1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2015 02 03 N Status No replacement named L. Sinclair, NA 2007 08 03 Activated B. Witkowski Copyright 2015, Ford Global Technologies, LLC Page 1 of 8 ADHESIVE, HEM FLANGE, STEEL BONDING, FLOWABLE WSS-M2G571-A NOT TO BE USED FOR NEW DESIGN 1. S
2、COPE The materials defined by this specification are pumpable one-component, flowable, structural adhesives for bonding metal. Full adhesive strengths are attained after an oven cure. 2. APPLICATION This specification was released originally for materials to structurally bond metal-to-metal body com
3、ponents 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. The Manufacturing Properties and Engineering Performance requirements defined in this specification are based upon laboratory coupon testing
4、and define the minimum acceptance criteria for adhesive performance. The assembly process and design for the component will determine the specific adhesive processing parameters for each assembly line. The component engineering performance requirements are defined by the component SDS (Sub-system De
5、sign Specification). Recommended material oven cure schedules are minimum 171 C metal temperature for 10 minutes and maximum 205 C metal temperature for 30 minutes. Prior to use, the adhesive must be evaluated under the component production parameters. The choice of substrates, stamping lubricants,
6、stamping plant processing conditions, assembly plant processing conditions and specific design application may affect adhesive performance. Compliance with this specification does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.1 STANDARD REQUI
7、REMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stamping lubri
8、cants and adhesive. The originally approved material system was induction heated or room temperature cured followed by an oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may
9、affect adhesive performance. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSS-M2G571-A Copyright 2015, Ford Global Technologies, LLC Page 2 of 7 3.3 MATERIAL PROPERTIES 3.3.1 Weight Per Volume +/- 0.06
10、 kg/L (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.06 kg/L, based on the recorded weight of their original approved production sample. Reference para 4.1 3.3.2 Viscosity at 50 C, % +/- 5 (SAE J1524, 4 mm orifice, 90 psi) 3.3.2.1 Initial (as received) 3.3.2.2 Accelerated Agin
11、g Test at 50 C after 14 days at 32 C Test at 50 C after 90 days at 23 +/-2 C, 50 +/- 5% R.H. The viscosity tolerance for any one supplier shall be +/- 5%, based on the recorded viscosity of their original approved production sample. Reference para 4.2. 3.3.3 Expansion No porosity or (Substrates per
12、para 4.4, room temperature expansion cure per para 4.5, one panel each substrate) Extrude a 13 x 200 mm adhesive bead onto a 100 x 300 mm panel. Place the test panel in an air circulating oven and bake at 205 +/- 2 C for 40 minutes oven time. After bake, condition test panel at 23 +/- 2 C for 1 h mi
13、nimum. Cut the panel lengthwise through the center of the adhesive. Examine the adhesive for any voids, porosity or expansion caused by entrapped air or internal gassing. 3.4 MANUFACTURING PROPERTIES 3.4.1 Rheology (SAE J1524, rotational rheometer with 40 mm diameter parallel plates, 1000 micron gap
14、, 1.5 1/s shear rate, variable shear stress, evaluate material by keeping constant shear rate 1.5 1/s with variable shear stress, report material batch/lot number, identify rheometer make and model, for each test condition report plots). Initial (as received) Test at 50 +/- 2 C ENGINEERING MATERIAL
15、SPECIFICATION WSS-M2G571-A Copyright 2015, Ford Global Technologies, LLC Page 3 of 7 Aged (age then test at 50 C and application temperature) 7 d at 40 +/- 2 C 90 d at 32 +/- 2 C The flow curves established for initial approval shall constitute the reference standard and shall be kept on file at the
16、 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 shipments shall be made by the affected manufacturing activity. In all cases, the rheology shall
17、be within the limits as identified on the material control plan. 3.4.2 Sag Resistance/Flow Rate No measurable movement or flow, no loss of material 3.4.2.1 North American Production Define process window and flow capabilities of the material, perform DOE and report minimum and maximum flow condition
18、s. Supplier should flow capabilities (i.e low/ high bake on a vertical panel, and flow on a horizontal panel with a typically sized daub.) DOE should describe flow properties to assist in design guideline development. 3.4.3 Phosphate Wash Resistance No measurable movement, displacement or wash off.
