1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 01 2018 04 25 Update See Summary of Revisions P. Konopka, FNA 2015 08 05 Released P. Konopka, FNA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 7 ADHESIVE, PERFORMANCE REQUIREMENTS FOR WSS-M11P66-
2、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 metal brackets to automotive glass. The adhesive materials may be pressure sensitive adhe
3、sive 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. 2. APPLICATION This specification is released for materials used to bond brackets for
4、 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 brackets used for rain sensors and GPS sensors. These products come to Ford as parts
5、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 SYSTEM COMPONENT REQUIREMENTS Performance and compatibility of the adhesive with base materials is the responsibility of the tier one supplier. In addi
6、tion to the requirements listed in 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. 3.2.1 Substrate Condition The bonding surface shall be f
7、ree from contaminates including but 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
8、and Control Plan. 3.2.2 Adhesive Measure 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
9、 been correlated to a recommend percent tape cure, then the curing cycles time and temperature are used as SCs (Significant Characteristics) to ensure the cure of the tape. If production settings affecting cure are changed from the initial approval, revalidation is required. ENGINEERING MATERIAL SPE
10、CIFICATION WSS-M11P66-A1 Copyright 2018, Ford Global Technologies, LLC Page 2 of 7 The process window for both tape and polyurethane adhesives must be defined per section 3.4. 3.2.3 Wet Out Requirement Samples for initial approval and production must have a minimum of 95% wetout. 3.3 PERFORMANCE REQ
11、UIREMENTS 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 represents the production process. The preparation procedure shall
12、 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 below shall conform to the following: No visible deterioration o
13、f 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 cracking after exposure due to thermal expansion differences bet
14、ween 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 perpendicular pull to the glass (pluck adhesion) force equivalent to
15、 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 conditions outlined below. The calculated load is also the minimum requi
16、rement 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 Specimens may be kept at -40 C overnight as necessary. After 4 cycles, condition 16 hours (minimum) at 23 +/-2 C & 50%+/-5% RH
17、then test to paragraph 3.3.1 (Pluck Adhesion) ENGINEERING MATERIAL SPECIFICATION WSS-M11P66-A1 Copyright 2018, Ford Global Technologies, LLC Page 3 of 7 3.3.1.5 Thermal Shock 4 cycles, maximum 1 minute between conditions, each cycle consisting of: 2 h at 88 +/- 2 C 4 h at -40 +/- 2 C 2 h at 88 +/- 2
18、 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 paragraph 3.3.1 (Pluck Adhesion) 3.3.1.6 Weathering Resistance 1
19、.5 x total weight, min Interior Exposure FLTM BO 116-01 3609.6kJ/m2 After exposure, condition for 16 hours (min.) at 23 +/-2C 50%+/-5% RH then test to para 3.3.1 (Pluck Adhesion) Required for initial approval only Position the bracket facing the light source during exposure. NOTE: Bond and test 3 br
20、ackets 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, etc. processes as the finished bracket. Test the bonding system
21、 once as proof for all applications. 3.3.2 Long Term Humidity Exposure Torque testing must utilize a fixture that engages the bracket to evenly distribute the torque over the entire bonding area. See Figure 2 for an example of a torque test fixture head. 3.3.2.1 Long Term Humidity Resistance with Lo
22、ad 800 hrs. (Bond 22 brackets to safety glass) Condition samples for 24 h at 23 +/- 2 C and 50 +/-5% RH after complete adhesive cure (3.2.2). Hang test specimens vertically at temperature and gently attach weights as specified in section 3.3 to each specimen. See example in Figure 1. Hold samples fo
23、r 800 hours at 50 +/- 2 C, 90% RH. All bonded assemblies must support the specified weight for a minimum of 800 hours. Torque samples to failure failure must be 100% CF, bracket breakage or glass breakage. 3.3.2.2 Torque Strength Bracket or Glass Breakage Bond 6 brackets (minimum) to safety glass) S
24、pecimens to be chosen at random from beginning, middle and end of production run. Condition samples for 24 h at 23 +/- 2 C and 50 +/-5% RH after complete adhesive cure (3.2.2). Torque all samples to failure and record values and failure modes. Compare torque values to 3.3.2.1 and record failure mode
25、s (must be 100% CF, glass or bracket failure). ENGINEERING MATERIAL SPECIFICATION WSS-M11P66-A1 Copyright 2018, Ford Global Technologies, LLC Page 4 of 7 3.4 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments (DOE) to determine the process window of the adhesive cure. The v
26、ariables/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 materials engineer. An initial screening experiment should be run to determine wha
27、t 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 spring load. Responses for the DOE shall include, but are not limited to, the f
28、ollowing: Adhesive Cure, para 3.2.2 Initial Pluck Adhesion, para 3.3.1.1 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 para 3.3 of this specification, with the DOE parameters above. Review DOE res
29、ults 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 applicable Glass Primer Surface Prep. Cure Mechanism ENGINEERING MATERIAL SPECIFI
30、CATION WSS-M11P66-A1 Copyright 2018, Ford Global Technologies, LLC Page 5 of 7 TABLE 1 All tests must be performed on full brackets unless otherwise specified. *DV: new adhesive bonding system, new bracket design or material, new bonding substrate (glass or frit). DV testing must be performed on ran
31、dom, non-sequential parts. PV testing must be performed on random, non-sequential parts selected from the beginning, middle, and end of a run. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact f
32、or questions concerning Engineering Material Specifications. 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of
33、their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Performance Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upo
34、n request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval w
35、as 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 Assistance (STA), Purchasing, and Materials Engineering a
36、ctivities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. No of specimens per test Required for Initial Approval Required for DV* Required for PV 3.2.2 Adhesive Cure (DSC) 6 6 3 3.2.3 Wet Out 6 6 3 3.3.1.1 Pluck (as received) 6 6
37、3 3.3.1.2 Pluck (- 40 C) 6 6 3.3.1.3 Pluck (88 C) 6 6 3.3.1.4 Thermal Cycling 6 6 3.3.1.5 Thermal Shock 6 6 3 3.3.1.6 Weathering Resistance 3 (may test plaques) 3.3.2.1 Long Term Humidity Resistance with Load 22 22 3.3.2.2 Torque Test 6 6 4.4 Torque Strength After Water Immersion N/A N/A N/A ENGINEE
38、RING MATERIAL SPECIFICATION WSS-M11P66-A1 Copyright 2018, Ford Global Technologies, LLC Page 6 of 7 For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approva
39、l Process (PPAP) sign off must be kept until Job 1. 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
40、-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. 4.4 WATER IMMERSION TORQUE STRENGTH Report This test is recommended as an initial screening to evaluate the system used to bond the bracket
41、. 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 at 50 +/- 2 C. Immediately upon removal from the water bath, apply torque in plane of glass. Torqu
42、e all samples to failure and record values and failure modes. Figure 1: Samples and weights attached. ENGINEERING MATERIAL SPECIFICATION WSS-M11P66-A1 Copyright 2018, Ford Global Technologies, LLC Page 7 of 7 Figure 2: Torque Test Fixture Head 5. Summary of Revisions 2018 04 25 Removed VOC testing 3
43、.3.1.6 Weathering Resistance updated to FLTM BO 116-01 3609.6kJ/m2 3.3.2.3 Moved Water Immersion Torque Strength to section 4.4 Test to be used as an initial screening test for the bonding system. Table 1 Specified DV test specimens must be random, non-sequential parts. PV test specimens must be random, non-sequential, and be chosen from the beginning, middle and end of a production run. Torque testing requirement moved from Initial Approval to PV. Added Figure 2 example of fixture to be used for torque testing.
