1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 01 19 Revised Added A5; Revised Title A2 deleted 3.1, 3.2 3.3, 3.6, 3.7 revised 3.4.1, 3.4.8, 3.4.9, 3.4.10, 3.4.11,3.4.17.7, 3.4.18 changed from 8% to 1% and 3.4.19; added 3.4.15.1, 3.4.15.2, 3.4.18.1,3.4.18.2 and 3.4.21 W. Janitschke 19
2、93 08 02 EP00E10258823000 Revised 1, 3.4.4 to 3.4.7, 3.4.11, added 3.5 WS Printed copies are uncontrolled Copyright 2007, 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
3、-A2 WSK-M4G325-A3 SEALER, HEAT CURING, PUMPABLE, SPOT WELDABLE, HIGH EXPANDING WSS-M4G325-A4 SEALER, HEAT CURING, PUMPABLE, SPOT WELDABLE, EXPANDING WSS-M4G325-A5 1. SCOPE The materials defined by these specifications are spot weldable, heat curing, heat expanding sealers based on polyisobutylene or
4、 polyacrylic ester. 2. APPLICATION WSK-M4G325-A1: This specification was 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/A3: These specifications were released ori
5、ginally for non-dimensioned materials 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 oile
6、d surfaces by an extrusion apparatus. 3. REQUIREMENTS: Material specification 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
7、 Materials (WSS-M99P1111-A). 3.4 PERFORMANCE REQUIREMENTS A1 A2/A3/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) ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technol
8、ogies, LLC Page 2 of 7 3.4.4 Flash Point 56 C (ASTM D 56) 3.4.5 Density at 20 C 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 only) (ASTM D 5, 0.981 N total weight force, 5 s dwell time) 3.4.
9、6.1 As received 60 - 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/A3/A4/A5 only) (FLTM BV 103-01, line pressure 0.392 MN/m2, nozzle dia. 2 mm) A2/A4/A5 A3 3.4.7.1 As Received 70 200 10 - 20 3.4.7.2 After Ageing, max 200 100 (14 days at 35 +/-
10、 2 C) Note: Final approval 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 R
11、eport). A1 A2/A3/A4/A5 3.4.8 Flow Rate, max No flow 3 mm (FLTM BV 153-01, Method A, except oiled panels acc. to FLTM BV 150-11, “Oiling Grade 3g/m“) ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 7 3.4.9 Cold
12、 Resistance After Ageing No loss 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 to FLTM BV 150-11, “Oiling Grade 3g/m“. (b) Expose test assemblies according to FLTM BV 150-05, Table 2 for: . minimum curin
13、g cycle (165 C, 10 Materials Temp in EC oven) . maximum curing 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 a
14、t -30 +/- 1 C for 4 h. (e) While still in the cold box, bend test assemblies within 2 s around the 100 mm mandrel through an angle of 90. 3.4.10 Wash-off Resistance (A2/A3/A4/A5 only) No wash-off of sealer, deformation of sealer surface permitted. Test Method: (a) Apply two ribbons of material under
15、 test 250 x 30 x 3 mm and 50 mm apart from each other to a 300 x 300 mm oiled panel, prepared in accordance with FLTM BV 150-11, “Oiling Grade 3g/m“. (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 Ful
16、l Jet and a pressure of 200 kN/m2. The distance between the nozzle and test material shall be 300 mm. The water jet shall be applied between the beads for 1 minute. 3.4.11 Wash and Phosphating Solution Resistance A. Non-Cured Material No evidence of dissolution of material or lifting from panel. Tes
17、t Method: (1) Apply 250 x 40 x 0.1 - 0.2 mm ribbons of material under test to 250 x 60 mm oiled test panels, prepared according to FLTM BV 150-11, “Oiling Grade 3g/m“. (2) After conditioning for 2 h at 23 +/- 2 C expose test assemblies one after another in each wash and phosphating solution of the a
18、ffected plant where this material is to be used and maintain for 15 minutes at 60 +/- 1 C. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 7 B. Cured Material No loss of adhesion, no chipping Test Method: (1)
19、Test specimens as prepared and tested under para 3.4.10 shall be exposed for 20 minutes 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 F
20、LTM BV 153-04, Method A, para 4 and 5, except -30 +/- 1 C. 3.4.12 Welding Acceptance Test (For A1 use FLTM BV 159-02, for A2/A3/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
21、Corrosion Self extinguishing (FLTM BV 159-02, Method A) within 5 s, no corrosion 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. 3.4.14 Wetting (FLTM BV 153-08, Method A) The enamel shall form a continuo
22、us film over the sealer. Discoloration or staining permitted. 3.4.15 Tensile Strength, (A2/A3/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 Strength, min 1
23、0 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 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 and maximum heat cu
24、ring cycle to FLTM BV 150-05, Table 2) ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 7 3.4.16.1 Shear Strength, min 3 N/cm2(Method B at 23 +/- 2 C) 3.4.16.2 Peel Strength, min 10 N/cm (Method C at 23 +/- 2 C
25、) 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 C wash, phosphate and electrocoat test assemblies under norma
26、l 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 ASTM B 117 for 480 h. (d2) For Precoated Steel. After 34 h at 2
27、3 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, 3.4.18.1 (FLTM BV 153-07) max 1% 3.4.18.2 After Heat Aging (500 h at 80C, A4/A5 only) m
28、ax. 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 Expansion, % 25 65 25 55 300 400 100 - 200 Test Method: (a) Determine the volume V1 of clean 150 x 25 mm test panels. (b) Apply test strips, 8 mm in diameter an
29、d 100 mm in length (see sketch in FLTM BV 153-07) and determine volume V2. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 6 of 7 (c) Expose test assemblies separately according to FLTM BV 150-05, Table 2: . minimu
30、m curing cycle (165 C, 10 Materials Temp in EC oven) . maximum curing cycle, Phase 1 and 2. (d) After cooling to 23 +/- 2 C determine volume V3. Note: Determine volumes by water displacement. The volume increase in % of the original volume shall be determined as follows: % Volume Expansion = V3 - V2
31、 - x 100 V2 - V1 Where: V1 = Volume of test panel V2 = Volume of test panel and sealing strip V3 = Volume of test panel and sealing strip after cure 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
32、 the PSW 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 153-07, paragraph 1 to 3. (b) After cooling to 23 +/- 2 C test specimens are cut
33、 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 of application, number of test cycles, etc. for the individual cars are defi
34、ned by Materials Engineering, Body & Materials Engineering. 3.5 STORAGE STABILITY (From date of receipt at Ford Motor Company) Min 6 months when stored between 5 C and 32 C in unopened drums out of direct sunlight. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Co
35、pyright 2007, Ford Global Technologies, LLC Page 7 of 7 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. Specification WSK-M4G325-A1 WSK-M4G325-A2/A3/A4/A5 Paragraph (Dimensioned Material) (Non-dim. Material) 3.4.1 X X 3.4.2 X X 3.4.3 X X 3.4.4 - X 3.4.5 X X 3.4.6 X - 3.4.7 - X 3.4.8 X X 3.4.9 X X 3.4.10 - X 3.4.11 X X 3.4.12 X X 3.4.13 X X 3.4.14 X X 3.4.15 - X 3.4.16 X - 3.4.17 X X 3.4.18 X X 3.4.19 X X 3.4.20 X X 3.4.21 X X
