1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 04 2016 10 17 Revised See Summary of Revisions S. Short, NA 2014 01 03 Revised See Summary of Revisions J.Herl EU 1993 07 22 Released NB00E10263630004 W. Curtiss, E. Rezendes Controlled document at www.MATS Copyright 2016, Ford Global Te
2、chnologies, LLC Page 1 of 10 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 mat
3、erial 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 expan
4、d 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 laboratory
5、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 SDS
6、 (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 perfor
7、mance. 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 APPROVED SOURCES This specification requires the use of ap
8、proved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. 3.1 SYSTEM
9、 COMPATIBILITY Initial sealer approval was based on a specific material system which included the substrate, stamping lubricants and sealer. The originally approved material system was induction heated or room temperature cured followed by an oven cured using specific production process parameters.
10、Substrate choice, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may affect sealer performance. If any of these parameters are changed, the sealer performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-
11、B4 Copyright 2016, Ford Global Technologies, LLC Page 2 of 10 3.2 MATERIAL PROPERTIES 3.2.1 Weight per Volume +/- 0.05 kg/L (ASTM D816) The weight tolerance for any one supplier shall be within the specified variance, based on the recorded weight of their original approved production sample. Referen
12、ce 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) The hardness tolerance for any one supplier shall be within the specified variance, based on the recorded hardness of their original ap
13、proved production sample. Reference paragraph 4.2. 3.3 MANUFACTURING PROPERTIES 3.3.1 Rheology (SAE J1524, rotational rheometer with 40 mm diameter parallel plates, 500 micron gap, 50 Pa/sec ramp, stress controlled rheometers use stress range 0 - 3500 Pa, strain controlled rheometers use strain rang
14、e 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 each test condition report yield stress and submit plots for shear stress verses shear rate, submit plot for viscosity verses tempera
15、ture 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 application 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 temperat
16、ure) 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 the designated material laboratory. All samples shall produce flow curves that correspond to the reference standard when tested under
17、the same conditions. Final approval of material rheology for production shipments shall be made by the affected manufacturing activity. In all cases, the rheology shall be within the limits as identified on the material control plan. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2016, Fo
18、rd Global Technologies, LLC Page 3 of 10 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 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.
19、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 the center line of six CRLC steel panels and six galvanized panels per para 4.4. Scribe panels to mark the initial material location.
20、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, place panels in an oven to cure the material at the minimum bake per para 4.5. Maintain panels in the specified attitude during bac
21、king 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 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,
22、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 to fill the gap. The second coupon is placed on top of the sealer and spacers (Figure 1). Clamp the assembly with spring clips at eac
23、h 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 Electrocoat Compatibility Shall not contaminate (FLTM BV 119-01) electrocoat primer bath or cause electrocoat film irregularities 3.3.7 We
24、lding 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 days storage at temperature 40 +/- 2 C. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2016, Ford Global Technologies, LL
25、C Page 4 of 10 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. 3.3.9 Material Consistency and Process Compatibility Materials shall be a smooth homogenous mixture, free from entrapped air, for
26、eign materials and properties detrimental to normal production operation. The material shall work with all the plant processes (cleaning operations, phosphating process, welding operations, etc.) and shall not deteriorate the performance of phosphating, electrocoat primer or other materials applicat
27、ions. 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 initial fill. It is understood that the residual materials will be the base of the next refill and will not affect the quality of the
28、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 material should be tested at a ratio of 10 old to 1 part by weight new, and other ratios defined at approval. Supplier shall pres
29、ent 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 lubricants.) For mini-tote sytem information, the VO procedure should be reviewed as master for the process, reference (VOPGNN002). 3.3
30、.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 shall be 6 months from date of manufacture when stored below 27 C. When these materials are stored at temperatures below 23 C, they sh
31、all be conditioned at room temperature 24 h prior to application. Adequate conditioning permits the material to retain its optimum application properties. Suppliers indicating that shelf life can exceed six months shall present full specification package data to materials engineering showing complia
32、nce 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 mm/minute. Substrates per para 4.4, material cure per para 4.5) Cohesive failure of sealer required, no adhesive failure allowed. N
33、ormal, 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) Corrosion Resistance 700 kPa min (CETP 00.00-L-467, 6 weeks) ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2016, Ford Global Technologies, L
34、LC Page 5 of 10 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.) Test at 23 +/- 2 C 40 N/25 mm min Cohesive failure of sealer required, no adhesive failure
35、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 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. Posit
36、ion 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 the bake schedule in para 4.5. Allow the assemblies to cool to 23 +/- 2 C and remove the clam
37、ps 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, material cure per para 4.5) Shall exhibit no cracking or adhesion failure 3.4.6 Water Absorption 5%
38、max (FLTM BV 117-01, Method A, use Sample prepared per para 3.4.3) ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2016, Ford Global Technologies, LLC Page 6 of 10 3.4.7 Fogging (SAE J1756: 3 h at 100 +/- 2 C heating, 21 C cooling plate, post test conditioning 1 and 16 hours) Fog Number 70
39、 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 cutting through the skin and sponge of a cured specimen. The sponge system shall be visually exam
40、ined 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 this requirement must be reviewed by regional materials engineering activity and may be used if
41、 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 shipped. 3.5 CORROSION RESISTANCE (Ford 00.00-L-467, 6 weeks) Test panels of 200 x 100 x 0.8 m
42、m 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 FLTM BV 150-05 for the applicable region, then condition for 24 h at 23 +/- 2 C. 3.5.1 Test ma
43、terial 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 panel. Under the material and at the border line of material edges there shall be no visible
44、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. Functional trial results must be approved by the affected assembly operation and Design Engineering.
45、 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 source approval. The workplan is to state the number of samples to be tested, the environmenta
46、l conditions for testing and dates for periodic review of the test data with Materials Engineering. ENGINEERING MATERIAL SPECIFICATION WSB-M4G60-B4 Copyright 2016, Ford Global Technologies, LLC Page 7 of 10 3.8 TESTING REQUIREMENTS Test Material Approval Functional Trial Annual Every Lot 3.1 System
47、Compatibility X X 3.2.1 Weight Per Volume (ASTM D816) X X 3.2.2 Hardness (ISO 868/ ASTM D2240) X X 3.3.1 Rheology (SAE J1524) X X 3.3.2 Viscosity (SAE J1524/ VIS-2) X X 3.3.3 Sag Resistance/Flow Rate X X 3.3.4 Slump Resistance X X 3.3.5 Wash Resistance (FLTM BV 116-01) X X 3.3.6 E-coat Compatability
48、 (FLTM BV 119-01) X 3.3.7 Welding Acceptance Test (FLTM BV 114-01) X 3.3.8 Flammability with Continuous Spot Welding (FLTM BV 114-01) X X 3.3.9 Material Consistency and Process Compatability X X X 3.3.10 Storage Stability X 3.4.1 Shear Adhesion Strength (SAE J1523) X X 3.4.2 Peel Adhesion (ASTM D187
49、6) X X 3.4.3 Volume Expansion (FLTM BV 108-02) X X 3.4.4 Adhesion Vertical Expansion X X 3.4.5 Cold Adhesion (FLTM BV 101-02) X X 3.4.6 Water Absorption (FLTM BV 117-01) X X 3.4.7 Fogging (SAE J1756) X 3.4.8 Sponge and Cell Structure After Cure X X 3.4.9 Odor (FLTM BO 131-03) X X 3.5 Corrosion Resistance (Ford 00.00-L-467) X X 3.6 Functional Approval X X 3.7 Testing to Failure X ENGINEERING MATERIAL SPEC
