1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1998 10 19 Revised Revised para 3.6; Updated D. Whyte1994 08 29 NB00I10043054358 Released GEH KPM BCFWP 3948-a Page 1 of 9DEADENER, ASPHALT MASTIC, MELT ON WSB-M5G61-A1. SCOPEThe material defined in this specific
2、ation is a high specific weight,heat bondable, sheet mastic to be used as a sheet metal vibrationdampner.2. APPLICATIONThis specification was released o riginally for materials used to dampvibrating body panels. Unique material applications are defined by thematerial matrix incorporated in the speci
3、fication.Prior to use, the material must be evaluated under the componentproduction parameters. The choice of substrates, stamping lubricants,plant processing conditions and specific design application may affectmaterial performance. Compliance with this specification does notguarantee the material
4、will function for all potential applications on avehicle.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers and part producers must conform to QualitySystem Requirements, QS-9000. Material specification requirementsare to be used for initial qualification of materials. A ControlPlan fo
5、r ongoing production verification is required. This planmust be reviewed and approved by the relevant Ford Materialsactivity and/or Ford Supplier Technical Assistance (STA) prior toproduction parts submission. Appropriate statistical tools must beused to analyze process/product data and assure consi
6、stentprocessing of the materials.Part producers using this material in their products, must use Fordapproved materials and must conform to a process control plan whichhas been approved by STA and/or the relevant Materials Activity.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Comp
7、any, at its option, may conduct infrared and/orthermal analysis of material/parts supplied to this specification.The IR spectra and thermograms established for initial approvalshall constitute the reference standard and shall be kept on fileat the designated material laboratory. All samples shall pr
8、oduce IRspectra and thermograms that correspond to the reference standardwhen tested under the same conditions.ENGINEERING MATERIAL SPECIFICATION WSB-M5G61-AWP 3948-b Page 2 of 93.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on material conditionedin a controlled atmo
9、sphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested underthe same conditions unless otherwise specified.3.4 MATERIAL MATRIXThe matrix below provides information on basic material type,manufacturing process location, method of application, andaccept
10、able in-vehicle orientation for each material specificationnumber.Material Type. Asphaltic Mastic X. Polyvinyl Chloride. Ethylene Vinyl Acetate. Polyvinyl Acetate. Urethane. Butyl. SBR based X. Saturated Felt. Aluminum Foil. Adhesive. Magnetic. Special Requirement. R elease LinerAssembly Location (w
11、hereapplied in mfg. process). Stamping Plant or AssyPlant body-in-white. Paint Shop ( assy Plant Xafter E-coat bake). Trim Shop(assemblyplant after paint)Method of Application. Spray. Lay by Hand X. Pressurize. Extrude. Special RequirementIn-vehicle Orientation. Horizontal Only X. Vertical or Horizo
12、ntal. Inverted or Other. Special RequirementENGINEERING MATERIAL SPECIFICATION WSB-M5G61-AWP 3948-b Page 3 of 93.5 SAMPLE PREPARATION3.5.1 Applying Material to Substr ate3.5.1.1 Materials Applied with PressureRoll once (in the forward direction only) with a2.2 kg roller having a 83 mm diameter.3.5.2
13、 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 identifiedbelow. All processing
14、 sequences encountered with thematerial should be evaluated (see material matrix, para3.4, for process information) unless otherwise specifiedherein.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 1
15、65 CPredelivery 10 100 C3.5.4 Production Representative SubstratesAll metals, oils/draw compounds, coatings, and othersurfaces used with the material should be evaluated (fortypical substrates, oils and coatings see para 3.5.5).3.5.4.1 Materials Applied at Metal Stamping or in theAssembly Plant Body
16、 Shop (body in white)-allmetals, galvanize coatings, oils/draw compoundsand other surfaces used with the material shouldbe evaluated.3.5.4.2 Materials Applied in the Assembly Plant PaintShop (after E-coat bake)-all E-coats, primers,and other surfaces used with the material shouldbe evaluated.3.5.4.3
17、 Materials Applied in the Assembly Plant Trim Shop(after paint)-all topcoats and other surfacesused with the material should be evaluated.ENGINEERING MATERIAL SPECIFICATION WSB-M5G61-AWP 3948-b Page 4 of 93.5.5 SYSTEM PROCESS COMPATIBILITYInitial material approval was based on specific materialsyste
18、ms which included the substrate, stamping lubricantsand deadener system. The originally approved materialsystem was processed and cured using specific productionprocess parameters. Substrate choice, stamping lubricants,and assembly plant processing conditions may affectadhesive performance. If any o
19、f these parameters arechanged, material performance must be validated using thenew parameters.3.6 TEST MATRIXThe test matrix below and more detailed requirements referenced inthis specification identify the testing requirements for eachmaterial specification.Total Thickness, mm, avg, +/- 10 % As spe
20、cified on(ASTM D 461, w/o release liner) Engineering DrawingTotal Mass, kg/m2, max 5.4(ASTM D 461,w/o release liner)Damping Loss Factor, min(ASTM E 756, 200 hz). At 0 C 0.12. At 15 C 0.14. At 30 C 0.16. At 45 C 0.10. At 60 C 0.06Peel Adhesion, N, min. No Bake, 1 h dwell 15. No Bake, 24 h dwell 15. N
21、o Bake, 250 h dwell. Bake & 250 h 88 C 25. Bake & 250 h 38 C & 100 % RH 10Sustained Heat and Sag XCold Adhesion(FLTM BV 101-02)E-Coat Compatibility(FLTM BV 119-01)Wash Resistance(FLTM BV 116-01)Severe Wash Resistance(FLTM BV 116-02)Flammability, mm/minute, max 100 100(ISO 3795/SAE J369)Fogging (FLTM
