1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 05 26 Activated J. Crist Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 9 SEALER, HEAT EXPANDING, LOWER EXPANSION, HIGH TEMPERATURE WSS-M18P19-A CURE, NON WELDABLE, PERFORMANCE REQUIREMENT 1. SCOPE
2、 The material defines the performance requirements for a die cut, injection molded, or extruded sealer that expands upon exposure to heat. This material can be supplied with or without a pressure sensitive adhesive coating (PSA) or a release liner. 2. APPLICATION This specification was originally re
3、leased for materials used to isolate bodyside strainers, seal fuel fillers, and roof bows from exterior sheet metal panels. The material can be supplied with or without an aggressive pressure sensitive adhesive which promotes adhesion to oily, uncleaned cold rolled and galvanized steel. This materia
4、l expands during the electrocoat bake schedules per para. 4.2. Material cure is critical to long term material performance. It is recommended that time/temperature data packs be placed on a vehicle in the intended locations to determine the time at temperature requirements for a given application pr
5、ior to release. The on-vehicle material time at electrocoat oven temperatures must fall within the cure window for the approved material. After release, periodic follow-up time/temperature checks are recommended to insure cure performance is maintained. The Manufacturing Properties and Engineering P
6、erformance requirements defined in these specifications are based on laboratory sample testing and define the minimum acceptance criteria for adhesive/polymer material performance. The function and design requirements for the engineered part are defined by the component SDS (Sub-system Design Specif
7、ication), key life test requirements, or vehicle program requirements. Prior to use, the engineered part must be evaluated under the intended application processing parameters. The choice of substrates, stamping lubricants, stamping and assembly plant processing conditions and specific design applic
8、ation may affect engineered part performance. Compliance with this specification does not guarantee the engineered part will function for all potential applications on a vehicle. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 STANDARD R
9、EQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2
10、 of 9 3.2 SYSTEM COMPATIBILITY Initial material approval was based on a specific material system which included the substrate, stamping lubricants and adhesive/polymer. The originally approved material system was oven cured using specific production process parameters. The choice of substrates, stam
11、ping lubricants, stamping and assembly plant processing conditions and specific design application may affect adhesive/polymer/engineered part performance. If any of these parameters are changed, the material performance must be validated using the new parameters. 3.3 DIMENSIONS Cross sections/dimen
12、sions for tape shall be specified on the engineering drawing. 3.4 MATERIAL PROPERTIES 3.4.1 Density +/- 0.1 kg/m3 (ISO 845/ASTM D 3574, cured per para 4.2, Test A, interior density) The density variation for any one supplier shall be +/- 0.1 kg/m3, based on the recorded density of their original app
13、roved production sample. 3.4.2 Water Absorption, max 5% (FLTM BV 117-01, Method A, 8 h soak time, cure material per paragraph 4.2) 3.4.3 Volume Expansion, min (FLTM BV 108-02, material cure per para 4.2) 3.4.3.1 Minimum bake 200 - 450% 3.4.3.2 Maximum bake 200 - 450% The volume change variation for
14、any one supplier shall be +/- 25%, based on the recorded volume change of their original approved production sample. 3.4.4 Volatile Organic Compounds (VOC) Content, kg/L Report (EPA Method 24, Procedure B) The VOC Content variation for any one supplier shall be +/- 0.05 kg/L, based on the recorded V
15、OC Content of their original approved production sample. 3.4.5 Hardness, Durometer “D“ 20 - 35 (ASTM D 2240, reading after 15s, cure per para. 4.2) ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 9 3.4.6 Cure Requ
16、irements Report (Define the process cure window for material cure, Report minimum and maximum time at temperature requirements to define performance boundaries) Critical performance characteristics shall include, but are not limited to, the following: Volume Expansion, para 3.4.3 Adhesion, para 3.5.
