1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2011 09 20 Revised See Summary of Revisions B. Witkowski, NA 2011 01 04 Revised See Summary of Revisions B. Witkowski, NA 1996 04 19 Activated N. Lindsay G. Molnar Controlled document at www.MATS Copyright 2011, Ford Global Technologies, Inc.
2、 Page 1 of 8 ADHESIVE, EPOXY, WELDABLE, THERMAL CURE, STRUCTURAL WSB-M2G388-A 1. SCOPE The material defined by this specification is a pumpable, one component, thermal curing, weldable epoxy resin base, structural adhesive for steel. 2. APPLICATION This specification was released originally for mate
3、rial used to structurally bond body components such as top rails, rear sills, and cross members to floor pans and inners to outers in a wheel house. This adhesive can be used to bond oily, unclean cold rolled and galvanized steel for body-in-white applications. Optimal adhesion strengths and bond du
4、rabilitys are achieved with an adhesive bondline of 0.25 mm and the use of galvanized steel. The material cure schedules used for material testing were 171 C metal temperature for 10 minutes and 205 C metal temperature for 30 minutes. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIAL
5、S Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.4 RHEOLOGY Suppliers must submit flow characterization data to Ford Motor Company for flow modeling and process window determination. For a specified temperature ra
6、nge, the requested properties include, but are not limited to, viscosity, yield stress, apparent activation energy for viscosity and apparent activation energy for yield stress. This data constitutes the referenced standard and shall be kept on file at the designated material laboratory. 3.5 SYSTEM
7、COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stamping lubricants and adhesive. The material system was oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions
8、 and assembly plant processing conditions may affect adhesive performance. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSB-M2G388-A Copyright 2011, Ford Global Technologies, Inc. Page 2 of 8 3.6 MATER
9、IAL PROPERITIES 3.6.1 Solids 99% min (ASTM D 2834, except heat for 3 h at 102 +/- 3 C in a mechanical convection oven, save sample for next test) 3.6.2 Ash +/- 3% (ISO 3491, Method A, 760 +/- 30 C ) The ash tolerance for any one supplier shall be +/- 3%, based on the recorded ash of their original a
10、pproved production sample. Reference para 5.3. 3.6.3 Weight Per Volume (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.02 kg/L, based on the recorded weight to their original approved production sample. Reference para 5.2. 3.7 MANUFACTURING PROPERTIES 3.7.1 Viscosity (FLTM BV 1
11、03-01 2.64 mm orifice, 550 kPa pressure, Method A, test at 25 +/- 2 C ) 3.7.1.1 As Received +/- 4 s The viscosity tolerance for any one supplier shall be +/- 4 s, based on the recorded viscosity of the original approved production sample. Reference para 5.1. 3.7.1.2 Aged, 7 days at 40 +/- 2 C 10% ma
12、x increase from as received viscosity 3.7.1.3 Aged, 90 days at 27 +/- 2 C 30% max increase from as received viscosity Final approval of a specified material viscosity for production shipments shall be made by the affected manufacturing activity. In all cases, the viscosity shall be within specificat
13、ion limits as identified on the material control plan. 3.7.2 Differential Scanning Calorimetry (20 +/- 1 mg sample size, 5 C / min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) Onset of reaction 80 C min ENGINEERING MATERIAL SPECIFICATION WSB-M2G388-A Copyright
14、2011, Ford Global Technologies, Inc. Page 3 of 8 3.7.3 Sag Resistance (FLTM BV 11801, 6 mm material thickness, substrates per para 5.4, oven schedule per para 5.5, one panel each bake) Horizontal No measurable Movement Vertical No measurable movement Inverted No loss of material 3.7.4 Slump Resistan
15、ce, max * Assembly aged 24 h at 23 +/- 2 C * Assembly aged 30 days at 23 +/- 2 C * Assembly aged 30 days at 50 +/- 1 C Test Assembly: Two 25 x 100 mm coupons, prepared per para 5.4, with two 38 x 12 x 3 mm spacers. The spacers are placed at each end of one of the coupons, and sufficient adhesive is
16、applied between the spacers to fill the gap. The second coupon is placed on top of the adhesive and spacers (Figure 1). Clamp the assembly with spring clips at each end. Remove excess adhesive from all exterior edges with a spatula. Test Method: * Prepare 3 assemblies per substrate. * Subject one as
