1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 1 2016 06 08 Revised K.Mueller, NA 2014 01 07 Released R Harris, C McComb, NA Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 1 of 7 ADHESION REQUIREMENTS, ADHESIVE FOR WSS-M11P28-D BONDING EXTERIOR FRO
2、NT AND REAR LAMP ASSEMBLIES 1. SCOPE This specification defines the performance requirements for an adhesive or adhesive system suitable for bonding front and rear lighting. 2. APPLICATION This specification was released originally for an adhesive or an adhesive system used to bond lenses to bodies
3、in the construction of lamp assemblies. 2.1 LIMITATIONS 2.1.1 Use of thermoplastic sealers and adhesives are not allowed. 2.1.2 Surface treatment (adhesion promoting CPO primer or plasma fluming) of polypropylene is necessary to achieve adequate bonding. 3. REQUIREMENTS Materials meeting these perfo
4、rmance specifications are identified on the Approved Source List Adhesive bonded lamp assemblies must meet all other exterior lighting system requirements. Initial material approval testing is to be conducted at DV using plaques. PV testing is on full lamp assemblies. See Table 1 for sample sizes an
5、d required testing. 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 CONDITIONING AND TEST CONDITIONS All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5%
6、relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 ADHESION STRENGTH LAP SHEAR (ASTM D3163, 12.7 mm/min crosshead speed) The lap shear coupons shall consist of typical production materials. Clean the surfaces to be bonded with a hot, so
7、apy water solution. The soap shall be free rinsing, similar to that used for glassware. After cleaning, the coupons are blown dry and conditioned at 23 +/- 2 C for 24 h to ensure dryness. Dispense an amount of adhesive on to the housing material coupon that will fill a 25 mm overlap with a minimum b
8、ond thickness of 0.76 mm. Shim the interface with 0.76 mm wire or glass beads to maintain the required minimum thickness and overlap. Apply the lens material coupon onto the adhesive/housing coupon and remove any excess adhesive. Maintain proper alignment of the ENGINEERING MATERIAL SPECIFICATION WS
9、S-M11P28-D Copyright 2016, Ford Global Technologies, LLC Page 2 of 7 assemblies during cure. Follow the cure schedule as recommended by the adhesive manufacturer. Include the manufacturers recommended open time and cure schedule in the test report. Note: Proper alignment of the test assembly is crit
10、ical. Every effort should be made to maintain uniform tension across the bond area. Cleavage or peel of the bond area could yield inaccurate results. Evaluate a minimum of three assemblies per condition. Report failure mode (both the lens and housing substrates) and peak load. Min Load, N Failure Mo
11、de (lens and housing) Normal (Condition for 30 minutes at specified temperature prior to test) 3.3.1 Test at 23 +/- 2 C 600 Report 3.3.2 Test at 107 +/- 2 C 450 Report 3.3.3 Test at -30 +/- 1 C 900 Report Exposed (After environmental aging in paragraphs 3.3.4- 3.3.8 condition samples for 24 h at 23
12、+/- 2 C prior to lap shear testing) 3.3.4 Heat Age 700 Report (14 days at 107 +/- 2 C) 3.3.5 Humidity 500 Report (14 days at 38 +/- 1 C and 95-100% R.H ) 3.3.6 Water Immersion 500 Report (14 days, FLTM BI 104-01) 3.3.7 Accelerated Weathering 700 Report (ASTM D7869, 1500 hours) - Preferred or (SAE J2
13、527 (Boro/Boro), 2000 hours) 3.3.8 Thermal Cycle 600 Report (10 cycles, DVO-19766) 1 cycle = 2 h at 50 C Ramp to -40 C (rate 0.75 1.5 C/min) 2 h at -40 C Ramp to 50 C (rate 0.75 1.5 C/min) ENGINEERING MATERIAL SPECIFICATION WSS-M11P28-D Copyright 2016, Ford Global Technologies, LLC Page 3 of 7 3.4 S
