1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 01 2013 11 07 Editorial Revised Section. 4.3 Editorial C. Mracna, NA 2003 01 23 Activated N. Lindsay-Merte/J. Crist, NA Controlled document at www.MATS Copyright 2013, Ford Global Technologies, Inc. Page 1 of 13 ADHESIVE, WELDABLE, RIVET
2、ABLE, THERMAL CURE, WSS-M2G410-A STRUCTURAL, ALUMINUM 1. SCOPE The material defined by this specification is pumpable, one component, thermal curing, weldable or rivetable structural adhesives for aluminum. 2. APPLICATION This specification was released originally for materials used to structurally
3、bond body components such as top rails, rear sills, and cross members to floor pans and inners to outers in a wheel house. This adhesive can be used to bond oily, unclean mill finish and pretreated aluminum sheet, castings and extrusions for body-in white applications. The use of pretreated aluminum
4、 sheet, castings and extrusions provide optimal adhesion performance for long term durability. Optimal adhesion strengths are achieved with adhesive bondlines of 0.25 mm. The material is cured in the electrocoat oven. The Manufacturing Properties and Engineering Performance requirements defined in t
5、his specification are based on laboratory sample testing and define the minimum acceptance criteria for adhesive performance. The function and design requirements for the application are defined by the Sub-system Design Specification (SDS), key life test requirements, or vehicle program requirements
6、. Prior to use, the adhesive must be evaluated under the production parameters. The choice of substrates, stamping lubricants, stamping plant processing conditions, assembly plant processing conditions and specific design application may affect adhesive performance. Compliance with this specificatio
7、n does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 SYST
8、EM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stamping lubricants and adhesive. The material system was oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditi
9、ons and assembly plant processing conditions may affect adhesive performance. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2013, Ford Global Technologies, Inc. Page 2 of 13 3.3 M
10、ATERIAL PROPERTIES 3.3.1 Weight Per Volume +/- 0.02 (ASTM D816) The weight tolerance for any one supplier shall be +/- 0.02 kg/L, based on the recorded weight of their original approved production sample. Reference para 4.1. 3.3.2 Volatile Organic Compounds (VOC) Content +/- 10% (EPA Method 24, Proc
11、edure B) The VOC Content variation for any one supplier shall be +/- 10%, based on the recorded VOC Content of their original approved production sample. Reference para 4.2. 3.3.3 Cure Requirements Report (Define the process cure window for material cure, report minimum and maximum time at temperatu
12、re requirements to define performance boundaries). Critical performance characteristics shall include, but are not limited to, the following Stress Durability, para 3.5.2 Fracture Toughness, para 3.5.4 Fatigue, para 3.5.5 Tensile Properties, para 3.5.7 3.4 MANUFACTURING PROPERTIES 3.4.1 Rheology Rep
13、ort (SAE 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 sec-1, evaluate material to highest stress or strain as the formulation will allo
14、w, report 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) Initial (as received) Test at 23 +/- 1 C Test at application temperat
15、ure +/- 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 days at 40 +/- 1 C 90 days at 32 +/- 1 C The rheology variation for any one supplier shall be +/- 10 %, based on the recorded rheology of the original approved production sample. T
16、he 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. ENGINEERING MATERIAL SPECIFI
17、CATION WSS-M2G410-A Copyright 2013, Ford Global Technologies, Inc. Page 3 of 13 Final approval of material 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. 3.4.2 P
18、umpability/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 operation and Design Enginee