22、 BO 116-03), min 60 60Odor (SAE J1351), max 2 2Note: X = Requirement is specified in the appropriate paragraphsof this specification which follow.ENGINEERING MATERIAL SPECIFICATION WSB-M5G61-AWP 3948-b Page 5 of 93.7 DAMPING LOSS FACTOR As specified in TEST MATRIX(ASTM E 756, avg of 5 beams,at each
23、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 damping material as specified in test matrix. Cure te
24、mp 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 linearinterpolation between the loss factor values of the resonancesdirectly on either side of 200 Hz.3.8 PEEL ADHESION As specified in TEST MATRIXTes
25、t Method (also see SAMPLE PREPARATION paragraph above for moredetailed information): Apply 25 x 125 mm length strips of materialto production representative substrate panels. The material mayhave to be backed with mylar or duct tape for reinforcement duringpeel. Suspend panels as oriented in-vehicle
26、 during dwell periodsand bake cycling. Use low bake and high bake schedules only formaterials that are processed thru Body and Assembly paint process.Use predelivery bake and no bake schedules (oriented as in-vehicle)only, for materials applied at Body and Assembly Division afterpaint processing. Pu
27、ll ninety degrees to surface at a rate of 305mm/minute. The peel value reported must be that obtained for theaverage load.3.9 SUSTAINED HEAT AND SAG No sagging or materialdegradationTest Method (also see SAMPLE PREPARATION paragraph above for moredetailed information): This requirement is for materi
28、als that areprocessed thru Body and Assembly paint process only. Apply,orient, and bake (high bake only) 150 x 150 mm test samples toproduction representative substrate panels. Suspend panels asoriented in-vehicle during the bake cycle. No smoking, materialdegradation, or sag of the material is allo
29、wed.ENGINEERING MATERIAL SPECIFICATION WSB-M5G61-AWP 3948-b Page 6 of 93.10 COLD ADHESION No loss of adhesion(FLTM BV 101-02)Test Method (also see SAMPLE PREPARATION paragraph above for moredetailed information): Apply 150 x 150 mm test samples toproduction representative substrate panels. Conduct c
30、old slamprocedure after low bake and after high bake for materials that areprocessed through Body and Assembly paint process. Suspend panelsas oriented in-vehicle during the bake cycle. Conduct cold slamprocedure on panels without bake also, for materials applied atMetal Stamping Division. Conduct c
31、old slam procedure on panelswithout bake and on panels with predelivery bake (oriented as in-vehicle) only, for materials applied at Body and Assembly Divisionafter paint processing.3.11 E-Coat Compatibility No film irregularities(FLTM BV 119-01) or material incompatibilities3.12 Wash Resistance Sha
32、ll 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 FOGGING(SAE J1756, 3 h at 100 C heating, 21 C coolingplate, post test
33、conditioning 1 h)Fog Number, min As specified in test matrixFormation of 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 be evaluated after exp
34、osure to normal processingconditions.3.17 FUNCTIONAL APPROVALMaterials being evaluated for approval to this specification shallbe subjected to a production trial. Functional trial results mustbe approved by the affected assembly operation and DesignEngineering. Results shall be made available to Mat
35、erialsEngineering prior to material approval and release.ENGINEERING MATERIAL SPECIFICATION WSB-M5G61-AWP 3948-b Page 7 of 93.18 ADDITIONAL REQUIREMENTSSpecific requirem ents for material and/or manufactured parts shallbe specified on the Engineering drawing, Engineering partsspecification and/or pe
36、rformance specification. All critical areaswith respect to these properties shall be clearly designated on theengineering drawing.3.19 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inall characteristics to the material upon which approval wasoriginally grant
37、ed.Prior to making any change in the properties, composition,construction, color, processing or labeling of the materialoriginally approved under this specification, whether or not suchchanges affect the materials ability to meet the specificationrequirements, the Supplier shall notify Purchasing, T
38、oxicology 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 imposed by law, regulations or Ford,
39、applyto the materials addressed by this document. The regulations aredefined in Engineering Materials Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSMaterials defined by this specification must have prior approval by theresponsible Materials Engineering activity. Suppliers desiring approvalof
40、 their materials shall first obtain an expression of interest from theaffected 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 autho
41、rized representative of the test facility,demonstrating full compliance with all the requirements of thisspecification (test results, not nominal values), the materialdesignation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on itsper
42、formance to this specification and on an assessment of suitabilityfor intended processes and/or applications. Upon approval, the materialwill be added to the Engineering Material Approved Source List.5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein mee
43、ting the requirements of this specification.5.1 MATERIAL TEST DATA FORMSelected testing from the list below, mutually agreed to betweenthe supplier and the responsible Materials Engineering Activity,must be submitted prior to initial material approval. Selectedtests, which are included in the materi
44、al control plan should beupdated as referenced on the control plan.ENGINEERING MATERIAL SPECIFICATION WSB-M5G61-AWP 3948-b Page 8 of 9Specification _Supplier _ GSDB Code _Product Code _Manufacturing Plant Location _Physical/Chemical Properties Selected Test Results Product LimitsTest (Mean, Std Dev,
45、 (99.994 % ofsample size) production)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 dw
46、ell _ _ _. 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) 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)ENGINEERING MATERIAL SPECIFICATION WSB-M5G61-A
