1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 11 12 Revised See Summary of Revisions M. Mehandru 1995 11 22 Activated W. Curtiss, G. Molnar Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 10 SEALER, VINYL BASED, SELF-LEVELING, PAINTABLE, WSB-M4
2、G177-D BIOCIDE ENHANCED, IMPROVED PAINTABILITY 1. SCOPE The material defined by this specification is a vinyl based, self-leveling, paintable, heat curing sealer. This material has biocide added and has improved paintability. 2. APPLICATION This specification was released originally for sealing the
3、roof ditch and is intended for use over electrocoat primer. Acceptable paintability is achieved with or without sealer gel bake. Ultraviolet light absorbers, light stabilizers, and biocide have been added to these materials to improve paint durability. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR P
4、RODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 RHEOLOGY Suppliers must submit flow characterization data to Ford Motor Company for flow modeling and process window determination. For a specif
5、ied temperature range, 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 reference standard and shall be kept on file at the designated material labora
6、tory. 3.3 SOLIDS, min 95% min (ASTM D 2834, except heat at 102 +/- 1 C for 3 h in a mechanical convectional oven. Save sample for next test, para 3.4) 3.4 ASH, max +/- 5% (ISO 3491, Method A, 760 +/- 30 C) The ash content tolerance for any one supplier shall be +/- 5 % based on the recorded ash cont
7、ent for their originally approved production sample (refer to para 4.1). 3.5 WEIGHT PER VOLUME +/- 0.02 kg/L (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.02 kg/L, based on the recorded weight of their original approved production sample (refer to para 4.2). ENGINEERING MATER
8、IAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 9 3.6 VISCOSITY (SAE J 1524, VIS-2, 1.32 mm orifice, 280 kPa) Final approval of a specific material viscosity for production shipments shall be made by the affected manufacturing act
9、ivity. In all cases, the viscosity shall be within process limits as identified on the material control plan. The viscosity tolerance for any one supplier shall be +/- 10%, based on the recorded viscosity of the original approved production sample. Reference para 4.3. 3.6.1 As Received +/- 10% (Cond
10、itioning Method A) 3.6.2 Aged, max No more than 100% (Material aged in closed increase from container for 72 h at 40 +/- original approval 1 C, conditioning Method A) The supplier shall provide a viscosity profile versus temperature at 16oC, 20 oC, 23 oC, 27 oC, 43 oC, and after 2 weeks at 32 oC 3.6
11、.3 90 Day Storage Stability at 23 +/-2 C and 32 +/- 2 C The supplier shall provide a viscosity profile versus time from initial through 90 days storage at 23 +/- 2 C and 32 +/-2 C. Measurements shall be taken at weekly intervals. Curves shall be made available to Materials Engineering prior to addit
12、ion on the Approved Source List. 3.7 FLOW RATE (Initial at 23 +/- 2 C and 15 - 250 mm after 90 days storage at 23 +/- 2 C and 32 +/- 2 C) Test Method: Block the 6.4 mm groove in the flow rate fixture (Fig. 1) 150 mm from the top edge. Fill the 150 mm upper portion of the groove with material specifi
13、ed in this specification. Remove the block, allow material to flow for 30 minutes, then subject the test assembly to the minimum bake per para 4.4. Remove test assembly from heat exposure and measure the total amount of flow. Final approval of a specific material flow rate for production shipments s
14、hall be made by the affected manufacturing activity. In all cases, the flow rate shall be within limits identified on the Material Control Plan. ENGINEERING MATERIAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 9 3.8 ADHESION Shall
15、 not be peeled off in a continuous film. Test Method: . Apply a ribbon of material, 25 x 200 x 3 mm on two electrocoated panels, identified per para 4.5. . Subject one test panel to the minimum bake schedule and the other test panel to the maximum bake schedule identified per para 4.4. . Evaluate ad
16、hesion by cutting a 25 mm wide strip across the ribbon. Using the tip of a square spatula, lift the material, then attempt to hand peel material at 90 deg from substrate. . Save test panels for heat resistance test, para 3.9, and corrosion resistance test, para 3.10. 3.9 HEAT RESISTANCE TEST No evid