17、6 Shear Adhesion Strength para. 3.6.3.1 3.5 MANUFACTURING PROPERTIES 3.5.1 Differential Scanning Calorimetry Report (10 +/- 1 mg sample size, 5 C/min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) Report onset of reaction 3.5.2 Bridging, max 3 mm (SAE J243, ADS-9
18、, Section 3.3, Method D, non-flow fixture, substrates per para 4.1, cure conditions per para 4.2) 3.5.3 Sag Resistance 3 mm (FLTM BV 118-01, substrates per para. 4.1, cure conditions per para 4.2) 3.5.4 Phosphate Wash Resistance (For PSA/Tacky only) (FLTM BV 116-03, 2000 psi, 23 C, substrates per pa
19、ra 4.1) Panel Preparation: Cut a 100 x 150 strip at production thickness of and apply a 300 x 300 mm panels prepared for each substrate per para 5.1. Pass a 2.2 kg roller over samples per ASTM D1000. Condition at 23 +/- 2 C for 1 hour prior to performing wash test. 3.5.5 Electrocoat Compatibility Mu
20、st Pass (FLTM BV 119-01, use current production paints as identified by Materials Engineering) Shall not contaminate electrocoat primer bath or cause electrocoat film irregularities. ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologi
21、es, LLC Page 4 of 9 3.5.6 Uncured Adhesion (PSA/Tacky only) Test Method: Prepare four panels for each substrate per para 4.1. Cut four 100 x 150 x 4 mm strips of the material and apply to four 300 x 300 mm panels prepared for each substrate per para 4.1. Pass a 2.2 kg roller over samples per ASTM D1
22、000. Invert two panels immediately after material application and condition for 72 h at 40 C. Observe for peeling or lifting of adhesive/polymer from panel or slump or sag between attachments, as appropriate. Stand the remaining two panels vertically immediately after material application and condit
23、ion for 72 h at 40 C. Observe for peeling or lifting of material from panel or slump or sag between attachments, as appropriate. 3.5.7 Adhesion Characteristics Test Method: Apply two 200 mm length ribbons of material to each of two 0.89 x 100 x 300 mm steel per para 4.1 and condition panels at 23 +/
24、-2 C for 1 h. Bake one panel at min and max bake per para 4.2. Position panels in a horizontal attitude during bake. After bake, condition panels at 23 +/-2 C for 4 h min. Evaluate adhesion by inserting the top of a sharp spatula under the end of the material strip. Grasp the tab of sealer and attem
25、pt to peel 180. The material shall not be removable in a continuous coherent film. Observe for any indication that the material fails to adhere to the substrate or is brittle. 3.5.8 Release Paper Adherence and Removal (Pressure Sensitive/Tacky Materials only) The release paper must remain attached t
26、o the adhesive/polymer surface during shipment and handling. It must be easily removed from the adhesive/polymer without part distortion or paper tear at ambient plant conditions (7 to 38 C). Final approval for the release paper may be part and plant specific. Release paper information shall be note
27、d in the supplier control plan. 3.5.9 Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 9
28、3.5.10 Storage Stability 6 Months Heat and moisture will accelerate aging. The materials shall be stored in sealed packages (if so recommended by the supplier) away from all sources of heat and moisture. The shelf life of the material shall be 6 months from date of manufacture when stored at tempera
29、tures below 32 C. Ambient plant conditions may fluctuate between 15 C and 38 C. Materials shall be evaluated for local plants conditions to determine plant specific requirements for temperatures in excess of 32 C. Deviations from the shelf life requirement shall be identified and concurred upon by t
30、he plant and noted in the supplier control plan. When materials are stored at temperatures below 23 C, they shall be conditioned at room temperature for a minimum of 24 hours prior to application. Application properties are optimized with adequate conditioning of the material. Critical performance c
31、haracteristics to evaluate for shelf life stability shall include, but are not limited to, the following: Volume Expansion, para 3.4.3 Uncured Adhesion, para 3.5.6 Adhesion Characteristics, para 3.5.7 Release Paper Adherence and Removal, para 3.5.8 Shear Adhesion Strength para. 3.6.3.1 3.6 ENGINEERI
32、NG REQUIREMENTS 3.6.1 Vertical Expansion (Ramp Expansion, SAE J1918, Method #3, cure material per para 4.2) 3.6.1.1 Minimum bake Report 3.6.1.2 Maximum bake Report The Vertical Expansion variation for any one supplier shall be +/- 25%, based on the recorded Vertical Expansion of their original appro
33、ved production sample. ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 9 3.6.2 Corrosion Resistance Test Method: Place a 39 cm2area section of production material (2.5mm thickness) on each of two 150 x 75 mm steel
34、 panels, substrates per para. 4.1 (EL & HD only). Cover the material with an identical steel panel and clamp in position with 2.5mm thick spacer. Cure test panels in a mechanical convection oven per para. 4.2, min and max bake. Remove clamps and subject the cured assemblies to the following exposure
35、 then separate assemblies and evaluate: After APGE cycles There shall be no (FLTM BI 120-01) corrosion beneath original material contact area Report after 10, 20 and 30 cycles One APGE cycle: 15 min salt water immersion (5% salt solution) 1 h at 45 min drip dry at 23 +/- 2 C 22 h at 50 +/- 2 C and 9
36、0% +/- 5% RH Samples are to remain in the 50 +/- 2 C and 90% +/- 5% environment over the weekends and holidays 3.6.3 Shear Adhesion Strength, kPa (SAE J1523, Material thickness 2.5 mm, bondline thickness 2.0 mm, 25 mm overlap, substrates per para. 4.1 (For NA, EL & HD only), material cure per para.
