1、c-2 ENGINEERING MATERIAL SPECIFICATION 1996 08 14 1996 05 08 Material Name Specification Number Revised Added Illustration 1 6c 2, p.9 J.Spencer L.Gullen Activated J. Spencer L. Gullen INSULATOR, ELASTOMER BASED, EXTRUDED, PRESSURE SENSITIVE WITH POLYESTER FILM, COMPRESSION RES I S TANT 1. SCOPE The
2、 material defined by this specification is an extruded elastomeric based compression resistant insulator material. This material is pressure sensitive and forms an immediate bond to oily galvanized steel at room temperature. 2. APPLICATION This specification was released originally to insulate heat
3、shields and fuel tank support components on the underbody. This material can be applied in trim area or in prefabricated applications at vendor plants. It may be applied over oily galvanized, CRLC steel, zinc rich primer, and plastic substrates. It will not bond to the hot melt wax used to coat fram
4、es. Material is supplied extruded onto a polyester film which becomes a permanent component of the part. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for
5、initial qualification of materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must
6、 be used to analyze process/product data and assure consistent processing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. Date I
7、Action I Chanses WP 3948-a Page 1 of 10 c-2 ENGINEERING MATERIAL SPECIFICATION 3.2 3.3 3.4 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermogra
8、ms 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 tested under the same conditions. CONDITIONING AND TEST CON
9、DITIONS 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 otherwise specified. DIMENSIONS 3.5 CONSISTENCY (ASTM D 1321, 300 g
10、tl cone) 3.5.1 As received at 25 C at 5 C at 49 C 3.5.2 Aged, 60 days at 23 C at 25 C at 5 C at 49 C As specified on engineering drawing and/or in Trim 6c Sealer Manual 3.6 SOLIDS, min, by weight (ASTM D 2834, except heat at 100 +/- 3 C in a mechanical convection oven) 7.0 - 9.0 mm 3.0 - 5.0 mm 9.5
11、- 11.5 mm 5.0 - 7.0 mm 4.0 - 6.0 mm 8.0 - 10.0 mm 99 % 3.7 ASH (Based on solids weight, max 40 % Test Method: Place the crucible containing the solids residue in a cool muffle furnace. Slowly heat to and maintain at 760 +/- 30 C for 1 h, cool in desiccator and weigh. 3.8 SPECIFIC GRAVITY (ASTM D 297
12、, Hydrostatic Method) 3.9 TENSILE STRENGTH, min ELONGATION, min 1.20 +/- 0.1 0.20 MPa 2000 % WP 3948-b Page 2 of 10 ENGINEERING MATERIAL SPECIFICATION WSL-M5G51-A3 Test Method: . Prepare specimens of the material which are 2 mm x 25 mm x 150 mm . Condition the test specimens for 2 h at 23 +/- 2 C. .
13、 Place the test specimens in the holders of a device appropriate to measure the tensile strength and extensibility of the material. Samples should be centered between the jaws of a tensile tester which are 25 mm apart at the beginning of the test. Run the test at a rate of extension of 500 mm per mi
14、nute. Extend the material until the material fails by breaking or tearing. Compute the tensile strength by dividing the load in N at the time of failure by the cross-sectional area of the specimen in m2 and multiply by 1,000,000. . Compute the elongation by measuring the displacement between the jaw
15、s in mm at the time of failure. Subtract 25 mm from this displacement and divide by 25 mm. Multiply this ratio by 100 to obtain the percent elongation. 3.10 PEEL STRENGTH 3.10.1 180 degree peel, on 0.75 mm polyester, 125 mm/minute jaw speed initial 7 days at 70 +/- 2 C 7 days salt spray, 38 +/- 2 C
16、7 days 100 % R.H., 38 +/- 2 C 600 N/m 600 N/m 600 N/m 600 N/m Test Method: . Prepare test specimens by extruding a 2 mm x 35 mm section of material onto a .O75 x 55 mm strip of polyester film. The material should be extruded so that it runs down the center of the film. Cut these extruded parts to a
17、length of 125 mm. Condition the samples so extruded for 7 days at 23 +/- 2 c. Manually peel back the material from the polyester to a distance of 75 mm from one end. WP 3948-b Page 3 of 10 ENGINEERING MATERIAL SPECIFICATION WSL-M5G51-A3 Place the polyester in one jaw of the peel tester and the mater
