1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 2 2014 06 24 Revised see 5. Summary of Revision J.Herl, EU 2012 05 08 Revised see 5. Summary of Revision J.Herl, EU 1991 03 01 Released EP00E01089482000 B. Lange Controlled document at www.MATS Copyright 2014, Ford Global Technologies, L
2、LC Page 1 of 11 PERFORMANCE, STRUCTURAL ADHESIVE, REPAIR WSK-M11P47-A1 PERFORMANCE, STRUCTURAL ADHESIVE, 0.1 - 0.3 mm GAP WSK-M11P47-A2 PERFORMANCE, STRUCTURAL ADHESIVE, 0.3 - 7 mm GAP WSK-M11P47-A3 PERFORMANCE, STRUCTURAL ADHESIVE, 0.1 - 0.3 mm GAP WSK-M11P47-A4 PERFORMANCE, STRUCTURAL ADHESIVE, 0.
3、1 - 0.3 mm GAP WSK-M11P47-A5 PERFORMANCE, STRUCTURAL ADHESIVE, 0.1 - 1.0 mm GAP WSK-M11P47-A6 1. SCOPE These specifications define the performance requirements for solvent free, epoxy resin and epoxy/PVC blend based, structural metal-to-metal adhesives as follows: WSK-M11P47-A1: Two component materi
4、als to be used for production repair as well as dealer repair (see 4.1), WSK-M11P47-A2: One component material, low viscose, airless and/or ADFOSY sprayable, E-coatable, induction heat precurable, oven curing (see 4.1). WSK-M11P47-A3: One component material, pumpable, warm bead applied and oven curi
5、ng (see 4.1). WSK-M11P47-A4: One component material, pumpable, cold bead or ADFOSY applied pregellable and oven curing (see 4.1). WSK-M11P47-A5: Two component material, pumpable, induction curable, cold bead for body in white application (see 4.1). WSK-M11P47-A6: One component material, pumpable, in
6、duction heat precurable, warm bead applied and oven curing (see 4.1). 2. APPLICATION These specifications were released originally to provide lifetime structural bonding for body components such as inner and outer panel (hem flange) of doors, rear door lock reinforcement, roof panel and pillar, hood
7、, deck lid etc. made from cold rolled as well as precoated steel. The materials are applicable on oiled surfaces with acceptable oil film weights (European applications limit the oil/pre-lubricant film weight to max 3 g/m, see para. 3.6). Note: Care must be taken to ensure that the local oil film we
8、ight in the area of the adhesive/sealer application does not exceed the critical limit. Monitoring of the film thickness, adequate storage of the part and/or cleaning of the surface prior to sealer/adhesive application is necessary to avoid critical film thickness values, which would then cause malf
9、unction of the sealer/adhesive. ENGINEERING MATERIAL SPECIFICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Page 2 of 11 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Re
10、quirements for Production Materials (WSS-M99P1111-A). 3.3 SYSTEMS COMPONENTS 3.3.1 Substrates Cold rolled steel as specified on engineering drawing. Panel thickness: 0.8 mm unless otherwise specified. Note 1: If any other steel, such as precoated with Zn, Zn/Ni, Duplex, galvanized, galvanealed, etc.
