1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 03 2015 04 06 Revised Activated -A5/-A6. Revised A, A3, A4 J. Herl EU (See Summary of Revisions) 2011 09 20 Revised See Summary of Revisions B. Wtikowski, NA 1995 05 15 Activated A, A3, A4 N. E. Lindsay, G. A. Molnar Controlled document
2、at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 10 SEALER, EXPANDING, PUMPABLE, ANTI-FLUTTER, WSB-M4G348-A 35 - 55 A HARDNESS SEALER, EXPANDING, PUMPABLE, ANTI-FLUTTER, WSS-M4G348-A3 10 - 20 A HARDNESS SEALER, NON-EXPANDING, PUMPABLE, ANTI-FLUTTER, WSS-M4G348-A4 25 45 A HARDNESS
3、SEALER, LOW EXPANDING, PUMPABLE, ANTI-FLUTTER, WSS-M4G348-A5 5-10 A HARDNESS, ELONGATION 100-200% SEALER, LOW EXPANDING, PUMPABLE, ANTI-FLUTTER, WSS-M4G348-A6 5-10 A HARDNESS, ELONGATION 50-100%, SPECIFIED DAMPENING PROPERTIES 1. SCOPE The materials defined by these specifications are pumpable, expa
4、nding and non-expanding anti-flutter sealers. 2. APPLICATION These specifications were released originally for sealers used to isolate inner from outer closure panels, and body and roof reinforcements from exterior sheet metal areas normally inaccessible after welding operations. The materials can b
5、e applied over oily metal surfaces and expand when processed through the electrocoat bake oven. Anti-flutter materials are required to perform in a number of applications and closure designs. Each design and/or application has unique requirements. Compliance with this materials specification does no
6、t guarantee the anti-flutter will function for all potential applications on a vehicle. Selection of the appropriate material should therefore be based on jury evaluations or other NVH test procedures as well as the required functional trial. Note: Material defined by WSS-M4G348-A3 replaces the form
7、er ESB-M4G60-B and ESB-M4G60-B2. 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). ENGINEERING MATERIAL SPECIFICATION WSB-M4G348-A WSS-M4G348-A3/A4/A5/
8、A6 Copyright 2015, Ford Global Technologies, LLC Page 2 of 10 3.2 SYSTEM COMPATIBILITY Initial sealer approval was based on a specific material system which included the substrate, stamping lubricants and sealer. Substrate choice, stamping lubricants, stamping plant processing conditions, assembly p
9、rocessing condition may affect sealer performance. If any of these parameters are changed, the sealer performance must be validated using these parameters. Material Consistency and Process Compatibility Materials shall be a smooth homogenous mixture, free from entrapped air, foreign materials and pr
10、operties 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 of phosphating, electrocoat primer or other materials applications. All bulk mastic
11、, 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 base of the next refill and will not affect the quality of the refilled certified pr
12、oduct 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 new, and other ratios defined at approval. Supplier shall present data to manufactu
13、ring 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 sytem information, the VO procedure should be reviewed as master for the process, reference(VOPGNN002). No minitote should be ref
14、illed with residual material exceeding the above mentioned amount and should be returned to the plant of origin for follower plate removal and container/residual material disposal. The follower plate will be returned to the supplier after extraction by the plant of origin for insertion into a new dr
15、um. (VOPGNN002) 3.3 SOLIDS 98% min (ASTM D2834, except heat at 100 +/- 2 C for 3 h in a mechanical convection oven. Save sample for next test, para 3.4) 3.4 ASH 70% max (ISO 3491, Method A, 760 +/- 30 C based on the solids weight) 3.5 WEIGHT PER VOLUME (ASTM D816) The weight tolerance for any one su
16、pplier shall be +/- 0.02 kg/L, based on the recorded weight of his original approval production sample (refer to para 4.1). 3.6 VISCOSITY (SAE J1524, VIS-2, 2.64 mm orifice, 550 kPa) 3.6.1 As Received +/- 10 s (Conditioning Method B) 3.6.2 Aged No more than 50% (Material aged in closed container inc
17、rease from original for 72 h at 40 +/- 1 C, conditioning approval Method B) ENGINEERING MATERIAL SPECIFICATION WSB-M4G348-A WSS-M4G348-A3/A4/A5/A6 Copyright 2015, Ford Global Technologies, LLC Page 3 of 10 The viscosity tolerance for any one supplier shall be +/- 10 s, based on the recorded viscosit
18、y of the original approved production sample. Reference para 4.2. 3.6.3 90 day Storage Stability at 23 +/- 2 C and 32 +/- 2 C The supplier shall provide a viscosity profile versus time from initial through 90 days storage at 23 +/- 2 C and 32 +/- 2 C. Measurements shall be taken at weekly intervals.