18、ial in the other jaw. The polyester should be held in the jaw at a point approximately 12 mm from where the polyester and material are joined. The material should be put in the jaw at a point approximately 25 mm from where the polyester and material meet. . The peel tester should be started and the
19、maximum value obtained while peeling 25 mm of material or the maximum value obtained before the material break from the polyester film shall be recorded. Compute the peel strength by dividing the maximum force recorded in N, by the width in m of the material section. 3.10.2 90 degree peel on galvani
20、zed steel, 127 mm/minute initial 14 days at 70 C 14 days, salt spray, at 38 C 14 days, 100 % R.H., at 37 C 500 N/m 1200 N/m 700 N/m 700 N/m Test Method: . Cut test specimens which are 2 mm x 22 mm x 100 mm Condition the test specimens for 24 h at 23 +/- 2 C. Prepare 4 panels of galvanized steel whic
21、h are 0.80 x 100 x 150 mm. Clean the surface by wiping with mineral spirits and allowing 10 minutes to dry. Apply 3 test specimens to each of the four panels. The length of the specimens should be parallel to the length of the panel (see illustration 1). . Immediately cover each panel with a piece o
22、f release paper and pass a 5 kg roller over each panel 6 times. When passed over the specimens, no force should be applied downward except the mass of the roller. After subjecting each panel to the specified environmental conditions, condition the panels for 24 h at 23 C. Using a chisel nose spatula
23、, manually peel back a 50 mm strip of material from each specimen on the panel. Place the panel in a fixture which will hold it firmly. Place 25 mm of the peeled back material in the jaw of the peel tester. WP 3948-b . Peel the material back at a 90 deg angle to the panel at a rate of 125 mm per min
24、ute. Page 4 of 10 c-2 ENGINEERING MATERIAL SPECIFICATION Record the maximum value obtained in Newtons while 25 mm is being peeled from the panel or the maximum value obtained before the material breaks. . Compute the peel strength by dividing the value recorded in N by the width of the specimen in m
25、. 3.10.3 Inverted Peel (on oily galvanized steel) Distance, max 7 days at 23 C 7 days at 70 C Peel strength, min 7 days at 23 C 7 days at 70 C 10 mm 10 mm 2000 N/m 3000 N/m Test Method: . Prepare specimens per para 3.10.1 . Cut the samples to a length of 250 mm . Prepare 6 panels of galvanized steel
26、 0.80 x 100 x 300 mm per para 5.2.1. Apply one sample to each of the panels. The pressure sensitive side should be applied to the panel. After applying the sample, it should be affixed by rolling each sample no more than 6 passes with a 5 Kg roller. . After fixturing, peel back 25 mm in length from
27、one end of each strip. While holding it away from the metal, invert the panel so that the sample is facing downward. (See illustration 2). . Place the panel in a fixture which will keep it inverted for the time and condition specified. It must be positioned so that the sample has no support undernea
28、th it nor any obstruction to prevent its falling or peeling. At the conclusion of the test, measure the distance in mm which the material has peeled back from the original position. Then perform a 90 deg peel test according to para 3.10.2 recording the maximum value obtained during a 50 mm long peel
29、. WP 3948-b Page 5 of 10 c-2 ENGINEERING MATERIAL SPECIFICATION 3.11 FORCE TO COMPRESS, min initial 50 cycles 2000 N 2000 N Test Method: . Prepare samples of material which are 4 x 25 x 100 mm. Apply a polyester film .O75 x 25 x 100 mm to each sample. Place each of these samples on a galvanized stee
30、l panel 0.80 x 100 x 150 mm. Apply samples with the pressure sensitive side down against the panel. Prepare a steel loading assembly of approximately 6 mm thick steel. The assembly should be 25 x 100 mm. . Place this steel loading assembly on top of the sample to be tested. Put this into a compressi
