1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2018 06 13 Released P. Konopka, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 8 ADHESIVE, MOISTURE CURING URETHANE, TWO COMPONENT, WSS-M2G41-A1 PRIMERLESS TO ELECTROCOAT, HIGH MODULUS 1. SCO
2、PE The material defined by this specification is a two component moisture curing urethane adhesive which is primerless to electrocoat chemistries. This material is designed to be used in hidden areas not exposed to direct sunlight. This material is not intended to be bonded directly to glass. 2. APP
3、LICATION This specification was released for bonding a moon roof module electrocoated frame to an electrocoated body. The material will bond primerless to e-coated surfaces that are contaminate free and can also be used in conjunction with metal flange primers. 2.1 MANUFACTURING PROCESS RECOMMENDATI
4、ON These adhesives are moisture sensitive and require special handling for manual and automated process. Mix ratio shall be as recommended by the material supplier and testing to be performed with recommended mix ratio unless otherwise stated. Approved suppliers are responsible for maintaining the a
5、ccuracy and relevancy of these process parameters (in their Process Standard). Approved suppliers must submit any changes to these process parameters in a timely manner (within 30 days) for review and approval by Materials Engineering, Vehicle Operations, and Product Development Engineer. 3. REQUIRE
6、MENTS 3.1 APPROVED SOURCES This specification 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 o
7、r available externally through a Ford Materials Engineer. 3.2 UNCURED ADHESIVE PROPERTIES 3.2.1 Viscosity at 23 C (Rotational Rheometer) Tempering Time: 300 s Pause Interval: 180 s at 131 1/s Downward Measure: 131 1/s - 20 1/s in 120 s (30 Measure Points) Viscosity (Pa.s) Yield Point (Pa) 3.2.1.1 As
8、 received Component A 35.0 45.0 1500 2500 Component B 15.0 25.0 2000 3000 3.2.1.2 After Aging, 5% change after aging, max. (336 h at 30 +/- 2 C) ENGINEERING MATERIAL SPECIFICATION WSS-M2G41-A1 Copyright 2018, Ford Global Technologies, LLC Page 2 of 8 3.2.2 Rheology (Component A and B) (SAE J1524, co
9、ne and plate 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 sec-1, evaluate material to highest stress of strain as the formulation will allow, report mate
10、rial 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. 3.2.2.1 Initial (as received) Test at 23 +/- 1 C Test at application temperature +/
11、- 2 C Test over range 10 to 50 C at increments of 10 C 3.2.2.2 Aged (Age then test at 23 C and application temperature) 7 days at 40 +/- 1 C 90 days at 32 +/- 1 C The rheology variation for any one supplier shall be +/- 30%, based on the recorded rheology of the original approved production sample.
12、The flow curves established for initial approval shall constitute the reference standard and shall be kept on file 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
13、rheology for production shipments shall be made by the affected manufacturing activity. In all cases, the Rheology shall be within the limits as identified on the material control plan. 3.2.3 Solids 97% min (ASTM D2834, except heat for 3 h at 100 +/- 3 C in a mechanical convection oven or FLTM BV 15
14、0-10 ) 3.2.4 Ash, based on solids weight A Comp: 0.9% max (ASTM D482, or FLTM BV 150-10) B Comp: 47 % max 3.2.5 Weight per Volume (ASTM D816) Component A Isocyanate: 1.19 +/- 0.02 kg/L Component B Resin: 1.45 +/- 0.02 kg/ 3.2.6 Sag 20 mm max Test Method: Apply a 76 mm long right triangular shaped be
15、ad of material 6 mm wide at the base And 15 mm high on a glass or steel panel. Permit the panel to air dry for 30 minutes at 23 +/- 2 C triangle form, 9 mm base and 13 mm height) of material under test to a 100 x 300 x 0.8 mm ecoat panel and check for correct weight of applied bead of adhesive. 2 mi