17、ence of blistering, (336 h Heat Age at 70 +/- 2 C) cracking, charring or other deleterious effects Test Method: . Examine the test material prepared for Adhesion Test, para 3.8, for any of the above conditions. 3.10 LABORATORY ACCELETRATED CYCLIC No corrosion or CORROSION TEST adhesion loss 3.14.1 O
18、ption 1 (FLTM BI 123-03, 30 cycles for North America, 50 cycles for Europe) Or 3.14.2 Option 2 (CETP 00.00-L-467, 6 weeks) Note: Report the test method used. .Evaluate material adhesion as described in para 3.8. Observe for any evidence of corrosion originating directly under material. 3.11 MANDREL
19、BEND TEST No cracking or (FLTM BV 122-01, substrates per adhesion failure para 4.5, material bake schedule per para 4.4, heat age test specimen 14 days at 70 +/- 1 C before test) 3.11.1 Test at 23 +/- 2 C ENGINEERING MATERIAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009,
20、Ford Global Technologies, LLC Page 4 of 9 3.12 COMPATIBILITY WITH PRODUCTION PAINTS - INITIAL REQUIREMENTS No tackiness, staining, discoloration, dulling, softening, paint transfer, significant color shift, difference in orientation of metallic flakes (metallic paints) or other objectionable appeara
21、nce defects in the paint over the sealer. Note: Evidence of any defects as stated above shall be reviewed with Body and Assembly Paint Operations and Materials Engineering. Test Method: . Prepare test panels per matrix provided by the material engineering of the region. Use current production paints
22、 as identified by the Paint Engineering. Panels shall be kept horizontal prior to baking, during the painting operation and during cure. Use gas fired oven for paint cure. . Condition painted panels at 23 +/- 2 C for 4 - 24 h. . After 4 - 24 h at 23 +/- 2 C, perform the following tests on each panel
23、: . Cross hatch adhesion check - FLTM BI 106-01, Method B . Resistance to Xylene - Using a back and forth motion, rub surface of enamel 10 times with a small wad of cheesecloth which has been wetted with xylene. 3.13 COMPATIBILITY WITH PRODUCTION PAINTS - WEATHERING REQUIREMENTS No tackiness, staini
24、ng, discoloration, chalking, gloss change or other deleterious effects on topcoats when compared to paint not over sealer. After 2 years Florida exposure, 5 % adhesion loss and 20 % UVA loss maximum when compared to paint not over sealer. Test Method: Prepare test panels per matrix provided by the m
25、aterial engineering of the region. Use current production paints as identified by the Paint Engineering. Panels shall be kept horizontal prior to baking, during the painting operation and during cure. . Condition painted panels at 23 +/- 2 C for 72 h. . Subject panels for each paint/bake condition t
26、o each exposure listed below. Retain an unexposed panel as control. 3.13.1 6000 h Xenon ARC (SAE J2527, modified borosilicate inner and outer filters, 0.55 W/m2. Panels are reviewed initially and at 2000 h intervals.) 3.13.2 2 year Florida Exposure (SAE J1976, panels are washed and reviewed yearly.
27、Note: Examine panels for evidence of fungal growth PRIOR to washing. Reference para 3.19.). ENGINEERING MATERIAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 9 After exposure, perform the following evaluations on each panel: . Cros
28、s hatch adhesion test per FLTM BI 106-01, Method B . UVA extraction per FLTM BI 126-01 . Examine test panels and compare to the control panel and to the paint not over sealer side of the panel for evidence of fungal growth (prior to washing), tackiness, staining, discoloration, gloss change, adhesio
29、n loss, UVA loss or other deleterious effects on topcoats. 3.14 LOW TEMPERATURE RESISTANCE No cracking or (FLTM BV 101-02) adhesion failure Test Method: . Condition the white and silver panels prepared in para 3.12 for 7 days at 70 +/- 1 C. . Place the panels in the slamming apparatus and condition
30、for 4 h at - 29 +/- 1 C. . The panels shall be slammed a total of 10 times. 3.15 REPAINT CRACK RESISTANCE No cracks Test Method: Fill the inside cover of six can lids with sealer. The lids will have a nominal diameter of 70 mm and a depth of 6 mm (see para 4.6). Paint three test panels (lids) per ma
31、trix provided by the material engineering of the region Apply current production paints as identified by the Paint Engineering Expose painted lids to the following paint repair cycles 10 times: 140 +/- 2 C for 17 minutes oven time 23 +/- 2 C for 20 minutes Observe for any evidence of paint/sealer cr
