1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1995 12 05 Revised Revised para 3.5.14, 5.3, 5.4, 5.51995 11 22 Activated W. Curtiss G. MolnarWP 3948-a Page 1 of 10 SEALER/GASKET, FOAM-IN-PLACE NITROGEN EXPANDING, TACKY WSB-M4G278-BSEALER/GASKET, FOAM-IN-PLACE
2、 NITROGEN EXPANDING, NON-TACKY WSB-M4G278-B21. SCOPEWSB-M4G278-B:The material defined by this sp ecification is a sealant that is mixed withan ine rt gas such as nitrogen or carbon-dioxide to form a tacky, expandedelastomeric foam gasket.WSB-M4G278-B2:The material defined by this sp ecification is a
3、 sealant that is mixed withan inert gas such as nitrogen or carbon-dioxide to form a non-tacky,expanded elastomeric foam gasket.2. APPLICATIONThis material is intended for use in areas where a water, dust, and airbarrie r is required. These applications include, but are not limited to:interior trim,
4、 and HVAC (Heat Ventilation Air Conditioni ng). This materialcan be robotically applied.This m aterial is not intended for use in engine compartment applications.Applications should be avoided where the material may come in contact withen gine oil, gasoline, diesel fuel, automatic transmission fluid
5、, solventcleaners or degreasers, as degradation of the material will occur.This specification does not def ine all the intended uses of this material.Each application/substrate/coating/foam level combinatio n must be evaluatedacc ording to the applicable performance specification and/or designrequir
6、ements.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers and part producers must conform to Quality SystemRequirements, QS-9000. Material specification r equirements are to beused fo r initial qualification of materials. A Control Plan forong oing production verification is required.
7、This plan must bereviewed and approved b y the relevant Ford Materials activity and/orFor d Supplier Technical Assistance (STA) prior to production partssubmission. Appropriate statistical tools must be used to analyzepr ocess/product data and assure consistent processing of thematerial.ENGINEERING
8、MATERIAL SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 2 of 10 Part producers using this material in their products, must use Fordapproved materials and must conform to a process control plan whichhas been approved by STA and/or the relevant Materials Activity.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THER
9、MAL ANALYSISFord Motor Company, at its option, may conduct infrared and/ortherma l analysis of material/parts supplied to this specification.The IR spectra and thermograms established for i nitial approval shallconst itute the reference standard and shall be kept on file at thedesignated material la
10、boratory. All samples sha ll produce IR spectraand thermograms that correspond to the reference standard when testedunder the same conditions.3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on ma terial conditioned ina control led atmosphere of 23 +/- 2 C and 50 +/- 5
11、% relativehumidity for not less than 24 h prior to testing and tested under thesame conditions unless otherwise specified.3.4 UNFOAMED BULK MATERIAL3.4.1 Solids, min 97 %(ASTM D 2834, except heat at177 C for 4 h in a mechanicaloven)3.4.2 Ash +/- 5 %(ISO 3541, Method A, 760 +/- 30 C,based on solids w
12、eight)3.4.3 Specific Gravity(ASTM D 297)The specific gravity to lerance for any one supplier shall be+/- 0.3 based on the recorded specific gravity of theoriginal approved production sample, reference para 5.2.3.4.4 Softening Point +/- 15 C(ASTM E 28)The softening point tolerance for any one supplie
13、r shall be+/- 15 deg based on the softening point of the originalapproved production sample, reference para 5.3.3.4.5 Needle Penetrometer +/- 2 mm(ASTM D 1321, 200 g/5 sec/23 C). The needle penetration tolerance for any one suppliershall be +/- 2 based on the recorded needle penetrationof the origin
14、al approved production sample, referencepara 5.4.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 3 of 10 3.4.6 Viscosity (Brookfield)(ASTM D 3236)Thermosel spindle #SC4-27. At 191 C, 5 rpm +/- 40 %. At 204 C, 5 rpm +/- 40 %The vi scosity tolerance for any one supplier shall be +/-40
15、% based on the recorded viscosity of the orig inal approvedprod uction sample. In all cases, the viscosity shall bewithi n the process limits as identified on the materialcontrol plan, reference para 5.5.3.5 FOAMED GASKET MATERIALNote: Unless otherwise specified, testing is done at a foamreduction d
16、ensity of 55 %.Procedure: An unfoamed sample of the material is dispensed to aspeci fic volume. A foamed sample is dispensed to the same volume,the wei ghts of both samples are recorded. Calculations are asfollows:1 - weight of foamed sample/weight of unfoamed sample x 100 =Percent Foam Reduction3.5