17、sembly per substrate to exposures. * After exposure, condition assemblies at 23 +/- 2 C for 24 hours, then bake at minimum bake per para 5.5. * Determine the slump by measuring adhesive loss from the bottom of the assembly. * Record observations of any adhesive loss after exposure or after bake. * R
18、epeat the above procedures for maximum bake per para 5.5. 3.7.5 Bridging 3 mm max (SAE J243 ADS-9, Section 3.3, Method D, nonflow fixture, substrates per para 5.4, bake conditions per para 5.5) * Assembly aged for 24 h at 23 +/- 2 C * Assembly aged 30 days at 23 +/- 2 C * Assembly aged 30 days at 50
19、 +/- 1 C ENGINEERING MATERIAL SPECIFICATION WSB-M2G388-A Copyright 2011, Ford Global Technologies, Inc. Page 4 of 8 3.7.6 Wash Resistance (FLTM BV 116-01, Method A, 1.5 mm material thickness, substrates per para 5.4) No measurable movement, displacement or wash-off. 3.7.7 Electrocoat Compatibility (
20、FLTM BV 119-01, use current production paint as identified by Material Engineering, substrates per para 5.4) Shall not contaminate electrocoat primer bath or cause electrocoat film irregularities. 3.7.8 Welding Acceptance Test Must pass (FLTM BV 109-01, gun application, 25 coupon assemblies per cond
21、ition) * As prepared (fresh material) * Assembly aged 30 days at 23 +/- 2 C * Assembly aged 30 days at 40 +/ - 2 C 3.7.9 Flammability with Continuous Spot Welding (FLTM BV 114-01, substrates per para 5.4) During welding tests, less than 5% of the welds shall exhibit a flame and all shall be self-ext
22、inguishing within 30 s. 3.7.10 Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. FLTM BO-131-03 max 3 3.7.11 Material Consistency and Process Compatibility Materials shall be a smooth homogenous mixture, free from entrapped a
23、ir, foreign materials and properties detrimental to normal production operation. The material shall work with all the plant processes (cleaning operations, phosphating process, welding operations, etc.) and shall not deteriorate the performance of phosphating, electrocoat primer or other materials a
24、pplications. All bulk mastic, sealer or adhesives packaged in minitotes will be returned to the supplier with some residual material in the bottom of the container from the initial fill. It is understood that the residual materials will be the base of the next refill and will not affect the quality
25、of the refilled certified product and supplier shall demonstrate via testing of retain materials of production lots of materials to support the above, the ratio of old to virgin material should be tested at a ratio of 10 old to 1 part by weight new, and other ratios defined at approval. Supplier sha
26、ll present data to manufacturing and materials engineering prior to approval, as well as data showing compatibility with process aids used in mini-tote assembly (i.e. seal lubricants.) For mini-tote system information, the VO procedure should be reviewed as master for the process, reference(VOPGNN00
27、2). ENGINEERING MATERIAL SPECIFICATION WSB-M2G388-A Copyright 2011, Ford Global Technologies, Inc. Page 5 of 8 3.7.12 Storage Stability Heat greatly accelerates aging. The material shall be stored in closed containers away from all sources of heat. The shelf life of the material shall be 3 months fr
28、om date of manufacture when stored below 27 C. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature 24 h prior to application. Adequate conditioning permits the material to retain its optimum application properties. Suppliers indicating that shelf
29、 life can exceed three months shall present full specification package data to materials engineering showing compliance to the listed date. 3.8 ENGINEERING REQUIREMENTS 3.8.1 Adhesion Strength, min (SAE J1523, substrates per para 5.4, 0.25 mm adhesive bondline thickness, 13 mm length overlap, 13 mm/
30、min pull rate, oven cure per para 5.5) 3.8.1.1 Normal (Condition for 30 minutes at specified temperature prior to test ) * Test at 23 +/- 2 C 13.0 MPa * Test at 82 +/- 2 C 11.0 MPa * Test at -40 +/- 2 C 14.0 MPa 3.8.1.2 Exposed 11.0 MPa (Condition at 23 +/- 2 C for 1 h, subject to environmental cycl
