1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1997 12 01 Activated W. CurtissWP 3948-a Page 1 of 7SEALER/GASKET, FOAM-IN-PLACE NITROGEN WSS-M4G278-B3EXPANDING, THERMOSETTING, EXTERIOR1. SCOPEThe material defined by this specification is a sealant that is mix
2、edwith an inert gas such as nitrogen or carbon-dioxide to form an expandedelastomeric thermosetting foam gasket.2. APPLICATIONThis material is intended for use in areas where a water or dust seal,vibration isolator, or gap filling gasket is required. Theseapplications include, but are not limited to
3、: exterior trim and appliquevibration isololaters, rear stop lamp gaskets, and sealed lamp gapfillers. This material can be robotically applied.This specification does not define all the intended uses of thismaterial. Each application/substrate/coating/foam level combination mustbe evaluated accordi
4、ng to the applicable performance specificationand/or design requirements.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers and part producers must conform to QualitySystem Requirements, QS-9000. Material specification requirementsare to be used for initial qualification of materials.
5、A ControlPlan for ongoing production verification is required. This planmust be reviewed and approved by the relevant Ford Materialsactivity and/or Ford Supplier Technical Assistance (STA) prior toproduction parts submission. Appropriate statistical tools must beused to analyze process/product data
6、and assure consistentprocessing of the materials.Part producers using this material in their products, must use Fordapproved materials and must conform to a process control plan whichhas been approved by STA and/or the relevant Materials Activity.ENGINEERING MATERIAL SPECIFICATIONWSS-M4G278-B3WP 394
7、8-b Page 2 of 73.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may conduct infrared and/orthermal analysis of material/parts supplied to this specification.The IR spectra and thermograms established for initial approvalshall constitute the reference standard
8、and shall be kept on fileat the designated material laboratory. All samples shall produce IRspectra and thermograms that correspond to the reference standardwhen tested under the same conditions.3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on material conditionedin
9、a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested underthe same conditions unless otherwise specified.3.4 UNFOAMED BULK MATERIAL3.4.1 Solids, min 97 %(ASTM D 2834, except heat at 177 C for4 h in a mechanical oven)3.4.2 Ash +/- 5
10、%(ISO 3541, Method A, 760 +/- 30 C, basedon solids weight)The ash tolerance for any one supplier shall be +/- 5 %based on the recorded ash value of the original approvedproduction sample, reference para 5.2.3.4.3 Specific Gravity +/- 0.1(ASTM D 297)The specific gravity tolerance for any one supplier
11、 shallbe +/- 0.1 based on the recorded specific gravity of theoriginal approved production sample, reference para 5.3.3.4.4 Viscosity (Brookfield Thermosel), Pa*s +/- 25 %(ASTM D 1238, Procedure A, 100 deg C,spindle SC4-27, except an in-lineapparatus used with pump, adjustedto 5 rpm)The viscosity to
12、lerance for any one supplier shall be +/-25 % based on the recorded viscosity of the originalapproved production sample. In all cases, the viscosityshall be within the process limits as identified on thematerial control plan, reference para 5.4.3.5 FOAM DENSITY REDUCTION LEVELThe level of foam densi
13、ty reduction must be specified on theengineering drawing. Ultimate part performance is dependent on thelevel of density reduction. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G278-B3WP 3948-b Page 3 of 73.6 FOAMED GASKET MATERIALNote: Unless otherwise specified, testing is done at a foamreduction densit
14、y of 60 +/- 3%. The sample dimensions are 6 +/-0.3 mm diameter with an allowable 3 mm flat surface.Procedure: An unfoamed sample of the material is dispensed to aspecific volume. A foamed sample is dispensed to the same volume,the weights of both samples are recorded. Calculations are asfollows:1 -
15、weight of foamed sample/weight of unfoamed sample x 100 =PercentFoamReduction3.6.1 Tensile Strength, min 300 kPa(ASTM D 412, Die A)3.6.2 Elongation, min 250 %(ASTM D 412, Die A)3.6.3 Compression Set, max 20 % (ASTM D 1056, Method B, 25 % compressionat 70 +/-1 C for 22 h. 24 h at 23 +/-2 Cprior to me
16、asurement)3.6.4 Water Absorption 5 % max by(SAE J18, without vacuum, 24 h weightimmersion, 75 mm static head of water)3.6.5 Cold Flexibility No evidence ofcrackingTest Method: Expose a specimen 200 mm in length to atemperature of - 40 C for 5 h. Bend 180 degrees arounda 13 mm temperature controlled
17、mandrel.3.6.6 Compression/Deflection(ASTM D 1056, 30% compression, with1 minute dwell for deflection)Force to Compress 40 - 80 Deflection Force 20 - 60 kPa3.6.8 Environmental Resistance No flowing,endlifting orloss of adhesionand 1 mm sagENGINEERING MATERIAL SPECIFICATIONWSS-M4G278-B3WP 3948-b Page
18、4 of 7Test Method: Apply two 100 mm lengths of sealer material toa 300 x 300 mm electrocoated panel per para 5.5 (see figure1 for material placement). The cross-sectional area of thesealer shall be specified on the applicable part drawing.If none is specified, use 7 +/- 0.5 mm diameter material.Main