19、No dissolution of material or lifting from panel. 3.4.3.1 North American Production (FLTM BV 116-01, Method B, 1.5 mm material thickness, room temperature cure per para. 4.5 prior to test) 3.4.4 Electrocoat Compatibility (FLTM BV 119-01, use current production paints as identified by Materials Engin
20、eering, cure per para 4.5 prior to test) Shall not contaminate electrocoat primer bath or cause electrocoat film irregularities. 3.4.5 Cure Requirements Report (Define the process cure window for material cure, Report minimum and maximum time at temperature requirements to define performance boundar
21、ies) Critical performance characteristics shall include, but are not limited to, the following Lap Shear (3.5.1.1) Peel Resistance (3.5.2) ENGINEERING MATERIAL SPECIFICATION WSS-M2G571-A Copyright 2015, Ford Global Technologies, LLC Page 4 of 7 3.4.6 Exposed Adhesion Strength, min (SAE J1523, substr
22、ates per para 4.4, 0.25 mm adhesive bondline thickness, 13 mm length overlap, cure per para 4.5, 13 mm/minute pull rate) 3.4.6.1 Exposure after 1 h, min 8.0 MPa (condition at 23 +/- 2 C for 1 h, subject to environmental cycle and test at 23 C) 3.4.6.2 Exposure after 24 h, min 8.0 MPa (condition at 2
23、3 +/- 2 C for 24 h, subject to environmental cycle and test at 23 C) Environmental cycle: -40 +/- 1 C for 7 d PLUS 40 +/- 1 C for 98 +/- 2% RH for 7 d PLUS 40 +/- 1 C for 7 d PLUS 23 +/- 2 C for 1 d 3.4.7 Color The material color for any one supplier shall not visually deviate from the originally ap
24、proved production sample. Reference para 4.3. 3.4.8 Odor Shall be free from objectionable odors as determined by the manufacturing facility. 3.4.9 Material Consistency Shall be a smooth homogenous mixture, free from entrapped air, foreign materials and properties detrimental to normal production ope
25、ration. 3.4.10 Pumpability/Dispense Capability Materials being considered for approval to this specification shall be evaluated for processing capability using extrusion. The pumpability/dispense capability report must be approved by the affected assembly operation and Design Engineering. Results sh
26、all be made available to Materials Engineering prior to material approval and release. 3.4.11 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 when stored below 27 C. Wh
27、en these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature 24 h prior to application. Adequate conditioning permits the material to retain its optimum application properties. ENGINEERING MATERIAL SPECIFICATION WSS-M2G571-A Copyright 2015, Ford Global Tech
28、nologies, LLC Page 5 of 7 3.5 ENGINEERING REQUIREMENTS 3.5.1 Oven Cured Adhesion Strength, min (SAE J1523, Substrates per para 4.4, 0.25 mm adhesive bondline thickness, 13 mm length overlap, 13 mm/minute pull rate, oven cure per para 4.5) 3.5.1.1 Normal, min (Condition for 30 minutes at specified te
29、mperature prior to test) Test at 23 +/- 2 C 8.0 MPa Test at 82 +/- 2 C 5.0 MPa Test at -40 +/- 2 C 8.0 MPa 3.5.1.2 Exposed, min Exposure after 1 h 10.0 MPa (condition at 23 +/- 2 C for 1 h, subject to environmental cycle, oven cure, test at 23 C) Exposure after 24 h 10.0 MPa (condition at 23 +/- 2 C
30、 for 24 h, subject to environmental cycle, oven cure, test at 23 C) Environmental cycle: -40 +/- 1 C for 7 d PLUS 40 +/- 1 C for 98 +/- 2% RH for 7 d PLUS 40 +/- 1 C for 7 d PLUS 23 +/- 2 C for 1 d 3.5.1.3 Aged, min (Condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2) 10 Thermal Cycle