31、e, oven cure per para 5.5, test at 23 C) Environmental cycle: -40 +/- 1 C for 7 days PLUS 38 +/- 1 C for 98 +/- 2% RH for 7 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for 1 day 3.8.1.3 Aged (Condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2 C) * 10 thermal Cycles 14.0 MPa One Cy
32、cle: 90 +/- 1 C for 4 h PLUS 38 +/- 1 C and 98 +/- 2% RH for 4 h PLUS -40 +/- 1C for 16 h 1000 Salt Spray 10.0 MPa (ASTM B 117, Report after 500 and 1000 hours) ENGINEERING MATERIAL SPECIFICATION WSB-M2G388-A Copyright 2011, Ford Global Technologies, Inc. Page 6 of 8 3.8.1.4 30 APGE Cycles 8.0 MPa (
33、FLTM BI 123-01, modified cycle, galvanized steel per para 5.4, report after 10, 20 and 30 cycles) One APGE cycle: 15 min salt water immersion (5% salt solution), plus 1 h and 45 min drip dry at RT 22 h at 50 +/- 2 C and 90 +/- 5% RH Samples are to remain in the 50 +/- 2 C and 90% +/- 5% environment
34、over the weekends and holidays. 3.8.2 Stress Durability, min (FLTM BV 101-07, galvanized and hot dipped steel per para 5.4, all coupons from one manufacturers lot, report thickness for each coupon and substrate yield strength for manufacturers lot, material cure 30 minutes at 180 +/- 2 C, two fixtur
35、es, cyclic corrosion exposure, report data per test method) The average of all samples at a specified load shall meet the minimum amount of cycles at 10, 20, 40% of failure load established for unexposed samples. * 10 +/- 1% 22 cycles * 20 +/- 1% 15 cycles * 40 +/- 1% 10 cycles 3.8.3 Peel Resistance
36、, 2000 N/m min (ASTM D 1876, galvanized steel per para 5.4, condition at 23 +/- 2 C for 24 h, oven cure per para 5.5) 3.8.4 Cold Adhesion (FLTM BV 101-02, Procedure “E“) 0.51 mm material thickness, substrates per para 5.4, oven cure per para 5.5) No adhesion failure or material cracking. 3.8.5 Tensi
37、le Properties (ASTM D638, 3 +/- 0.5 mm thick, cure on release paper between 3 mm aluminum panels for 30 minutes at 180 C material temperature, Type I specimen, W=10 +/- 0.5 mm G= 50 +/- 0.5 mm, condition at 23 +/- 2 C for 24 h, test at 23 +/- 2 C, 5 mm/min pull rate, use extensometer or strain gage,
38、 test at 40, 23, 50 and 80 +/- 2 C) Modulus of elasticity 0.6 GPa min Elongation at break 1.0% min Poissons Ratio 0.10 0.48 Actual material properties are temperature and formulation dependent. Results are on file with Materials Engineering. ENGINEERING MATERIAL SPECIFICATION WSB-M2G388-A Copyright
39、2011, Ford Global Technologies, Inc. Page 7 of 8 3.9 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made a
40、vailable to Materials Engineering prior to material approval and release. 3.10 TESTING TO FAILURE Suppliers must submit a mutually agreed upon testing to failure workplan for a material source approval. The workplan is to state the number of samples to be tested, the environmental conditions for tes
41、ting and dates for periodic review of the test data with Materials Engineering. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 VISCOSITY, Typical as received 43 s 5.2 WEIGHT PER VOLUME, Typical 1.
42、26 kg/L 5.3 ASH, Typical 15% 5.4 SUBSTRATES Galvanized Steel (WSB-M1A250-C3, 60G60G-EL): Electrogalvanized, clean unpolished, nominal 0.8 mm thickness, surface to be precoated with lubricants as specified by the Materials Engineering Activity. Cold Rolled Steel (WSB-M1A250-A): Clean unpolished, nomi
43、nal 0.8 mm thickness, surface to be precoated with lubricants as specified by the Material Engineering Activity. 5.5 MATERIAL CURE SCHEDULES (After bake, condition at 23 +/- 2 C for 1 h minimum, then test) Minimum Bake: 171 C metal temperature for 10 minutes (not to exceed 20 minutes oven time) Maxi
44、mum Bake 205 C metal temperature for 30 minutes (not to be less than 40 minutes oven time) 5.6 DYNAMIC MECHANICAL ANALYSIS/DYNAMIC MECHANICAL THERMAL ANALYSIS (Cure on release paper between 3 mm aluminum panels for 30 minutes at 180 +/- 2 C material temperature, sample dimensions are instrument depe
45、ndant, 5 replicate samples +/- 0.5 mm for length, width and thickness, report sample size, 2 C/min heating rate, bending mode, record at 1 and 10 Hz, -40 to 200 C temperature range, submit Log E vs. Temperature and Log Tan Delta vs. Temperature Curves). Maximum Tan Delta 90 - 120 C Typical Range 6. SUMMARY OF REVISIONS 2011 01 04 Revised 3.7.10 2011 09 20 Revised 3.7.11 editorial ENGINEERING MATERIAL SPECIFICATION WSB-M2G388-A Copyright 2011, Ford Global Technologies, Inc. Page 8 of 8
