1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 3 2016 10 18 Editorial See Summary of Revisions S. Short, NA 2014 05 08 Revised See Summary of Revisions B. Witkowski, NA 2010 07 20 Activated B. Witkowski, NA Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC
2、 Page 1 of 7 ADHESIVE, EPOXY, WELDABLE, THERMAL CURE, STRUCTURAL, HEM FLANGE WSS-M2G575-A 1. SCOPE The material defined by this specification is a pumpable, one component, thermal curing, weldable epoxy resin base, structural adhesive for steel with bondline spacers for bonding metal in hem applicat
3、ions. 2. APPLICATION This specification was released originally for materials to structurally bond metal-to-metal body components 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. Bondline spacers ar
4、e added to the component to maintain a 0.25 mm bondline thickness during the hemming process. 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 RHE
5、OLOGY Suppliers must submit flow characterization data to Ford Motor Company for flow modeling and process window determination. For a specified temperature range, the requested properties include, but are not limited to, viscosity, yield stress, apparent activation energy for viscosity and apparent
6、 activation energy for yield stress. This data constitutes the referenced standard and shall be kept on file at the designated material laboratory. 3.3 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stamping lubricants and adhesiv
7、e. 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. If any of these parameters are changed, the adhesive performance m
8、ust be validated using the new parameters. 3.4 MATERIAL PROPERITIES 3.4.1 Solids, min 99% (ASTM D 2834, except heat for 3 h at 102 +/- 3 C in a mechanical convection Oven, save sample for next test) ENGINEERING MATERIAL SPECIFICATION WSS-M2G575-A Copyright 2016, Ford Global Technologies, LLC Page 2
9、of 7 3.4.2 Ash +/- 3% (ISO 3491, Method A, 760 +/- 30 C ) The ash tolerance for any one supplier shall be +/- 3%, based on the recorded ash of their original approved production sample. Reference para 4.3. 3.4.3 Weight Per Volume (ASTM D 816) Weight tolerance for any one supplier shall be +/- 0.02 k
10、g/L, based on the recorded weight to their original approved production sample. Reference para 4.2. 3.5 MANUFACTURING PROPERTIES 3.5.1 Viscosity (FLTM BV 103-01 2.64 mm orifice, 550 kPa pressure, Method A, test at 25 +/- 2 C ) 3.5.1.1 As Received +/- 4 s The viscosity tolerance for any one supplier
11、shall be +/- 4 s, based on the recorded viscosity of the original approved production sample. Reference para 4.1 3.5.1.2 Aged, 7 days at 40 +/- 2 C 10% max increase from as received viscosity 3.5.1.3 Aged, 90 days at 27 +/- 2 C 30% max increase from as received viscosity Final approval of a specifie
12、d material viscosity for production shipments shall be made by during material trial, preferably at equipment suppliers lab testing. In all cases, the viscosity shall be within specification limits as identified on the material control plan. 3.5.2 Differential Scanning Calorimetry, Onset of reaction
13、, min 80 C (20 +/- 1 mg sample size, 5 C / min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) 3.5.3 Sag Resistance (FLTM BV 11801, 6 mm material thickness, substrates per para 4.4, oven schedule per para 4.5, one panel each bake) Horizontal No measurable movement
14、 Vertical No measurable movement Inverted No loss of material 3.5.4 Slump Resistance, max * Assembly aged 24 h at 23 +/- 2 C * Assembly aged 30 days at 23 +/- 2 C * Assembly aged 30 days at 50 +/- 1 C Test Assembly: Two 25 x 100 mm coupons, substrates per para 4.4, with two 38 x 12 x 3 mm spacers. T
15、he spacers are placed at each end of one of the coupons, and sufficient adhesive is ENGINEERING MATERIAL SPECIFICATION WSS-M2G575-A Copyright 2016, Ford Global Technologies, LLC Page 3 of 7 applied between the spacers to fill the gap. The second coupon is placed on top of the adhesive and spacers (F
16、igure 1). Clamp the assembly with spring clips at each end. Remove excess adhesive from all exterior edges with a spatula. Test Method: Prepare 3 assemblies per substrate. Subject one assembly per substrate to exposures. After exposure, condition assemblies at 23 +/- 2 C for 24 hours, then bake at m