11、 is used for manufacturing, the adhesive has to be tested according to this specification on these substrates. Note 2: Repair adhesives per WSK-M11P47-A1 must be tested, only for documentation, on e-coated surfaces according to manufacturing standard UC-800. 3.3.2 Preparation of Substrate WSK-M11P47
12、-A1: E-coated surfaces need to be cleaned, without damaging the coating. WSK-M11P47-A2 to A6: According to para. 3.6 3.3.3 Adhesives, One or Two Component (see 4.1) Suitable to meet the requirements of these specifications or as specified on engineering drawing. 3.3.4 Recommended Adhesive Applicatio
13、n Temperature WSK-M11P47-A1: 23 +/- 2 C WSK-M11P47-A2: 23 +/- 2 C WSK-M11P47-A3: 80 +/- 2 C WSK-M11P47-A4: 23 +/- 2 C WSK-M11P47-A5: 23 +/- 2 C WSK-M11P47-A6: 30 +/- 2 C 3.3.5 Adhesive Coating Thickness WSK-M11P47-A1: X = 0.2 mm, unless otherwise specified WSK-M11P47-A2: X = 0.2 mm, unless otherwise
14、 specified WSK-M11P47-A3: X = 3 mm, unless otherwise specified WSK-M11P47-A4: X = 0.2 mm, unless otherwise specified WSK-M11P47-A5: X = 0.25 mm, unless otherwise specified WSK-M11P47-A6: X = 0.2 mm, unless otherwise specified 3.3.6 Curing Conditions WSK-M11P47-A1: 48 h at 23 +/- 2 C or 30 minutes at
15、 80 +/- 2 C WSK-M11P47-A2 to A6: According to FLTM BV 150-05, Table 2, min and max curing cycle (separate test specimens for each cycle). 3.4 PERFORMANCE PROPERTIES OF PRECURED ADHESIVE 3.4.1 Wash and Dip Tank Resistance (A3 only) (Also A4 to A6, except after pre-gelling per ENGINEERING MATERIAL SPE
16、CIFICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Page 3 of 11 FLTM BU 119-01) There shall be no evidence of material wash-out or displacement. Test Method: . Apply two parallel (X = see 3.3.5) mm x 10 mm beads of adhesive with 50 mm (edge) distance from each othe
17、r to a 300 x 300 x 0.8 mm body steel panel (prepared according to para. 3.6). . No pre-curing, but pre-gelling for WSK-M11P47-A4 to WSK-M11P47-A6 per FLTM BU 119-01, induction heat with 25 s hold time at 180 +/- 5 C. . Position the panel horizontally and maintain a spray of water at a temperature of
18、 55 +/- 2 C using a jet spray (Spraying System Co., Nozzle No. 1/2 GG-25 Full Jet) at 200 kPa. Direct the spray at a distance of 250 mm between the two beads of adhesive for 1 minute. 3.4.2 Green Shear Strength, A1 A2 A5/A6 MPa, min (FLTM BV 154-03) 0.1 1.0 3.0 Test Method: . Prepare test specimens
19、(body steel quality per para 3.3.1 + 3.3.2 of specification) according to section A, para 1 to 3 of FLTM BV 154-03. . Pre-cure test specimens for: WSK-M11P47-A1: 6 h at 23 +/- 2 C. WSK-M11P47-A2: Induction heat with 5 s hold time at 185 +/- 5 C. WSK-M11P47-A5/-A6: Induction heat with 30 s hold time
20、at 185 +/- 5 C. Note: Induction heating to be done according to FLTM BU 119-01 (temperatures mentioned refer to adhesive temperature, not substrate temperature). . Condition for 2 h at 23 +/- 2 C. . Determine shear strength according to Method B of FLTM BV 154-03. ENGINEERING MATERIAL SPECIFICATION
21、WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Page 4 of 11 3.5 PERFORMANCE PROPERTIES OF CURED ADHESIVE 3.5.1 Hardness Durometer “D“ (ISO 868, 3 s dwell) 3.5.1.1 After Room Temperature Curing A1 A5 (A1 and A5 only) 48 h at 23 +/- 2 C 60 - 75 70 - 85 3.5.1.2 After Acceler
22、ated Curing, max (A1 and A5 only) 30 minutes at 80 +/- 2 C, 75 75 (1 h at 23 +/- 2 C) 3.5.1.3 After Heat Curing, max A2, A4 & A6 A3 & A5 (per 3.3.6) (1 h at 23 +/- 2 C) 70 80 3.5.2 Shear Strength, MPa, min (FLTM BV 154-03, panel thickness for A1, A3, A4 and A6, 1.5 mm/Panel preparation see para 3.6)
23、 A1 A2/A4/A5 A3 A6 3.5.2.1 Original At 23 +/- 2 C 20 7.5 6.0 25 (24 h after curing) 3.5.2.2 At 90 +/- 2 C* 4.0 1.5 2.0 10 3.5.2.3 At - 40 +/- 2 C* 25 8.0 5.0 25 Samples shall be conditioned for 30 minutes at the test temperature before measurement. Test Method: . Prepare and pre-cure per 3.4.2. . Fo