19、ring. Results shall be made available to Materials Engineering prior to material approval and release. 3.4.3 Differential Scanning Calorimetry (20 +/- 1 mg sample size, 5 C/min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) Onset of reaction 80 C min Glass Transi
20、tion Temperature Report 3.4.4 Sag Resistance (FLTM BV 118-01, lab caulking gun applied 5 mm diameter bead, substrates per para 4.3, condition for 24 h at 40 C, oven schedule per para 4.4, one panel each bake) Horizontal No measurable movement Vertical No measurable movement Inverted No loss of mater
21、ial 3.4.5 Slump Resistance 3 mm max Assembly aged 30 days at 50 +/- 1 C Test Assembly: Two 25 x 100 mm coupons, prepared per para 4.3, with two 38 x 12 x 3 mm 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. Th
22、e 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 exterior edges with a spatula. Test Method: Prepare three assemblies per substrate and subject to exposure. After exposure, condition assemblies
23、at 23 +/- 2 C for 24 hours, then bake at minimum bake per para 4.4. Determine the slump by measuring adhesive loss from the bottom of the assembly. Photograph and record observations of any adhesive loss after exposure and after bake. Repeat the above procedures for maximum bake per para 4.4. ENGINE
24、ERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2013, Ford Global Technologies, Inc. Page 4 of 13 3.4.6 Bridging 3 mm max (SAE J243 ADS-9, Section 3.3, Method D, non-flow fixture, substrates per para 4.3, photograph after exposure and after material cure, bake conditions per para 4.4) Assembly a
25、ged 30 days at 50 +/- 1 C 3.4.7 Wash Resistance No measurable movement, displacement or wash-off. 3.4.7.1 Jaguar Production (JNS 30.03.24) 3.4.7.2 North American Production (FLTM BV 116-03, Method B, 10.0 x 200.0 mm substrates, per para 4.3) 3.4.7.3 European Production (Concurrence Required) Test Me
26、thod: Prepare a 300 x 100 x 1.0 mm test panel with lubricants as directed by Materials. Apply a 250 x 10 mm strip at production tape thickness to the panel. Condition for 2 h at 23 +/- 2 C. Wash, phosphate and electrocoat the test panel under current process conditions 3.4.8 Electrocoat Compatibilit
27、y (FLTM BV 119-01, use current production paints as identified by Material Engineering, substrates per para 4.3) Shall not contaminate electrocoat primer bath or cause electrocoat film irregularities. 3.4.9 Welding Acceptance Test Must Pass (FLTM BV 109-01, gun application, 25 coupon assemblies per
28、condition, substrates per para 4.3) As prepared (fresh material) Assembly aged 30 days at 23 +/- 2 C Assembly aged 30 days at 40 +/- 2 C ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2013, Ford Global Technologies, Inc. Page 5 of 13 3.4.10 Flammability with Continuous Spot Welding (FLTM
29、BV 114-01, substrates per para 4.3) During welding tests, less than 5 % of the welds shall exhibit a flame and all shall be self-extinguishing within 30 degrees. 3.4.11 Rivetability The adhesive shall not cause excess quilting as defined in Figure 2, nor cause a break through of the sheet metal or b
30、uckling of the rivet. Original approval was based on laboratory / plant trials using hydraulic/electric and manual/robotic parameters. New applications shall be validated using the intended production parameters Test Method: Perform rivet tests using methods typical of the production application, e.
31、g. hydraulic/electric, manual/robotic. Using 1.0 x 100 x 400 mm aluminum coupons construct an assembly as defined in Figure 3. A 3 mm bead of adhesive shall be applied 9.5 mm from edge of lower coupon prior to mating with the top coupon. Use rivet and type as specified by the application. After rive
32、ting, cure adhesive per para 4.4. Examine the assembly. Cross section the assembly through the rivet. A rivetability report must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. 3.4
33、.12 Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.4.13 Material Consistency Shall be a smooth homogenous mixture, free from entrapped air, foreign materials and any properties detrimental to normal production operation.
