1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 03 09 Revised Revised 2., 3.4.8, 3.4.9, 3.4.10, 3.4.11, 3.4.14, 3.4.18.1; Inserted 3.6, 3.7, 3.7.1, 3.7.1.1, 3.7.1.2, 3.7.1.3, 3.8, 5.1, 5.2, 5.3; Deleted 3.5 B. trecht 2007 01 19 Revised Added A5; Revised Title A2 Revised 1, 3.4.4 to 3.4
2、.7, 3.4.11, added 3.5 WS Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 8 SEALER, HEAT CURING, TAPE, SPOT WELDABLE, EXPANDING WSK-M4G325-A1 SEALER, HEAT CURING, PUMPABLE, SPOT WELDABLE, LOW EXPANDING WSK-M4G325-A2 WSK-M4G325-A3 SEALER, HEAT CURING, PUMPABLE,
3、SPOT WELDABLE, HIGH EXPANDING WSS-M4G325-A4 SEALER, HEAT CURING, PUMPABLE, SPOT WELDABLE, EXPANDING WSS-M4G325-A5 1. SCOPE The materials defined by these specifications are spot weldable, heat curing, heat expanding sealers based on polyisobutylene or polyacrylic ester. 2. APPLICATION WSK-M4G325-A1:
4、 This specification was released originally for dimensioned materials used for sealing spot weld joints on the body-in-white. It is applied to oiled surfaces in the form of self adhesive strips. WSK-M4G325-A2/A3: These specifications were released originally for non-dimensioned materials used for se
5、aling spot weld joints on the body-in-white. It is applied to oiled surfaces by an extrusion apparatus. WSK-M4G325-A4/A5: These specifications were released originally for non-dimensioned materials used for sealing joints in BIW. It is applied to oiled surfaces by an extrusion apparatus. The materia
6、ls are applicable on oiled surfaces with acceptable oil film weights (European applications limit the oil/pre-lubricant film weight to max 3 g/m, see para. 3.7). Note: Care must be taken to ensure that the local oil film weight in the area of the adhesive/sealer application does not exceed the criti
7、cal limit. Monitoring of the film thickness, adequate storage of the part and/or cleaning of the surface prior to sealer/adhesive application is necessary to avoid critical film thickness values, which would then cause malfunction of the sealer/adhesive. 3. REQUIREMENTS: Material specification requi
8、rements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Pri
9、nted copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 8 3.4 PERFORMANCE REQUIREMENTS A1 A2/A3/A4/A5 3.4.1 Color Black Black 3.4.2 Solids, %, min 99 85 (FLTM BV 150-10) 3.4.3 Ash, %, max 50 45 (FLTM BV 150-10) 3.4.4 Flash Point 56 C (ASTM D 56) 3.4.5 Density at 20 C 1.0
10、 to 1.6 g/cm3(ASTM D 1475, tolerance +/- 0.05 g/cm3, based on the recorded density of suppliers original approved sample) 3.4.6 Penetration at 23 C (A1 only) (ASTM D 5, 0.981 N total weight force, 5 s dwell time) 3.4.6.1 As received 60 - 90 3.4.6.2 After ageing 50 - 90 (14 days at 30 +/- 2 C) Note:
11、See 3.4.7 3.4.7 Viscosity at 23 C, s (A2/A3/A4/A5 only) (FLTM BV 103-01, line pressure 0.392 MN/m2, nozzle dia. 2 mm) A2/A4/A5 A3 3.4.7.1 As Received 70 200 10 - 20 3.4.7.2 After Ageing, max 200 100 (14 days at 35 +/- 2 C) Note: Final approval of a specific viscosity of material for production shipm
12、ents shall be made by affected Manufacturing Division. In all cases, however, the viscosity shall be within the limits specified above and shall meet all requirements of this specification (Control Sample Laboratory Report). A1 A2/A3/A4/A5 3.4.8 Flow Rate, max No flow 3 mm (FLTM BV 153-01, Method A,
13、 except oiled panels acc. to para. 3.7. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 8 3.4.9 Cold Resistance After Ageing No loss of adhesion, no chipping. Test Method: (a) Apply 250 x 30 x 3 mm ribbons of
14、material under test to 300 x 100 mm test panels prepared according para 3.7. (b) Expose test assemblies according to FLTM BV 150-05, Table 2 for: . minimum curing cycle (165 C, 10 Materials Temp in EC oven) . maximum curing cycle (c) Expose test assemblies in a mechanically convected air-dry oven at
15、 80 +/- 2 C for two weeks. (d) After cooling to 23 +/- 2 C expose test assemblies and bending fixture (see FLTM BV 153-04, except 100 mm mandrel) in a cold box at -30 +/- 1 C for 4 h. (e) While still in the cold box, bend test assemblies within 2 s around the 100 mm mandrel through an angle of 90. 3
16、.4.10 Wash-off Resistance (A2/A3/A4/A5 only) No wash-off of sealer, deformation of sealer surface permitted. Test Method: (a) Apply two ribbons of material under test 250 x 30 x 3 mm and 50 mm apart from each other to a 300 x 300 mm oiled panel, prepared in accordance para. 3.7. (b) After conditioni
17、ng for 2 h at 23 +/- 2 C expose test assembly in horizontal position to a water jet of 50 +/- 5 C using a nozzle No. 1/2 GG-25 Full Jet and a pressure of 200 kN/m2. The distance between the nozzle and test material shall be 300 mm. The water jet shall be applied between the beads for 1 minute. 3.4.1