17、.1 Tensile Strength, min 130 kPa(ASTM D 412, Die A)3.5.2 Elongation, min 350 %(ASTM D 412, Die A)3.5.3 Tear Resistance, min 0.5 kN/m(ASTM D 624, Die C)3.5.4 Compression Set, max 20 % after 24 h(ASTM D 1056, Method B)3.5.5 Water Absorption 5 % max by weight(SAE J18)3.5.6 Cold Flexibility No evidence
18、ofcrackingTest Met hod: Expose a specimen 200 mm in length to atempe rature of - 40 C for 5 h. Bend 180 degrees arounda 13 mm temperature controlled mandrel.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 4 of 10 3.5.7 Compression Deflection(ASTM D 1056)Original (as received) 10 - 40
19、 kPaAfter 24 h in the following fluids:Engine Coolant at 90 C(50/50 WSE-M97B44-B (coolant and tap water)(Climate Control Applications Only)% change from original, max +/- 35 %Test Method: The test specimen should have a 6. 5 cm2 surfacearea and approximately 13 mm thickness. The thi ckness can beobt
20、ained by plying 3 layers of the foamed sealer. Compressspecimen 25 % of original thickness at a rate of 25.4 mm/min.3.5.8 Plasticizer Exudation No exudationevidentTest Method: Prepare two test samples as follows:Apply 15 +/- 0.5 g of the material to the center of a 75 x 75x 6.4 mm glass plate. Place
21、 the sealer in contact with theelectrocoated surface of a 75 x 75 x 0.89 mm panel preparedac cording to para 5.5. Compress the assembly until these aler covers approximately 50 % of the 75 x 75 mm area ofthe glass.Clamp the assemblies to prevent shifting of the glass (# 4,75 mm wide bulldog clam ps
22、have been found suitable). Exposeone a ssembly for 30 minutes at 121 +/- 3 C. Expose theremai ning assembly for 72 hours at 70 +/- 1 C. Duringexposure, the panels shall be in a horizontal position withthe glass at the top. After exposure, examine the areasurrou nding the sealer for evidence of any e
23、xudedplasticizer.3.5.9 Tackiness WSB-M4G278-B 200 N/m widthWSB-M4G278-B2 200 N/m widthSample Preparation:Prepar e test samples by casting of molding 1.1 to 1.4 mmthick test plaques. The test surface should be formedagainst a smooth silico ne coated release paper. Cut 5 25 mmx 150 mm test strips from
24、 the plaques. Laminate a strip ofmaskin g tape, or equivalent, to the back of each sample toreinforce the material and minimize elongation e ffects on thetest results.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 5 of 10 Test Method:. Laminate th e 25 x 150 mm sample to a clean 50
25、x 150 mmsta inless steel panel (ASTM D 3330, PSTC-1) with twopasses of a 4.5 kg rolle r (ASTM D 3330, PSTC-1) at a rateof 5 mm/second. Allow the assembly to co ndition 20 +/- 5 minutes prior totesting at 23 +/- 2 C. Insert assembly into 90 degree peel fixture. Begin jaw separation at a constant rate
26、 of 300 mm/minute.Disregard the first 25 mm of peel and record the averagepeel force in N/m of width over the next 75 mm.3.5.10 Bacteria/Fungus Resistance Must Pass(WS-F4VH-19A672-AA), for ClimateControl Applications Only3.5.11 Fogging(FLTM BO 116-03,except 100 C for 3 h)Fog Number, min 60Formation
27、of a clear fi lm, droplets or crystals is cause forrejection.3.5.12 Flammability Self-extinguishing (SE)(SAE J369)Burn Rate, max 100 mm/minute3.5.13 Ozone Resistance, rating, max 0(FLTM BP 101-01, at 20 %elongation)3.5.14 Environmental Resistance No flowing, endliftingor loss of adhesio n and 1 mm s
28、ag.Test Method: Apply two 100 mm lengths of sealer material toa 300 x 300 mm electrocoated panel per para 5.6 (see figure1 for material placement). The cross-sectional area of thesealer shall be specified on the applicable part drawing. Ifnone is specified, use 7 +/- 0.5 mm diameter material.Maintai
29、n the panel in a vertical position and subject it tothe exposures listed below. Use one panel per exposure.3.5.14.1 2 weeks at 90 +/- 2 CENGINEERING MATERIAL SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 6 of 10 3.5.14.2 Thermal/Humidity Cycling. 4 h at 90 +/- 2 C. 4 h at 38 +/- 2 C and 95 - 100 % rela
30、tivehumidity. 16 h at - 30 +/- 2 C. 4 h at 90 +/- 2 C. 4 h at 38 +/- 2 C and 95 - 100 % relativehumidity. 16 h at - 30 +/- 2 C3.5.14.3 2 weeks at 38 +/- 2 C and 95 - 100 % relativehumidityNote: Environmental resistance shall be performedon a ll substrates identified for use (e.g. ABS,PV C, RIM, PE,
31、PP, etc.). Test data shall beprovided to Materials Engineering prior to systemapproval.3.5.15 Water Leak ResistanceEvidence of water leaks will be cause for rejection.Test Assembly preparation: A test specimen, 275 mm in lengthsha ll be applied in a “U“ configuration to a 100 x 150 mmelectrocoated p
32、anel per para 5.6 (see figure 2 for materialplacement). The cross- sectional area of the sealer shall bespecifi ed on the applicable part drawing. If none isspecified, use 7 +/- 0.5 mm diameter material. A 100 x 150mm electrocoated panel per para 5.6 shall be placed over thesealer material. The asse
33、mbly shall be compress ed 10 % usingspacers as a guide. The fixture must be clamped or bolted tomaint ain the 10 % compression throughout the environmentalexposures and test procedure.Expose 2 assemblies to each exposure condition shown below:3.5.15.1 24 h at 23 +/- 2 C3.5.15.2 2 weeks at 90 +/- 2 C
