1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Released1994 08 29 NB00I10043054356 Released GEH KPM BCFWP 3948-a Page 1 of 9 DEADENER, BUTYL/ALUMINUM FOIL LAMINATE, WSB-M5G58-A1CONSTRAINED LAYER1. SCOPEAll of the materials defined by this specification are acou
2、sticaldeadeners. The various kinds of deadeners specified are described in amat erial matrix enclosed herein. Each unique material described in thematrix is assigned its own specification number.2. APPLICATIONThi s specification was released originally for materials used to dampvib rating body panel
3、s. Unique material applications are defined by thematerial matrix incorporated in the specification.Prior to use, the material must be evaluated under the c omponent productionparameters. The choice of substrates, stamping lubricants, plantproces sing conditions and specific design application may a
4、ffect materialperform ance. Compliance with this specification does not guarantee thematerial will function for all potential applications on a vehicle.3. REQUIREMENTS3.1 STATISTICAL PROCESSSupplie rs must conform to the requirements of Ford Quality SystemStand ard Q-101. A mutually acceptable Contr
5、ol 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.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may
6、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 laboratory. All samples sha ll produce IR spectraand
7、thermograms that correspond to the reference standard when testedunder the same conditions.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G58-AWP 3948-b Page 2 of 9 3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on ma terial conditioned ina control led atmosphere of 23 +/- 2
8、 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under thesame conditions unless otherwise specified.3.4 MATERIAL MATRIXThe matrix below provides information on basic material type,manufacturing process location, method of applic ation, and acceptablein-vehicle o
9、rientation for each material specification number.Material Type. Asphaltic Mastic. Polyvinyl Chloride. Ethylene Vinyl Acetate. Polyvinyl Acetate. Urethane. Butyl X. SBR based. Saturated Felt. Aluminum Foil X. Adhesive. Magnetic. Special Requirement. Release Liner XAssembly Location (whereapplied in
10、mfg. process). Stamping Plant or Assy XPlant body-in-white. Paint Shop (assy Plantafter E-coat bake). Trim Shop(assemblyplant after paint)Method of Application. Spray. Lay by Hand. Pressurize X. Extrude. Special RequirementIn-vehicle Orientation. Horizontal Only. Vertical or Horizontal. Inverted or
11、Other X. Special RequirementENGINEERING MATERIAL SPECIFICATIONWSB-M5G58-AWP 3948-b Page 3 of 9 3.5 SAMPLE PREPARATION3.5.1 Applying Material to Substrate3.5.1.1 Materials Applied with PressureRoll once (in the forward direction only) with a2.2 kg roller having a 83 mm diameter.3.5.2 Sample Orientati
12、onAl l in-vehicle orientations used should be evaluated (seematerial matrix (para 3.4) for in-vehicle orientations).3.5.3 Processing Temperature BakesTypical manufacturing-process minutes-at-metal-temperatures(MMT) minimums, nominals, and maximums are iden tified below.All processing sequences encou
13、ntered with the ma terial shouldbe e valuated (see material matrix, para 3.4, for processinformation) unless otherwise specified herein.Process Low Bake Nominal High BakeBake (MMT) (MMT) (MMT)E-coat 10 170 C 10 182 C 30 205 CPrimer 8 135 C 10 150 C 20 177 CTopcoat 10 125 C 10 130 C 20 165 CPredelive
14、ry 10 100 C3.5.4 Production Representative SubstratesAll metals, oils/draw compounds, coatings, and o ther surfacesused with the material should be evaluated (for typicalsubstrates, oils and coatings see para 3.5.5).3.5.4.1 Mater ials Applied at Metal Stamping or in theAssembly Plant Body Shop (body
15、 in white)-allmetals, galvanize coatings, oils/draw compound s andothe r surfaces used with the material should beevaluated.3.5.4.2 Materials Applied in the Assembly Plant Paint Shop(af ter E-coat bake)-all E-coats, primers, andothe r surfaces used with the material should beevaluated.3.5.4.3 Materi
16、als Applied in the Assembly Plant Trim Shop(after paint)-all topcoats and other surfaces usedwith the material should be evaluated.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G58-AWP 3948-b Page 4 of 9 3.5.5 SYSTEM PROCESS COMPATIBILITYInitia l material approval was based on specific materialsystems whi