24、r A1, cure samples for 30 minutes at 80 +/- 2 C and 48 h at 23 +/- 2 C, (separate samples). . A2 to A6: Use minimum and maximum curing cycles of FLTM BV 150-05, Table 2 (separate samples). . Condition for 2 h at 23 +/- 2 C. . Determine shear strength according to Method B. ENGINEERING MATERIAL SPECI
25、FICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Page 5 of 11 A1 A2/A4/A5/A6 A3 3.5.3 Aged Shear Strength, % max loss 3.5.3.1 After Heat Aging* 15 10 20 (14 d at 90 +/- 2 C, and 1 h at 23 +/- 2 C) 3.5.3.2 After Humidity Aging* 20 20 20 (14 d at 38 +/- 2 C and 98 +/
26、- 2 % R.H., 1 h at 23 +/- 2 C) 3.5.3.3 After Environmental Cycling* 10 10 10 Specimens are exposed to 8 cycles of the following sequence and then stored for 1 h at 23 +/- 2 C. After four cycles, specimens are to be stored at 23 +/- 2 C for 72 h before running remaining four cycles. One cycle consist
27、s of: . 16 h at 38 +/- 2 C and 98 +/- 2% R.H. . 4 h at - 40 +/- 2 C . 4 h at 90 +/- 2 C 3.5.3.4 After Cataplasma* A1 A2/A4 A3 A5 A6 30 30 45 40 40 Test Method: . Condition shear specimens at 23+/-2 C and 50+/-5% R.H. for 24 h. . Test specimens to be wrapped with hydrophilic cotton batting and 5 each
28、 to be put into sealed containers of approx. 160 mL volume space filled with 100 mL distilled water to provide constant conditions for following storage: . 14 d at 70 +/- 2 C . 2 h at - 20 +/- 2 C . 2 h at 23 +/- 2 C . Remove wet cotton and test shear strength within 2 hours of the completion of the
29、 conditioning. A1 A2/A4/A5 A3 A6 3.5.3.5 After (CETP 00.00-L-467) Test* 30 40 15 20 ( max loss after 6 Weeks, Protect substrate by painting) *Based on measured value according to 3.5.2.1. ENGINEERING MATERIAL SPECIFICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Pa
30、ge 6 of 11 3.5.4 Impact Peel, N/mm, min A1 A2/A4 A3 A5 A6 . At - 40 C 3 1 2 4 5 . At - 20 C 4 2 2 6 10 . At 0 C 8 3.5 2.5 8 20 . At + 23 C 10 4.5 5.5 15 30 Test Method: Use pendulum impact system from Messrs. Rosand Precision Ltd. or equivalent., ISO 11343. Specimen type: Symmetrical geometry Specim
31、en dimensions: 20 x 100 x 0.8 mm Bondline thickness: 0.3 mm Specimen preparation: FLTM BV 154-03, Section A, para 1 to 4 Exception: For A5 use 4h dwell time before oven bake instead of 10 minutes as mentioned in FLTM BV 154-03, paragraph 3. Test speed: 2 m/s Recorded information: Load versus time tr
32、ace Quoted result Measured average load between first and last peak in trace 3.5.5 Fatigue Resistance, Cycles x 16, min Test Method: . Prepare and pre-cure per 3.4.2 using 0.3 mm adhesive thickness. . For A1, cure for 30 minutes at 80 +/- 2 C. . A2, A3, A5 and A6: Use minimum and maximum curing cycl
33、es of FLTM BV 150-05, Table 2 (separate samples). . Condition the test specimens for 2 h at 23 +/- C. . Determine the fatigue resistance in a dynamic tensile testing machine with a sinusoidal cyclic axial load and a frequency of 30 Hz. . Minimum tensile load to be 10% of maximum tensile load. . Maxi
34、mum tensile load corresponds to 30% of original measured value according to 3.5.2.1. ENGINEERING MATERIAL SPECIFICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Page 7 of 11 A1 A2/A4 A3 A5 A6 3.5.5.1 Original . Cured at 23 +/- 2 C 1.5 - - - - for 48 h Cured at 80 +/
35、- 2 C 2.5 - - - - for 30 minutes Cured at minimum - 5 10 6 10 conditions Cured at maximum - 4 3.5 1 10 conditions 3.5.5.2 Environmental Cured at 23 +/- 2 C 2.5 - - - - for 48 h Cured at 80 +/- 2 C 3.5 - - - - for 30 minutes cured at minimum - 5 6.5 6 6.5 conditions Cured at maximum - 4 1.0 3 6.5 con
36、ditions Specimens are exposed to 8 cycles of the following sequence and then stored for 1 h at 23 +/- 2 C. After four cycles, specimens are to be stored at 23 +/- 2 C 72 h before running remaining four cycles. One cycle consists of: . 16 h at 38 +/- 2 C and 98 +/- 2% R.H. . 4 h at - 40 +/- 2 C . 4 h
