1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Ver 7 2016 06 08 Revised Seperated out A2 suffix J. Herl, EU 2015 04 15 A Active Move A suffix back to active status J. Herl, EU 1995 07 13 Activated N.E. Lindsay, G. A. Molnar Controlled document at www.MATS Copyright 2016, Ford Global Techn
2、ologies, LLC Page 1 of 12 ADHESIVE, HEM FLANGE, ALUMINUM BONDING, WSS-M2G373-A2 TWO COMPONENT 50 - 70 C GEL POINT NOT TO BE USED FOR NEW DESIGN 1. SCOPE The materials defined by these specifications are pumpable two-component, induction heat responsive structural adhesives with bondline spacers for
3、bonding metal. Full adhesive strengths are attained after an oven cure. The mixed adhesive performance for bonding aluminum and steel is defined as follows: A-series: Defines the mixed adhesive performance requirements for aluminum bonding: WSS-M2G373-A2: The mixed adhesive is room temperature curin
4、g or induction responsive. The ramped heat gel point is 50 - 70 C as defined by para 3.5.2. A heat induction process with induction coils covering a minimum of 85% of the adhesive bonding area is required to achieve acceptable adhesive bond durability. 2. APPLICATION These specifications were releas
5、ed originally for materials to structurally bond metal-to-metal body components such as the inner and outer panels (hem flange) of deck lids, doors, and hoods, etc. This adhesive can be used to bond oily, unclean metal substrates. Bondline spacers are added to one of the components to maintain a 0.2
6、5 mm bondline thickness during the hemming process. The Manufacturing Properties and Engineering Performance requirements defined in these specifications are based upon laboratory coupon testing and define the minimum acceptance criteria for adhesive performance. The assembly process and design for
7、the component will determine the specific adhesive processing parameters for each assembly line. The component engineering performance requirements are defined by the component SDS (Sub-system Design Specification). The materials are two component induction heat or room temperature cure responsive s
8、tructural adhesives. Reactivity build rate of the adhesive to generate required component handling strengths for manufacturing is a function of the assembly line processing conditions. Full adhesive strengths are attained after an oven cure. Recommended material oven cure schedules are minimum 171 C
9、 metal temperature for 10 minutes and maximum 205 C metal temperature for 30 minutes. Prior to use, the adhesive must be evaluated under the component production parameters. The choice of substrates, stamping lubricants, stamping plant processing conditions, assembly plant processing conditions and
10、specific design application may affect adhesive performance. Compliance with this specification does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must con
11、form to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATION WSS-M2G373-A2 Copyright 2016, Ford Global Technologies, LLC Page 2 of 12 3.4 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included
12、the substrate, stamping lubricants and adhesive. The originally approved material system was induction heated or room temperature cured followed by an oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions and assembly pla
13、nt processing conditions may affect adhesive performance. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. 3.5 MATERIAL PROPERTIES 3.5.1 Weight Per Volume +/- 0.06 kg/L (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.0
14、6 kg/L, based on the recorded weight of their original approved production sample. Reference para 5.1. 3.5.2 Cure Behavior (ASTM D 4473, 25 mm or 40 mm parallel plate with a 1.0 mm gap, Induction responsive materials - ramped heating at a 35 - 40 C/minute ramp rate over the temperature range 23 C to
15、 205 C, room temperature curing materials record at 23 +/- 2 C, Report gel point - inter-section of elastic (G) and viscous (G“) moduli) Room Temperature Induction Curing Responsive (Ramped Heat) WSS-M2G373-A2 Not Feasible 50 - 70 C The gel point tolerance for any one supplier shall be +/- 5 minutes
16、 for room temperature curing at 23 C and +/- 5 C for ramped heating, based on the recorded gel point of their original approved production sample. 3.5.3 Expansion No porosity or (Substrates per para 5.5, induction expansion heat per para 5.6.1 or room temperature cure per para 5.6.2, one panel each
17、substrate and cure) Extrude a 13 x 200 mm adhesive bead onto a 100 x 300 mm panel. Induction heat or room temperature cure. Place the test panel in an air circulating oven and bake at 205 +/- 2 C for 40 minutes oven time. After bake, condition test panel at 23 +/- 2 C for 1 h min. Cut the panel leng
