1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 03 2014 01 03 Revised See Summary of Revisions J.Herl EU 2011 09 20 Revised See Summary of Revisions B. Witkowski, NA 1993 07 22 Released NB00E10263630004 W. Curtiss, E. Rezendes Controlled document at www.MATS Copyright 2014, Ford Globa
2、l Technologies, LLC Page 1 of 8 SEALER, 150 - 250% EXPANDING, PUMPABLE, WELDABLE WSB-M4G60-B4 1. SCOPE The material defined by this specification is a pumpable 150 - 250% expanding, weldable sealer for sealing metal joints. It is recommended that the material be warm applied up to 49 C for enhanced
3、material dispensing properties. 2. APPLICATION This specification was released originally for materials to seal weld joints (cowl area, back panel, wheel house assemblies to quarter panels, body side to underbody assembly). The materials are applied to oily metal surfaces, steel and aluminum, and ex
4、pand when processed through the electrocoat bake oven. Optimal material dispensing properties are achieved when these materials are temperature conditioned between 38 - 49 C. The Manufacturing Properties and Engineering Performance requirements defined in these specifications are based upon laborato
5、ry coupon testing and define the minimum acceptance criteria for sealer performance. The assembly process and design for the sub-assembly will determine the specific sealer processing parameters for each application. The sub-assembly engineering performance requirements are defined by the component
6、SDS (Sub-system Design Specification). Prior to use, the sealer must be evaluated under the component production parameters. The choice of substrates, stamping lubricants, stamping plant processing conditions, assembly plant processing conditions and specific design application may affect sealer per
7、formance. Compliance with this specification does not guarantee the sealer will function for all potential applications on a vehicle. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material
8、 suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.1 SYSTEM COMPATIBILITY Initial sealer approval was based on a specific material system which included the substrate, stamping lubricants and sealer. The originally approved m
9、aterial system was induction heated or room temperature cured followed by an oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may affect sealer performance. If any of these pa
10、rameters are changed, the sealer performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2014, Ford Global Technologies, LLC Page 2 of 8 3.2 MATERIAL PROPERTIES 3.2.1 Weight per Volume +/- 0.05 kg/L (ASTM D816) The weight tolerance for any on
11、e supplier shall be within the specified variance, based on the recorded weight of their original approved production sample. Reference paragraph 4.1. 3.2.2 Hardness, Durometer A +/- 5 (ISO 868/ASTM D2240, instantaneous reading, cure material for 30 minutes oven time at 182 C, cool to 23 +/- 2 C) Th
12、e hardness tolerance for any one supplier shall be within the specified variance, based on the recorded hardness of their original approved production sample. Reference paragraph 4.2. 3.3 MANUFACTURING PROPERTIES 3.3.1 Rheology (SAE J1524, rotational rheometer with 40 mm diameter parallel plates, 50
13、0 micron gap, 50 Pa/sec ramp, stress controlled rheometers use stress range 0 - 3500 Pa, strain controlled rheometers use strain range 0 - 100 sec-1, evaluate material to highest stress or strain as the formulation will allow, report material batch/lot number, identify rheometer make and model, for
14、each test condition report yield stress and submit plots for shear stress verses shear rate, submit plot for viscosity verses temperature at mid-range shear rate. If applicable, plots for each components and the final mixture must be submitted) Initial (as received) Test at 23 +/- 2 C Test at applic
15、ation temperature +/- 2 C Test over range 10 to 50 C at increments of 10 C Aged (age then test at 23 +/- 2 C and application temperature) 7 days at 40 +/- 2 C 90 days at 32 +/- 2 C The flow curves established for initial approval shall constitute the reference standard and shall be kept on file at t
16、he designated material laboratory. All samples shall produce flow curves that correspond to the reference standard when tested under the same conditions. Final approval of material rheology for production shipments shall be made by the affected manufacturing activity. In all cases, the rheology shal