31、on testing device capable of applying a force of at least 2240 N. . Bring the compression testing device down to where it just makes contact with the sample. . Compress the sample a distance of no more than 1 mm at the rate of 125 mm/minute. Record the value in N obtained on the first compression Re
32、peat the compression cycle 49 times in a period of 10 minutes. Record the maximum value obtained on the compression phase of the 50th cycle. 3.12 COMPRESSION RECOVERY, min Thickness Recovery, 14 days at 23 C 24 hours at 54 C 24 hours at 70 C 95 % 90 % 80 % Test Method: Prepare material samples per p
33、ara 3.10.1. Place the samples with the pressure sensitive side down on galvanized panels 0.80 x 100 x 150 mm. Measure the thickness of the sample to an accuracy of +/- .O5 mm. . Place a metal block measuring 50 x 50 x 50 mm and weighing no less than .9 kg on top of the samples. . Run the test for th
34、e time and at the temperature specified. . Remove the block and condition the samples for 1 hr at 23 +/- 2 C. WP 3948-b Page 6 of 10 c-2 ENGINEERING MATERIAL SPECIFICATION Measure the thickness of the sample where the block has been positioned on the sample. Measure to an accuracy of +/- .O5 mm. Rec
35、ord value. . Divide the thickness after test by the original thickness of the sample and report as a percentage. 3.13 ELASTIC RECOVERY, max at max 160 mm 60 sec Test Method: Prepare a sample of material 2 x 35 x 152 mm (152 +/- 1 mm). Lay sample on a piece of release paper 150 mm wide x 380 mm long.
36、 Hold the sample down on one end and stretch the other end out in no more than 5 seconds to a length of no less than 300 mm. . Immediately release the sample and allow it to recover its original length while laying on the release paper. . At 60 seconds from the time of release of the sample, measure
37、 the length in mm. Record this value. 3.14 COLD FLEXIBILITY (24 h at - 40 C) No cracking, splitting or breaking A 2 x 35 x 150 mm sample, conditioned for 24 h at - 40 C is bent 180 degrees over a 175 mm mandrel, with mastic side down, in less than 5 seconds. 3.15 STORAGE STABILITY The material shall
38、 be stored at temperatures below 55 C. Under these storage conditions, the minimum shelf life of the material shall be 6 months. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature prior to application. 3.16 FUNCTIONAL APPROVAL Materials being ev
39、aluated for approval to this specification shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. 3.17 ADDITIONAL R
40、EQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or performance specification. All critical areas with respect to these properties shall be clearly designated on the engineering drawing. WP 394
41、8-b Page 7 of 10 c-2 ENGINEERING MATERIAL SPECIFICATION 3.19 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construc
42、tion, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the p
43、roposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restri
44、ctions are defined in Engineering Materials Specification WSS-M99P9999-A1. 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 i
45、nterest from the affected Purchasing, Design and Materials Engineering 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, demonst
46、rating full compliance with all the requirements of this specification (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 asses
47、sment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specificati
48、on. 5.1 MECHANICAL CONVECTION OVEN The mechanical oven(s) used to test the material shall be capable of obtaining 205 C metal temperature on body steel (0.8 - 0.9 mm thickness) within 8 - 10 minutes. WP 3948-b Page 8 of 10 c-2 ENGINEERING MATERIAL SPECIFICATION 5.2 SUBSTRATES Nominal panel dimension
49、s are 0.8 x 100 x 300 mm; injection molded specimen. 5.2.1 Galvanized steel (WSB-MlA250-C3) : Surface precoated with M-99C47-A Mineral Oil at an application of approximately 2.2 cm3/m2. WP 3948-b Page 9 of 10 c-2 ENGINEERING MATERIAL SPECIFICATION Test Panel 150 x 100 mm ILLUSTRATION 1 / / / fl- Test Panel 300 x 100 mm / Insulator (125 x 32 x 2 mm thick) extruded onto Polyester film (1 25 x 55 x .O75 mm thick) Peel Polyester film from Insulator 75 mm from end ILLUSTRATION 2 WP 3948-b Page 10 of 10