37、4.2) 3.6.3.1 Initial- 24 h at 23 +/- 2 C 600 min 3.6.3.2 14 days at 83 +/- 2 C Retain greater than 70% of initial (3.6.3.1) 3.6.3.3 14 days at 38 +/- 1 C and 95 - 100 % R.H. Retain greater than 70% of initial (3.6.3.1) 3.6.3.4 30 Cycles APGE Retain greater than (FLTM BI 120-01) 70% of initial (3.6.3
38、.1) Prepare five samples per exposure per bake schedule. After curing, condition coupons for 24 h at 23 +/- 2 C. Prior to beginning exposure tests. Test Method: Subject test assemblies to exposures noted. After completing exposure, the test specimens shall be conditioned at 23 +/- 2 C for a minimum
39、of 2 h and a maximum of 3 h prior to testing on a tensile machine at a jaw separation rate of 25 mm/min. ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 7 of 9 3.6.4 Fuel Resistance, kPa 350 min After a controlled imme
40、rsion in ASTM Type “B“ fuel (ASTM D 471-98, Table 3) and diesel fuel and recovery at 23 +/- 2 C, the minimum adhesion value for overlap shear samples shall be 350 kPa. Test Method: Prepare overlap shear test samples as described in 3.6.3. Test five samples from each cure schedule in ASTM type “B“ fu
41、el, and five from each schedule in diesel fuel. Immerse total bonded area of all samples in each type of fuel. NOTE: Because of precise time constraints for immersion, recovery and tensile period, store samples in a panel rack in testing, it is recommended each fuel type be tested separately. Vessel
42、s containing fuel should be maintained at 23 +/- 2 C. All fuel work should be conducted in a laboratory hood. Samples to be immersed for 2 h. Remove samples from fuel immersion and condition 4 h at 23 +/- 2 C. After conditioning period, test samples immediately on a tensile test machine at a jaw sep
43、aration rate of 25 mm/min. The 10 samples should be tested within 15 minutes of completing conditioning. 3.6.5 Cold Slam Resistance No cracking or (FLTM BV 101-02, Procedure E, 300 x 300 mm panel for Delamination each substrate per para 4.1, cured per para. 4.2, 4 mm cured material thickness, condit
44、ion for 4 h minimum at -40 +/- 2 C prior to testing, test at -40 C for 10 slams) Sample preparation: Apply a 150 x 150 mm piece of material on a 300 x 300 mm panel. Material thickness to be determine by minimum expansion assumption used for engineering part design. Pass a 2.2 kg roller per ASTM D 10
45、00 over sample within 15 minutes of patch application. Cure between aluminum plates lined with release paper or in a fixture to maintain a 4 mm cured material thickness. Initial ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, L
46、LC Page 8 of 9 3.6.6 Water Tightness No leaks visible through sealer or between sealer substrate surface within 2 hours. Test Method: Use two 75 x 150 mm CRS steel panels. Form one of the panels into the configuration shown below. Place a 12 x 150 x 1.5 mm strip of material on the 15 mm area of the
47、formed panel. Weld this panel to the flat panel placing one weld at each end (12 mm from the edge). Immerse the entire fixture into a 50 C constant temperature water bath for 20 minutes. Remove from bath and bake at material cure schedules per para 4.2. The fixture should remain in an upright positi
48、on (i.e. funnel end up) during the baking process. After bake, condition at 23 +/- 1 C for 1 h. Seal each end of the funnel end of the fixture to form a trough. Place fixture in a vise grip, trough side up. Fill the trough with water at 23 +/- 1 C. Aim a 5 mm diameter air nozzle set at 0.2 MPa line
49、pressure into bottom of fixture and make lengthwise passes along bondline for 30 seconds. Hold air nozzle approximately 25 mm from bottom of fixture. No air should pass through sealer material. Allow fixture to sit for 1 hour at 23 +/- 1 C while watching for water leaks at bottom of fixture. ENGINEERING MATERIAL SPECIFICATIONWSS-M18P19-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 9 of 9 3.7 SPONGE AND CELL STRUCTURE AFTER CURE Shall exhibit uniform cell structure
