1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2016 10 17 Revised See Summary of Revisions S. Short, NA 2009 04 02 Revised See Summary of Revisions M. Mehandru, FNA 2006 10 27 Activated M. Mehandru Controlled document at www.MATS.com Copyright 2016, Ford Global Technologies, LLC P
2、age 1 of 11 SEALER, VINYL, LOW DENSITY, EXTRUDABLE, SPRAYABLE WSS-M4G252-E2 ABRASION RESISTANT, NON-PAINTABLE 1. SCOPE The material defined by this specification is a vinyl based, extrudable, sprayable, sag resistant, abrasion resistant, non-paintable, heat cured sealer. 2. APPLICATION This specific
3、ation was released originally as an interior seam sealer and underbody stone chip resistance material. The material will not have good appearance when top-coated and therefore should be used only on non-paintable surfaces. This material can be sealer gun extruded and spray applied to body electrocoa
4、t primed surfaces. Recommended material cure schedules are specified in para 5.3. A 0.50 mm wet film thickness is recommended for abrasion resistance. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 APPROVED SOURCES This specification re
5、quires the use of approved sources. Only the sources identified on the Ford Approved Source 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
6、Engineer. 3.2 SOLIDS 95% min (ASTM D2834, except heat at 102 +/- 1 C for 3 h in a mechanical convectional oven. Save sample for next test, para 3.3) 3.3 ASH (Based on solids weight), (ISO 3491, Method A, 760 +/- 30 C) The ash content tolerance for any one supplier shall be +/- 5% based on the record
7、ed ash content for their originally approved production sample. See paragraph 4.4. 3.4 WEIGHT PER VOLUME 0.87 kg/L, max (ASTM D816) 0.93 kg/L sprayed max The weight per volume shall be measured after the material has undergone airless spraying. Spray the sealer at a 300 mm distance thru a -0.79 mm/6
8、0 tip at 20 MPa onto a clean steel panel. Measure the density of sprayed sealer with a pycnometer. The weight tolerance for any one supplier shall be +/- 0.06 kg/L, based on the recorded weight of his original approved production sample See paragraph 4.5. ENGINEERING MATERIAL SPECIFICATION WSS-M4G25
9、2-E2 Copyright 2016, Ford Global Technologies, LLC Page 2 of 11 3.5 VISCOSITY (SAE J1524, VIS-2, 1.32 mm orifice, 280 kPa) Final approval of a specific material viscosity for production shipments shall be made by the affected manufacturing activity. In all cases, the viscosity shall be within proces
10、s limits as identified on the material control plan. The viscosity tolerance for any one supplier shall be +/- 10%, based on the recorded viscosity of the original approved production sample. 3.5.1 As Received Viscosity +/- 10% (Unagitated - Method “A“) 3.5.2 Aged Viscosity original +50% (Material a
11、ged in closed container for increase 72 h at 40 +/- 1 C, Unagitated - Method “A“) 3.6 BRIDGING 6.4 mm max Test Method: Apply a 13 mm diameter material bead over the 6.4 mm diameter holes shown in sketch below. Condition the test fixture with material bead for 15 minutes at 23 +/- 2 C, then bake fixt
12、ure at the minimum bake schedule per para 4.3. Measure the amount of material sag through hole. BRIDGING TEST FIXTURE ENGINEERING MATERIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, Ford Global Technologies, LLC Page 3 of 11 3.7 SAG RESISTANCE 3.7.1 Horizontal 6.4 mm max 3.7.2 Vertical 6.4 mm max 3
13、.7.3 Inverted No loss of material Test Method: Apply a 3 x 30 x 200 mm ribbon of material along the center line of three electrocoated panels prepared per para 4.2 Scribe panels to mark the initial material location. Position the panels with the material in the attitude above for 1 h. Immediately af
14、ter conditioning, place panels in an oven to cure material at the minimum bake schedule per para 4.3. Maintain panels in the specified attitude during baking and cooling. Allow the panel to cool to 23 +/- 2 C. Determine the sag by measuring the material movement below the scribe mark. 3.8 ADHESION S
15、hall not be peeled off in a continuous film at any thickness. Test Method: Apply 6.4 - 0 mm tapered material ribbon on two electrocoated panels prepared per para 4.2. See sketch below. Subject one test panel, to the minimum bake schedule and the other test panel to the maximum bake schedule identifi
16、ed per para 4.3. Condition panels after baking at 23 +/- 2 C for 1 h minimum. Evaluate adhesion by cutting a 25 mm wide strip across the tapered ribbon. Using the tip of a square spatula, lift the material at both the thin and thick film edges then attempt to had peel material at 90 from substrate.
