1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Release No. Released 2011 03 29 A-STATUS re-activated, Materials are still in use J.Herl 2009 10 14 N-STATUS Replaced by global strategy B. Witkowski, NA 1994 04 27 C10400758 Released W. Scholz WP 3948-a Page 1 of 6 SEALER,
2、BUTYL RUBBER, PROFILED, WSK-M4G292-B1 SPOT WELDABLE, HEAT CURING 1. SCOPE The material defined by this specification is a solvent free sealer based on butyl rubber. It is die cut from extruded, laminated sheeting, spot weldable, heat curing, and heat meltable. It has pressure sensitive adhesive on o
3、ne side covered by release paper or foil. The other side is covered by a very thin PE support film for handling. After curing this film does not interfere with the adhesion of the butyl sealer to the metal surface. 2. APPLICATION This specification was released originally for material for sealing th
4、e front fender at cross member upper and is applied to oiled surfaces in body assembly. 3. REQUIREMENTS 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source ap
5、proval. Appropriate statistical tools must be used to analyze process/product data so that variation in the final product is continuously reduced. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts
6、supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when
7、 tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless oth
8、erwise specified. ENGINEERING MATERIAL SPECIFICATION WSK-M4G292-B1 WP 3948-b Page 2 of 6 3.4 DIMENSIONS As specified on Engineering Drawing 3.5 COLOUR Black 3.6 SOLIDS, min 99.0 % (FLTM BV 150-10) 3.7 ASH, max 30.0 % (FLTM BV 150-10) 3.8 THICKNESS 0.6 +/- 0.1 mm (ISO 4593) 3.9 DENSITY at 23 C 1.3 +/
9、- 0.5 g/cm3 (ISO R 1183, Method A) 3.10 PENETRATION at 23 C (ASTM D 5, needle 2.5 g, 1.5 N total weight force, 5 s dwell time) If the finished part does not allow the preparation of specimens, the supplier is required to provide, together with the Initial Sample Report, specimens of same material an
10、d equivalent manufacture used for the finished part. Samples for control and routine checks shall be submitted as required by Quality Control. 3.10.1 Original (in 0.1 mm) 5 - 8 mm 3.10.2 After Ageing (in 0.1 mm), max 10 mm (14 d at 35 +/- 2 C) 3.11 STORAGE STABILITY, min 6 months (From date of recei
11、pt at Ford Motor Company) When stored in sealed unopened containers out of direct sunlight at ambient temperatures between 5 and 32 C. The supplier must label each container to indicate expiration date of the material and production usage beyond expiration date is not permitted. 3.12 COLD RESISTANCE
12、 AFTER AGEING No loss of adhesion or chipping Test Method: 1) Apply 250 x 40 x 0.6 +/- 0.1 mm pieces of test material in the middle to 300 x 100 x 0.8 - 0.9 mm test panels, prepared according to FLTM BZ 150-11 “Normal Grade“ and press down lightly. ENGINEERING MATERIAL SPECIFICATION WSK-M4G292-B1 WP
13、 3948-b Page 3 of 6 2) Expose separate test assemblies according to FLTM BV 150-05, Table 2: a) min curing cycle b) max curing cycle 3) Expose test assemblies in a mechanically convected air-dry oven at 80 +/- 2 C for two weeks. 4) After cooling to 23 +/- 2 C expose test assemblies and bending fixtu
14、re (see FLTM BV 153-04, except 100 mm mandrel) in a cold box at minus 30 +/- 1 C for 4 h. 5) While still in the cold box bend test assemblies within 2 s around the 100 mm mandrel through an angle of 90 deg. 3.13 HEAT RESISTANCE AFTER AGEING No loss of adhesion or chipping Test Method: Specimen prepa
15、ration according to 3.11, test method, para 1-3. Proceed as outlined under FLTM BV 153-02. Method C, para 6, mandrel diameter 100 mm. 3.14 FLOW RATE No flow Test Method: Prepare test assemblies according to 3.11 test method, para 1, except test material to 250 x 20 x 0.6 +/- 0.1 mm. After 10 minutes
