1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 09 24 Revised Para 3.0 inserted; para 3.1, 3.4 and 4 deleted 1991 01 23 C10090438 Released R.D. Moore, L. Moriarty Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 3 WIRE, COMPOSITE CORED ELECTRODE,
2、 MODIFIED WSB-M4A179-A1 SILICON BRONZE, BARE 1. SCOPE The material defined by this specification is a wire basically comprised of a copper sheath with alloying ingredients in the form of metallic powders on the inside. The alloy, when melted, forms a modified silicone bronze, and used as a metal fil
3、ler material by the thermal arc-spray process. 2. APPLICATION This specification was released originally as a filler material for metal cladding body panels. The thermal spray process is used to repair vehicle defects prior to painting. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERI
4、ALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 CHEMICAL COMPOSITION (Weight Percent) Tin 4.5 - 6.5 Silicon 1.6 - 2.4 Aluminum 0.8 - 1.2 Copper 90.0 - 93.0 Test Method: Electrodeposition and ARL-3580 inductiv
5、ely coupled plasma emission spectroscopy. Note: To obtain samples for chemical analysis, electric arc spray the wire on a clean plain carbon steel surface, according to para 5.4 “Chemistry and Procedure.“ Allow the metal coating to cool, then scrape the chemical sample from the pad surface. 3.3 Part
6、s clad with the deposits from the wire, shall meet all engineering drawing requirements when the wire is used under the conditions specified by the manufacturing engineering department. The wire shall be a nominal diameter as specified on the purchase order. 5. GENERAL INFORMATION The information gi
7、ven below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 Prior to engineering approval, satisfactory results on a minimum trial quantity of two production coils of actual application will be required. The body Resident Engineer will inform Body Ma
8、terials Engineering of the successful plant trial. ENGINEERING MATERIAL SPECIFICATIONWSB-M4A179-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 3 5.2 This composite cored electrode wire, used as a filler material for body panels by the thermal spray process
9、 has no AWS classification. It is similar to a modified silicon bronze AWS A5.7, Class ER Cu Si-A. 5.3 COATING PHYSICAL PROPERTIES Wire size 1.1 mm Deposit efficienty *80% Melting point, approximate 1050 C Bond strength 28.0 MPa Tensile strength 179.3 MPa Coating texture *Variable Hardness 29 Rockwe
10、ll B Coating density *7.60 g/cc Coating weight 0.6635 g/m2/ micrometre Shrink 0.008 mm/mm SPRAYING Spray Rate 4.5 kg/h/100 amps, 1.1 mm wire Coverage (wire consumption) 1.10 kg/m2/100 microns Spray Pattern*(approx. Cross Nozzle/Positioner - 25 mm 200 mm standoff) vertical height x 44 mm width Slot N
11、ozzle/Positioner - 50 mm vertical height x 25 mm width Length of wire per kg 123 m/kg (1.1 mm wire) *Depends on air pressure, standoff, nozzle cap and target size. *Coating texture, 150 mm standoff 275 kPa, depends on air pressure - fine with high psi, average with medium psi, and rough with low psi
12、. *Depends on atomizing air pressure. *Higher air pressures and lower amperage gives smallest diameter pattern. ENGINEERING MATERIAL SPECIFICATIONWSB-M4A179-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 3 5.4 CHEMISTRY PAD PROCEDURE H - Chemistry pad height shall be a minimum of 6 passes W - 1/2“ minimum L - 1“ minimum. Hardness readings and Chemical analysis shall be taken from this area, free of weld starts and craters. Base material shall be plain carbon steel, ground or sanded clean.
