1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Released1994 10 15 NB00E10402791001 Released D.DiGregorio E.RezendesWP 3948-a Page 1 of 8 SEALER, TAPE FORM, EPDM BASE (TACKY SIDE) AND WSB-M4G355-A1EVA FILM (NON-TACKY SIDE), HEAT EXPANDABLE, WELDABLESEALER, TAPE
2、FORM, COEXTRUDED EPDM BASE, TACKY ONE SIDE, WSB-M4G355-A2SEMI-TACKY ONE SIDE, HEAT EXPANDABLE, WELDABLESEALER, TAPE FORM, EPDM BASE, TACKY BOTH SIDES, HEAT WSB-M4G355-A3EXPANDABLE, WELDABLE1. SCOPEWSB-M4 G355-A1: The material defined by this specification is an extrudedtape fo rm, heat expanding EPD
3、M base sealer. It incorporates an ethylenevinyl acetate film on one side to facilitate application of the sealer tothe sheet metal.WSB-M4G355-A2: The material de fined by this specification is a coextrudedtape form, heat expanding EPDM sealer, tacky on one side to adhere to sheetmetal and semi-tacky
4、 on the other side.WSB-M4 G355-A3: The material defined by this specification is an extrudedtape form, heat expanding EPDM base sealer that is tacky on both sides.2. APPLICATIONThese specifications were released originally for materi al used in the bodyshop for sealing weld joints and openings where
5、 welding is not arequirem ent. The materials have good adhesion to CRLC andelectr ogalvanized steel substrates. The materials expand during theprocess bake schedules noted per para 5.3.3. REQUIREMENTS3.1 STATISTICAL PROCESSSupplie rs must conform to the requirements of Ford Quality SystemStand ard Q
6、-101. A mutually acceptable Control Plan as describedtherein is required for material/source approval. Appropriatestatist ical tools must be used to analyze process/product data sothat variation in the final product is continuously reduced.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G355-A1/A2/A3WP 3948
7、-b Page 2 of 83.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL 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 standar
8、d and shall be kept on file at thedesignated material laboratory. 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 conditione
9、d ina control led atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under thesame conditions unless otherwise specified.3.4 DIMENSIONSAs specified on the engineering drawing and/or weld sealer manual.3.5 CONSISTENCY(ASTM D 5, 150 g total weig
10、ht)Initial and After Material Aged 6 - 11 mm(72 h at 45 +/- 2 C)3.6 SOLIDS, min 97 %(ASTM D 2834, except heat at 100 +/- 2 Cfor 3 h in a mechanical convection oven)3.7 SPECIFIC GRAVITY 1.30 +/- 0.20(ASTM D 297, hydrostatic method)3.8 VOLUME EXPANSION(FLTM BV 108-02)3.8.1 At 171 C 90 - 200 %3.8.2 At
11、205 C 140 - 220 %3.9 WATER ABSORPTION, max(FLTM BV 117-01)3.9.1 Method A Less than 5 %3.9.2 Method B Less than 5 %ENGINEERING MATERIAL SPECIFICATIONWSB-M4G355-A1/A2/A3WP 3948-b Page 3 of 83.10 BRIDGING, max 2 mm(SAE J243, ADS-9, part 3.3, Fixture 1)Test Method: Position a 150 mm length strip of mate
12、rial over theholes in the fixture. Prepare two assemblies an d condition at 23 +/-2 C for 1 h. Subject one assembly to each mater ial cure schedule perpara 5.3.3.11 SAG RESISTANCE, max 3 mm(FLTM BV 118-01, substrate per para 5.2,material cure schedules per para 5.3)3.12 ADHESION CHARACTERISTICSTest
13、Method: Apply two 200 mm length ribbons of material to each oftwo 0.9 x 100 x 300 mm steel panels per para 5.2 and condition panelsat 23 +/- 2 C for 1h. Bake one panel at each material cure scheduleper par a 5.3. Position panels in a horizontal attitude duringmaterial bake . After bake, condition pa
14、nels at 23 +/- 2 C for 4 hminimum. Evaluate adhesion by inserting the tip of a sharp spatulaunder the end of the material strip. Grasp the tab of sealer andattempt to peel at 180 deg.The material shall not be removeable in a continuous coherent film.Observe for any indication that the material fails
15、 to adhere to thesubstrate or is brittle or friable.3.13 LOW TEMPERATURE RESISTANCE No cracking or adhesion failureTest Metho d: Prepare two 0.9 x 100 x 300 mm test panels per para3.12. Condition the panels in a mechanical conv ection oven at 70 +/-2 C for 7 days. Condit ion the samples at 23 +/- 2
16、C for 1 h. Placethe panels in the slamming apparatus (FLTM BV 101-02) at - 30 +/- 2C for 4 h. Slam each panel a total of 10 times.3.14 RESISTANCE TO CORROSION 500 h(ASTM B 117)No loss of adhesion or blistering of the material and no evidence ofcorrosion on the metal surface when subjected to salt sp
17、ray.Test Method: Apply a 1 50 mm length strip of material at the edge oftwo 0.9 x 75 x 150 mm oily steel panels per para 5.2. Sandwich thematerial with another s teel panel as shown in drawing below and weldat interv als indicated. Cure two samples at each of the bakeschedules indicated in para 5.3.
