1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2015 06 03 B. Witkowski, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 9 ADHESIVE, EPOXY, WELDABLE, THERMAL CURE, HEM FLANGE WSS-M2G393-A1 1. SCOPE The material defined by this specification
2、 is a pumpable, one component, thermal curing, weldable epoxy resin base, structural adhesive for aluminum and steel with bondline spacers for bonding metal in hem applications. This material has a lower modulus which may allow for better part processing during curing conditions. 2. APPLICATION This
3、 specification was released 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 the component
4、to maintain a 0.25 mm bondline thickness during the hemming process. 2.1 LIMITATIONS This material has not been evaluated for applications in vehicle body structure and proper DV/PV testing should be developed if these applications are considered. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specificat
5、ion requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Mate
6、rials Engineer. 3.2 CONDITIONING AND TEST CONDITIONS All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after
7、 removal, some portions of this specification indicate alternative conditioning. 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms from initial material approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. T
8、he material supplier shall ensure that all future material supplied to the specification shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 RHEOLOGY Suppliers must submit flow characterization data to Ford Motor Company for f
9、low modeling and process window determination. For a specified temperature range, the requested properties include, but are not limited to, viscosity, yield stress, apparent activation energy for viscosity and apparent activation energy for yield stress. This data constitutes the referenced standard
10、 and shall be kept on file at the designated material laboratory. ENGINEERING MATERIAL SPECIFICATION WSS-M2G393-A1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 9 3.5 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stampi
11、ng lubricants and adhesive. The material system 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, t
12、he adhesive performance must be validated using the new parameters. 3.6 MATERIAL PROPERITIES 3.6.1 Solids 99% min (ASTM D 2834, except heat for 3 h at 102 +/- 3 C in a mechanical convection Oven, save sample for next test) 3.6.2 Ash +/- 3% (ISO 3491, Method A, 760 +/- 30 C ) The ash tolerance for an
13、y one supplier shall be +/- 3%, based on the recorded ash of their original approved production sample. Reference para 4.3. 3.6.3 Weight Per Volume Report (ASTM D 816) Weight tolerance for any one supplier shall be +/- 0.02 kg/L, based on the recorded weight to their original approved production sam
14、ple. Reference para 4.2. 3.6.4 Bondline Spacers Material shall contain spacers to allow a bondline gap of 0.25mm 3.7 MANUFACTURING PROPERTIES 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, Report The viscosity tolerance
15、for any one supplier shall be +/- 4 s, based on the recorded viscosity of the original approved production sample. Reference para 4.1 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 a
16、pproval of a specified material viscosity for production shipments shall be made by during material trial, preferably at equipment suppliers lab testing. In all cases, the viscosity shall be within specification limits as identified on the material control plan. 3.7.2 Differential Scanning Calorimet
17、ry, Onset of reaction, min 80 C (20 +/- 1 mg sample size, 5 C / min heating rate, 25 - 250 C temperature range, ENGINEERING MATERIAL SPECIFICATION WSS-M2G393-A1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 9 Submit Heat Flow vs. Temperature curve) 3.7.3 Sag Resistance (FLTM BV 11801, 6 mm
18、 material thickness, substrates per para 4.4, oven schedule per para 4.5, one panel each bake) Horizontal No measurable movement Vertical No measurable movement Inverted No loss of material 3.7.4 Slump Resistance Test Assembly: Two 25 x 100 mm coupons, substrates per para 4.4, with two 38 x 12 x 3 m
19、m spacers. The spacers are placed at each end of one of the coupons, and sufficient adhesive is applied between the spacers to fill the gap. The second coupon is placed on top of the adhesive and spacers (Figure 1). Clamp the assembly with spring clips at each end. Remove excess adhesive from all ex