17、Save test panels for Heat Stability Test, para 3.9 and Corrosion Resistance Test, para 3.10. ENGINEERING MATERIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, Ford Global Technologies, LLC Page 4 of 11 3.9 HEAT RESISTANCE TEST No evidence of blistering, cracking, charring or other deleterious effects
18、 Test Method: Examine the maximum bake panel prepared for Adhesion Test, para 3.8, for any of the above conditions. 3.10 CORROSION RESISTANCE TEST No corrosion or (CETP 00.00-L-467, 6 weeks) adhesion loss 3.11 MANDREL BEND TEST No cracking or (FLTM BV 122-01, material bake schedule adhesion failure
19、per para 5.3, heat age test specimen 14 days at 70 +/- 1 C before test) 3.11.1 Test at 23 +/- 2 C 3.11.2 Test at -20 +/- 1 C 3.12 CRACK RESISTANCE 5,000 cycles min (FLTM BV 115-01, except bake an additional set of panels for 15 minutes at 135 +/- 1 C for normal and aged test, use substrate identifie
20、d per para 4.2) ENGINEERING MATERIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, Ford Global Technologies, LLC Page 5 of 11 3.13 COMPATIBILITY WITH PRODUCTION PAINTS No color transfer of the topcoat from the sealer to other objects. Test Method: 3.13.1 Prepare test panels per FLTM BV 153-08, Procedu
21、re “A“, but with the following modifications: Spray a 7 micrometer (top of panel) to 25 micrometer (bottom of panel) body primer film wedge wet-on-wet over the sealer and bake for 8 minutes at 135 +/- 1 C metal temperature. Spray a 7 micrometer (top of panel) to 25 micrometer (bottom of panel) topco
22、at film wedge and bake for 10 minutes at 130 +/- 1 C metal temperature. Apply current production paint as identified by the B&CE Materials and Corrosion Protection Engineering Office. 3.13.2 Condition the test panels for 1 h at 23 +/- 2 C. 3.13.3 With moderate pressure, rub the painted sealer with a
23、 white cotton cloth. No paint shall transfer onto the cloth. 3.14 SHEAR ADHESION, (SAE J1523, substrate per para 4.2, 3 mm bondline thickness, 6.54 cm overlap,test at a crosshead speed of 25 mm per min, material bake schedules per para 4.3) Min Bake Max Bake Exposure Exposure 3.14.1 As received mate
24、rial 310 N min 800 N min 3.14.2 Aged material (Material aged in closed container 310 N min 800 N min for 72 h at 41 +/- 1 C) 3.15 HARDNESS, DUROMETER “A“ (ASTM D 2240) The hardness tolerance for any one supplier shall be +/- 5 points, based on the original approved production sample. Test Method: Ap
25、ply enough material into a container (such as an ointment tin) to give a 6 mm thickness slab. Bake material at 135 +/- 1 C for 30 minutes. Condition test sample at 23 +/- 2 C for 4 h, then check instantaneous material hardness. ENGINEERING MATERIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, Ford Gl
26、obal Technologies, LLC Page 6 of 11 3.16 ABRASIVE None Test Method: Dilute a 1 g sample of the material with 1 g of M14J167 special spirits or equivalent, and mix thoroughly. Rub a portion of the diluted material 100 times between 2 pieces of flat, clean plate glass. The appearance of scratches on t
27、he glass plate shall be considered failure. 3.17 SPRAYABILITY Shall be suitable for use in the airless spray equipment designated by the Paint Operation Activity. 3.18 UNDERBODY STONE ABRASION (SAE J400, for North America only) Less than 5% average material loss per test area per panel and less than
28、 5 average rust point per test panel after 72 h. Test Method: Spray apply sealer to a dry film thickness of 0.5 mm to five 100 x 300 x 0.8 mm electrocoated panels. Bake the panels according to the minimum bake schedule per para 4.3. Subject the bottom portion of the panels to 4.75 L of stones total,
29、 0.475 L at a time. Use 7 gauge aluminum backing plate. Manually remove (without rubbing or abrading) all loose and/or blistered materials. Report percentage of material lost (per panel and average over all panels). Ignore any material loss within 5 mm of panel edge. After abrasion testing is comple
30、ted, condition the panels in an environmental chamber. Use Corrosion Resistance test (CETP 00.00-L-467, 2 weeks). Remove the panels and carefully scrape off remaining sealer with spatula. Record the number of rust spots per panel. Report the average number of rust spots over the 5 panels. ENGINEERIN
31、G MATERIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, Ford Global Technologies, LLC Page 7 of 11 3.19 ABRASION RESISTANCE (ASTM D 968 for Europe only) There shall be no exposed metal area showing after 300 L gravel impact. No loss of adhesion on and around the area of stone impact. Panel Preparatio
32、n: Test panels of 300 x 100 mm (prepared according to FLTM BI 120-01) shall be coated with the material under test in such a manner (airless) that after curing a dry coating thickness of 0.5 - 0.65 mm is obtained. After 10 minutes at 23 +/- 2 C cure test specimens separately according to FLTM BV 150