34、 3.4.14 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 months from date of manufacture when stored below 32 C. When materials are stored at temperatures below 23 C, they shal
35、l be conditioned at room temperature 24 hours prior to application. Application properties are optimized with adequate conditioning of the material. Ambient plant conditions may fluctuate between 7 C and 38 C. Materials shall be evaluated for local plant conditions to determine plant specific requir
36、ements in excess of 32 C. Critical performance characteristics to evaluate for shelf life stability shall include, but are not limited to, the following: Rheology, para 3.4.1 ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2013, Ford Global Technologies, Inc. Page 6 of 13 Sag Resistance, p
37、ara 3.4.4 Slump Resistance, para 3.4.5 Rivetability, para 3.4.11 Stress Durability, para 3.5.2 Fracture Toughness, para 3.5.4 Fatigue, para 3.5.5 Tensile Properties, para 3.5.7 3.5 ENGINEERING REQUIREMENTS 3.5.1 Adhesion Strength, min 12.0 MPa, not to exceed (SAE J1523, substrates per para 4.3, more
38、 than 30% reduction 0.25 mm adhesive bondline thickness, of strength after aging or 13 mm length overlap, 13 mm/min pull exposure. rate, oven cure per para 4.4) 3.5.1.1 Normal (Condition for 30 minutes at specified temperature prior to test) Test at 23 +/- 2 C Test at 80 +/- 2 C Test at -40 +/- 2 C
39、3.5.1.2 Exposed (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 38 +/- 1 C for 98 +/- 2 % RH for 7 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for 1 day 3.5.1.3 Aged (Condition at 23 +/- 2 C
40、 for 24 h after exposure, test at 23 +/- 2 C) 10 Thermal Cycles One Cycle: 90 +/- 1 C for 4 h PLUS 38 +/- 1 C and 98 +/- 2 % RH for 4 h PLUS - 40 +/- 1 C for 16 h 10 Moisture Intrusion Cycles One Cycle: 16 h at 38 +/- 2 C and 95 +/-5 % condensing RH 4 h at -40 +/- 2 C 4 h at 80 +/- 2 C Samples are t
41、o be conditioned at 23 +/- 2 C and 50 +/- 5% RH over weekends and holidays. Time between conditions shall not exceed 5 minutes. 30 APGE Cycles ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2013, Ford Global Technologies, Inc. Page 7 of 13 (FLTM BI 123-01, modified cycle, substrates per p
42、ara 4.3 oven cure, per para 4.4, report after 10, 20 and 30 cycles) One APGE cycle: 15 min salt water immersion (5 % salt solution), plus 1 h and 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 % environment over the weekends and holid
43、ays. 3.5.2 Stress Durability (FLTM BV 101-07, substrates per para 4.3, all coupons from one manufacturers lot, report thickness for each coupon and substrate yield strength for manufacturers lot, oven cure para 4.4, two fixtures, cyclic corrosion exposure, report data per test method) All samples at
44、 a specified load shall meet the minimum amount of cycles at 10, 20, 30, and 40 % of failure load established for unexposed samples tested at 23 C per para 3.5.1. 10 +/- 1 % 75 cycles min 20 +/- 1 % 60 cycles min 30 +/- 1 % 45 cycles min 40 +/- 1 % 30 cycles min 3.5.3 Peel Resistance (ASTM D1876, 0.
45、25 mm adhesive bondline thickness, 76.2 mm overlap, 127 mm/min pull rate, substrates per para 4.3, oven cure per para 4.4, condition for 30 minutes at specified temperature prior to test) Test at 23 +/- 2 C 125 N/25 mm min Test at 80 +/- 2 C 125 N/25 mm min Test at - 40 +/- 2 C 125 N/25 mm min 3.5.4
46、 Fracture Toughness (FLTM BU 121-01, 0.25 mm bondline thickness, substrates per para 4.3, oven cure per para 4.4, condition at specified temperature 30 minutes prior to test, 2 m/s impact velocity, Report A, h and n for the characterized metal, report R1 and R2 for each coupon assembly) Test at 23 +
47、/- 2 C 0.5 kJ/m2 min Test at 80 +/- 2 C 0.5 kJ/m2 min Test at - 40 +/- 2 C 0.5 kJ/m2 min 3.5.5 Fatigue Values shall be above the minimum in Figure 4. Test Method: Prepare 36 lap shear coupons as prepared per para 3.5.1, substrates per para 4.3, oven cure per para 4.4. Condition at 23 +/- 2 C for 2 h
48、. Refer to para 3.5.1 Shear Adhesion testing at 23 C to determine average static peak load failure. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2013, Ford Global Technologies, Inc. Page 8 of 13 Determine fatigue resistance in a dynamic tensile testing machine with a sinusoidal cyclic a
49、xial load and a frequency of 20 Hz at less than 1E6 cycles and 20 Hz at greater than 1E6 cycles. Maximum tensile loads to range from 20 to 65% of the static peak failure load. Determine fatigue resistance over range at 20, 30, 40, 50, 60, and 65 %, 3 coupons at each load. Minimum tensile load to be 10% of maximum tensile load. Report peak load vs cycles to failure and description of failure mode. Normal, Te