18、ENGINEERING MATERIAL SPECIFICATIONWSB-M4G355-A1/A2/A3WP 3948-b Page 4 of 8Subje ct the cured assemblies to 500 h salt spray per ASTM B 117.After exposure, conditi on assemblies at 23 +/- 2 C for 24 h minimum.Disassemble panels and examine metal surface under sealer forevidence of corrosion.CORROSION
19、 TEST ASSEMBLYENGINEERING MATERIAL SPECIFICATIONWSB-M4G355-A1/A2/A3WP 3948-b Page 5 of 83.15 WATER TIGHTNESS No water leaks after 1 hTest Method: Use two 7 5 x 150 mm CRS steel panels. Form one of thepanels into the configuration shown below. Plac e a 12 x 150 x 1.5 mmstrip of material on the 15 mm
20、area of the formed panel. Weld thispanel to the flat panel placing one weld at each end (12 mm from theedge). Immerse the entire fixture into a 50 degree C constanttemperature water bath for 20 minutes. Remove from bath and bake atmaterial cure schedules per para 5.3. The fixture should remain inan
21、upright position (i.e. funnel end up) during the baking process.After bake, condition at 23 +/- 1 C for 1 h. Seal each end of thefunnel end of the fixtu re to form a trough. Place fixture in a visegrip, trough side up. Fill the trough with wate r at 23 +/- 1 C. Aima 5 mm diameter air nozzle set at 0
22、.2 MPa line pressure into bottomof fixture and make len gthwise passes along bondline for 30 seconds.Hold air nozzle approximately 25 mm from bottom of fixture. No airshould pass through sealer material. Allow fixt ure to sit for 1 hourat 23 +/- 1 C while watching for water leaks at bottom of fixtur
23、e.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G355-A1/A2/A3WP 3948-b Page 6 of 83.16 WASH RESISTANCE No evidence of material wash off(FLTM BV 116-01, Method A and B) or displacement3.17 ELECTROCOAT COMPATIBILITY(FLTM BV 119-01)Sha ll not contaminate electrocoat primer bath or cause electrocoatfilm irreg
24、ularities.3.18 WELD ACCEPTANCE TEST3.18.1 Shunt method A1,A2,and A3 shall be weldable(FLTM BV 109-02)3.18.2 No Shunt method A2 and A3 shall be weldable(FLTM BV 109-01)3.19 FLAMMABILITY WITH CONTINUOUS Less than 5 % of the welds shallSPOT WELDING exhibit flame and shall be self-(FLTM BV 114-01) extin
25、guishing within 30 s3.20 FOGGING(FLTM BO 116-03, on cured material)Fog Number, min 60Formati on of a clear film, droplets or crystals is cause forrejection.3.21 UNCURED ADHESION AND RELEASE PAPER REMOVALTh e sealer shall adhere when hand applied to oily steel surfaces.Th e material shall be capable
26、of having the release paper backingremoved without distorting the shape of the sealer.3.22 PACKAGINGThe material shall be supplied in sealed packages and materialblocking is not permitted during container shipping or storage.3.23 STORAGE STABILITYShall be stored below 40 C away from all sources of h
27、eat andsunligh t. Under these storage conditions, the shelf life of themat erial shall be 3 months. When these materials are stored atte mperatures below 23 C, they shall be conditioned at roomtemperature prior to ap plication. Adequate conditioning permits thematerial to obtain its optimum applicat
28、ion properties.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G355-A1/A2/A3WP 3948-b Page 7 of 83.24 FUNCTIONAL APPROVALMaterials being evaluated for approval to this s pecification shall besubject ed to a production trial. Functional trial results must beapproved by the affected assembly operation and Des
29、ign Engineering.Results shall be made available to Materials Engineering prior tomaterial approval and release.3.25 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to makin
30、g any change in the properties, composition,constr uction, color, processing or labeling of the materialorig inally approved under this specification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the Supplier shall notify Purchasing, Toxicology and
31、the affected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Test 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
32、materials addressed by this document. The restrictions aredefined in Engineering Material Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSMat erials defined by this specification must have prior approval by theresp onsible Materials Engineering activity. Suppliers desiring approvalof thei r ma
33、terials shall first obtain an expression of interest from theaffec 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 re
34、presentative of the test faci lity, demonstratingful l compliance with 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 perfor
35、mance to this specification and on anassessment of suitability for i ntended processes and/or applications. Uponapprov al, the material will be added to the Engineering Material ApprovedSource List.ENGINEERING MATERIAL SPECIFICATIONWSB-M4G355-A1/A2/A3WP 3948-b Page 8 of 85. GENERAL INFORMATIONThe in
36、formation below is provided for clarification and assistance inmeeting the requirements of this specification.5.1 MECHANICAL CONVECTION OVENThe mechanical convecti on oven(s) used to cure the material shall becapab le of achieving 205 C metal temperature on body steel (0.9 mmthickness) within 8 - 10
37、 minutes.5.2 SUBSTRATES5.2.1 CRCL steel meeting WSB-M1A250-A1: Nominal 0.80 mm thickness,surface precoated with a 0.013 mm wet film of stampinglub ricant as specified by the responsible MaterialsEngineering Activity.5.2.2 Galvan ized steel meeting WSB-M1A250-C3: Nominal 0.80 mmthic kness, surface precoated with a 0.013 mm wet film ofstamping lubricant as s pecified by the responsible MaterialsEngineering Activity.5.3 MATERIAL BAKE SCHEDULES5.3.1 Minimum 171 C for 10 minutes metaltemperature (20 minutes oven time,min)5.3.2 Maximum 205 C for 30 minutes metaltemperature (40 minutes oven time,min