32、acking after each cycle. 3.16 SHEAR ADHESION, min (SAE J1523, substrate per para 4.5, 0.25 mm bondline thickness, 6.45 cm2overlap, material bake schedules per para 4.4) 3.16.1 Minimum bake 2.5 MPa 3.16.2 Maximum bake 2.5 MPa 3.17 HARDNESS, DUROMETER, A +/- 5 (ASTM D 2240) The hardness tolerance for
33、any one supplier shall be +/- 5 based on the recorded hardness of their originally approved production sample. Reference para 4.7. ENGINEERING MATERIAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 9 Test Method: . Apply enough mate
34、rial into a container (such as an ointment tin) to give a 6.4 mm thickness slab. . Bake material at 149 +/- 1 C for 20 minutes. . Condition test sample at 23 +/- 2 C for 4 h, then check instantaneous material hardness. 3.18 CURED SEALANT PROPERTIES 3.18.1 Normal Tensile Strength, min 2.5 MPa (ASTM D
35、 412, die C, pulled at 300 mm/min. Minimum 5 samples per minimum bake per para 4.4) Elongation, min 70% Tear Strength, min 9.0 N/mm (ASTM D 624, Die C, pulled at 500 mm/min. Minimum 5 samples minimum bake per para 4.4) 3.18.2 Aged (Cured samples aged 2 w at 90 +/- 2 C) Tensile Strength, min 2.5 MPa
36、(ASTM D 412, die C, pulled at 300 mm/min. Minimum 5 samples per minimum bake per para 4.4) Elongation, min 70% Tear Strength, min 10.0 N/mm (ASTM D 624, Die C, pulled at 500 mm/min Minimum 5 samples per minimum bake per para 4.4) 3.19 BACTERIA/FUNGUS RESISTANCE - FLORIDA EXPOSURE Florida Exposure Ex
37、amine panels prepared and exposed per para 3.13.2. Panels shall be examined after 3 and 6 months for evidence of fungal growth. Do not wash panels after the 3 and 6 month review. Panels will be washed yearly. Growth observed on the painted sealer shall be comparable to growth on paint not over seale
38、r. Any growth shall be easily removed by washing. ENGINEERING MATERIAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7 of 9 3.20 ABRASIVES None Test Method: . Dilute a 1 g sample of the material with 1 g of M14J507 Naptha or equivalent,
39、and mix thoroughly. . Rub a portion of the diluted material 100 times between 2 pieces of flat, clean plate glass. The appearance of scratches on the glass plate shall be considered failure. 3.21 STORAGE STABILITY The material shall be stored at temperatures below 40 C away from all sources of heat
40、and sunlight. Heat greatly accelerates aging. Under these storage conditions, the shelf life of the material shall be 3 months from the date of receipt at the plant. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature prior to application. Adequa
41、te conditioning permits the material to obtain its optimum application properties. Material may not be used after the expiration date unless the supplier has given written documentation to Materials Engineering and the affected Manufacturing Plant that the material conforms to requirements outlined
42、in the material control plan. The supplier shall also indicate in the letter the number of additional days the material will be usable. 3.22 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification shall be subjected to a production trial. Functional trial results must be app
43、roved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specif
44、ication. 4.1 ASH, Typical 34% (Refer to para 3.4) 4.2 WEIGHT PER VOLUME, Typical 1.2 - 1.7 kg/L (Refer to para 3.5) 4.3 VISCOSITY, Typical 25 - 100 s (As Received; refer to para 3.6) Viscosity is dependent on rheological properties of the material. 4.4 BAKE SCHEDULES According to FLTM BV 150-05 for
45、each individual region. 4.5 SUBSTRATES Electrocoat primed steel panel or HDG panel (as per manufacturing facility) 100 x 300 x 0.90 mm. Use current production paints as identified by paint engineering. ENGINEERING MATERIAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009, For
46、d Global Technologies, LLC Page 8 of 9 4.6 REPAINT CRACK RESISTANCE Originally performed in 500 ml can lids. 4.7 HARDNESS, Durometer A, Typical 60 - 80 4.8 VOLATILE ORGANIC CONTENT, max ppm 1500 5. SUMMARY OF REVISIONS 2009 11 12 1. Changed Numbering 2. Updated Corrosion Resistance Test 3. Updated P
47、ara 3.7 ( Flow Rate) 4. Updated Para 3.10 (Corrosion Resistance) 5. Updated Para 3.18.2 ( Aged Elongation) 6. Updated Para 4.2 (Wt Per Volume) 7. Updated para 4.4 ( Bake Schedules) 8. Updated pare 4.5 (Substrates) 9. Updated para 4.7 (Hardness) 10. Added 4.8 Para ( VOC Content) 11. Deleted Table 1 ENGINEERING MATERIAL SPECIFICATIONWSB-M4G177-D Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 9 of 9 FIGURE I