20、terior edges with a spatula. Test Method: Prepare 3 assemblies per substrate. Subject one assembly per substrate to exposures. After exposure, condition assemblies at 23 +/- 2 C for 24 hours, then bake at minimum bake per para 4.5. Determine the slump by measuring adhesive loss from the bottom of th
21、e assembly. Record observations of any adhesive loss after exposure or after bake. Repeat the above procedures for maximum bake per para 4.5. 3.7.4.1 Aged at 24 h at 23 +/- 2 C 3 mm max (Method and Assembly per 3.7.4) 3.7.4.2 Aged at 30 days at 23 +/- 2 C 3 mm max (Method and Assembly per 3.7.4) 3.7
22、.4.3 Aged at 30 days at 50 +/- 1 C 3 mm max (Method and Assembly per 3.7.4) 3.7.5 Bridging 3 mm max (SAE J243 ADS-9, Section 3.4, Method D,nonflow fixture, substrates per para 4.4, bake conditions per para 5.5) 3.7.5.1 Aged at 24 h at 23 +/- 2 C 3 mm max (Method and Assembly per 3.7.4) 3.7.5.2 Aged
23、at 30 days at 23 +/- 2 C 3 mm max (Method and Assembly per 3.7.4) 3.7.5.3 Aged at 30 days at 50 +/- 1 C 3 mm max (Method and Assembly per 3.7.4) 3.7.6 Wash Resistance No measurable movement, (FLTM BV 116-01, Method A, displacement or wash-off. 1.5 mm material thickness, substrates per para 4.4) ENGI
24、NEERING MATERIAL SPECIFICATION WSS-M2G393-A1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 9 3.7.7 Electrocoat Compatibility (FLTM BV 119-01, use current production paint as identified by Material Engineering, substrates per para 4.4) Shall not contaminate electrocoat primer bath or cause
25、electrocoat film irregularities. 3.7.8 Odor 3.7.8.1 Cured Odor Rating 3 max (FLTM BO 131-03, method D) 3.7.8.2 Uncured Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.7.9 Material Consistency Shall be a smooth homogenous
26、mixture, free from entrapped air, foreign materials and any properties detrimental to normal production operation. 3.7.10 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 material shall be 3 month
27、s from date of manufacture when stored below 27 C. If stored at 4 C, the shelf life is extended to 6 months. When materials are stored at temperatures below 23 C, they shall be conditioned at room temperature 24 hours prior to application. Application properties are optimized with adequate condition
28、ing of the material. 3.7.11 Pumpability/Dispense Capability Materials being considered for approval to this specification shall be evaluated for processing capability using extrusion, stream and swirl methodologies. The pumpability/dispense capability report must be approved by the affected assembly
29、 operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. Materials shall be a smooth homogenous mixture, free from entrapped air, foreign materials and properties detrimental to normal production operation. The material shall
30、 work with all the plant processes (cleaning operations, phosphating process, welding operations, etc.) and shall not deteriorate the performance of phosphating, electrocoat primer or other materials applications. All bulk mastic, sealer or adhesives packaged in minitotes will be returned to the sup
31、plier with some residual material in the bottom of the container from the initial fill. It is understood that the residual materials will be the base of the next refill and will not affect the quality of the refilled certified product and supplier shall demonstrate via testing of retain materials of
32、 production lots of materials to support the above, the ratio of old to virgin material should be tested at a ratio of 10 old to 1 part by weight new, and other ratios defined at approval. Supplier shall present data to manufacturing and materials engineering prior to approval, as well as data showi
33、ng compatibility with process aids used in mini-tote assembly (i.e. seal lubricants.) For minitote system information, the VO procedure should be reviewed as master for the process, reference(VOPGNN002). 3.8 ENGINEERING REQUIREMENTS 3.8.1 Adhesion Strength, (SAE J1523, substrates per para 4.4, 0.25
34、mm adhesive bondline thickness, 13 mm length overlap, 13 mm/min pull rate, oven cure per para 4.5) ENGINEERING MATERIAL SPECIFICATION WSS-M2G393-A1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 9 3.8.1.1 Normal (Condition for 30 minutes at specified temperature prior to test) Test at 23 +/
