1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 08 03 N-STATUS Replaced by WSB-M2G388-A B. Witkowski 2003 02 26 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.3, 3.10, 3.11, 4 deleted 1996 05 21 Activated H. Kon, B. Curtiss Printed copies are uncontrolled Copyright 2007, Ford Global Techn
2、ologies, LLC Page 1 of 6 ADHESIVE - EPOXY BASED, STRUCTURAL, 10 - 40% EXPANDING, WSS-M2G337-B HEAT CURING, WELDABLE, IMPACT RESISTANT NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a pumpable epoxy resin base, high temperature heat curing, 10 - 40% expanding, st
3、ructural, weldable adhesives with improved impact and peel resistance properties. The material exhibits excellent strength retention through environmental exposures. 2. APPLICATION This specification was released originally to structurally weld-bond body-in-white parts. Applications include bonding
4、steel body structures such as wheelhouse outer to bodyside outer, cowltop inner to outer and pickup box front panel to front pillar extension. Optimal adhesion strengths are achieved with 0.25 mm adhesive bondline thicknesses. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Materi
5、al suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.5 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stamping lubricants and adhesive. The material system
6、 was oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may affect adhesive performance. If any of these parameters are changed, adhesive performance must be validated using the
7、 new parameters. 3.6 MATERIAL PROPERTIES 3.6.1 Solids, min 99% (ASTM D 2834, except heat for 3 h at 100 +/- 2 C in a mechanical convection oven; save samples for Ash Test, para 3.6.2) 3.6.2 Ash, max 30% (ISO 3491, Method A, 760 +/- 30 C) ENGINEERING MATERIAL SPECIFICATIONWSS-M2G337-B Printed copies
8、are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 6 3.6.3 Weight per Volume (ASTM D 816) The weight tolerance for any one supplier will be +/- 0.02 kg/L, based on the recorded weight of their original approved production sample. Refer to para 5.5. 3.7 MANUFACTURING PROPERTIES
9、3.7.1 Viscosity (FLTM BV 103-01, 2.64 mm orifice, 550 kPa pressure, Method A, test at 25 +/- 2 C) 3.7.1.1 As received +/- 4 s The viscosity tolerance for any one supplier will be +/- 4 sec based on the recorded viscosity of the originally approved production sample. Refer to para 5.5 for additional
10、information. 3.7.1.2 Aged, 7 days at 40 +/- 2 C 10% max increase from as-received viscosity 3.7.1.3 Aged, 90 days at 27 +/- 2 C 30% max increase from as-received viscosity Final approval of a specific material viscosity for production shipments will be made by the affected manufacturing activity. In
11、 all cases, the viscosity shall be within the specification limits as identified on the material control plan. 3.7.2 Sag Resistance (FLTM BV 118-01, 6 mm material thickness, substrate per para 5.2, material cure per para 5.3, one panel at each bake schedule) 3.7.2.1 Horizontal No measurable movement
12、 3.7.2.2 Vertical No measurable movement 3.7.2.3 Inverted No loss of material 3.7.3 Flow Phosphate Wash Resistance (FLTM BV 116-01, Method B, ribbon thickness 1.5 mm) No evidence of material wash-off or displacement due to precleaning or phosphating solutions in flow phosphate tanks. 3.7.4 Electroco
13、at Compatibility (FLTM BV 119-01, Use current production paints as identified by Materials Engineering) Must not contaminate electrocoat primer bath or cause electrocoat film irregularities ENGINEERING MATERIAL SPECIFICATIONWSS-M2G337-B Printed copies are uncontrolled Copyright 2007, Ford Global Tec
14、hnologies, LLC Page 3 of 6 3.7.5 Weld Acceptance Test Must Pass (FLTM BV 109-01, gun application, weld 25 coupon assemblies per condition) 3.7.5.1 As prepared (fresh material) 3.7.5.2 Assembly aged 30 days at 23 +/- 2 C 3.7.6 Flammability With Continuous Spot Welding (FLTM BV 114-01) During the weld
15、 tests, less than 5% of the welds will exhibit flame and all must be self-extinguishing within 30 s. 3.7.7 Quality Must be a smooth homogeneous mixture free from foreign materials and properties detrimental to normal production operations. 3.7.8 Abrasives None Test Method: Dilute a 1 g sample of the
16、 material with 1 g of M14J167 special spirits, and mix thoroughly. Rub a portion of the diluted material 100 times between two pieces of flat, clean plate glass. The appearance of scratches on the glass plate will be considered a failure. 3.7.9 Storage Stability Heat greatly accelerates aging. Mater
17、ial must be stored in sealed containers away from all sources of heat and sunlight. The shelf life of the material shall be 3 months from the date of manufacture when stored below 27 C. When material is stored at temperatures below 23 C, they must be conditioned at room temperature for 24 h prior to
18、 application. Application properties of the material are optimized with adequate conditioning. 3.8 ENGINEERING REQUIREMENTS 3.8.1 Peel Resistance (T-Peel) (ASTM D 1876, substrates per para 5.2, material cure per para 5.3, 76.2 mm overlap, 0.25 mm adhesive bondline) 3.8.1.1 Normal, N/m Condition for
19、30 minutes at specified temperature prior to test. No single test value to be less than specified limit. Test at 23 +/- 2 C 5000 ENGINEERING MATERIAL SPECIFICATIONWSS-M2G337-B Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 6 3.8.2 Shear Adhesion Strength, min
20、 (SAE J1523, 13 mm length overlap, 0.25 mm bondline thickness, 13 mm/min pull rate, substrates per para 5.2, material cure per para 5.3) 3.8.2.1 Normal, MPa (Condition for 30 minutes at specified temperature prior to test. No single test value to be less than specified limit.) Test at 23 +/- 2 C 15.