33、-05 for the individual region a) min curing cycle b) max curing cycle Condition for 2 h at 23 +/- 2 C and expose in mechanical convection oven maintained at 70 +/- 2 C for 120 h. Test Method: After conditioning for 24 h at 23 +/- 2 C, determine the abrasion resistance according to ASTM D 968, except
34、 I.D. of tube 25 mm and at a gravel throughput rate of 30 - 40 liters/h. For each specimen a 5 L volume of fresh gravel shall be used. Check for abrasion resistance and loss of adhesion after 300 L gravel impact. Continue abrasion test until exposure of metal area and again check for loss of adhesio
35、n. Gravel: Type “GABBRO“ grain size 5 - 8 mm Possible Supply Source: ODENWAELDER HARTSTEIN INDUSTRIE GMBH Lise-Meitner-Str. 35 D 63457 Hanau 3.20 ODOR Rating 3 max (FLTM BO 131-03, for interior application only) 3.21 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditionin
36、g 16 hrs.) Fog Number 70 min Any fog film present shall be examined for the formation of droplets or coalescence into a clear film. Such conditions, if present, shall be cause for rejection. Uncured and cured samples shall be tested. ENGINEERING MATERIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, F
37、ord Global Technologies, LLC Page 8 of 11 3.22 STORAGE STABILITY The material shall be stored at temperatures below 40 C away from all sources of heat and sunlight. Heat greatly accelerates aging. Under these storage conditions, the shelf life of the material shall be 4 months from date of manufactu
38、re. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature prior to application. Adequate conditioning permits the material to obtain its optimum application properties. Material may not be used after the expiration date unless the supplier has give
39、n written documentation to Materials Engineering and the affected Manufacturing Plant that the material conforms to requirements outlined in the material control plan. The supplier shall also indicate in the letter the number of additional days the material will be usable. 3.23 FUNCTIONAL APPROVAL M
40、aterials being evaluated for initial specification shall be subjected to a production trial. Functional trial results should be available to Design and Materials Engineering prior to material approval and release. 3.24 TESTING REQUIREMENTS Test Material Approval Functional Trial Annual Every Lot 3.2
41、 Solids, Min (ASTM D2834) X X 3.3 Ash (ISO 3491) X 3.4 Weight Per Volume (ASTM D 816) X X 3.5 Viscosity (SAE J1524, VIS-2) X X 3.6 Bridging X X 3.7 Sag Resistance X X 3.8 Adhesion X X 3.9 Heat Resistance Test X X 3.10 Corrosion Resistance Test (CETP 00.00-L-467) X 3.11 Mandrel Bend Test (FLTM BV 122
42、-01) X X 3.12 Crack Resistance, Min (FLTM BV 115-01) X X 3.13 Compatibility with Production Paints X 3.14 Shear Adhesion (SAE J1523) X 3.15 Hardness (ASTM D2240) X X 3.16 Abrasive X 3.17 Sprayability X 3.18 Underbody Stone Abrasion (SAE J400) X 3.19 Abrasion Resistance (ASTM D968) X ENGINEERING MATE
43、RIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, Ford Global Technologies, LLC Page 9 of 11 3.20 Odor (FLTM BO 131-03) X X 3.21 Fogging (SAE J1756) X X 3.22 Storage Stability X 3.23 Functional Approval X X 4. GENERAL INFORMATION The information given below is provided for clarification and assistanc
44、e in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 MECHANICAL CONVECTION OVEN The mechanical oven(s) used to cure the material shall be capable of obtaining 205 C metal temperature on body steel (0.8 - 0.9 mm thickness) wit
45、hin 8-10 minutes. 4.2 SUBSTRATES Nominal panel dimensions are 0.8 x 100 x 300 mm. Electrocoat primed steel panel: Use current production paints as identified by the Paint Engineering. 4.3 MATERIAL CURE SCHEDULES 4.3.1 Minimum (includes two bakes): First Bake: 8 minutes at 135 +/- 1 C metal temperatu
46、re Second Bake: 8 minutes at 120 +/- 1 C metal temperature plus 3 minutes at 130 +/- 1 C metal temperature 4.3.2 Maximum : 20 minutes at 177 +/- 1 C metal temperature 4.4 ASH 40% 4.5 WEIGHT PER VOLUME, Typical 0.87 kg/L (Refer to para 3.4) 0.93 kg/L sprayed 4.6 COLOR Gray or as specified by B&AGO Pa
47、int Operation Activity 4.7 VOLATILE ORGANIC CONTENT 1500 max ppm ENGINEERING MATERIAL SPECIFICATION WSS-M4G252-E2 Copyright 2016, Ford Global Technologies, LLC Page 10 of 11 4.8 ALCANE RESTRICTION (European use and for interior applied materials only) (VDA 278 (Thermodesorption) The supplied materia
48、l shall not contain Alcanes (n-Aliphates as C10H22 thru C16H34) based on VOC test method and requirements. 4.9 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering.
49、The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Proces
