1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Released1994 08 29 NB00I10043054357 Released GEH KPM BCFWP 3948-a Page 1 of 9DEADENER, MASTIC/ALUMINUM FOIL LAMINATE, WSB-M5G60-AWITH PRESSURE SENSITIVE ADHESIVE,CONSTRAINED LAYER1. SCOPEThe ma terial defined in th
2、is specification is an acoustic deadenercomprised of a formulated mastic sheet with a presessure sensitive adhesivesurface for sheet metal application and an aluminum foil constraining layeron the opposite surface.2. APPLICATIONThi s specification was released originally for materials used to dampvi
3、b rating body panels. 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 desig
4、n application may affect 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 mutual
5、ly 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.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company,
6、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 laboratory. All samples sha ll pro
7、duce IR spectraand thermograms that correspond to the reference standard when testedunder the same conditions.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G60-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 atm
8、osphere 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 MATERIAL MATRIXThe matrix below provides information on basic material type,manufacturing process location, method of applic ation, and acc
9、eptablein-vehicle orientation for each material specification number.Material Type. Asphaltic Mastic. Polyvinyl Chloride. Ethylene Vinyl Acetate. Polyvinyl Acetate. Urethane. Butyl. SBR based X. Saturated Felt. Aluminum Foil X. Adhesive X. Magnetic. Special Requirement. Release Liner XAssembly Locat
10、ion (whereapplied in mfg. process). Stamping Plant or AssyPlant body-in-white. Paint Shop (assy Plant Xafter E-coat bake). Trim Shop(assembly Xplant after paint)Method of Application. Spray. Lay by Hand. Pressurize X. Extrude. Special RequirementIn-vehicle Orientation. Horizontal Only. Vertical or H
11、orizontal X. Inverted or Other. Special RequirementENGINEERING MATERIAL SPECIFICATIONWSB-M5G60-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
12、.3.5.2 Sample OrientationAll 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 identified below.All proc
13、essing sequences encoun tered with the material shouldbe eva luated (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 1
14、30 C 20 165 CPredelivery 10 100 C3.5.4 Production Representative SubstratesAll metals, oils/draw compounds , coatings, and other surfacesused wi th the material should be evaluated (for typicalsubstrates, oils and coatings see para 3.5.5).3.5.4.1 Materials Applied at Metal Stamping or in theAssem bl
15、y Plant Body Shop (body in white)-allmetals, galvanize coatings, oil s/draw compounds andother surfaces used with the material should beevaluated.3.5.4.2 Materi als Applied in the Assembly Plant Paint Shop(aft er E-coat bake)-all E-coats, primers, andother surfaces used with the material should beev
16、aluated.3.5.4.3 Mater ials Applied in the Assembly Plant Trim Shop(after paint)-all topcoats and other surfaces usedwith the material should be evaluated.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G60-AWP 3948-b Page 4 of 9 3.5.5 SYSTEM PROCESS COMPATIBILITYIni tial material approval was based on speci
17、fic materialsystems which included the subs trate, stamping lubricants anddeadener system. The originall y approved material system wasprocessed and cured using specific production processparam eters. Substrate choice, stamping lubricants, andasse mbly plant processing conditions may affect adhesive
18、performance. If any of these parameters are changed, ma terialperformance must be validated using the new parameters.3.6 TEST MATRIXThe test matrix below and more detailed requirements referenced inthis specification identify the testing requirements for each materialspecification.Total Thickness, m
19、m As specified on Engineering Drawing(ASTM D 461, w/o release liner)Total Mass, kg/m2, max 2.44(ASTM D 461,w/o release liner)Damping Loss Factor, min(ASTM E 756, 200 hz). At 0 C 0.10. At 15 C 0.15. At 30 C 0.10. At 45 C 0.07. At 60 C 0.05Peel Adhesion, N, min. No Bake, 1 h dwell 4.0. No Bake, 24 h d
20、well 4.0. No Bake, 250 h dwell 6.0. Bake & 250 h 88 C 20. Bake & 250 h 38 C & 100 % RH 15Sustained Heat and Sag XCold Adhesion X(FLTM BV 101-02)E-Coat Compatibility(FLTM BV 119-01)Wash Resistance(FLTM BV 116-01)Severe Wash Resistance(FLTM BV 116-02)Foil Thickness, mm, avg, +/- 10 % As Specified on E
21、ngineering Drawing(ASTM D 461)Flammability, 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-M5G60-AWP 3948-b Page 5 of
22、9 3.7 DAMPING LOSS FACTOR As specified 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,
23、 280 mm free length damped. Mass of 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 re
24、sonancesdirectly on either side of 200 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
25、with mylar or duct tape for reinforcement 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 i
26、n-vehicle) only,for materials applied 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
27、 SAMPLE PREPARATION paragraph above 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 orient
28、ed in-vehicle during the bak e cycle. No smoking, material degradation, orsag of the material is allowed.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G60-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
29、 information): Apply 150 x 150 mm test 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 col
30、d sl am procedure on panelswithout bake 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 C
31、ompatibility No film irregularities(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 J36
32、9)Burn Rate, max 100 mm/minute3.15 FOGGING(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
33、matrix(SAE J1351)The material shall 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 an
34、d Design Engineering.Results shall be made available to Materials Engineering prior tomaterial approval and release.ENGINEERING MATERIAL SPECIFICATIONWSB-M5G60-AWP 3948-b Page 7 of 9 3.18 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manuf actured parts shall bespecified on the En
35、gineering drawing, Engineeri ng parts 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 character
36、istics 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 specification, whether or not suchchange s affect the materials ability to meet the
37、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. Test data, test samples and a new code identification areto be submitted with the r
38、equest.Substance restrictions imposed 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
39、 nsible Materials Engineering activity. 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
40、 copy of their laboratory test reports, 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 eval
41、uation. Fords engineering approval of 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 SPECI
42、FICATIONWSB-M5G60-AWP 3948-b Page 8 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 res
43、po nsible Materials Engineering Activity, 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/Chemi
44、cal Properties Selected Test Results 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
45、Peel Adhesion, N, min. No bake, 1 h 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-
46、01) ENGINEERING MATERIAL SPECIFICATIONWSB-M5G60-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-M2A1
47、50-A Aluminum alloy (SAE 2008)WSB-M1A250-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