37、 at 90 +/- 2 C 3.5.6 Resistance to Corrosion No evidence of (FLTM BV 153-11, Method A, corrosion addition to para 3, expose specimens subsequently for 20 minutes at 220 +/- 2 C metal temperature) Coating Thickness 0.3 mm 3.5.6.1 Corrosion Resistance, Proving Ground (European Production) New material
38、 technologies require LPG/APG approval prior to their introduction. Test details including film thickness, method of application, number of test cycles, etc. for the individual cars are defined by Materials Engineering, PV&T. ENGINEERING MATERIAL SPECIFICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright
39、2014, Ford Global Technologies, LLC Page 8 of 11 3.5.7 Breaking Strength and Elongation, min (ISO 527-2, specimens Type 5A, 2 mm adhesive thickness) (Recommended testing speed 10mm/min) Test Method: Original A1 A2 A3 A4 A5 A6 At 23 +/- 2 C, Mpa* (24 h after curing) 18 14 20 10 10 35 Elongation at Br
40、eak, % 2.5 20 12 10 15 10 Elastic Modulus, MPa 1200 350 1400 300 300 1200 At 90 +/- 2 C, Mpa* 5 1 2 1 1 5 Elongation at Break, % 15 20 40 7 11 20 Elastic Modulus, MPa 60 4 3.7 100 10 75 At 40 +/- 2 C, Mpa* 35 32 55 25 40 50 Elongation at Break, % 1 1.5 1.5 1.5 3.5 3 Elastic Modulus, MPa 2000 2500 42
41、00 100 1200 2000 *Samples shall be conditioned for 30 minutes at the test temperature before measurement. After Aging Specimens are exposed to 8 cycles of the following sequence and then stored for 1 h at 23 +/- 2 C. After four cycles, specimens are to be stored at 23 +/- 2 C 72 h before running rem
42、aining four cycles. One cycle consists of: 16 h at 38 +/- 2 C and 98 +/- 2% R.H. 4 h at - 40 +/- 2 C 4 h at 90 +/- 2 C After aging loss based on value measured per 3.5.7. Original tests above. A1 A2 A3 A4 A5 A6 At 23 +/- 2 C, %, max Loss* 20 30 20 30 25 25 Elongation at Break, %, min 2.5 10 10 5 15
43、10 Elastic Modulus, Mpa, min 1200 150 1450 150 300 1200 ENGINEERING MATERIAL SPECIFICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Page 9 of 11 A1 A2 A3 A4 A5 A6 At 90 +/- 2 C, % max loss* 3 85 25 85 10 60 Elongation at Break, %, min 15 25 60 5 20 20 Elastic Modulu
44、s, Mpa, min 45 25 2.6 25 10 70 At 40 +/- 2 C, % max loss* 25 10 15 10 10 40 Elongation at Break, %, min 1 1 1.5 1 1 1 Elastic Modulus, Mpa, min 2000 2500 3300 2000 1000 2000 *Samples shall be conditioned for 30 minutes at the test temperature before measurement. A1 A2/A4 A3 A5 A6 3.5.8 Peel Resistan
45、ce, N/mm, min 5 12 10 5 5 (FLTM BV 154-03) Test Method: . Use steel panels per 3.3.1 + 3.3.2 . after curing per 3.3.6 condition the samples for 2 h at 23 +/- 2 C. . Determine peel adhesion according to Method C. A1 A2/A4 A3 A5 A6 3.5.9 Glass Transition Point, 70 65 50 65 80 C, min (ISO R537, torsion
46、 test value: Lambda max, cure test specimens per 3.5.2) 3.6 OIL COMPATIBILITY & REFERENCE OIL (Not applicable to A1) All materials released to this specification must be applicable to oiled surfaces, including corrosion protection oil, wash oils, pre-lubricants, draw oils, hotmelts etc. The approved
47、 products for use in Ford of Europe or the European brands are listed in the applicable approved source list (contact materials engineering for details). The supplier must confirm the compatibility of the adhesive/sealer material to these specific coating materials in the appropriate lab tests liste
48、d in para 3 and - prior to vehicle production - in a line trial in cooperation with Ford manufacturing engineering. The lab test panels (see para 3.6.1) must be oiled with maximum permissible oil film thickness. Reference oil for adhesive performance comparison is Fuchs Anticorit 4107S for Europe, Q
49、uaker 6130 for North America. Attention: New compatibility tests are necessary if the oil grade of the affected part is changed! ENGINEERING MATERIAL SPECIFICATION WSK-M11P47-A1/A2/A3/A4/A5/A6 Copyright 2014, Ford Global Technologies, LLC Page 10 of 11 Nominal oil film weight is: 1 - 1.5 g/m The maximum permissible oil weight for full adhesive performance is: 3 g/m Note: All necessary actions must be taken to prevent an