18、thwise through the center of the adhesive. Examine the adhesive for any voids, porosity or expansion caused by entrapped air or internal gassing. ENGINEERING MATERIAL SPECIFICATION WSS-M2G373-A2 Copyright 2016, Ford Global Technologies, LLC Page 3 of 12 3.6 MANUFACTURING PROPERTIES 3.6.1 Rheology (S
19、AE J1524, rotational rheometer with 40 mm diameter parallel plates, 500 micron gap, 50 Pa/sec ramp, stress controlled rheometers use stress range 0 - 3500 Pa, strain controlled rheometers use strain range 0 - 100 s-1, evaluate material to highest stress or strain as the formulation will allow, repor
20、t material batch/lot number, identify rheometer make and model, for each test condition report yield stress and submit plots for shear stress vs. shear rate, submit plot for viscosity vs. temperature at mid-range shear rate, each component and mixed). Initial (as received) . Test at 23 +/- 2 C . Tes
21、t at application temperature +/- 2 C . Test over range 10 to 50 C at increments of 10 C Aged (age then test at 23 C and application temperature) . 7 d at 40 +/- 2 C . 90 d at 32 +/- 2 C The flow curves established for initial approval shall constitute the reference standard and shall be kept on file
22、 at the designated material laboratory. All samples shall produce flow curves that correspond to the reference standard when tested under the same conditions. Final approval of material rheology for production shipments shall be made by the affected manufacturing activity. In all cases, the rheology
23、 shall be within the limits as identified on the material control plan. 3.6.2 Sag Resistance/Flow Rate No measurable movement or flow, no loss of material 3.6.2.1 North American Production (FLTM BV 118-01, 6 mm diameter bead, substrates per para 5.5, room temperature cure per para 5.6.2, oven cure p
24、er para 5.6.3, one panel each bake) . Horizontal . Vertical . Inverted 3.6.2.2 European Production (FLTM BV 153-01, Method A, 8 mm diameter bead, substrates per para 5.5, room temperature cure per para 5.6.2, bake 30 minutes at 110 +/- 2C) ENGINEERING MATERIAL SPECIFICATION WSS-M2G373-A2 Copyright 2
25、016, Ford Global Technologies, LLC Page 4 of 12 3.6.3 Phosphate Wash Resistance No measurable movement, displacement or wash off. No dissolution of material or lifting from panel. 3.6.3.1 North American Production (FLTM BV 116-01, Method B, 1.5 mm material thickness, room temperature cure per para.
26、5.6.2 prior to test) 3.6.3.2 European Production Test Method: . Prepare a test panel (300 X 100 X 0.8 - 0.9 mm) according to FLTM BZ 150-11 oiling grade Normal. . Apply a ribbon of test material (250 x 30 x 5 mm) to the panel. . Condition for 2 h at 23 +/- 2 C. . Wash, phosphate and electrocoat the
27、test panel under current process conditions. 3.6.4 Electrocoat Compatibility (FLTM BV 119-01, use current production paints as identified by Materials Engineering, room temperature cure per para 5.6.2 prior to test) Shall not contaminate electrocoat primer bath or cause electrocoat film irregulariti
28、es. 3.6.5 Color Each component is distinctly different in color. The mixed adhesive is dark in color and shall meet manufacturing process control requirements. Final approval of material color for production shipments shall be made by the affected manufacturing activity. The material color for any o
29、ne supplier shall not visually deviate from the originally approved production sample. Reference para 5.3. 3.6.6 Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received, after storage, and mixed. 3.6.7 Material Consistency Shall be a smooth homogenou
30、s mixture, free from entrapped air, foreign materials and properties detrimental to normal production operation. ENGINEERING MATERIAL SPECIFICATION WSS-M2G373-A2 Copyright 2016, Ford Global Technologies, LLC Page 5 of 12 3.6.8 Volume Off-Ratio Mix Ratio Tolerance +/- 10% (SAE J 1523, Substrates per
31、para 5.5, 0.25 mm adhesive bondline thickness, 13 mm length overlap, 13 mm/minute pull rate, induction heat per para 5.6.1 or room temperature cure per para 5.6.2, oven cure per para 5.6.3, test at 23 +/- C) Test Method: . Prepare coupons using adhesive at nominal mix ratio, at +10% off-ratio and at
32、 -10% off-ratio. . Mix ratio by volume is determined by the following formulas: Volume A * 1.1 = RATIO at + 10% Volume A * 1.0 = RATIO at nominal, control Volume A * 0.9 = RATIO at - 10 % . Induction heat or room temperature cure. . Proceed with oven curing and testing. Overlap shear adhesive streng
33、ths for mix ratios conditions at +/- 10% shall meet the min requirement for 3.7.1.1 tested at 23 C and shall be no more that 10% lower than the strengths for the nominal mix ratio. 3.8.9 Adhesive Open Time, min 60 minutes (SAE J 1523, substrates per para 5.5, 0.25 mm adhesive bondline thickness, 13