21、0 Test at 80 +/- 2 C 10.0 Test at -30 +/- 1 C 15.0 3.8.2.2 Aged, MPa (Condition for 24 h at 23 +/- 2 C after exposure, then test at 23 +/- 2 C. No single test value to be less than specified limit.) 2 weeks at 90 +/- 2 C 15.0 500 h salt spray (ASTM B 117) 12.0 30 APGE cycles, unstressed 12.0 (FLTM B
22、I 123-01, galvanized steel per para 5.2.2, cycles as follows) One APGE cycle: . 15 minute salt water immersion (5% salt solution), plus . 1 h 45 min drip dry at RT . 22 h at 50 +/- 2 C and 90 +/- 5% RH Samples are to remain in the 50 +/- 2 C and 90 +/- 5% RH environment over weekends and holidays. 3
23、.8.3 Tensile Properties (ASTM D 638, 3 +/- 0.5 mm thick, material cure on release paper between 3 mm aluminum panels for 30 min at 180 C material temperature, Type I specimen (W = 10 +/- 0.5 mm, G = 50 +/- 0.5 mm), condition at 23 +/- 2 C for 24 h, test at 23 +/- 2 C, 5 mm/min pull rate, use extenso
24、meter/strain gauge) 3.8.3.1 Elongation (at break), min 1.5% 3.8.3.2 Tensile Strength (ultimate), MPa 20 - 30 3.8.3.3 Modulus of Elasticity, min, GPa 0.6 3.8.3.4 Poissons Ratio 0.25 - 0.50 Actual material properties are temperature and formulation dependent. Results are on file with Materials Enginee
25、ring. ENGINEERING MATERIAL SPECIFICATIONWSS-M2G337-B Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 6 3.8.4 Cold Adhesion (FLTM BV 101-02, Procedure “E“, 0.5 mm material thickness, substrates per para 5.2, material cure per para 5.3) No cracking or adhesion f
26、ailure 3.8.5 Volume Expansion, % 10 - 40 (FLTM BV 108-02) 3.9 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification must be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results must be
27、 made available to Materials Engineering prior to material approval and release. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 MECHANICAL CONVECTION OVEN The mechanical convection oven(s) used to
28、 cure the material must be capable of achieving 205 C metal temperature on body steel (0.80 mm thickness) within 8 - 10 minutes. 5.2 SUBSTRATES 5.2.1 CRLC Steel meeting WSB-M1A250-B1: Nominal 0.80 mm thickness, surface precoated with stamping lubricant at a coating weight as specified by the respons
29、ible Materials Engineering Activity. 5.2.2 Galvanized steel meeting WSB-M1A250-C3-60G60G-EL: Nominal 0.80 mm thickness, surface precoated with stamping lubricant at a coating weight as specified by the responsible Materials Engineering Activity. 5.3 MATERIAL CURE SCHEDULES 5.3.1 Minimum: 170 C for 1
30、0 minutes metal temperature, not to exceed 20 minutes oven time. 5.3.2 Maximum: 205 C for 30 minutes metal temperature, for no less than 40 minutes oven time. 5.4 VISCOSITY, typical 43 s 5.5 WEIGHT PER VOLUME, typical 1.2 kg/L 5.6 COLOR, typical Black, Dark Grey ENGINEERING MATERIAL SPECIFICATIONWSS
31、-M2G337-B Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 6 of 6 5.7 IMPACT RESISTANCE, min, Total Energy 93 J (ASTM D 950, bondline 0.5 mm, material cure per para 4.3 except ensure bondline time at metal temperature. 3.4 m/s impact velocity, 93 J impact energy) 5.
32、8 IMPACT EQUIPMENT The impact equipment must be capable of measuring and reporting impact velocity, impact energy, time, load and total failure energy. Original specification values were developed using a Dynatup Model 8250 drop tower and Dynatup Model 730 instrumentation. A firing pin assembly (IDRa Model T9661) developed by Ireland, Donald R. and Associates was used in conjunction with the drop tower.