17、ch included the substrate, stamping l ubricants anddeadener system. The originally approved materi al system wasprocessed and cured using specific production processparam eters. Substrate choice, stamping lubricants, andasse mbly plant processing conditions may affect adhesiveperform ance. If any of
18、 these parameters are changed,material performance must be validated using the newparameters.3.6 TEST MATRIXThe test matrix below and more detailed requirements referenced inthis specification identify the testing requirements for eachmaterial specification.Total Thickness, mm As Specified on Engine
19、ering Drawing(ASTM D 461, w/o release liner)Total Mass, kg/m2, max 2.29(ASTM D 461,w/o release liner)Damping Loss Factor, min(ASTM E 756, 200 hz). At 0 C 0.12. At 15 C 0.17. At 30 C 0.14. At 45 C 0.10. At 60 C 0.07Peel Adhesion, N, min. No Bake, 1 h dwell 11. No Bake, 24 h dwell 30. No Bake, 250 h d
20、well 30. Bake & 250 h 88 C 30. Bake & 250 h 38 C & 100 % RH 30Sustained Heat and Sag XCold Adhesion X(FLTM BV 101-02)E-Coat Compatibility X(FLTM BV 119-01)Wash Resistance X(FLTM BV 116-01)Severe Wash Resistance X(FLTM BV 116-02)Foil Thickness, mm As specified on Engineering Drawing(ASTM D 461)Flamma
21、bility, mm/minute, max 100(ISO 3795/SAE J369)Fogging (FLTM BO 116-03), min 60Odor (SAE J1351), max 2Note: X = Requirement is specified in the appropriate paragraphs of thisspecification which follow.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G58-AWP 3948-b Page 5 of 9 3.7 DAMPING LOSS FACTOR As specifi
22、ed in TEST MATRIX(ASTM E 756, avg of 5 beams,at each temperature, 200 Hz,15 C increments from 0 - 60 C)Test Conditions (unless otherwise specified):. 320 x 20 x 0.8 mm clean cold rolled steel Oberst bar. Oberst bar damped one side only. 40 mm root length undamped, 280 mm free length damped. Mass of
23、damping material as specified in test matrix. Cure temp and time as specified by the Matls. Engrg. Activity. Report the composite bar loss factor only.Note: The calculated value at 200 Hz is obtained by linearinter polation between the loss factor values of the resonancesdirectly on either side of 2
24、00 Hz.3.8 PEEL ADHESION As specified in TEST MATRIXTest Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information): Apply 25 x 125 mm length strips of materialto production representative substrate panels. The material may haveto be backed with mylar or duct tape for reinforc
25、ement during peel.Suspend panels as oriented in-vehicle during dwell periods and bakecycling. Use low bake and high bake schedules only for materialsth at are processed thru Body and Assembly paint process. Usepredelivery bake and no bake schedules (oriente d as in-vehicle) only,for materials applie
26、d at Body and Assembly Division after paintprocessing. Pull ninety degrees to surface at a rate of 305mm/minut e. The peel value reported must be that obtained for theaverage load.3.9 SUSTAINED HEAT AND SAG No sag ging or material degradationTest Me thod (also see SAMPLE PREPARATION paragraph above
27、for moredetailed information): This requirement is for materials that areprocessed thru Body an d Assembly paint process only. Apply, orient,and bake (high bake only) 150 x 150 mm test samples to productionrepr esentative substrate panels. Suspend panels as oriented in-vehicle during the bak e cycle
28、. No smoking, material degradation, orsag of the material is allowed.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G58-AWP 3948-b Page 6 of 9 3.10 COLD ADHESION No loss of adhesion(FLTM BV 101-02)Test Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information): Apply 150 x 150 mm te
29、st samples to productionrepres entative substrate panels. Conduct cold slam procedure afterlow b ake and after high bake for materials that are processed thruBody an d Assembly paint process. Suspend panels as oriented in-vehicle during the bake cycle. Conduct cold sl am procedure on panelswithout b
30、ake also, for materials applied at Metal Stamping Division.Conduct cold slam procedure on panels without b ake and on panels withpredelivery bake (oriented as in-vehicle) only, for materials appliedat Body and Assembly Division after paint processing.3.11 E-Coat Compatibility No film irregularities(
31、FLTM BV 119-01) or material incompatibilities3.12 Wash Resistance Shall remain unaffected(FLTM BV 116-01) No edge loss or displacement3.13 Severe Wash Resistance Shall remain unaffected(FLTM BV 116-02) No edge loss or displacement3.14 FLAMMABILITY(ISO 3795/SAE J369)Burn Rate, max 100 mm/minute3.15 F