16、n after application assemble with a 100 x 300 x 0.8 mm ecoat panel to a bead thickness of 4mm and fix in that position for 10 s. Assemble test specimens with one each of both production ecoat substrates. Remove distance spacers and turn assembly to vertical position and fix one glass plate, add a we
17、ight to lower glass specimen to a total weight force of 8 N and measure the slippage after 2 h. Record all details of measurements and material under test. ENGINEERING MATERIAL SPECIFICATION WSS-M2G41-A1 Copyright 2018, Ford Global Technologies, LLC Page 4 of 8 3.0 CURE RATE PROPERTIES 3.3.1 Tack Fr
18、ee 60 minutes max A 150 mm long and 6 mm diameter bead shall be tack free in 60 minutes max and cured after 72 h at 23 +/- 2 C, 50% +/- 5% R.H. Apply beads of adhesive to a clean ecoated panel. Touch the bead gently using a cotton swab for tack free test. Cut the bead using a sharp razor blade for c
19、uring test. 3.3.2 Sandwich Tensile Pull Strength Versus Cure Time Cure Time Sandwich Tensile Pull Strength 1.5 hours 150 kPa min 3.0 hours 200 kPa min 6.0 hours 900 kPa min 24.0 hours 1.5 MPa min 72.0 hours 2.5 Mpa min Test Method: Sandwich Tensile Pull Strength . Prepare a minimum of 3 sandwich ass
20、emblies for each cure time tensile pull strength test as per Figure 1. . Apply a 50 mm long by 6.4 mm diameter bead of adhesive to a clean ecoated panel, as illustrated. Within 5 minutes after adhesive application, position the adhesive on the ecoated coupon in contact with the opposing ecoated surf
21、ace. Assemble test specimens with one each of both production ecoat substrates. Maintain a 3 mm nominal adhesive bondline thickness. . Condition the assemblies at 23 +/- 2 C fixed strain of 0.5% at 1 Hz frequency. 3.5 CURED MATERIAL PERFORMANCE PROPERTIES 3.5.1 Green Strength 0.1 MPa min Test Method
22、: Prepare test specimens per SAE J1529, or FLTM BV 154-03, section B, para. 1 and 2 except maintain a 3 mm nominal adhesive bondline thickness. Test specimens shall be assembled from one type of ecoat. Both types of ecoat must be tested. Cure test specimens for 3 h at 23 +/- 2 C and 50 +/- 5% RH. De
23、termine shear strength according to para 3.5.2. 3.5.2 Shear Adhesion 5.0 MPa (3.0 MPa at 90 C) min Prepare ecoat shear assemblies per SAE J1529 or FLTM BV 154-03 section B, para. 1 and 2. Test specimens shall be assembled from one type of ecoat. Both types of ecoat must be tested. Tests to be perfor
24、med at recommended mix ratio, +/- 5% and +/-10%. Evaluate at recommended mix ratio, report at +/- 5% and +/-10%. Maintain a 3 mm nominal adhesive bondline thickness. Determine the shear adhesion in a tensile machine having a jaw separation rate of 25 mm/minute. A minimum of 5 specimens shall be test
25、ed for each condition. Report individual values and failure modes. No single value allowed below 5.0 MPa (3.0 MPa at 90C). The material shall exhibit 100% cohesive failure of the urethane to production pretreatment and electrocoat except paint delamination is allowed at -40 C at values above 5.0 MPa
26、. -40 C 23 C 50 C 80 C Tensile at break, MPa min 8.0 8.0 7.0 5.0 Tensile Modulus MPa 30.0-40.0 20.0-25.0 15.0-20.0 13.0-17.0 Elongation at break, % min 60 150 120 100 ENGINEERING MATERIAL SPECIFICATION WSS-M2G41-A1 Copyright 2018, Ford Global Technologies, LLC Page 6 of 8 Test Method Exceptions: Lap
27、 Shear Test panels are to be prepared according to process standards of the adhesives and primer, using production as well as supplier ecoated substrates. See section 4.1. Apply 8 mm overlap bead adhesive along the ecoated coupon surface. Within 5 minutes after adhesive application, position the adh
28、esive on the coupon in contact with the second ecoated metal surface. Both substrates should be the same ecoat for each condition. Allow adhesive to cure for 7 d at 23 +/- 2 C and 50 +/- 5% RH. Exposure Conditions - Bonded Test Assemblies: 3.5.2.1 Normal (fresh materials) test at R.T., -40 +/- 1 C,
29、and 90 +/- 2 C 3.5.2.2 Normal (urethane aged 3 months at 35 +/- 2C) test at R.T., -40 +/- 1 C, and 90 +/- 2 C 3.5.2.3 1 week heat age at 90 +/- 2 C, and 1 hour at RT 3.5.2.4 240 h water immersion at 32 +/- 1 C (FLTM BI 104-01) 3.5.2.5 2 weeks humidity age at 98 +/- 2% relative humidity and 38 +/- 2