19、 Curves shall be made available to Materials Engineering prior to addition to the Approved Source List. Final approval of a specified material viscosity for production shipments shall be made by the affected manufacturing activity. In all cases, the viscosity shall be within specification limits as
20、identified on the material control plan. 3.7 HARDNESS (ISO 868, instantaneous reading, cure material for 30 min oven time at 182 C, cool to 23 +/- 2 C) WSB-M4G348-A Shore A 35 55 WSS-M4G348-A3 Shore A 10 25 WSS-M4G348-A4 Shore A 25 45 WSS-M4G348-A5 Shore A 5 10 WSS-M4G348-A6 Shore A 5 - 10 The hardn
21、ess tolerance for any one supplier shall be +/- 5 based on the recorded hardness of their originally approved production sample. 3.8 COLOR The material color shall meet manufacturing process control requirements. Final approval of material color for production shipments shall be made by the affected
22、 manufacturing activity. The material color for any one supplier shall not visually deviate from the originally approved production sample. Reference para 4.3. 3.9 FOGGING (SAE J1756 use max curing condition and 10g of material) Fog Number 60 min The formation of droplets or coalescence into a clear
23、 film is cause for rejection. 3.10 ELECTROCOAT COMPATIBILITY (FLTM BV 119-01) Shall not contaminate electrocoat primer bath or cause electrocoat film irregularities 3.11 WASH RESISTANCE (FLTM BV 116-01, Method A, 1.5 mm material thickness) No wash off ENGINEERING MATERIAL SPECIFICATION WSB-M4G348-A
24、WSS-M4G348-A3/A4/A5/A6 Copyright 2015, Ford Global Technologies, LLC Page 4 of 10 3.12 SAG RESISTANCE 3.12.1 Horizontal 3 mm max 3.12.2 Vertical 3 mm max 3.12.3 Inverted No loss of material Test Method: . Apply a 13 x 25 x 200 mm ribbon of material along the center line of three panels for each subs
25、trate per para 4.6. . Scribe panels to mark the initial material location. . Position one panel for each substrate in the positions per para 3.12.1, 3.12.2 and 3.12.3 and condition at 23 +/- 2 C for one hour. . Immediately after conditioning, place panels in an oven to cure material at the minimum b
26、ake schedule per para 4.5. 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. . Repeat the above procedure for the max bake schedule per para 4.5. 3.13 SLIDE RESIS
27、TANCE 3.13.1 Vertical Free Standing 3 mm max Test Method: . Prepare three panels for each substrate per para 4.6. Apply five drops of sealer, 20 mm diameter x 20 mm height, per panel per substrate, Figure 1. . Scribe panels at top of drop to mark initial material location. . Place panels in a vertic
28、al position and allow panels to sit undisturbed for 21 days at 23 +/- 2 C. . Determine the slide by measuring the material movement below the scribe mark. . Bake panels at minimum bake per para 4.5. 3.13.2 Vertical Sandwiched 3 mm max Test Fixture Preparation: . Prepare three fixtures per Figure 2 f
29、or each substrate per para 4.6. Test Method: ENGINEERING MATERIAL SPECIFICATION WSB-M4G348-A WSS-M4G348-A3/A4/A5/A6 Copyright 2015, Ford Global Technologies, LLC Page 5 of 10 . Apply five drops of sealer to the bottom panel for each substrate using drop sizes described in para 3.13.1. . Scribe panel
30、s at top of drop to mark initial material location. . Assemble test fixtures per Figure 2. . Expose panels to the following cycle. Place fixtures in a vertical position during exposure: -40 +/- 1 C for 7 days PLUS 38 +/- 1 C and 98 +/- 2% RH for 7 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for
31、1 day . Bake panels at minimum bake per para 4.5. . Separate test fixtures. . Determine the slide by measuring the material movement below the scribe mark. 3.14 VOLUME EXPANSION FLTM BV 108-02, bake schedules per para 4.5 A/A3/A4 100-200% A5/A6 (depending on curing condition) 30-100% The volume expa
