1、 ENGINEERING MATERIAL SPECIFICATION ADHESIVE, PERFORMANCE REQUIREMENTS FOR WSS-M11P66-A1 STRUCTURAL BONDING OF FIXED GLASS MOUNTED BRACKETS 1. SCOPE This specification defines the adhesion requirements for an adhesive or adhesive system suitable for structurally bonding rigid plastic or sintered met
2、al brackets to automotive glass. The adhesive materials may be pressure sensitive adhesive films and / or polyurethane and may include the use of glass primer (glass) or plastic or metal flange primers (bracket). This testing is intended to be a system level test performed on production level parts.
3、 2. APPLICATION This specification is released for materials used to bond brackets for sensors to the ceramic frit or to bare automotive glass. This specification is not intended for mirror buttons (reference the most current revision of WSS-M2G389-A). Typical Applications: Sintered metal or plastic
4、 brackets used for rain sensors and GPS sensors. These products come to Ford as parts in assembly (PIA) on the glass. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 VEHICLE INTERIOR ENVIRONMENT QUALITY PERFORMANCE REQUIREMENTS Com
5、ponents used in interior applications must meet the requirements outlined in WSS-M99P2222-D1 / latest version. 3.3 SYSTEM COMPONENT REQUIREMENTS Performance and compatibility of the adhesive with base materials is the responsibility of the tier one supplier. In addition to the requirements listed in
6、 this specification, requirements listed in the current Glass SDS for the application must be met, unless otherwise agreed to by Ford engineering. Initial Approval, DV and PV testing are called out in Table 1. 3.3.1 Substrate Condition The bonding surface shall be free from contaminates including bu
7、t not limited to mold release agents prior to attaching any parts. Any cleaning process to ensure the absence of oil or residues, fingerprints, corrosion, mold release agents, dirt, moisture, and other foreign materials must be documented and specified on the PFMEA and Control Plan. 3.3.2 Adhesive M
8、easure the percent cure of the structural bonding tape after the tape has been exposed to the curing cycle with Differential Scanning Calorimetry (DSC). The measured percent cure must be greater than that recommended by the tape manufacturer. Once a curing cycle has been correlated to a recommend pe
9、rcent tape cure, then the curing cycles time and temperature are used as SCs (Significant Characteristics) to ensure the cure of the Date Action Revisions Rev. 00 2015 08 05 Released P. Konopka, FNA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 6 ENGINEERING
10、 MATERIAL SPECIFICATION WSS-M11P66-A1 tape. If production settings affecting cure are changed from the initial approval, revalidation is required. The process window for both tape and polyurethane adhesives must be defined per section 3.5. 3.3.3 Wet Out Requirement Samples for initial approval and p
11、roduction must have a minimum of 95% wetout. 3.4 PERFORMANCE REQUIREMENTS FOR ASSEMBLIES The following requirements shall be assessed on samples of the brackets bonded to glass representative of current automotive glass (unless otherwise specified). Test samples shall be prepared in a manner that re
12、presents the production process. The preparation procedure shall be documented and provided with the test data. Separate specimens are required for each test (6 specimens per test unless otherwise specified). The test specimens as received and after exposure to each of the test requirements defined
13、below shall conform to the following: No visible deterioration of the adhesive medium. No separation of adhesive from the glass or bracket. All failure modes must be 100% cohesive failure or glass failure or bracket failure. No unreasonable staining or discoloration of the adhesive medium. No glass
14、cracking after exposure due to thermal expansion differences between the adhesive and glass. The bracket to glass bond shall be capable of withstanding the pull force as described below within 2 minutes of removal from each test condition unless otherwise specified. The bracket must withstand a perp
15、endicular pull to the glass (pluck adhesion) force equivalent to 1.5 times the total weight (bracket + sensor + attached trim + any spring load). If the calculated load (CL) is below 60 N (13.5 pounds), use 60 N as the force on the bracket before and after exposure to all environmental test conditio
16、ns outlined below. The calculated load is also the minimum requirement for pluck tests. Calculated Load (CL) = 1.5 x total weight* Total weight = (bracket + sensor + attached trim + spring load) *If (CL) 90% RH 4 h minimum at -40 +/-2 C Copyright 2015, Ford Global Technologies, LLC Page 2 of 6 ENGIN
17、EERING MATERIAL SPECIFICATION WSS-M11P66-A1 Specimens may be kept at -40 C overnight as necessary. After 4 cycles, condition 16 hours (minimum) at 23 +/-2 C & 50%+/-5% RH then test to paragraph 3.4.1 (Pluck Adhesion) 3.4.1.5 Thermal Shock 4 cycles, maximum 1 minute between conditions, each cycle con
18、sisting of: 2 h at 88 +/- 2 C 4 h at -40 +/- 2 C 2 h at 88 +/- 2 C 16 h at -40 +/- 2 C Specimens may be kept at -40 C overnight as necessary. Perform visual examination of specimens after each portion of the cycle. After 4 cycles, condition 16 hours (minimum) at 23 +/-2 C & 50%+/-5% RH then test to