14、TABILITY When subjected to the following exposures, the adhesive viscosity and adhesion strength shall be +/- 25% of that obtained when originally tested. 3.4.1 Shelf Life (6 months at 23 +/- 2 C) 3.4.1.1 Viscosity +/- 25% 3.4.1.2 Adhesion strength, Para 3.2.1 3.2.8 +/- 25% 3.4.2 Viscosity, original
15、 Report (per ASTM) (ASTM D3236 - spindle, temperature and speed per suppliers recommendation) 3.5 CREEPAGE No slippage (ASTM D1780, prepare test samples per para 3.2, apply a 4.5 kg dead weight load to test samples and expose to 85 +/- 2 C for 24 h) 3.6 COLD SLAM RESISTANCE No cracking, adhesive (FL
16、TM BV 101-02, 10 cycles of 6 slams or cohesive failure per cycle at -30 +/- 1 C) Prepare test assemblies as illustrated in Figure 1. Test substrates shall consist of 100 x 250 mm panels Follow the cure schedule as recommended by the adhesive manufacturer. Mechanically attach bonded test assembly to
17、a 0.8 x 300 x 300 mm CRS base panel. Centrally locate test assembly on base panel. Conduct test as outlined per FLTM BV 101-02 following steps 9, 10 and 11. Position panel in slam fixture with reinforcement facing inward. Subject each test assembly to 10 cycles of six slams per cycle at -30 +/- 1 C.
18、 3.7 LAMP ASSEMBLY TESTING Test parts shall be manufactured with production or production representative processes and equipment. Evaluate a minimum of 2 pair (left and right) per condition at 23 +/- 2 C. Every lamp shall be pressure tested prior to, and after the specific exposures listed below. 3.
19、7.1 Seal Integrity Under Air Pressure, Baseline No leaks (RQT-170000-011017, Legacy (EX-0224) 3.7.2 Resistance to Thermal Cycle (RQT-170000-010972, Legacy (EX-0009) Para 3.2.8: All lamps are lit at point A, off at point B - Reverse lamps are cycled separately Lamp assembly shall not exhibit warpage,
20、 degradation in photometrics, or sink marks when subjected to thermal conditioning. They shall not leak when tested for seal integrity under air pressure. 3.7.3 Resistance to Heat Age (14 days at 107 +/- 2 C, DVM-14455) ENGINEERING MATERIAL SPECIFICATION WSS-M11P28-D Copyright 2016, Ford Global Tech
21、nologies, LLC Page 4 of 7 They shall not leak when tested for seal integrity under air pressure. The adhesive bond is being evaluated only, and doesnt include cosmetic (warp, etc.) of the lamp plastic components. 3.7.4 Resistance to Vibration (RQT-170000-010971, Legacy (EX-0008) Lamp assembly shall
22、not exhibit visible cracks, breakage or deformation when subjected to thermal cycling / vibration exposure. They shall not leak when tested for seal integrity under air pressure. 3.7.5 Resistance to Thermal Shock (Heat soak lamp assembly 4 h at 82 +/- 2 C, immediately immerse the lens in ice water b
23、ath at 0 C, DVM-14455) Lamp assembly shall not exhibit warpage, degradation in photometrics, or sink marks when subjected to thermal shock. They shall not leak when tested for seal integrity under air pressure. 3.7.6 Adhesive Resistance to Reflow / Expulsion (Following a 24 h maximum cure at 23 +/-2
24、 C, expose lamp assembly to 85 C, all lamp functions energized at their highest wattage mode at 14V (turn signals flashing at 90 flashes per minute and 70% On), for 24 h of test time. Examine at 6 and 24 h for reflow/expulsion) There shall be no adhesive blistering or flow outside the glue “U” track
25、. For adhesives not complying within 24 hours of maximum cure time, the lamp supplier Control Plan will include a hold time at the supplier equal to or greater than the time required to meet the reflow/expulsion performance test 4. GENERAL INFORMATION The information given below is provided for clar