35、- 2 C 13.0 MPa min Test at 82 +/- 2 C 11.0 MPa min Aluminum at 82 +/- 2 C 2.0 MPa min Test at -40 +/- 2 C 14.0 MPa min 3.8.1.2 Exposed 11.0 MPa min (Condition at 23 +/- 2 C for 1 h, subject to environmental cycle, oven cure per para 4.5, test at 23 C) Environmental cycle: -40 +/- 1 C for 7 days PLUS
36、 38 +/- 1 C for 98 +/- 2% RH for 7 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for 1 day 3.8.1.3 Aged 13.0 MPa min (Condition at 23 +/- 2 C, expose 10 thermal Cycles, 24 h after exposure, test at 23 +/- 2 C) One Cycle: 90 +/- 1 C for 4 h PLUS 38 +/- 1 C and 98 +/- 2% RH for 4 h PLUS -40 +/- 1C f
37、or 16 h 3.8.2 Stress Durability 40 +/- 1% load, 10 cycles min (FLTM BV 101-07, galvanized and hot dipped steel per para 4.4, all coupons from one manufacturers lot, report thickness for each coupon and substrate yield strength for manufacturers lot, material cure 30 minutes at 180 +/- 2 C, two fixtu
38、res, cyclic corrosion exposure, report data per test method) All samples at a specified load shall meet the minimum amount of cycles at 40% of failure load established for unexposed samples. Supplier shall run testing beyond the minimum number of cycles to demonstrate compliance. 3.8.3 Peel Resistan
39、ce (ASTM D 1876, galvanized steel and aluminum per para 4.4, Condition at 23 +/- 2 C for 24 h, oven cure per para 4.5) 3.8.3.1 As received 2000 N/m min 3.8.3.2 Assembly aged prior to bake at 38+/- 2 C, 95+/- 5% for 30 days, then oven cure per para 4.5) 2000 N/m min 3.8.3.3 Peel resistance at 82C 125
40、0 N/m min 3.8.3.4 Peel resistance at -40C 2000 N/m min 3.8.4 Cold Adhesion No adhesion failure or material cracking. (FLTM BV 101-02, Procedure “E“, 0.51 mm material thickness, substrates per para 4.4, oven cure per para 4.5) ENGINEERING MATERIAL SPECIFICATION WSS-M2G393-A1 Copyright 2015, Ford Glob
41、al Technologies, LLC Page 6 of 9 3.8.5 Tensile Properties (ASTM D638, 3 +/- 0.5 mm thick, cure on release paper between 3 mm aluminum panels for 30 minutes 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
42、 pull rate, use extensometer or strain gage, test at 40, 23, and 80 +/- 2 C) 3.8.5.1 Modulus of Elasticity 1.3 GPa max 3.8.5.2 Elongation at Break 10.0% min 3.8.5.3 Poissons Ratio 0.10 0.48 3.8.6 Fracture Toughness, 0.3 kJ/m2 min (FLTM BU 121-01, 2 m/s Velocity, cure per 4.5) EG and HD substrates on
43、ly 3.9 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification 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 mat
44、erial approval and release. 3.10 TESTING TO FAILURE Suppliers must submit a mutually agreed upon testing to failure workplan for a material source approval. The workplan is to state the number of samples to be tested, the environmental conditions for testing and dates for periodic review of the test
45、 data with Materials Engineering. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 VISCOSITY 43 s typical as received 4.2 WEIGH
46、T PER VOLUME 1.26 kg/L typical 4.3 ASH 15% typical 4.4 SUBSTRATES Currently released HD, EG, and CRS materials, 0.8 mm thickness. Nominal 0.8 mm thickness, coated per WSS-M1P94-A to coating weight 50G50G-EL and 50G50G-HD, panels electro-coated steel panels prepared per WSS-M3P1-D using current produ
47、ction paints as specified by Materials Engineering. Aluminum Substrates: Currently released, nominal 0.9 mm thickness. Adhesive performance may be significantly influenced by aluminum alloy and surface pretreatment. A supplier is recommended to evaluate the adhesive on the production aluminum alloy,
48、 nominal 0.9 mm thickness, with the production surface pretreatment, if any specified, prior to production release. All test data shall be submitted to Materials Engineering. All related materials used for approval of adhesive/polymer according to this specification, eg. Paint materials or metallic
49、substrates, shall be note in the initial sample report of the adhesive/polymer/ part. 4.5 MATERIAL CURE SCHEDULES (FLTM BV 150-05, use table for appropriate regional vehicle assembly site, cure material per ENGINEERING MATERIAL SPECIFICATION WSS-M2G393-A1 Copyright 2015, Ford Global Technologies, LLC Page 7 of 9 material application “Prior to Electrocoat“, min and max bake, condition at 23 +/- 2 C for 1 h min. pr
