1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 03 2017 10 19 Revised See Summary of Revisions B. Witkowski, NA 2016 10 17 Editorial See Summary of Revisions S. Short, NA 2003 01 23 Activated N. Lindsay-Merte/J. Crist, NA Controlled document at www.MATS Copyright 2017, Ford Global Tec
2、hnologies, Inc. Page 1 of 17 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 was r
3、eleased 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 body
4、-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 Properties
5、 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), key l
6、ife 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 affect a
7、dhesive 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 Lis
8、t (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 material s
9、ystem 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 performance.
10、 If any of these parameters are changed, the adhesive performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 2 of 17 3.3 MATERIAL PROPERTIES 3.3.1 Weight Per Volume +/- 0.02 (ASTM D816) The weight to
11、lerance 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%, bas
12、ed on the recorded VOC Content of their original approved production sample. Reference para 4.2. 3.3.3 Cure Requirements Report minimum and maximum cure conditions, must meet requirements in this paragraph. (Define the process cure window for material cure, report minimum and maximum time at tempera
13、ture requirements to define performance boundaries). Critical performance characteristics shall include, but are not limited to, the following Lap-Shear, para 3.5.1 Stress Durability, para 3.5.2 Fracture Toughness, para 3.5.4 Fatigue, para 3.5.5 Tensile Properties, para 3.5.7 Peel Resistance, para 3
14、.5.3 Minimum and maximum cure conditions to be proven by the supplier. A cured material is one which will meet all minimum properties required in this specification. The cure conditions required for this specification for e-coat bake are: Minimum cure 10 minutes metal temperature (maximum 20 minutes
15、 in oven) at 160 C Maximum cure 30 minutes metal temperature (minimum 40 minutes in oven) at 205 C 3.4 MANUFACTURING PROPERTIES 3.4.1 Rheology Report (SAE J1524, rotational rheometer with 40 mm diameter parallel plates, 500 micron gap, 50 Pa/sec ramp, stress controlled rheometers use stress range 0
16、- 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, for each test condition report yield stress and submit plots for shear stress vs s
17、hear 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 then test at 23 C and application temperature) 7 days at 40 +/- 1 C ENGINEERING MAT
18、ERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 3 of 17 90 days at 32 +/- 1 C 72 hours at 45 +/- 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 establis
19、hed 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 rheology for production
20、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 this specification shall be evaluated for processing capa
21、bility 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 material approval and release. Materials shall be a smooth
22、homogenous mixture, free from entrapped air, foreign materials and properties detrimental to normal production operation. The material shall work with all the plant processes (cleaning operations, phosphating process, welding operations, etc.) and shall not deteriorate the performance of phosphating
23、, electrocoat primer or other materials applications. All bulk mastic, sealer or adhesives packaged in mini-totes will be returned to the supplier 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 ne
24、xt refill and will not affect the quality of the refilled certified product and supplier shall demonstrate via testing of retain materials of 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 othe
25、r ratios defined at approval. Supplier shall present data to manufacturing and materials engineering prior to approval, as well as data showing compatibility with process aids used in mini-tote assembly (i.e. seal lubricants). For mini-tote system information, the VO procedure should be reviewed as
26、master for the process, reference(VOPGNN002). 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
27、-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 material 3.4.5 Slump Resistance 3 mm max Assembly aged 30 days
28、 at 50 +/- 1 C Test Assembly: Two 25 x 100 mm coupons, prepared per para 4.3, with two 38 x 12 x 3 ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 4 of 17 mm spacers. The spacers are placed at each end of one of the coupons, and sufficient adhesive
29、 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 exterior edges with a spatula. Test Method: Prepare three assemblies per substrate and subject
30、 to exposure. After exposure, condition assemblies 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 abo
31、ve procedures for maximum bake per para 4.4. 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 (FLTM BV
32、116-01, Method B, 10.0 x 200.0 mm substrates, per para 4.3) No measurable movement, displacement or wash-off. 3.4.8 Electrocoat Compatibility (FLTM BV 119-01, use current production paints as identified by Material Engineering, substrates per para 4.3) Shall not contaminate electrocoat primer bath o
33、r 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 aged 30 days at 23 +/- 2 C Assembly aged 30 days at 40 +/- 2 C 3.4.10 Flammability wit
34、h Continuous Spot Welding (FLTM 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 seconds. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 5 of 1
35、7 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 trials using hydraulic/electric and manual/robotic parameters. New applications shall be
36、 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 coupons construct an assembly as defined in Figure 3. A 3 mm bead of adhesive shall be
37、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 assembly through the rivet. A rivetability report must be approved by the affected ass
38、embly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. 3.4.12 Odor Rating 3 max (FLTM BO 131-03, method D, cure per FLTM BV 150-05, high and low bake per para 4.4) 3.4.13 Material Consistency Shall be a smooth homogeno
39、us 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 shall be stored in closed containers away from all sources of heat. The shelf life of the material shall be 3 mo
40、nths 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. Application properties are optimized with adequate conditioning of the material. Ambient plant conditions may fluct
41、uate 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 for shelf life stability shall include, but are not limited to, the following: Rheology, para 3.4.1 Sag Resi
42、stance, para 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 ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 6 of 17 Tensile Properties, para 3.5.7 3.5 EN
43、GINEERING 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 aging or 13 mm length overlap, 13 mm/min pull exposure. rate, oven cure per para 4.4) 3.5.1.1 Normal (Condit
44、ion 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 cycle, oven cure per para 4.4, test at 23 C) Environmental cycle: - 40 +/- 1 C for 7 days PLUS 38 +/- 1 C fo
45、r 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 (Oven cure per 4.4, then expose per below, then condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2 C) 3.5.1.3.1 Expose to 10 Thermal Cycles prior to evaluation One Cycle: 90 +/- 1 C for 4 h PL
46、US 38 +/- 1 C and 98 +/- 2 % RH for 4 h PLUS - 40 +/- 1 C for 16 h 3.5.1.3.2 Expose to 10 Moisture Intrusion Cycles prior to evaluation 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 wee
47、kends and holidays. Time between conditions shall not exceed 5 minutes. 3.5.1.3.2 Corrosion Environment- Expose to (CETP 00.00-L-467, 6 weeks) prior to evaluation 3.5.2 Stress Durability (FLTM BV 101-07, substrates per para 4.3, all coupons from one manufacturers lot, report ENGINEERING MATERIAL SPE
48、CIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 7 of 17 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) Load condition of each tube, 2400N, all coupons
49、tested must exceed 45 cycles without failure. 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 4.3, oven cure per para 4.4, condition for 30 minutes at specified temperature prior to test) Test at 23 +/- 2 C 5 N/ mm min Test at 80 +/- 2 C 5 N/ mm min Test at - 40 +/- 2 C 5 N/ mm min 3.5.4 Fracture Toughness (FLTM BU 121-01, 0.25 m