34、mm length overlap, 13 mm/minute pull rate, induction heat per para 5.6.1 or room temperature cure per para 5.6.2, oven cure per para 5.6.3, test at 23 +/- C) “Adhesive Open Time“ for the assembly process is defined as the time interval between dispensing and hemming. Test Method: . Prepare coupons a
35、s described with the following exception: . Apply adhesive to coupons, let unmated coupons lay flat for 0, 15, 30, 45, 60, 75, and 90 minutes prior to mating with second coupon. . Induction heat or room temperature cure. . Proceed with oven curing and testing. Overlap shear adhesive strengths for op
36、en times up to 60 minutes shall meet the min requirement for para 3.7.1.1 tested at 23 C and shall be no more than 10% lower the strengths at 0 minutes open time. ENGINEERING MATERIAL SPECIFICATION WSS-M2G373-A2 Copyright 2016, Ford Global Technologies, LLC Page 6 of 12 3.6.10 Exposed Adhesion Stren
37、gth, min (SAE J1523, substrates per para 5.5, 0.25 mm adhesive bondline thickness, 13 mm length overlap, induction heat per para 5.6.1 or room temperature cure per para 5.6.2, 13 mm/minute pull rate) 3.6.10.1 Exposure after 1 h, min 8.0 MPa (Induction heat or room temperature cure, condition at 23 +
38、/- 2 C for 1 h, subject to environmental cycle and test at 23 C) 3.6.10.2 Exposure after 24 h, min 8.0 MPa (Induction heat or room temperature cure, condition at 23 +/- 2 C for 24 h, subject to environmental cycle and test at 23 C) Environmental cycle: -40 +/- 1 C for 7 d PLUS 40 +/- 1 C for 98 +/-
39、2% RH for 7 d PLUS 40 +/- 1 C for 7 d PLUS 23 +/- 2 C for 1 d 3.6.11 Creep Resistance, min (ASTM D 1780, substrates per para 5.5 0.25 mm adhesive bondline thickness, 13 mm bond overlap, induction heat per para 5.6.1 or room temperature cure per para 5.6.2, condition at 23 +/- 2 C for 72 h, test 205
40、C for 40 minutes oven time) Induction Heat No creep with dead load weight of 10 kg Room Temperature No creep with dead load weight of 5 kg 3.6.12 Storage Stability Heat greatly accelerates aging. The material shall be stored in closed containers away from all sources of heat. The shelf life of the m
41、aterial shall be 6 months when stored below 27 C. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature 24 h prior to application. Adequate conditioning permits the material to retain its optimum application properties. 3.7 ENGINEERING REQUIREMENTS
42、 3.7.1 Oven Cured Adhesion Strength, min (SAE J1523, Substrates per para 5.5, 0.25 mm adhesive bondline thickness, 13 mm length overlap, 13 mm/minute pull rate, induction heat per para 5.6.1 or room temperature cure per para 5.6.2, oven cure per para 5.6.3) ENGINEERING MATERIAL SPECIFICATION WSS-M2G
43、373-A2 Copyright 2016, Ford Global Technologies, LLC Page 7 of 12 3.7.1.1 Normal, min (Condition for 30 minutes at specified temperature prior to test) . Test at 23 +/- 2 C 10.0 MPa . Test at 82 +/- 2 C Aluminum 2.0 MPa Steel 5.0 MPa . Test at - 40 +/- 2 C 7.0 MPa 3.7.1.2 Exposed, min . Exposure aft
44、er 1 h 10.0 MPa (Induction heat or room temperature cure, condition at 23 +/- 2 C for 1 h, subject to environmental cycle, oven cure, test at 23 C) . Exposure after 24 h 10.0 MPa (Induction heat or room temperature cure, condition at 23 +/- 2 C for 24 h, subject to environmental cycle, oven cure, te
45、st at 23 C) Environmental cycle: -40 +/- 1 C for 7 d PLUS 40 +/- 1 C for 98 +/- 2% RH for 7 d PLUS 40 +/- 1 C for 7 d PLUS 23 +/- 2 C for 1 d 3.7.1.3 Aged, min (Condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2) . 10 Thermal Cycles 10.0 Mpa One Cycle: 90 +/- 1 C for 4 h PLUS 40 +/- 1
46、 C and 98 +/- 2% RH for 4 h PLUS -40 +/- 1 C for 16 h . 30 APGE Corrosion Cycles 10.0 Mpa (FLTM BI 123-01, Report after 10, 20 and 30 cycles) ENGINEERING MATERIAL SPECIFICATION WSS-M2G373-A2 Copyright 2016, Ford Global Technologies, LLC Page 8 of 12 One APGE cycle: 15 minute salt water immersion (5%
47、 salt solution) PLUS 1 h and 45 minute drip dry at 23 +/- 2 C PLUS 22 h at 50 +/- 2 C and 90 +/- 5% RH Samples are to remain in the 50 +/- 2 C and 90 % +/- 5 % environment over the weekends and holidays. . 500 h Salt Spray 10.0 MPa (ASTM B 117) . 2000 h Salt Spray, aluminum 10.0 MPa (ASTM B 117, alu
48、minum substrate only, report after 500, 1000, 1500 and 2000 h) 3.7.2 Peel Resistance, min Aluminum 50 N/25 mm (ASTM D 1876, substrates per para Steel 100 N/25 mm 5.5, induction heat per para 5.6.1 or room temperature cure per para 5.6.2, oven cure per para 5.6.3) 3.7.3 Cold Adhesion (FLTM BV 101-02,
49、 Procedure E, 0.51 mm material thickness, substrates per para 5.5, room temperature cure per para 5.6.2, oven cure per para 5.6.3) No cracking or adhesion failure 3.8 FUNCTIONAL APPROVAL Materials being evaluated for approval to these specifications shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to mate
