1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 07 28 N-STATUS Replaced by WSS-M11P64-A1/A2/A3 M. Mehandru 2003 01 21 Revised Para 3.0 inserted ; Para 3.1, 3.2, 3.3, 3.11, 3.12, 4 deleted 1995 05 16 Activated H. Kon, E.R.R. Printed copies are uncontrolled Copyright 2006, Ford Global Te
2、chnologies, LLC Page 1 of 7 ADHESIVE, HEAT CURING, EXPANDABLE, EPOXY/GLASS FIBER WSB-M2G281-D3 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 ba
3、cking. The epoxy layer 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. Recomm
4、ended material cure schedules are 170 C metal temperature for 10 minutes minimum and 205 C metal temperature for 30 minutes maximum. Cured material properties vary with epoxy/fiberglass laminate thickness. Refer to para 4.4 for additional information. 3. REQUIREMENTS Material specification requireme
5、nts are to be used for initial qualification of materials. Tests must be conducted on material having an original epoxy/fiberglass material thickness of 1.3 +/- 0.1 mm. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requ
6、irements For Production Materials (WSS-M99P1111-A). 3.4 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 para
7、meters. Substrate choice, 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. 3.5 FIBERGLASS CLOTH REQUIREMENTS
8、 Thickness of cloth, weave, and breaking strengths in warp and fill directions must be such that all requirements of this specification are met. See para 5.5 for additional information. 3.6 EPOXY POLYMER REQUIREMENTS 3.6.1 Specific Gravity 0.8 - 1.0 (ASTM D 792) ENGINEERING MATERIAL SPECIFICATIONWSB
9、-M2G281-D3 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 7 3.6.2 Volume Expansion, % 90 - 110 (FLTM BV 108-02, material cure per para 4.3) 3.7 UNCURED LAMINATE MATERIAL PROPERTIES 3.7.1 Construction Construction must consist of woven fiberglass cloth onto an
10、 epoxy adhesive film backed with release paper. There must not be any loose glass fibers after the die cut operation. 3.7.2 Thickness, uncured As specified on Engineering Drawing (ASTM D 461, 85 g load, 25 mm diameter foot, total fiberglass and adhesive) 3.8 UNCURED LAMINATE PERFORMANCE REQUIREMENTS
11、 3.8.1 Formability The material must not delaminate or crack when folded 180 upon itself. 3.8.2 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
12、para 4.2. Pass a 2.2 kg 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 3.8.2. Stand the remaining two panels vertically
13、immediately after laminate 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 3.8.3. 3.8.3 Phosphate Wash Resistance (FLTM BV 116-01, Method “A“ preparation specified below) Sample preparation: 1)
14、 Identify the cutting direction 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 met
15、hod, apply the designated lubricant at the specified amount to substrates described in para 5.2. - 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
16、25 x 150 mm panel prepared 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 5.3. 4) Reporting data - Record load at 2 mm deflection and peak load in Newtons. - Report
17、average load and sample standard deviation. Normal (Condition for 30 min at specified temperature prior to test.) Load at 2 mm Peak Deflection Load 3.9.1.1 Test at 23 +/- 2 C 55 120 3.9.1.2 Test at 90 +/- 1 C 30 90 ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D3 Printed copies are uncontrolled Copyr
18、ight 2006, Ford Global Technologies, LLC Page 4 of 7 3.9.1.3 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 3.9.1.1) after each of the following environmental exposures
19、: 14 days heat age at 90 +/- 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) 3.9.1.4 Adhesive storage prior to bonding. (Expose material in sealed packa
20、ges. Condition at 23 +/- 2 C for 24 h prior to testing). 72 h at 40 +/- 2 C 3.9.2 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 3.8.2 to 23 +
21、/- 2 C for 4 h. Panels must 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 a
22、nd cure per para 5.3. Save samples for Cold Slam Test, para 3.9.4. 3.9.3 Vertical Bake The material must exhibit a smooth, non-blistered surface and must not peel at edges, sag more than 2.5 mm or fall off from panel. Test Method: ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D3 Printed copies are un
23、controlled Copyright 2006, Ford Global Technologies, LLC Page 5 of 7 Condition one half of the panels of each substrate prepared per para 3.8.3 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
24、72 h at 40 +/- 2 C 98 +/- 2 % RH. Panels must remain vertical during conditioning. Place conditioned panels in an oven in the vertical position and cure per para 5.3. Save samples for Cold Slam Test, para 3.9.4. 3.9.4 Cold Slam (FLTM BV 101-02, Procedure “E“, condition 4 h min at -30 +/-2 C. Test at
25、 -30 +/- 2 C, panels prepared per para 3.9.2 and 3.9.3. The material must not crack or separate from panel before 10 slams. 3.9.5 Fogging Test (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 60% Formation of clear film, droplets or crystals
26、is cause for rejection. 3.10 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 Engi
27、neering prior to material approval and release. 5. 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. 5.1 MECHAN
28、ICAL CONVECTION OVEN The 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. 5.2 SUBSTRATES Nominal panel dimensions are 100 x 300 x 0.80 mm 5.2.1 RLC Steel meeting WSB-M1A250-A1: Nominal 0.80 mm thick
29、ness, surface precoated with stamping lubricant at a coating weight as specified by the responsible Materials Engineering Activity. 5.2.2 Galvanized steel meeting WSB-M1A250-C3-60G60G-EL: Nominal 0.80 mm thickness, surface precoated with stamping lubricant at a coating weight as specified by the res
30、ponsible Materials Engineering Activity. ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D3 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 7 5.3 MATERIAL CURE SCHEDULES Minimum bake: 170 C metal temperature for 10 minutes (not to exceed 20 minutes oven time) Max
31、imum bake: 205 C metal temperature for 30 minutes (not to be less than 40 minutes oven time) 5.4 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 thick
32、ness other than this is required, additional testing is recommended to ensure desired material properties are maintained after environmental exposures. 5.5 FIBERGLASS CLOTH This specification was originally written for a laminate with a fiberglass cloth with the following characteristics. 5.5.1 Styl
33、e Designation 7628 (ASTM D 579, Table 6) 5.5.2 Fabric Count, Warp, yarns/25 mm 43 (ASTM D 579, Table 6) 5.5.3 Fabric Count, Fill, yarns/25 mm 31 (ASTM D 579, Table 6) ENGINEERING MATERIAL SPECIFICATIONWSB-M2G281-D3 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 7
34、of 7 5.5.4 Yarn Designation, Warp ECG 75 1/0 (ASTM D 579, Table 6) 5.5.5 Yarn Designation, Fill ECG 75 1/0 (ASTM D 579, Table 6) 5.5.6 Mass per Unit Area, g/m2201 (ASTM D 579, Table 6) 5.5.7 Thickness, mm 0.178 (ASTM D 579, Table 6) 5.5.8 Breaking Strength, Warp, N/5cm 2189 (ASTM D 579, Table 6) 5.5.9 Breaking Strength, Fill, N/5cm 1751 (ASTM D 579, Table 6)