17、l be within the limits as identified on the material control plan. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2014, Ford Global Technologies, LLC Page 3 of 8 3.3.2 Viscosity (SAE J1524, VIS-2, 2.64 mm orifice, 550 kPa pressure) 3.3.2.1 As received +/- 10s Based on original submission
18、3.3.2.2 Aged ( Material aged in closed 60% max container for 72 h at 40 +/- 1 C, increase Conditioning Method B) from as received 3.3.3 Sag Resistance/Flow Rate Horizontal 3 mm max Vertical 3 mm max Inverted No loss of material Test Method: Apply a 200 mm bead, 4 mm in diameter, of material along th
19、e center line of six CRLC steel panels and six galvanized panels per para 4.4. Scribe panels to mark the initial material location. Condition six panels, two panels for each position per substrate 40 +/- 2 C for 24 hours if warm application of material is recommended. Immediately after conditioning,
20、 place panels in an oven to cure the material at the minimum bake per para 4.5. Maintain panels in the specified attitude during backing and cooling. Allow the panel to cool to 23 +/- 2 C. Determine the sag by measuring the material movement below the scribe mark. Repeat the above procedure for the
21、maximum bake per para 4.5. 3.3.4 Slump Resistance 3 mm max Assembly aged 24 h at 40 +/- 2 C Test Assembly: Two 25 x 100 mm coupons, prepared per para 4.4, with two 38 x 12 x 5 mm spacers. The spacers are placed at each end of one of the coupons, and sufficient sealer is applied between the spacers t
22、o fill the gap. The second coupon is placed on top of the sealer and spacers (Figure 1). Clamp the assembly with spring clips at each end. Remove excess sealer from all exterior edges with a spatula. 3.3.5 Wash Resistance No wash off (FLTM BV 116-01, Method B, 1.5 mm material thickness) 3.3.6 Electr
23、ocoat Compatibility Shall not contaminate (FLTM BV 119-01) electrocoat primer bath orcause electrocoat film irregularities 3.3.7 Welding Acceptance Test (FLTM BV 109-01, except 72 hours at 55 +/- 2 C heat exposure not required) The sealer shall be weldable immediately upon application and after 30 d
24、ays storage at temperature 40 +/- 2 C. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2014, Ford Global Technologies, LLC Page 4 of 8 3.3.8 Flammability with Continuous Spot Welding (FLTM BV 114-01) Less than 5% of welds shall exhibit flame and all shall be self-extinguishing within 30 s.
25、 3.3.9 Material Consistency and Process Compatibility Materials shall be a smooth homogenous mixture, free from entrapped air, foreign materials and properties detrimental to normal production operation. The material shall work with all the plant processes (cleaning operations, phosphating process,
26、welding operations, etc.) and shall not deteriorate the performance of phosphating, electrocoat primer or other materials applications. 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 init
27、ial fill. It is understood that the residual materials will be the base of the next refill and will not affect the quality 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
28、 material should be tested at a ratio of 10 old to 1 part by weight new, and other ratios defined at approval. Supplier shall 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 lubri
29、cants.) For mini-tote sytem information, the VO procedure should be reviewed as master for the process, reference (VOPGNN002). 3.3.10 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 shal
30、l be 6 months from 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 indic
31、ating that shelf life can exceed six months shall present full specification package data to materials engineering showing compliance to the listed date. 3.4 ENGINEERING REQUIREMENTS 3.4.1 Shear Adhesion Strength (SAE J1523, except 0.75 mm bondline thickness, 6.5 cm2 overlap, crosshead speed of 25 m
32、m/minute. Substrates per para 4.4, material cure per para 4.5) Cohesive failure of sealer required, no adhesive failure allowed. Normal, Unexposed 1000 kPa min Age 2 weeks at 38 +/- 2 C and 1000 kPa min 98 +/- 2 Relative humidity Thermal cycle 1000 kPa min (SAE J2100 para 4.8) 30 cycles APGE 700 kPa
33、 min (FLTM BI 123-01, Report after 10, 20 and 30 cycles) ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2014, Ford Global Technologies, LLC Page 5 of 8 One APGE cycle: 15 min salt water immersion (5% salt solution) PLUS 1 h and 45 min drip dry at 23 +/- 2 C PLUS 22 h at 50 +/- 2 C and 90