19、tain the panel in a vertical position and subject it tothe exposures listed below. Use one panel per exposure.3.6.8.1 2 weeks at 90 +/- 2 C3.6.8.2 Thermal/Humidity Cycling. 4 h at 90 +/- 2 C. 4 h at 38 +/- 2 C and 95 - 100 % relativehumidity. 16 h at - 30 +/- 2 C. 4 h at 90 +/- 2 C. 4 h at 38 +/- 2
20、C and 95 - 100 % relativehumidity. 16 h at - 30 +/- 2 C3.6.8.3 2 weeks at 38 +/- 2 C and 95 - 100 % relativehumidityNote: Environmental resistance shall be performedon all substrates identified for use (e.g. ABS,PVC, RIM, PE, PP, etc.). Test data shall beprovided to the appropriate materials enginee
21、ringactivity prior to system approval.3.6.9 Water Leak ResistanceEvidence of water leaks will be cause for rejection.Test Assembly preparation: A test specimen, 275 mm inlength shall be applied in a “U“ configuration to a 100 x150 mm electrocoated panel per para 5.5 (see figure 2 formaterial placeme
22、nt). The cross-sectional area of the sealershall be specified on the applicable part drawing. If noneis specified, use 7 +/- 0.5 mm diameter material. A 100 x150 mm electrocoated panel per para 5.5 shall be placedover the sealer material. The assembly shall be compressed10 % using spacers as a guide
23、. The fixture must be clampedor bolted to maintain the 10 % compression throughout theenvironmental exposures and test procedure.Expose 2 assemblies to each exposure condition shown below:3.6.9.1 24 h at 23 +/- 2 C3.6.9.2 2 weeks at 90 +/- 2 C3.6.9.3 2 weeks at 38 C and 98 +/- 2 % R.H.ENGINEERING MA
24、TERIAL SPECIFICATIONWSS-M4G278-B3WP 3948-b Page 5 of 73.6.9.4 Thermal Cycle(SAE J2100, para 4.8)3.6.9.5 30 minutes at 120 +/- 2 C (paint repair)3.6.9.6 2 weeks at - 30 +/- 1 C3.6.9.7 500 h Salt Spray(ASTM B 117)Test Method: Remove the assemblies from theenvironments listed above and condition for am
25、inimum of 4 h but not more than 24 h at 23 +/-2 C. Stand the assembly on edge with the openingof the “U“ channel up. Fill the channel to adepth of 100 mm (approximately 13 mm from the topedge) with colored water and let stand for 24 h.Observe for any evidence of water leaks. Note:Stand the test asse
26、mbly on a sheet of white paperfor easier water leak detection.3.7 FUNCTIONAL APPROVALMaterials being evaluated for approval to this specification shallbe subjected to a production trial. Functional trial results mustbe approved by the affected assembly operation(s) and DesignEngineering. Results sha
27、ll be made available to the appropriatematerials engineering activity prior to material approval andrelease.3.8 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manufactured parts shallbe specified on the Engineering drawing, Engineering partsspecification and/or performance specific
28、ation. All critical areaswith respect to these properties shall be clearly designated on theengineering drawing.3.9 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inall characteristics to the material upon which approval wasoriginally granted.Prior to making
29、any change in the properties, composition,construction, color, processing or labeling of the materialoriginally approved under this specification, whether or not suchchanges affect the materials ability to meet the specificationrequirements, the Supplier shall notify Purchasing, Toxicology andthe af
30、fected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Test data, test samples and a new code identification areto be submitted with the request.Substance restrictions imposed by law, regulations or Ford, applyto the materia
31、ls addressed by this document. The regulations aredefined in Engineering Materials Specification WSS-M99P9999-A1.ENGINEERING MATERIAL SPECIFICATIONWSS-M4G278-B3WP 3948-b Page 6 of 74. APPROVAL OF MATERIALSMaterials defined by this specification must have prior approval by theresponsible Materials En
32、gineering activity. Suppliers desiring approvalof their materials shall first obtain an expression of interest from theaffected Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity a completed copy of their labora
33、tory test reports, signed by aqualified and authorized representative of the test facility,demonstrating full compliance with all the requirements of thisspecification (test results, not nominal values), the materialdesignation and code number, and test specimens for Ford evaluation. Fords engineeri
34、ng approval of a material will be based on itsperformance to this specification and on an assessment of suitabilityfor intended processes and/or applications. Upon approval, the materialwill be added to the Engineering Material Approved Source List.5. GENERAL INFORMATIONThe information given below i
35、s provided for clarification and assistancein meeting the requirements of this specification5.1 COLOR Black or as specified onEngineering drawing5.2 ASH, typical 20 %5.3 SPECIFIC GRAVITY, typical 1.05 - 1.155.4 VISCOSITY, typical at 100 C 26 Pa*s5.5 SUBSTRATESElectrocoated primed steel panel: prepared per ESB-M2P4 performancespecification. Use current production paints as identified by theBody Engineering Office.ENGINEERING MATERIAL SPECIFICATIONWSS-M4G278-B3WP 3948-b Page 7 of 7