19、paragraph 3.4.1 (Pluck Adhesion) 3.4.1.6 Weathering Resistance 1.5 x total weight, min (Interior Exposure SAE J2412, 3985.6 kJ/m2 After exposure, condition for 16 hours (min.) at 23 +/-2C 50%+/-5% RH then test to para 3.4.1 (Pluck Adhesion) Required for initial approval only Position the bracket fac
20、ing the light source during exposure. NOTE: Bond and test 3 brackets to safety glass (clear unlaminated safety glass is acceptable). Surrogate testing may be performed with bracket material plaques, provided they are the same material as the finished bracket and undergo the same cleaning, priming, e
21、tc. processes as the finished bracket. Test the bonding system once as proof for all applications. 3.4.2 Long Term Humidity Exposure 3.4.2.1 Long Term Humidity Resistance with Load Bracket or Glass Breakage (Bond 22 brackets to safety glass) Condition samples for 24 h at 23 +/- 2 C and 50 +/-5% RH a
22、fter complete adhesive cure (3.3.2). Hang test specimens vertically at temperature and gently attach weights as specified in section 3.4 to each specimen. See example in Figure 1. Hold samples for 800 hours at 50 +/- 2 C, 90% RH. Immediately after perform torque per 3.4.2.2 All bonded assemblies mus
23、t support the specified weight for a minimum of 800 hours. 3.4.2.2 Long Term Humidity Torque Strength Bracket or Glass Breakage (Bond 12 brackets (minimum) to safety glass) Condition samples for 24 h at 23 +/- 2 C and 50 +/-5% RH after complete adhesive cure (3.3.2). Expose samples at 50 +/- 2 C 90%
24、 RH. After appropriate exposure, apply torque in plane of glass. Torque all samples to failure and record values and failure modes. Test Schedule: Test one sample per day for 7 days, then test one sample on the following days: 14, 21, 28, 35, 42, days. Copyright 2015, Ford Global Technologies, LLC P
25、age 3 of 6 ENGINEERING MATERIAL SPECIFICATION WSS-M11P66-A1 3.4.2.3 Water Immersion Torque Strength Bracket or Glass Breakage (Bond 6 brackets (minimum) to safety glass) Condition samples for 24 hr. at 23 +/- 2 C and 50 +/-5% RH after complete adhesive cure (3.2.2). Place in water bath for 72 hours
26、at 50 +/- 2 C. Immediately upon removal from the water bath, apply torque in plane of glass. Torque all samples to failure and record values and failure modes. Compare the torque values between Initial and PV samples, see Table 1. 3.5 PROCESS WINDOW DEFINITION The supplier shall perform a Design of
27、Experiments (DOE) to determine the process window of the adhesive cure. The variables/parameters to be included in the design should include adhesive cure time / temperature / humidity, adhesive thickness, and mix ratio (if applicable). The parameters to be investigated shall be decided by the mater
28、ials engineer. An initial screening experiment should be run to determine what levels should be tested for the variables/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DOE. The DOE should address possible shipping and handling concerns and sp
29、ring load. Responses for the DOE shall include, but are not limited to, the following: Adhesive Cure, para 3.3.2 Initial Pluck Adhesion, para 3.4.1.1 Standard Practice for Conducting Creep Tests of Metal-to-Metal Adhesives, ASTM D1780, see Note 1 Note 1: Determine creep using the load determined in
30、para 3.4 of this specification, with the DOE parameters above. Review DOE results with Ford Engineering to determine if it meets the system requirements. Information to be submitted with PPAP: Bracket Material / Supplier Adhesive Bracket Primer Calculated Load (CL) Glass Supplier Glass frit, if appl
31、icable Glass Primer Surface Prep. Cure Mechanism Copyright 2015, Ford Global Technologies, LLC Page 4 of 6 ENGINEERING MATERIAL SPECIFICATION WSS-M11P66-A1 TABLE 1 No of specimens per test Required for Initial Approval Required for DV* Required for PV 3.3.2 Adhesive Cure (DSC) 6 6 3 (random, not seq
32、uential) 3.3.3 Wet Out 6 6 3 3.4.1.1 Pluck (as received) 6 6 3 3.4.1.2 Pluck (- 40 C) 6 6 3.4.1.3 Pluck (88 C) 6 6 3.4.1.4 Thermal Cycling 6 6 3.4.1.5 Thermal Shock 6 6 3 3.4.1.6 Weathering Resistance 3 (may test plaques) 3.4.2.1 Long Term Humidity Resistance with Load 22 22 3.4.2.2 Long Term Humidi
33、ty Torque Strength 12 3.4.2.3 Water Immersion Test compare PV to initial 6 6 6 (random, not sequential) All tests must be performed on full brackets unless otherwise specified. *DV: Carryover tape, new bracket design or material, new bonding substrate (glass or frit). 4. GENERAL INFORMATION The info
34、rmation given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of inte
35、rest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Perfor
36、mance Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.2
37、SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all 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 req
38、uirements, the supplier shall notify the affected Supplier Technical Assistance (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 Engineerin
39、g Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. Copyright 2015, Ford Global Technologies, LLC Page 5 of 6 ENGINEERING MATERIAL SPECIFICATION W
40、SS-M11P66-A1 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. 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. Figure 1 Copyright 2015, Ford Global Technologies, LLC Page 6 of 6