31、s 8.0 Mpa One Cycle: 90 +/- 1 C for 4 h PLUS 40 +/- 1 C and 98 +/- 2% RH for 4 h PLUS -40 +/- 1 C for 16 h 30 APGE Corrosion Cycles 8.0 Mpa (FLTM BI 123-01, Report after 10, 20 and 30 cycles) ENGINEERING MATERIAL SPECIFICATION WSS-M2G571-A Copyright 2015, Ford Global Technologies, LLC Page 6 of 7 On
32、e APGE cycle: 15 minute salt water immersion (5% salt solution) PLUS 1 h and 45 minute drip dry at 23 +/- 2 C PLUS 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 holidays. 3.5.2 Peel Resistance, min 100 N/25 mm (ASTM D 187
33、6, substrates per para oven cure per para 4.5) 3.5.3 Cold Adhesion (FLTM BV 101-02, Procedure E, 0.51 mm material thickness, substrates per para 4.4, oven cure per para 4.5) No cracking or adhesion failure 3.5.4 Fracture Toughness, min 0.3 kJ/m2 (FLTM BU 121-01, 2 m/s Velocity, cure per 4.5) 3.6 FUN
34、CTIONAL APPROVAL Materials being evaluated for approval to these specifications 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 material ap
35、proval and release. 3.7 TESTING TO FAILURE Suppliers must submit a mutually agreed upon test 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 data with M
36、aterials Engineering. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 SPECIFIC GRAVITY, Typical 1.2 - 1.75 4.2 PRESSED FLOW VISCOSITY, typical as received 20 - 40 sec (FLTM BV 103-01, 4 mm orifice,
37、 90 psi pressure, Method A, test at 50 +/- 2 C) 4.3 COLOR, Typical Black ENGINEERING MATERIAL SPECIFICATION WSS-M2G571-A Copyright 2015, Ford Global Technologies, LLC Page 7 of 7 4.4 SUBSTRATES Materials being evaluated for approval to these specifications shall be tested with typical lubricants and
38、 at applications levels as specified by Materials Engineering. 4.4.1 North American Production Steel Substrates: WSD-M1A333-A2, nominal 0.8 mm thickness, coated per WSS-M1P94-A to coating weight 60G60G-EL and 60G60G-HD. 4.5 MATERIAL CURE SCHEDULES 4.5.1 North American Production Cure (FLTM BV 150-05
39、, condition at 23 +/- 2 C for 1 h min, then test) Min Bake: 171 C metal temperature for 10 minutes (not to exceed 20 minutes oven time) Max Bake: 205 C metal temperature for 30 minutes (not to be less than 40 minutes oven time) 4.6 TENSILE PROPERTIES (ASTM D 638, 3 +/- 0.5 mm thick, cure on release
40、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/minute pull rate, use extensometer or strain gage, test at -40, 23, 50 and 80 +/- 2 C, 5 samples) Modulus
41、 of elasticity at 23 C, Typical 2 - 3 GPa Elongation at break at 23 C. Typical 5 - 20% Poissons Ratio at 23 C, Typical 0.25 - 0.35 Actual material properties are temperature and formulation dependent. Results are on file with Materials Engineering. 4.7 DYNAMIC MECHANICAL ANALYSIS/DYNAMIC MECHANICAL
42、THERMAL ANALYSIS (Cure on release paper between 3 mm aluminum panels for 30 minutes at 180 +/- 2 C material temperature, sample dimensions are instrument dependent, test 1 sample per batch/lot for 3 batches/lots +/- 0.5 mm for length, width and thickness, report sample size for each batch/lot, 2 C/minute heating rate, bending mode, record at 1 and 10 Hz, -40 to 200 C temperature range, submit Log E vs. Temperature and Log Tan Delta vs. Temperature Curves) Max Tan Delta, Typical 90 - 120 C
