2 C 3.7.2 Inverted Bake The material must exhibit a smooth, non-blistered surface and must not peel at edges or fall off from panel. Test Method: Condition one half of the panels of each substrate prepared per para 3.6.2 to 23 +/- 2 C for 4 h. Panels m
21、ust remain inverted during conditioning. Condition the other half of the panels of each substrate prepared per para 3.4.2 to 72 h at 40 +/- 2 C and 98 +/- 2% RH. Panels should remain inverted during conditioning. Place conditioned panels in an oven in the inverted position and cure per para 4.3. Sav
22、e samples for Cold Slam Test, para 3.7.4. ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D2 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 7 3.7.3 Vertical Bake The material must exhibit a smooth, non-blistered surface and must not peel at edges, sag more than
23、2.5 mm or fall off from panel. Test Method: Condition one half of the panels of each substrate prepared per para 3.6.3 to 23 +/- 2 C for 4 h. Panels must remain vertical during conditioning. Condition the other half of the panels of each substrate prepared per para 3.4.3 to 72 h at 40 +/- 2 C 98 +/-
24、 2% RH. Panels must remain vertical during conditioning. Place conditioned panels in an oven in the vertical position and cure per para 4.3. Save samples for Cold Slam Test, para 3.7.4. 3.7.4 Cold Slam (FLTM BV 101-02, Procedure “E“, condition 4 h min at -30 +/- 2 C. Test at -30 +/- 2 C, panels prep
25、ared per para 3.7.2 and 3. 7.3. The material must not crack or separate from panel before 10 slams. 3.7.5 Fogging Test (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post teat conditioning 1 h and 16 h) Fog Number, min 60% Formation of clear film, droplets or crystals is cause for rejection.
26、3.8 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification will be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results must be made available to Materials Engineering prior to material
27、 approval and release. 4. GENERAL INFORMATION The information below is provided for clarification and assistance in meeting the requirements of this specification. These parameters should be verified with Materials Engineering prior to initiating material testing. 4.1 MECHANICAL CONVECTION OVEN The
28、mechanical convection oven(s) used to cure the material will be capable of obtaining 205 C metal temperature on 0.81 mm thick steel within 10 minutes. ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D2 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 7 4.2 SUBSTRA
29、TES Nominal panel dimensions are 100 x 300 x 0.80 mm 4.2.1 CRLC Steel meeting WSB-M1A250-A1: Nominal 0.80 mm thickness, surface precoated with stamping lubricant at a coating weight as specified by the responsible Materials Engineering Activity. 4.2.2 Galvanized steel meeting WSB-M1A250-C3-60G60G-EL
30、: Nominal 0.80 mm thickness, surface precoated with stamping lubricant at a coating weight as specified by the responsible Materials Engineering Activity. 4.3 MATERIAL CURE SCHEDULES Minimum bake: 170 C metal temperature for 10 minutes (not to exceed 20 minutes oven time) Maximum bake: 205 C metal t
31、emperature for 30 minutes (not to be less than 40 minutes oven time) 4.4 FLEXURAL STRENGTH VS. MATERIAL THICKNESS Cured material properties vary with epoxy/fiberglass material thickness. Material submitted for approval to the specification was 1.3 +/- 0.1 mm thick. If a thickness other than this is
32、required, additional testing is recommended to ensure desired material properties are maintained after environmental exposures. ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D2 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 7 of 7 4.5 FIBERGLASS CLOTH This specific
33、ation was originally written for a laminate with a fiberglass cloth with the following characteristics. 4.5.1 Style Designation 7628 (ASTM D 579, Table 6) 4.5.2 Fabric Count, Warp, yarns/25 mm 43 (ASTM D 579, Table 6) 4.5.3 Fabric Count, Fill, yarns/25 mm 31 (ASTM D 579, Table 6) 4.5.4 Yarn Designat
34、ion, Warp ECG 75 1/0 (ASTM D 579, Table 6) 4.5.5 Yarn Designation, Fill ECG 75 1/0 (ASTM D 579, Table 6) 4.5.6 Mass per Unit Area, g/m2 201 (ASTM D 579, Table 6) 4.5.7 Thickness, mm 0.178 (ASTM D 579, Table 6) 4.5.8 Breaking Strength, Warp, N/5cm 2189 (ASTM D 579, Table 6) 4.5.9 Breaking Strength, Fill, N/5cm 1751 (ASTM D 579, Table 6)