18、1 Wash and Phosphating Solution Resistance A. Non-Cured Material No evidence of dissolution of material or lifting from panel. Test Method: (1) Apply 250 x 40 x 0.1 - 0.2 mm ribbons of material under test to 250 x 60 mm oiled test panels, prepared according to para. 3.7. (2) After conditioning for 2
19、 h at 23 +/- 2 C expose test assemblies one after another in each wash and phosphating solution of the affected plant where this material is to be used and maintain for 15 minutes at 60 +/- 1 C. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford G
20、lobal Technologies, LLC Page 4 of 8 B. Cured Material No loss of adhesion, no chipping Test Method: (1) Test specimens as prepared and tested under para 3.4.10 shall be exposed for 20 minutes in a mechanically convected air-dry oven at 100 +/- 2 C, and subsequently subjected to maximum curing cycle
21、according to FLTM BV 150-05, Table 2, Phase 1 and 2. (2) After cooling to 23 +/- 2 C test according to FLTM BV 153-04, Method A, para 4 and 5, except -30 +/- 1 C. 3.4.12 Welding Acceptance Test (For A1 use FLTM BV 159-02, for A2/A3/A4/A5 use FLTM BV 159-01) The sealer shall be weldable immediately u
22、pon application and after 30 days storage at temperatures below 40 +/- 2 for C. 3.4.13 Flammability and Corrosion Self extinguishing (FLTM BV 159-02, Method A) within 5 s, no corrosion Immediately after welding, separate the welded parts using a test fixture according to FLTM BV 159-01, Fig. 4. Exam
23、ine after 48 h at 23 +/- 2 C. 3.4.14 Wetting (FLTM BV 153-08, Method A) The paint film (paint materials shall be noted in the Initial Sample Report of the adhesive, see also para 5.3) shall cover the sealer with a continuous film. Discoloration or staining permitted. 3.4.15 Tensile Strength, (A2/A3/
24、A4/A5 only) (FLTM BV 154-03, Method A, Type I, x = 3 mm, after 10 minutes at 23 +/- 2 C minimum and maximum heat curing cycle to FLTM BV 150-05, Table 2, test at 23 +/- 2 C) 3.4.15.1 Tensile Strength, min 10 N/cm23.4.15.2 After Heat Aging (500 h at 80 C, A4 only) max. deviation from original +/- 10%
25、 3.4.16 Adhesion Strength After Curing (A1 only) (FLTM BV 154-03, Method B and C, preparation of test panels according to Section I, 8 mm dia. test strips compressed to x = 3 mm, minimum and maximum heat curing cycle to FLTM BV 150-05, Table 2) ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Prin
26、ted copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 8 3.4.16.1 Shear Strength, min 3 N/cm2(Method B at 23 +/- 2 C) 3.4.16.2 Peel Strength, min 10 N/cm (Method C at 23 +/- 2 C) 3.4.17 Resistance to Corrosion No Corrosion, Blisters or loss of Adhesion The material shall
27、 protect the test panel from corrosion. Test Method: (a) Test panel preparation according to FLTM BV 159-02, Method A. (b) After 2 h at 23 +/- 2 C wash, phosphate and electrocoat test assemblies under normal production conditions. (c) Expose test assemblies according to FLTM BV 150-05, Table 2: . mi
28、n curing cycle . max curing cycle (d1) For Cold rolled Steel. After 24 h at 23 +/- 2 C expose test assemblies to a salt spray fog according to ASTM B 117 for 480 h. (d2) For Precoated Steel. After 34 h at 23 C +/- 2 C expose assemblies to a Scab Corrosion Test (FLTM BI 123-01) for 50 cycles. (e) Sep
29、arate welded assemblies using a test fixture according to FLTM BV 159-01, Fig. 4 and examine. 3.4.18 Water Absorption, 3.4.18.1 (FLTM BV 153-07) max 1% Curing conditions acc. To FLTM BV 150-05 Table 2 min. curing 10 Min. 175 C 3.4.18.2 After Heat Aging (500 h at 80 C, A4/A5 only) max. deviation from
30、 original +/- 10 % After heat aging the foam must meet the requirements of paragraph 3.4.20. A1 A2/A3 A4 A5 3.4.19 Volume Expansion, % 25 65 25 55 300 400 100 - 200 Test Method: (a) Determine the volume V1 of clean 150 x 25 mm test panels. (b) Apply test strips, 8 mm in diameter and 100 mm in length
31、 (see sketch in FLTM BV 153-07) and determine volume V2. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 6 of 8 (c) Expose test assemblies separately according to FLTM BV 150-05, Table 2: . minimum curing cycle (16
32、5 C, 10 Materials Temp in EC oven) . maximum curing cycle, Phase 1 and 2. (d) After cooling to 23 +/- 2 C determine volume V3. Note: Determine volumes by water displacement. The volume increase in % of the original volume shall be determined as follows: % Volume Expansion = V3 - V2 - x 100 V2 - V1 W
33、here: V1 = Volume of test panel V2 = Volume of test panel and sealing strip V3 = Volume of test panel and sealing strip after cure For Information only: Show tables and curves “Time over Volume expansion at different Temperatures (e. g. 110 C to 140 C)”. This has to be mentioned in the PSW 3.4.20 St
