1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 11 19 Revised Changed A3-Specification from pumpable into tape-version B. trecht, FoE 2007 08 27 Revised Corrected Specification number for A5 version K. Wolters 1993 08 02 Revised EP00E10258823000; Revised 1, 3.4.4 to 3.4.7, 3.4.11, adde
2、d 3.5 WS Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 1 of 7 SEALER, HEAT CURING, TAPE, SPOT WELDABLE, EXPANDING WSK-M4G325-A1 SEALER, HEAT CURING, PUMPABLE, SPOT WELDABLE, LOW EXPANDING WSK-M4G325-A2 SEALER, HEAT CURING, TAPE, SPOT WELDABLE, LOW EXPANDING, WSK-
3、M4G325-A3 MEDIUM STRENGHT SEALER, HEAT CURING, PUMPABLE, SPOT WELDABLE, HIGH EXPANDING WSS-M4G325-A4 SEALER, HEAT CURING, PUMPABLE, SPOT WELDABLE, MEDIUM EXPANDING WSK-M4G325-A5 1. SCOPE The materials defined by these specifications are spot weldable, heat curing, heat expanding sealers. 2. APPLICAT
4、ION WSK-M4G325-A1/A3: These specifications were released originally for dimensioned materials used for sealing spot weld joints on the body-in-white. It is applied to oiled surfaces in the form of self adhesive strips. WSK-M4G325-A2: This specification was released originally for non-dimensioned mat
5、erials used for sealing spot weld joints on the body-in-white. It is applied to oiled surfaces by an extrusion apparatus. WSK-M4G325-A4/A5: These specifications were released originally for non-dimensioned materials used for sealing joints in BIW. It is applied to oiled surfaces by an extrusion appa
6、ratus. 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. 3.7). Note: Care must be taken to ensure that the local oil film weight in the area of the adhesive/sealer application does no
7、t 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 malfunction of the sealer/adhesive. 3. REQUIREMENTS: Material s
8、pecification requirements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATIONWS
9、K-M4G325-A1/A2/A3/A5 WSS-M4G325-A4 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 7 3.4 PERFORMANCE REQUIREMENTS A1/A3 A2/A4/A5 3.4.1 Color Black Black 3.4.2 Solids, %, min 99 85 (FLTM BV 150-10) 3.4.3 Ash, %, max 50 45 (FLTM BV 150-10) 3.4.4 Flash Point n.a.
10、 56 C (ASTM D 56) 3.4.5 Density at 20 C 1.2 to 1.9 g/cm 1.0 to 1.6 g/cm3(ASTM D 1475, tolerance +/- 0.05 g/cm3, based on the recorded density of suppliers original approved sample) 3.4.6 Penetration at 23 C (A1/A3 only) (ASTM D 5, 0.981 N total weight force, 5 s dwell time) 3.4.6.1 As received 60 -
11、90 3.4.6.2 After ageing 50 - 90 (14 days at 30 +/- 2 C) Note: See 3.4.7 3.4.7 Viscosity at 23 C, s (A2/A4/A5 only) (FLTM BV 103-01, line pressure 0.392 MN/m2, nozzle dia. 2 mm) A2/A4 A5 3.4.7.1 As Received 70 200 500 - 700 3.4.7.2 After Ageing, max 200 700 (14 days at 35 +/- 2 C) Note: Final approva
12、l of a specific viscosity of material for production shipments shall be made by affected Manufacturing Division. In all cases, however, the viscosity shall be within the limits specified above and shall meet all requirements of this specification (Control Sample Laboratory Report). A1/A3 A2/A4/A5 3.
13、4.8 Flow Rate, max No flow 3 mm (FLTM BV 153-01, Method A, except oiled panels acc. to para. 3.7. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A2/A3/A5 WSS-M4G325-A4 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 7 3.4.9 Cold Resistance After Ageing No los
14、s of adhesion, no chipping. Test Method: (a) Apply 250 x 30 x 3 mm ribbons of material under test to 300 x 100 mm test panels prepared according para 3.7. (b) Expose test assemblies according to FLTM BV 150-05, Table 2 for: . minimum curing cycle (165 C, 10 Materials Temp in EC oven) . maximum curin
15、g cycle (c) Expose test assemblies in a mechanically convected air-dry oven at 80 +/- 2 C for two weeks. (d) After cooling to 23 +/- 2 C expose test assemblies and bending fixture (see FLTM BV 153-04, except 100 mm mandrel) in a cold box at -30 +/- 1 C for 4 h. (e) While still in the cold box, bend
16、test assemblies within 2 s around the 100 mm mandrel through an angle of 90. 3.4.10 Wash-off Resistance (A2/A4/A5 only) No wash-off of sealer, deformation of sealer surface permitted. Test Method: (a) Apply two ribbons of material under test 250 x 30 x 3 mm and 50 mm apart from each other to a 300 x
17、 300 mm oiled panel, prepared in accordance para. 3.7. (b) After conditioning for 2 h at 23 +/- 2 C expose test assembly in horizontal position to a water jet of 50 +/- 5 C using a nozzle No. 1/2 GG-25 Full Jet and a pressure of 200 kN/m2. The distance between the nozzle and test material shall be 3
18、00 mm. The water jet shall be applied between the beads for 1 minute. 3.4.11 Wash and Phosphating Solution Resistance (A2/A4/A5 only) A. Non-Cured Material No evidence of dissolution of material or lifting from panel. Test Method: (1) Apply 250 x 40 x 0.1 - 0.2 mm ribbons of material under test to 2