30、C, and 1 hour at RT 3.5.2.6 After Environmental Cycling Test Method: Samples must be exposed four times to the following cycle in the sequence indicated below: 16 hours at 38 +/- 2 C and 98 +/- 2% RH 4 hours at minus 40 +/- 1 C 4 hours at 80 +/- 2 C After four cycles specimens to be stored at 23 +/-
31、 2 C and 50 +/- 5% RH for 72 hours before testing. 3.5.2.7 After Cataplasma test Test Method: Test specimens to be wrapped with hydrophilic cotton padding and 5 each to be put into sealed containers of approximately 160 ml volume space with 100 ml distilled water to provide constant conditions for f
32、ollowing storage: 14 days at 70 +/- 2 C 2 hours at - 20 +/- 2 C 2 hours at 23 +/- 2 C Remove wet cotton and test shear strength within 2 hours. ENGINEERING MATERIAL SPECIFICATION WSS-M2G41-A1 Copyright 2018, Ford Global Technologies, LLC Page 7 of 8 3.5.3 Peel Adhesion (Quick Knife Adhesion) (FLTM B
33、U 154-01, use 9 mm x 13 mm x 254 mm ecoated panels) Allow to cure for 7 days at 23 C +/- 2 C Start testing on the first of the bead at original conditions to 3.5.2.1. Expose the remainder of the same bead to heat ageing at conditions according to 3.5.2.3. and test the second of the bead. Expose the
34、remainder of the same bead to environmental cycling at conditions according to 3.5.2.6 and test the third of the bead. Expose the remainder of the same bead to cataplasma conditions according to 3.5.2.7 and test the last of the bead. Report type of failure after every exposure The material shall exh
35、ibit 100% cohesive failure of the urethane to the substrate. In case of ecoat failure, the test is to be rated as satisfactory and the result noted in the report. 3.6 LINE TRIAL The requirements defined in this specification are based upon laboratory coupon testing and define the minimum acceptance
36、criteria for adhesive performance. Prior to use, the adhesive must be evaluated under the production parameters of the relevant production line. The choice of substrates, plant processing conditions and specific design application may affect adhesive performance. Compliance with this specification d
37、oes not guarantee the adhesive will function for all potential applications on a vehicle. Therefore 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. Results shall be ma
38、de available to Materials Engineering prior to material approval and release. 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
39、SUBSTRATES Metal Substrates: Moonroof frame and Ford Assembly Plant ecoated metal substrates. Prior to releasing to this specification, the adhesive must be tested to electrocoated steel panels of nominal thickness 0.80 mm. The substrates must be electrocoated with all of the production systems that
40、 are currently in use by the Ford assembly plant and the production systems that are currently in use by the moonroof frame supplier. If metal flange primer(s) are used in production, testing must performed with the primer(s). 4.2 APPROVAL OF MATERIALS Suppliers desiring approval of their materials
41、shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance
42、 with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, C
43、ertification testing) with Ford. ENGINEERING MATERIAL SPECIFICATION WSS-M2G41-A1 Copyright 2018, Ford Global Technologies, LLC Page 8 of 8 4.3 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to
44、 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 activities of the proposed chang
45、es (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. 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 Approval P
46、rocess (PPAP) sign off must be kept until Job 1. 4.4 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-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. Figure 1. Sandwich assemblies Top View View Side View 6.4 mm 150 mm 50 mm x 6.4 mm Bond Area 3 mm thick 50 mm mm Electrocoated Metal