34、ructure of Curing The sealer shall form a closed skin after heat curing. The inner cell structure shall be fine without large voids. Test Method: (a) Preparation of test assemblies according to FLTM BV 153-07, paragraph 1 to 3. (b) After cooling to 23 +/- 2 C test specimens are cut through and exami
35、ned visually. 3.4.21 Corrosion Resistance, Proving Ground (European Production) New material technologies require LPG/APG approval prior to their introduction. Test details including film thickness, method of application, number of test cycles, etc. for the individual cars are defined by Materials E
36、ngineering, Body & Materials Engineering. 3.6 QUALITY The adhesive shall be a smooth, homogeneous mixture, free from foreign materials. The material must be adaptable for application in accordance with the appropriate Ford Motor Company Process Specification and must be compatible with all related m
37、aterials. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 7 of 8 3.7 OIL COMPATIBILITY & REFERENCE OIL (For Europe) All materials released to this specification must be applicable to oiled surfaces, including corro
38、sion protection oil, wash oils, pre-lubricants, draw oils, hotmelts etc. The approved products for use in Ford of Europe or the European brands are listed in the applicable approved source list (contact materials engineering for details). The supplier must confirm the compatibility of the adhesive/s
39、ealer 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 (see para 3.7.1) must be oiled with maximum permissible oil film thickness. Ref
40、erence oil for adhesive performance comparison is Fuchs Anticorit 4107S. Attention: New compatibility tests are necessary if the oil grade of the affected part is changed! Nominal oil film weight is 1 - 1.5 g/m The maximum permissible oil weight for full adhesive performance is 3 g/m Note: All neces
41、sary actions must be taken to prevent any local oil film weight exceeding 3 g/m in the area of adhesive/sealer application. Critical areas are the lowest positions of parts during transport/storage, e.g. door hem flanges or other oil trapping areas. Unacceptable oil collection will require appropria
42、te storage geometries (critical areas turned to top) or in-process cleaning operations prior to sealer/adhesive application. 3.7.1 Oiling-Method of Lab Test Panels: 3.7.1.1 Test-Panel Cleaning Clean the test-panel with the lint-free cloth soaked with the solvent n-hexane. Rinse both sides of the tes
43、t panel with n-hexane until no process traces remain on the surface. Allow to dry at ambient-temperature until the n-hexane has completely evaporated. 3.7.1.2 Oiling the Test-Panel Small panels (Tensil, Shear-,Peel-Adhesion): Immediately after air drying, immerse the panel in a 250 ml glass beaker,
44、filled up to 200 ml with a mixture of approx. 10% n-hexane/90% reference oil. Prevent evaporation losses by covering the glass beaker with aluminum foil as airtight as possible. After immersion for 1 minute, remove the panel from the glass beaker. Allow the panel to drain in a vertical position at a
45、mbient temperature. Other panels (f.ex. Hardness): The cleaned panel should be warmed up for a short time in a heat cabin (for better oil-distribution). Apply some drops of oil on the panel and distribute them even over the panel with a lint-free cloth. Check the oil-weight. 3.7.1.3 Checking of Oil
46、Coating/Weight A test panel prepared as per 3.23.1.1 is weighed on an analytic scale with a precision of 0.001 g. After oiling weigh again. The oil coating in g/m is derived from the weight difference in relation with the panel-dimensions. If the oil-weight deviates approx. +/- 0.3 g/m from the spec
47、ified oil-weight, the panel can be used. Otherwise oil again or re-adjust the above mixture. ENGINEERING MATERIAL SPECIFICATIONWSK-M4G325-A1/A5 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 8 of 8 3.8 LINE TRIAL Materials being evaluated for approval to this spec
48、ification shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation. Results shall be made available to Materials Engineering prior to material approval and release. 5. GENERAL INFORMATION The information given below is provided for clarif
49、ication and assistance in meeting the requirements of these specifications. Specification WSK-M4G325-A1 WSK-M4G325-A2/A3/A4/A5 Paragraph (Dimensioned Material) (Non-dim. Material) 3.41 X X 23.43 X X -3.45 X X 6 -3.47 - X 8 X3.49 X 10 -3.4 X X 123.43 X X 143.45 X - 17 X3.48 X 19 X3.420 X 1 X5.1 STORAGE STABILITY (From date of receipt at Ford Motor Company) Min 6 months when stored between 5 C and 32 C in unopened drums out of direct sunlight. 5.2 OPEN ASS