32、OGGING(FLTM BO 116-03, 3 h at 100 C)Fog Number, min As specified in test matrixFormati on of a clear film, droplets or crystals is cause forrejection.The material shall be evaluated after exposure to normal processingconditions.3.16 ODOR, max As specified in test matrix(SAE J1351)The material shall
33、be evaluated after exposure to normal processingconditions.3.17 FUNCTIONAL APPROVALMaterials being evaluated for approval to this specification shall besubject ed to a production trial. Functional trial results must beapproved by the affected assembly operation and Design Engineering.Results shall b
34、e made available to Materials Engineering prior tomaterial approval and release.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G58-AWP 3948-b Page 7 of 9 3.18 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manuf actured parts shall bespecified on the Engineering drawing, Engineeri ng part
35、s specificationand/or performance specifications. All critical areas with respectto these properties shall be clearly designated on the engineeringdrawing.3.19 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which ap
36、proval 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 specification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the Supp
37、lier shall notify Purchasing, Toxicology andthe affected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Test data, test samples and a new code identification areto be submitted with the request.Substance restrictions impose
38、d by law, regulations or Ford, apply tothe materials addressed by this document. The restrictions aredefined in Engineering Material Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSMate rials defined by this specification must have prior approval by therespo nsible Materials Engineering activi
39、ty. Suppliers desiring approvalof their materials shall first obtain an expression of interest from theaffect ed Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity a completed copy of their laboratory test repor
40、ts, signed by aqualified and authorized representative of the test faci lity, demonstratingfull compliance with all the requirements of this specification (testresults, not nominal values), the material designation a nd code number, andtest specimens for Ford evaluation. Fords engineering approval o
41、f amateri al will be based on its performance 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-M5G58-AWP 3948-b Page 8
42、of 9 5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting the requirements of this specification.5.1 MATERIAL TEST DATA FORMSelected testing from the list below, mutually agreed to between thesupplier and the respo nsible Materials Engineering Acti
43、vity, must besubmitted prior to ini tial material approval. Selected tests, whichare inc luded in the material control plan should be updated asreferenced on the control plan.Specification Supplier GSDB Code Product Code Manufacturing Plant Location Physical/Chemical Properties Selected Test Results
44、 Product LimitsTest (Mean, Std Dev, (99.99 4 % ofsample size) produ ction)Total Thickness, mm (ASTM D 461, w/o release liner)Total Mass, Kg/m2 (ASTM D 461, w/o release liner)Damping Loss Factor(ASTM E 756, 200 hz). At 0 C _ . At 15 C . At 30 C . At 45 C . At 60 C Peel Adhesion, N, min. No bake, 1 h
45、dwell _ _ _ _. No bake, 24 h dwell _ _ _ _. No bake, 250 h dwell _ _ _ _. Bake & 250 h at 88 C _ _ _ _. Bake & 250 h at 38 C & _ _ _ _100 % r.h.Sustained Heat and Sag Cold Adhesion (FLTM BV 101-02) E-Coat Compatibility (FLTM BV 119-01)Wash Resistance (FLTM BV 116-01) ENGINEERING MATERIAL SPECIFICATI
46、ONWSB-M5G58-AWP 3948-b Page 9 of 9 Severe Wash Resistance (FLTM BV 116-02) Foil Thickness, mm (ASTM D 461)Specific Gravity (ASTM D 792, base material)Flammability, mm/min (ISO 3795/SAE J369)Fogging (FLTM BO 116-03)Odor (SAE J1351)5.2 SUBSTRATES5.2.1 MetalsESB-M2A150-A Aluminum alloy (SAE 2008)WSB-M1
47、A250-B1 Cold Rolled Low Carbon SteelWSB-M1A250-C3 Zinc and Zinc Alloy Coated Low Carbon Steel5.2.2 Oils/Draw CompoundsM14B90-A Oil (2.2 cc/m2 typica l, 4.4 cc/m2 excess)Quaker Prelube MAHCL-NI oil (5.4 cc/m2 typical)Kempec 4465 Draw compound (7:1 diluted, 4.3 cc/m2typical)5.2.3 CoatingsB-952 Zinc PhosphateESB-M64J23 Electrocoat PrimerTaupe PrimerTopcoat
