1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 04 29 Revised Revised 3.4.1 B. Witkowski, NA 2006 05 22 Activated M. Mehandru Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 6 PERFORMANCE, ADHESIVE, HEAT CURING, EPOXY/GLASS FIBER WSS-M11P64-A1 LA
2、MINATE, METAL REINFORCEMENT, PAINT SHOP APPLIED PERFORMANCE, ADHESIVE, HEAT CURING, EXPANDABLE, EPOXY/ WSS-M11P64-A2 GLASS FIBER LAMINATE, METAL REINFORCEMENT, BODY SHOP APPLIED PERFORMANCE, ADHESIVE, HEAT CURING, NON EXPANDABLE, WSS-M11P64-A3 EPOXY/GLASS FIBER LAMINATE, METAL REINFORCEMENT, BODY SH
3、OP APPLIED 1. SCOPE These specifications define the performance requirements for a heat curing, epoxy/ fiberglass laminate, supplied in die cut form with a release paper backing. 2. APPLICATION The materials released to these specifications were originally released to reinforce and stiffen sheet met
4、al body panels. WSS-M11P64-A1 can be applied to electrocoat primed steel surfaces. WSS-M11P64-A2/A3 can be applied to oily cold rolled steel and galvanized steel surfaces. Recommended bake schedule per para 4.2. Materials are required to perform in a number of applications. Each design and/or applic
5、ation has unique requirements. Compliance with this specification does not guarantee that material will function for all potential applications on vehicles. Selection of the appropriate material should therefore be based on jury evaluations or other test procedures as well as required functional tri
6、al. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. Tests must be conducted on material having an original epoxy/fiberglass material thickness of 1.27 +/- 0.1 mm. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part
7、 producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPATIBILITY Initial laminate approval was based on a specific material system which included the substrate, stamping lubricants and laminate. The originally approved material system
8、was oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may affect laminate performance. If any of these parameters are changed, the laminate performance must be validated using
9、the new parameters. ENGINEERING MATERIAL SPECIFICATIONWSS-M11P64-A1/A2/A3 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 6 3.3 FIBERGLASS CLOTH REQUIREMENTS Thickness of cloth, weave, and breaking strengths in warp and fill directions must be such that all re
10、quirements of this specification are met. 3.4 EPOXY POLYMER REQUIREMENTS A1 A2 A3 3.4.1 Specific Gravity 0.8 - 1.9 0.8 -1.9 0.8 - 1.9 (ASTM D 792) 3.4.2 Volume Expansion, % N/A 75 - 175 N/A (FLTM BV 108-02, material cure per para 4.3) 3.5 UNCURED LAMINATE MATERIAL PROPERTIES 3.5.1 Construction Const
11、ruction must consist of woven fiberglass cloth onto an epoxy adhesive film backed with release paper. There must not be any loose glass fibers after the die cut operation. 3.5.2 Thickness, uncured As specified on (ASTM D 461, 85 g load, Engineering Drawing 25 mm diameter foot, total fiberglass and a
12、dhesive) 3.6 UNCURED LAMINATE PERFORMANCE REQUIREMENTS 3.6.1 Formability The material must not delaminate or crack when folded 180 upon itself. 3.6.2 Tack Adhesion Test The laminate must not peel at the edges or fall off panel. Test method: Apply a 100 x 150 mm adhesive laminate strip on a 150 x 300
13、 mm panel. Prepare four panels for each substrate per para 4.1. Pass a 2.2 kg roller over samples per ASTM D 1000. Invert two panels immediately after laminate application and condition at 23 +/- 2 C for 1 h. Observe for peeling or lifting of laminate from panel. Save panels for Inverted Bake Test,
14、para 3.7.2. Stand the remaining two panels vertically immediately after laminate application and condition at 23 +/- 2 C for 1 h. Observe for peeling, sliding or slumping of laminate from panel. Save panels for Vertical Bake Test, para 3.7.3. ENGINEERING MATERIAL SPECIFICATIONWSS-M11P64-A1/A2/A3 Pri
15、nted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 6 3.6.3 Phosphate Wash Resistance (Not required for A1) (FLTM BV 116-01, Method “A“ preparation specified below) Sample preparation: 1) Identify the cutting direction for the fiberglass cloth - Cut 25 x 150 mm speci
16、mens of adhesive laminate in warp and fill directions. - For specification testing, cut all laminate specimens in the grain direction producing the highest mean Peak Loads 2) Lubricant application (Not required for A1) - Using appropriate method, apply the designated lubricant at the specified amoun
17、t to substrates described in para 4.1. - Allow coupon to sit undisturbed in horizontal position for at least 1 hour prior to use. 3) Preparing bonded assembly - Apply a 25 x 150 mm adhesive laminate specimen cut in a specified direction to a 25 x 150 mm panel prepared in Step 2. - Pass a 2.2 kg roll
18、er per ASTM D 1000 over sample within 15 minutes of patch application. - Condition at 23 +/- 2 C and 50 +/- 5% RH for 1 h prior to oven cure per para 4.2. ENGINEERING MATERIAL SPECIFICATIONWSS-M11P64-A1/A2/A3 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 6 4