34、3.5.15.3 2 weeks at 38 C and 98 +/- 2 % R.H.3.5.15.4 Thermal Cycle(SAE J2100, para 4.8)3.5.15.5 30 minutes at 120 +/- 2 C (paint repair)3.5.15.6 2 weeks at - 30 +/- 1 CENGINEERING MATERIAL SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 7 of 10 3.5.15.7 500 h Salt Spray(ASTM B 117)3.5.15.8 Sealability Af
35、ter Environmental Cycle Test Method17 h Ozone (80 pphm at 28 +/- 2 C)72 h at 93 +/- 2 C24 h salt spray (ref ASTM B 117; 5 % salt solu tion)7 h at - 30 +/- 2 C17 h at 38 +/- 2 C and 95 +/- 3 % R.H.7 h at 93 +/- 2 C24 h at 38 +/- 2 C and 93 +/- 3 % R.H.Te st Method: Remove the assemblies from theenvir
36、onments listed above and condition for aminim um of 4 h but not more than 24 h at 23 +/-2 C. Stand the assembly on edge with the openingof the “U“ channel up. Fill the channel to a depthof 100 mm (approximately 13 mm from the top edge)with colored water and let stand for 24 h. Ob servefor any eviden
37、ce of w ater leaks. Note: Stand thetest assembly on a sh eet of white paper for easierwater leak detection.3.5.16 Windshield Adhesive Compatibilty WSB-M4G278-B Only(Foam Dam Applications Only)Th e material must not degrade the windshield adhesive bondstreng th, must remain foamed and not react with
38、any of theglass bonding components.Test Method:. Apply a bead of material to a 25 x 100 mm glass couponprepared per SAE J1529. (Reference para 5.7). Immedia tely apply windshield adhesive to the sample (nextto the test material) and bond a metal coupon 25 x 100 per5.6. Place the sample in a chamber
39、at 38 C and 40 % relativehumidity for 6 h. Remove from humidity chamber and place in an oven at 121C for 16 h. Remove from oven, let cool to 23 +/- 2 C for 8 h and placeback in oven. Repeat 121 C/23 C cycle for 1 week. Te st samples after the 8 h period at 23 +/- 2 C on thelast cycle. Report shear a
40、dhesion strength and failure mode.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 8 of 10 . Obs erve for any softening or decomposition of the testmaterial. Any degradation of ma terial or urethane will because for rejection.3.6 FUNCTIONAL APPROVALMaterials being evaluated for approv
41、al to this s pecification shall besubject ed to a production trial. Functional trial results must beapproved by the affected assembly operation(s) and DesignEng ineering. Results shall be made available to MaterialsEngineering prior to material approval and release.3.7 ADDITIONAL REQUIREMENTSSpecifi
42、c requirements for material and/or manufa ctured parts shall bespecified on the Engineering drawing, Engineerin g parts specificationand/or performance specification. All critical areas with respect tothese properties shall be clearly designated on the engineeringdrawing.3.8 SUPPLIERS RESPONSIBILITY
43、All materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to making any change in the properties, composition,constr uction, color, processing or labeling of the materialorig inally approved under this spec
44、ification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the Supplier shall notify Purchasing, Toxicology andthe affected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Tes
45、t data, t est samples and a new code identification areto be submitted with the request.Substance restrictions imposed by law, regulations or Ford, apply tothe materials addressed by this document. The restrictions aredefined in Engineering Materials Specification WSS-M99P9999-A1.ENGINEERING MATERIA
46、L SPECIFICATIONWSB-M4G278-B/B2WP 3948-b Page 9 of 10 4. APPROVAL OF MATERIALSMat erials defined by this specification must have prior approval by theresp onsible Materials Engineering activity. Suppliers desiring approvalof thei r materials shall first obtain an expression of interest from theaffec
47、ted Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity a completed copy of their laboratory test reports, signed by aqualified and authorized representative of the test faci lity, demonstratingful l compliance w
48、ith all the requirements of this specification (testresults, not nominal values), the material designation a nd code number, andtes t specimens for Ford evaluation. Fords engineering approval of amateri al will be based on its performance to this specification and on anassessment of suitability for
49、intended processes and/or applications. Uponapprov al, the material will be added to the Engineering Material ApprovedSource List.5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting the requirements of this specification.5.1 COLOR Black or asspecified onEngineeringdrawing5.2 SPECIFIC GRAVITY, typical 0.9 - 1.15.3 SOFTENING POINT, typical 140 - 170 C5.4 NEEDLE PENETRATION, typical 4 - 8 mm5.5 VISCOSITY, typical at 204 C 3,000 - 9,000 cps5.6 SUBSTRATESElectrocoated primed st eel panel: prepared per ESB-M2P4 p