19、50 x 60 mm oiled test panels, prepared according to para. 3.7. (2) After conditioning for 2 h at 23 +/- 2 C expose test assemblies one after another in each wash and phosphating solution of the affected plant where this material is to be used and maintain for 15 minutes at 60 +/- 1 C. ENGINEERING MA
20、TERIAL SPECIFICATIONWSK-M4G325-A1/A2/A3/A5 WSS-M4G325-A4 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 7 B. Cured Material No loss of adhesion, no chipping Test Method: (1) Test specimens as prepared and tested under para 3.4.10 shall be exposed for 20 minut
21、es in a mechanically convected air-dry oven at 100 +/- 2 C, and subsequently subjected to maximum curing cycle according to FLTM BV 150-05, Table 2, Phase 1 and 2. (2) After cooling to 23 +/- 2 C test according to FLTM BV 153-04, Method A, para 4 and 5, except -30 +/- 1 C. 3.4.12 Welding Acceptance
22、Test (For A1/A3 use FLTM BV 159-02, for A2/A4/A5 use FLTM BV 159-01) The sealer shall be weldable immediately upon application and after 30 days storage at temperatures below 40 +/- 2 for C. 3.4.13 Flammability and Corrosion Self extinguishing (FLTM BV 159-02, Method A) within 5 s, no corrosion Imme
23、diately 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. 3.4.14 Wetting (FLTM BV 153-08, Method A) The paint film (paint materials shall be noted in the Initial Sample Report of the adhesive, see also para 4.3) shall
24、 cover the sealer with a continuous film. Discoloration or staining permitted. 3.4.15 Tensile Strength, (A2/A4/A5 only) (FLTM BV 154-03, Method A, Type I, x = 3 mm, after 10 minutes at 23 +/- 2 C minimum and maximum heat curing cycle to FLTM BV 150-05, Table 2, test at 23 +/- 2 C) 3.4.15.1 Tensile S
25、trength, min 10 N/cm23.4.15.2 After Heat Aging (500 h at 80 C, A4 only) max. deviation from original +/- 10% 3.4.16 Adhesion Strength After Curing (A1/A3 only) (FLTM BV 154-03, Method B and C, preparation of test panels according to Section I, 8 mm dia. test strips compressed to x = 3 mm, minimum an
26、d maximum heat curing cycle to FLTM BV 150-05, Table 2) ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A2/A3/A5 WSS-M4G325-A4 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 5 of 7 A1 A3 3.4.16.1 Shear Strength, min 3 N/cm2 120 N/cm2 (Method B at 23 +/- 2 C) 3.4.1
27、6.2 Peel Strength, min 10 N/cm 30 N/cm (Method C at 23 +/- 2 C) 3.4.17 Resistance to Corrosion No Corrosion, Blisters or loss of Adhesion The material shall protect the test panel from corrosion. Test Method: (a) Test panel preparation according to FLTM BV 159-02, Method A. (b) After 2 h at 23 +/- 2
28、 C wash, phosphate and electrocoat test assemblies under normal production conditions. (c) Expose test assemblies according to FLTM BV 150-05, Table 2: . min curing cycle . max curing cycle (d1) For Cold rolled Steel. After 24 h at 23 +/- 2 C expose test assemblies to a salt spray fog according to A
29、STM B 117 for 480 h. (d2) For Precoated Steel. After 34 h at 23 C +/- 2 C expose assemblies to a Scab Corrosion Test (FLTM BI 123-01) for 50 cycles. (e) Separate welded assemblies using a test fixture according to FLTM BV 159-01, Fig. 4 and examine. 3.4.18 Water Absorption, A1/A2/A3 A4 A5 3.4.18.1 (
30、FLTM BV 153-07) max 1% 3% 2% Curing conditions acc. To FLTM BV 150-05 Table 2 min. curing 10 Min. 175 C 3.4.18.2 After Heat Aging (500 h at 80 C, A4/A5 only) max. deviation from original +/- 10 % After heat aging the foam must meet the requirements of paragraph 3.4.20. A1 A2 A3 A4 A5 3.4.19 Volume E
31、xpansion, % 25 65 25 55 5 25% 300 400 100 - 200 (FLTM BV 108-02) For Information only: Show tables and curves “Time over Volume expansion at different Temperatures (e. g. 110 C to 140 C)”. This has to be mentioned in the PSW ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A2/A3/A5 WSS-M4G325-A4 Prin
32、ted copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 6 of 7 3.4.20 Structure of Curing The sealer shall form a closed skin after heat curing. The inner cell structure shall be fine without large voids. Test Method: (a) Preparation of test assemblies according to FLTM BV 153
33、-07, paragraph 1 to 3. (b) After cooling to 23 +/- 2 C test specimens are cut through and examined visually. 3.4.21 Corrosion Resistance, Proving Ground (European Production) New material technologies require LPG/APG approval prior to their introduction. Test details including film thickness, method
34、 of application, number of test cycles, etc. for the individual cars are defined by Materials Engineering, Body B. trecht - FoE Inserted 3.6, 3.7, 3.7.1, 3.7.1.1, 3.7.1.2, 3.7.1.3, 3.8, 5.1, 5.2, 5.3; 2007 03 09 Deleted 3.5 5.2. Corrected Specification number for A5 version K. Wolters FoE 2007 08 27 5.3. Revised name of version A3; revised para 1, 2 and all paras which B. trecht - FoE are related to A3, revised 3.4.16, 3.4.18, 3.4.19 2008 20 20