34、+/- 5% RH Samples are to remain in the 50 +/- 2 C and 90% +/- 5 % environment over the weekends and holidays. 3.4.2 Peel Adhesion (ASTM D1876, substrates per para 4.4, material cure per para 4.5, 76.2 mm overlap, 0.25 mm sealer bondline, Condition for 30 minutes at specified 23 +/- 2 C prior to test
35、.) Test at 23 +/- 2 C 40 N/25 mm min Cohesive failure of sealer required, no adhesive failure allowed 3.4.3 Volume Expansion, range 150 - 250% (FLTM BV 108-02, material cure para 4.5, min. and max. bake) 3.4.4 Adhesion Vertical Expansion 90 -100% cohesive failure to both panels Test Method: Apply a
36、5 x 200 mm bead of sealer to the center of a 0.9 x 100 x 300 mm oily panel per para 4.4. Position a 6.5 mm spacer at the midpoint of each side of the panel. Place a second oily metal panel on the spacers and secure the assembly with clamps. Bake the assemblies in the horizontal position according to
37、 the bake schedule in para 4.5. Allow the assemblies to cool to 23 +/- 2 C and remove the clamps and spacers. Separate the panels in a cleavage manner to fail the bond. Report the failure mode. 3.4.5 Cold Adhesion (FLTM BV 101-02, Procedure “E“,13 mm material thickness, oily steel substrates, materi
38、al cure per para 4.5) Shall exhibit no cracking or adhesion failure 3.4.6 Water Absorption 5% max (FLTM BV 117-01, Method A, use Sample prepared per para 3.4.3) ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2014, Ford Global Technologies, LLC Page 6 of 8 3.4.7 Fogging (SAE J1756: 3 h at
39、100 +/- 2 C heating, 21 C cooling plate, post test conditioning 1 and 16 hours) Fog Number 70 min The formation of droplets or coalescence into a clear film is cause for rejection. 3.4.8 Sponge and Cell Structure After Cure Test Method: Cross sectional observation of the sponge shall be made by cutt
40、ing through the skin and sponge of a cured specimen. The sponge system shall be visually examined Shall exhibit uniform cell structure with no large voids. A natural skin formulation shall result from oven cure cycles per para 4.5. 3.4.9 Odor 3 max (FLTM BO 131-03, Method D) Materials not meeting th
41、is requirement must be reviewed by regional materials engineering activity and may be used if vehicles are not exported out of region. Materials exceeding the above level and used outside of a region must be tested and approved by the materials engineering within the regions where vehicles will be s
42、hipped. 3.5 CORROSION RESISTANCE (Ford 00.00-L-467, 6 weeks) Test panels of 200 x 100 x 0.8 mm shall be coated by material under test centrally 10 mm away from the edges to produce the min required dry thickness of 0.75 mm. Panels shall be baked separately for the min and max curing cycles acc. to F
43、LTM BV 150-05 for the applicable region, then condition for 24 h at 23 +/- 2 C. 3.5.1 Test material on bare substrates (no-ecoat). 3.5.2 Test on e-coated (after applying the sealer) substrates. The material shall protect the test panel from corrosion. Disregard the area 10 mm from the edges of test
44、panel. Under the material and at the border line of material edges there shall be no visible corrosion, flaking, or any evidence of loss of adhesion of the material. 3.6 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification shall be subjected to a production trial. Functio
45、nal trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. 3.7 TESTING TO FAILURE Suppliers must submit a mutually agreed upon test to failure workplan for a material s
46、ource approval. The workplan is to state the number of samples to be tested, the environmental conditions for testing and dates for periodic review of the test data with Materials Engineering. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2014, Ford Global Technologies, LLC Page 7 of 8 4
47、. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications 4.1 WEIGHT PER VOLUME, Typical 1.0 - 1.6 kg/L 4.2 HARDNESS, DUROMETER A, Typical 40
48、60 4.3 PRESSED FLOW VISCOSITY, Typical (SAE J1524, VIS-2, 2.64 mm orifice, 550 kPa pressure) As received 25 - 100 s (Conditioning Method B Aged 60% max increase (Material aged in closed from as received container for 72 h at 40 +/- 1 C, Conditioning Method B) 4.4 SUBSTRATES Materials being evaluated
49、 for approval to this specification shall be tested with typical lubricants and at applications levels as specified by Materials Engineering. WSS-M1A365-A11 nominal 0.8 mm thickness, clean, bare, unpolished WSS-M1A365-A14 nominal 0.8 mm thickness, coated per WSS-M1P94-A to coating weight 60G60G-EL, 60G60G-HDG clean, unpolished Other substrates for testing: must report values but are not currently required to meet strengths as listed Alumi