26、ification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 SYSTEM COMPONENTS Primers or other surface treatments utilized to achieve adequate adhesion of adhesive material to the substrates shall not adversel
27、y affect the physical properties of the substrate material. 4.1.1 Substrates As specified on the Engineering Document, all potential combinations shall be evaluated during plaque testing. 4.1.2 Adhesive Shall be free from unwanted flow and outgassing from the lamp “glue track” during cure and post c
28、ure. The adhesive product code must be noted in the initial submission package and identified on the Tier suppliers drawing. 4.2 CURE SCHEDULES Cure schedules as specified by the adhesive manufacturer. 4.3 VISCOSITY ENGINEERING MATERIAL SPECIFICATION WSS-M11P28-D Copyright 2016, Ford Global Technolo
29、gies, LLC Page 5 of 7 Viscosity should be recorded and referenced for Stability Testing baseline (Para 3.3) and submitted at PPAP for subsequent batch Certificate of Compliance. 4.4 SYSTEM DESIGN REQUIREMENTS EX-0010 = RQT-170000-010973 Exterior Lighting Clearance to Radiant Heat Sources EX-0224 = R
30、QT-170000-011017 Water Ingress and Condensation Prevention EX-0009 = RQT-170000-010972 Resistance to Thermal Cycle EX-0008 = RQT-170000-010971 Vibration Endurance DVM-14455 = Legacy DVM ID 14455 DVO-19766 = As per Para 3.3.8 4.5 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in al
31、l characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical As
32、sistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for
33、 Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.6 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document.
34、The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2016 06 08 Revisions Updated Acce
35、lerated Weathering (para 3.2.7) Eliminated Transit Requirements (para 3.3) Clarified Failure Mode Requirements and Lap Shear Requirements (para 3.2) Clarified FSMS references (para 3.6) Clarified Resistance to Heat Age (para 3.6.3) Updated standard paragraphs ENGINEERING MATERIAL SPECIFICATION WSS-M
36、11P28-D Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 COLD SLAM TEST ASSEMBLY Figure 1 ENGINEERING MATERIAL SPECIFICATION WSS-M11P28-D Copyright 2016, Ford Global Technologies, LLC Page 7 of 7 MINIMUM SAMPLE REQUIREMENTS Table 1 TESTS Number of Parts/Test Specimens DV PV 3.3 Adhesion Str
37、ength, Plaque Testing 3.3.1 At Ambient, 23 C 6 plaques*: 3 as received 3 after Shelf Stability X 3.3.2 At 107 C 6 plaques*: 3 as received 3 after Shelf Stability X 3.3.3 At -30 C 6 plaques*: 3 as received 3 after Shelf Stability X 3.3.4 After 14 days at 107 C 6 plaques*: 3 as received 3 after Shelf
38、Stability X 3.3.5 After 14 days Humidity 6 plaques*: 3 as received 3 after Shelf Stability X 3.3.6 After 14 days Water Immersion 6 plaques*: 3 as received 3 after Shelf Stability X 3.3.7 After Weatherometer 12 plaques*, 1 each for 500, 1000, 1500 and 3 for 2000 h exposures Repeated: as received afte
39、r Shelf Stability X 3.3.8 After Thermal Cycling 12 plaques*, 1 each for 500, 1000, 1500 and 3 for 2000 h exposures Repeated: as received after Shelf Stability X 3.4.1 Shelf Stability, 6 months at 23 C Identified above X 3.4.2 Viscosity 3 consecutive scale readings (per ASTM) X 3.5 Creep Resistance 3
40、 plaques* X 3.6 Cold Slam Resistance 3 plaques* X 3.7 Assembly Testing 3.7.1 Seal Integrity (leak test baseline) 2 pair X 3.7.2 Thermal Cycling (leak test) 2 pair X 3.7.3 Heat Age (leak test) 2 pair X 3.7.4 Vibration (leak test) 2 pair X 3.7.5 Thermal Shock (leak test) 2 pair X 3.7.6 Reflow / Expulsion Resistance 2 pair X * : Replicates identified are for all applicable substrate combinations DV: Testing to be performed on plaques PV: Testing must be performed on parts
