1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2016 10 17 Revised See Summary of Revisions S. Short, NA 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 2016, Ford Global
2、Technologies, Inc. Page 1 of 15 ADHESIVE, WELDABLE, RIVETABLE, 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 wa
3、s released originally for materials used to structurally 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 b
4、ody-in white applications. The use of pretreated aluminum 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 Propert
5、ies and Engineering Performance requirements defined in this 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), ke
6、y life test requirements, or vehicle program requirements. 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 affec
7、t adhesive performance. Compliance with this specification does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source
8、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 Materials Engineer. 3.2 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific materia
9、l 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 conditions and assembly plant processing conditions may affect adhesive performan
10、ce. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2016, Ford Global Technologies, Inc. Page 2 of 15 3.3 MATERIAL PROPERTIES 3.3.1 Weight Per Volume +/- 0.02 (ASTM D816) The weight
11、 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, Procedure B) The VOC Content variation for any one supplier shall be +/- 10%,
12、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 temperature requirements to define performance boundaries). Critical performance ch
13、aracteristics 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 Report (SAE J1524, rotational rheometer with 40 mm diameter parallel plates,
14、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 allow, report material batch/lot number, identify rheometer make and model, fo
15、r 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 temperature +/- 2 C Test over range 10 to 50 C at increments of 10 C Aged (age the
16、n 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. The flow curves established for initial approval shall constitute the refer
17、ence 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 SPECIFICATION WSS-M2G410-A Copyright 2016, Ford Global Technologies, Inc. Page 3
18、of 15 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 Pumpability/Dispense Capability Materials being considered for approval to
19、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 Engineering. Results shall be made available to Materials Engineering prior to ma
20、terial 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 Transition Temperature Report 3.4.4 Sag Resistance (FLTM BV 118-01, lab caulking
21、 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 material 3.4.5 Slump Resistance 3 mm max Assembly aged 30 days at 50 +/- 1 C Te
22、st 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. The second coupon is placed on top of the adhesive and spacers (Figure 1). C
23、lamp 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 at 23 +/- 2 C for 24 hours, then bake at minimum bake per para 4.4. Determ
24、ine 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. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2016, Ford Global Tech
25、nologies, Inc. Page 4 of 15 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 aged 30 days at 50 +/- 1 C 3.4.7 Wash Resistance No measurable movement, di
26、splacement 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 Method: Prepare a 300 x 100 x 1.0 mm test panel with lubricants as directed
27、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 Compatibility (FLTM BV 119-01, use current production paints as identified by Material
28、 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 condition, substrates per para 4.3) As prepared (fresh material) Assembly
29、aged 30 days at 23 +/- 2 C Assembly aged 30 days at 40 +/- 2 C ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2016, Ford Global Technologies, Inc. Page 5 of 15 3.4.10 Flammability with Continuous Spot Welding (FLTM BV 114-01, substrates per para 4.3) During welding tests, less than 5 % of
30、 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 buckling of the rivet. Original approval was based on laboratory / plant tr
31、ials 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.g. hydraulic/electric, manual/robotic. Using 1.0 x 100 x 400 mm aluminum c
32、oupons 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 riveting, cure adhesive per para 4.4. Examine the assembly. Cross section the
33、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. 3.4.12 Odor Shall be free from objectionable odors as determined by the manuf
34、acturing 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. 3.4.14 Storage Stability Heat greatly accelerates aging. The material sha
35、ll 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 shall be conditioned at room temperature 24 hours prior to application. Applic
36、ation 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 requirements in excess of 32 C. Critical performance characteristics to evaluate
37、 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 2016, Ford Global Technologies, Inc. Page 6 of 15 Sag Resistance, para 3.4.4 Slump Resistance, para 3.4.5 Rivetability, para 3.4.11 Stress Du
38、rability, 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 than 30% reduction 0.25 mm adhesive bondline thickness, of strength after
39、 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 3.5.1.2 Exposed (Condition at 23 +/- 2 C for 1 h, subject to environmental
40、 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 for 24 h after exposure, test at 23 +/- 2 C) 10 Thermal Cycles One Cycle:
41、 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 to be conditioned at 23 +/- 2 C and 50 +/- 5% RH over weekends and holidays
42、. Time between conditions shall not exceed 5 minutes. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2016, Ford Global Technologies, Inc. Page 7 of 15 Corrosion Resistance (CETP 00.00-L-467, 6 weeks) 3.5.2 Stress Durability (FLTM BV 101-07, substrates per para 4.3, all coupons from one ma
43、nufacturers 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 a specified load shall meet the minimum amount of cycles at 10, 20, 30, and 40 % of failure l
44、oad 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, 0.25 mm adhesive bondline thickness, 76.2 mm overlap, 127 mm/min pull rate, substrates per para
45、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 Fracture Toughness (FLTM BU 121-01, 0.25 mm bondline thickness, substrates per para 4.3, oven
46、 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 +/- 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
47、 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. Refer to para 3.5.1 Shear Adhesion testing at 23 C to determine average static peak load fai
48、lure. Determine fatigue resistance in a dynamic tensile testing machine with a sinusoidal cyclic axial 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 resistan
49、ce 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. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2016, Ford Global Technologies, Inc. Page 8 of 15 Normal, Test at 23 C 3.5.6 Cold Adhesion (FLTM BV 101-02, Procedure “E“, 0.5 mm material