16、 at 23 +/- 2 C expose test assemblies at an angle of 45 deg to the horizontal in a mechanically convected air-dry oven maintained at 120 +/- 2 C for 30 minutes and with the longitudinal axis of the strip in the horizontal (see FLTM BV 153-11, Fig. 1). 3.15 FLAMMABILITY AND CORROSION No burning, no c
17、orrosion (FLTM BV 159-02, Method A, except use sealing strip of 600 x 20 x 0.6 +/- 0.1 mm. Immediately after welding separate the welded parts using a test fixture according to FLTM BV 159-01, Fig. 4. Examine after 48 h at 23 +/- 2 C) ENGINEERING MATERIAL SPECIFICATION WSK-M4G292-B1 WP 3948-b Page 4
18、 of 6 3.16 CORROSION RESISTANCE The material shall protect the test panel from corrosion. No corrosion or blistering at the borderline sealer/EC/steel. Test Method: 1) Test panel preparation according to FLTM BV 159-02, Method A, except use sealing strip of 600 x 20 x 0.6 +/- 0.1 mm, weld spot dista
19、nce of 40 mm. 2) After 2 h at 23 +/- 2 C wash, phosphate and electrocoat test assemblies under normal production conditions. 3) Expose separate test assemblies according to FLTM BV 150-05, Table 1, Phase 2 and 3: a) min curing cycle b) max curing cycle 4) After 24 h at 23 +/- 2 C expose test assembl
20、ies to a salt spray fog according to ASTM B 117 for 480 h. 5) Separate welded assemblies using a test fixture according to FLTM BV 159-01, Fig. 4 and examine. 3.17 WASH AND PHOSPHATING SOLUTION No evidence of dissolution or RESISTANCE lifting from panel Test Method: 1) Prepare specimens according to
21、 3.15 test method, para 1. 2) After 2 h at 23 +/- 2 C wash and phosphate test assemblies under normal production conditions. 3.18 SHEAR STRENGTH 3.18.1 At 23 +/- 2 C, min 15.0 N/cm2 3.18.2 At 90 +/- 2 C, min 3.5 N/cm2 3.18.3 At - 30 +/- 1 C, min 150.0 N/cm2 Test method: FLTM BV 154-03, Method B. Pre
22、pare test specimens according to para I except use sealing strip of 0.6 +/- 0.1 mm thickness. Minimum and maximum heat curing cycle according to FLTM BV 150-05, Table 1. Adhesion failure permitted. 3.19 PEEL STRENGTH 3.19.1 At 23 +/- 2 C, min 18.0 N/cm 3.19.2 At 90 +/- 2 C, min 8.0 N/cm ENGINEERING
23、MATERIAL SPECIFICATION WSK-M4G292-B1 WP 3948-b Page 5 of 6 3.19.3 At - 30 +/- 1 C, min 70.0 N/cm Test Method: FLTM BV 154-03, Method C. Prepare test specimens according to para I, except use sealing strip of 0.6 +/- 0.1 mm thickness. Minimum and maximum heat curing cycle according to FLTM BV 150-05,
24、 Table 1. Adhesion failure permitted. 3.20 WETTING The enamel shall form a continuous film over the sealing strip. Discolouration or staining permitted. Test Method: Prepare specimens according to 3.15 test method, para 1 and 2, except test panels 350 x 50 x 0.8 -0.9 mm and sealer strip of 340 mm. P
25、roceed as outlined under FLTM BV 153-08, Method A, para 2-7, except without wet on wet. 3.21 QUALITY The material shall be of uniform quality, free from foreign materials and properties detrimental to normal production use. 3.22 SUPPLIERS RESPONSIBILITY All materials supplied to this specification m
26、ust be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect
27、 the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identi
28、fication are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1. ENGINEERING MATERIAL SPECIFICATION WSK-M4G292-B1 WP 3948-b
29、 Page 6 of 6 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Eng
30、ineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this speci
31、fication (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List.