19、) Reporting data - Record load at 2 mm deflection and peak load in Newtons. - Report average load and sample standard deviation. Normal (Condition for 30 min at specified temperature prior to test.) Load at 2 mm Peak Deflection Load A1 A2 A3 A1 A2 A3 3.7.1.1 Test at 23 +/- 2 C, N 30 50 45 75 120 175
20、 3.7.1.2 Test at 90 +/- 1 C 25 30 25 120 90 120 3.7.1.3 Environmentally Aged Assemblies (Condition for 24 h at 23 +/- 2 C and 50 +/- 5% RH after exposure, then test at 23 +/- 2 C) Material must meet Flexural Strength Requirement (para 3.7.1.1) after each of the following environmental exposures: 14
21、days heat age at 90 +/- 1 C 500 h humidity at 38 +/- 2 C and 98 +/- 2 % RH 10 thermal cycles One cycle: 90 +/- 2 C for 4 h PLUS 40 +/- 2 C and 98 +/- 2% RH for 4 h PLUS -30 +/- 2 C for 16 h 30 APGE Cycles (FLTM BI 123-01, report after 10, 20, and 30 cycles) (Not Required for A1) 3.7.1.4 Adhesive sto
22、rage prior to bonding. (Expose material in sealed packages. Condition at 23 +/- 2 C for 24 h prior to testing). 72 h at 40 +/- 2 C 3.7.2 Inverted Bake The material must exhibit a smooth, non-blistered surface and must not peel at edges or fall off from panel. Test Method: Condition one half of the p
23、anels of each substrate prepared per para 3.6.2 to 23 +/- 2 C for 4 h. Panels must remain inverted during conditioning. ENGINEERING MATERIAL SPECIFICATIONWSS-M11P64-A1/A2/A3 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 6 Condition the other half of the pane
24、ls of each substrate prepared per para 3.6.2 to 72 h at 40 +/- 2 C and 98 +/- 2% RH. Panels should remain inverted during conditioning. Place conditioned panels in an oven in the inverted position and cure per para 4.2. Save samples for Cold Slam Test, para 3.7.4. 3.7.3 Vertical Bake The material mu
25、st exhibit a smooth, non-blistered surface and must not peel at edges, sag more than 2.5 mm or fall off from panel. Test Method: Condition one half of the panels of each substrate prepared per para 3.6.2 to 23 +/- 2 C for 4 h. Panels must remain vertical during conditioning. Condition the other half
26、 of the panels of each substrate prepared per para 3.6.2 to 72 h at 40 +/- 2 C 98 +/- 2% RH. Panels must remain vertical during conditioning. Place conditioned panels in an oven in the vertical position and cure per para 4.2 Save samples for Cold Slam Test, para 3.7.4. 3.7.4 Cold Slam (FLTM BV 101-0
27、2, Procedure “E“, condition 4 h min at -30 +/-2 C. Test at -30 +/- 2 C, panels prepared per para 3.6.2 and 3.7.3, and cured per para 4.2. The material must not crack or separate from panel before 10 slams. 3.7.5 Fogging Test (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditionin
28、g 1 h and 16 h) Fog Number, min 70 Formation of clear film, droplets or crystals is cause for rejection. 3.8 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification will be subjected to a production trial. Functional trial results must be approved by the affected assembly op
29、eration and Design Engineering. Results must be made available to Materials Engineering prior to material approval and release. 4. GENERAL INFORMATION The information below is provided for clarification and assistance in meeting the requirements of these specifications. These parameters should be ve
30、rified with Materials Engineering prior to initiating material testing. ENGINEERING MATERIAL SPECIFICATIONWSS-M11P64-A1/A2/A3 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 6 4.1 SUBSTRATES North American Production Materials being evaluated for approval to t
31、his specification shall be tested with typical lubricants and at applications levels as specified by Materials Engineering. 4.1.1 Paint Shop Materials (A1) Steel per 4.1.2 plus: Phosphate: WSS-M3P1-D E-Coat: WSS-M64J39 or equivalent 4.1.2 Body Shop Materials (A4) Steel: WSD-M1A333-A2, nominal 0.8 mm
32、 thickness, coated per WSS-M1P94-A to coating weight 60G60G-EL, 60G60G-HD, and 55A, clean, unpolished Materials being evaluated to this specification shall be tested with the applicable lubricants and coatings (if necessary) at appropriate thicknesses. See the applicable Materials Engineering Activi
33、ty for the latest requirements. 4.2 CURE SCHEDULE A1, A2 & A3 Cure According to FLTM BV 150-05. Use the cure schedule appropriate for the regions of intended usage. 4.3 FIBERGLASS CLOTH Report the following characteristics for a laminate with a fiberglass cloth. 4.3.1 Style Designation (ASTM D 579,
34、Table 6) 4.3.2 Fabric Count, Warp, yarns/25 mm (ASTM D 579, Table 6) 4.3.3 Fabric Count, Fill, yarns/25 mm (ASTM D 579, Table 6) 4.3.4 Yarn Designation, Warp (ASTM D 579, Table 6) 4.3.5 Yarn Designation, Fill (ASTM D 579, Table 6) 4.3.6 Mass per Unit Area, g/m2(ASTM D 579, Table 6) 4.3.7 Thickness, mm (ASTM D 579, Table 6) 4.3.8 Breaking Strength, Warp, N/5cm (ASTM D 579, Table 6) 4.3.9 Breaking Strength, Fill, N/5cm (ASTM D 579, Table 6)