17、inimum bake per para 4.5. Determine the slump by measuring adhesive loss from the bottom of the assembly. Record observations of any adhesive loss after exposure or after bake. Repeat the above procedures for maximum bake per para 4.5. 3.5.5 Bridging max 3 mm (SAE J243 ADS-9, Section 3.4, Method D,n
18、onflow fixture, substrates per para 4.4, bake conditions per para 5.5) Assembly aged for 24 h at 23 +/- 2 C Assembly aged 30 days at 23 +/- 2 C Assembly aged 30 days at 50 +/- 1 C 3.5.6 Wash Resistance (FLTM BV 116-01, Method A, 1.5 mm material thickness, substrates per para 4.4) No measurable movem
19、ent, displacement or wash-off. 3.5.7 Electrocoat Compatibility Shall not contaminate electrocoat primer bath or cause electrocoat film irregularities. (FLTM BV 119-01, use current production paint as identified by Material Engineering, substrates per para 4.4) 3.5.8 Welding Acceptance Test Must pass
20、 (FLTM BV 109-01, gun application, 25 coupon assemblies per condition) steel substrates only As prepared (fresh material) Assembly aged 30 days at 23 +/- 2 C Assembly aged 30 days at 40 +/ - 2 C 3.5.9 Flammability with Continuous Spot Welding (FLTM BV 114-01, substrates per para 4.4) During welding
21、tests, less than 5% of the welds shall exhibit a flame and all shall be self-extinguishing within 30 s. 3.5.10 Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. Cured samples should be tested per FLTM BO 131-03 and have a max
22、imum rating of 3. Materials with a rating higher than 3 must be reviewed with materials engineering, and additional testing including testing of odor samples in all regions of potential use must be performed. Region of use is defined as where completed vehicle will be shipped to customer. 3.5.11 Mat
23、erial Consistency Shall be a smooth homogenous mixture, free from entrapped air, foreign materials and any properties detrimental to normal production operation. 3.5.12 Storage Stability Heat greatly accelerates aging. The material shall be stored in closed containers away from all sources of heat.
24、The shelf life of the material shall be 3 months from date of ENGINEERING MATERIAL SPECIFICATION WSS-M2G575-A Copyright 2016, Ford Global Technologies, LLC Page 4 of 7 manufacture when stored below 27 C. If stored at 4 C, the shelf life is extended to 6 months. When materials are stored at temperatu
25、res 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. 3.5.13 Pumpability/Dispense Capability Materials being considered for approval to this specification shall be evaluated for pr
26、ocessing 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 material approval and release. Materials shall
27、 be a smooth 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 o
28、f phosphating, electrocoat primer or other materials applications. All bulk mastic, sealer or adhesives packaged in minitotes 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 ba
29、se of the next 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 n
30、ew, and other 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
31、reviewed as master for the process, reference(VOPGNN002). 3.6 ENGINEERING REQUIREMENTS 3.6.1 Adhesion Strength, min (SAE J1523, substrates per para 4.4, 0.25 mm adhesive bondline thickness, 13 mm length overlap, 13 mm/min pull rate, oven cure per para 4.5) 3.6.1.1 Normal (Condition for 30 minutes at
32、 specified temperature prior to test ) Test at 23 +/- 2 C 13.0 MPa Test at 82 +/- 2 C 11.0 MPa Aluminum at 82 +/- 2 C 2.0 MPa Test at -40 +/- 2 C 14.0 MPa 3.6.1.2 Exposed 11.0 MPa (Condition at 23 +/- 2 C for 1 h, subject to environmental cycle, oven cure per para 4.5, test at 23 C) Environmental cy
33、cle: -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 3.6.1.3 Aged 13.0 MPa (Condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2 C) 10 thermal Cycles One Cycle: 90 +/- 1 C for 4 h PLUS ENGINEERING MATERIAL SPECIFICA
34、TION WSS-M2G575-A Copyright 2016, Ford Global Technologies, LLC Page 5 of 7 38 +/- 1 C and 98 +/- 2% RH for 4 h PLUS -40 +/- 1C for 16 h 3.6.1.4 Cyclical Corrosion Exposure 10.0 MPa (CETP 00.00-L-467, 6 weeks) 3.6.2 Stress Durability, min (FLTM BV 101-07, galvanized and hot dipped steel per para 4.4
35、, all coupons from one manufacturers lot, report thickness for each coupon and substrate yield strength for manufacturers lot, material cure 30 minutes at 180 +/- 2 C, two fixtures, cyclic corrosion exposure, report data per test method) All samples at a specified load shall meet the minimum amount
36、of cycles at 10, 20, 40% of failure load established for unexposed samples. Supplier shall run testing beyond the minimum number of cycles to demonstrate compliance. 10 +/- 1% 22 cycles 20 +/- 1% 15 cycles 40 +/- 1% 10 cycles 3.6.3 Peel Resistance, (ASTM D 1876, galvanized steel and aluminum per par
37、a 4.4, Condition at 23 +/- 2 C for 24 h, oven cure per para 4.5) 3.6.3.1 As received min 2000 N/m 3.6.3.2 Assembly aged prior to bake at 38+/- 2 C, 95+/- 5% for 30 days, then oven cure per para 4.5) min 2000 N/m 3.6.4 Cold Adhesion No adhesion failure or material cracking. (FLTM BV 101-02, Procedure
38、 “E“) 0.51 mm material thickness, substrates per para 4.4, oven cure per para 4.5) 3.6.5 Tensile Properties Report (ASTM D638, 3 +/- 0.5 mm thick, cure on release 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, condi
39、tion at 23 +/- 2 C for 24 h, test at 23 +/- 2 C, 5 mm/min pull rate, use extensometer or strain gage, test at 40, 23, 50 and 80 +/- 2 C) Modulus of elasticity, min 0.6 Gpa Elongation at break, min 1.0% Poissons Ratio 0.10 0.48 3.6.6 Fracture Toughness, min 0.3 kJ/m2 (FLTM BU 121-01, 2 m/s Velocity,
40、cure per 4.5), EG and HD substrates only 3.7 FUNCTIONAL APPROVAL 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 and Design Engineering. Results shall be made available
41、 to Materials Engineering prior to material approval and release. ENGINEERING MATERIAL SPECIFICATION WSS-M2G575-A Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 3.8 TESTING TO FAILURE Suppliers must submit a mutually agreed upon testing to failure workplan for a material source approval.
42、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 Materials Engineering. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements
43、 of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 VISCOSITY, Typical as received 43 s 4.2 WEIGHT PER VOLUME, Typical 1.26 kg/L 4.3 ASH, Typical 15% 4.4 SUBSTRATES Currently released HD, EG, and CRS materials, 0.8mm thickness. Reference specifications
44、WSD-M1A333-A2,WSD-M1A333-A2, nominal 0.8 mm thickness, coated per WSS-M1P94-A to coating weight 50G50G-EL and 50G50G-HD, panels electrocoated steel panels prepared per WSS-M3P1-D using current production paints as specified by Materials Engineering. Aluminum Substrates: Original adhesive approval wa
45、s established using WSB-M2A152-A1, AA-6111-T4, nominal 0.9 mm thickness. Adhesive performance may be significantly influenced by aluminum alloy and surface pretreatment. A supplier is recommended to evaluate the adhesive on the production aluminum alloy, nominal 0.9 mm thickness, with the production
46、 surface pretreatment, if any specified, prior to production release. All test data shall be submitted to Materials Engineering. All related materials used for approval of adhesive/polymer according to this specification, eg. Paint materials or metallic substrates, shall be note in the initial sampl
47、e report of the adhesive/polymer/ part. 4.5 MATERIAL CURE SCHEDULES (FLTM BV 150-05, use table for appropriate regional vehicle assembly site, cure material per material application “Prior to Electrocoat“, min and max bake, condition at 23 +/- 2 C for 1 h min. prior to testing) 4.6 OIL COMPATIBILITY
48、 & REFERENCE OIL All materials released to this specification must be applicable to oiled surfaces, including corrosion protection oil, wash oils, pre-lubricants, draw oils, hot melts etc. The approved products for use are listed in the applicable approved source list (contact local materials engine
49、ering for details). The supplier must confirm the compatibility of the adhesive/sealer material to these specific coating materials in the appropriate lab tests listed in para 3 and - prior to vehicle production - in a line trial in cooperation with Ford manufacturing engineering. The lab test panels must be oiled with maximum permissible oil film thickness (see FLTM BZ 150-11 Oiling of Steel Surfaces for proper region). Reference oil for adhesive performanc