32、nsion for any one supplier shall be +/- 15%, based on the recorded volume expansion of the original approved production sample. Reference para 4.4. 3.15 WATER ABSORPTION (FLTM BV 117-01, Method A, use samples prepared in para 3.14) A/A3/A4 5% max A5/A6 2% max 3.16 CROSS LAP ADHESION, min (FLTM BV 10
33、1-04, bondline thickness after bake 4 mm, substrates per para 4.6, material bake schedules per para 4.5) A/A4 A3 A5/A6 3.16.1 Normal, Unexposed 200 kPa 150 kPa 100 kPa 3.16.2 Thermal Cycle 200 kPa 150 kPa - (SAE J2100, para 4.8) 3.16.3 21 days at 50 +/- 2 C and 150 kPa 100 kPa - 90 +/- 5% Relative H
34、umidity 3.16.4 Ford 00.00-L-467 150 kPa 100 kPa - (FSMS/CETP Test Method, 6 weeks) 3.17 SHEAR ADHESION STRENGTH, min (SAE J1523, except 0.75 mm bondline thickness, ENGINEERING MATERIAL SPECIFICATION WSB-M4G348-A WSS-M4G348-A3/A4/A5/A6 Copyright 2015, Ford Global Technologies, LLC Page 6 of 10 25.4 m
35、m overlap, crosshead speed of 25 mm/minute. Substrate per para 4.6, material cure schedules per para 4.5) A/A4 A3 A5/A6 3.17.1 Normal, Unexposed 350 kPa 250 kPa 200 kPa 3.17.2 Thermal Cycle 350 kPa 250 kPa 200 kPa (SAE J2100, para 4.8) 3.17.3 21 days at 50 +/- 2 C and 250 kPa 200 kPa - 90 +/- 5% Rel
36、ative Humidity 3.17.4 Ford 00.00-L-467 250 kPa 200 kPa 150 kPa (FSMS/CETP Test Method, 6 weeks) 3.18 COLD ADHESION (FLTM BV 101-02, Procedure E, 13 mm No cracking or material thickness, oily steel and adhesion failure aluminum substrate, bake schedules per para 4.5) 3.19 SPONGE AND CELL STRUCTURE AF
37、TER CURE Test Method: Cross sectional observation of the sponge shall be made by cutting through the skin and sponge mass of a baked specimen. The sponge system shall be visually examined. 3.20 ABRASIVES None Test Method: . Dilute a 1 g sample of the material with 1 g of M14J167 special spirits or e
38、quivalent, 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 the glass plate shall be considered failure. 3.21 STORAGE STABILITY The material shall be stored at temperatures below 40 C, away from all sour
39、ces of heat and sunlight. Heat greatly accelerates aging. Under these storage conditions, the shelf life of the material shall be 3 months. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature prior to application. Adequate conditioning permits th
40、e material to retain its optimum application properties. 3.22 ODOR/QUALITY Material shall be a smooth homogenous product free from abrasive particles, it shall be consistent in color and texture, and free from objectionable odors during normal storage. It shall be suitable for the intended applicati
41、on. 3.22.1 Odor Rating 3 max (FLTM BO 131-03, method D) Materials not meeting this requirement must be reviewed by regional materials engineering activity and may be used if vehicles are not exported out of region. ENGINEERING MATERIAL SPECIFICATION WSB-M4G348-A WSS-M4G348-A3/A4/A5/A6 Copyright 2015
42、, Ford Global Technologies, LLC Page 7 of 10 Materials exceeding the above level and used outside of a region must be tested and approved by the materials engineering within the regions where vehicles will be shipped. 3.23 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specificat
43、ion 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 approval and release. 3.24 TESTING TO FAILURE Suppliers must submit a mutually
44、 agreed upon testing 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 Materials Engineering. 3.25 MODULUS (-A5 / -A6 only) 0.5 MPa max Procedur
45、e: adhesive applied between teflon papers (with 2 mm teflon distance holders) and cured in a heated press at 180C for 35 min). From the resulting material, test pieces are cut (dimensions according to Figure5 DIN EN ISO 527-3 thickness h=2mm) and tested at 23C 50% RH with a cross-head speed of 50 mm
46、/min Secant between 0.5 - 5.0% elongation 3.26 ELONGATION AT BREAK (-A5 / -A6 only) -A5 100 200 % -A6 50 100 % procedure as described above (#3.25). 3.27 DAMPING PROPERTIES (-A6 only) (ISO 6721-4) Supplier shall furnish report demonstrating loss factor vs frequency at target bake conditions. Minimum
47、 Damping Loss Factor Targets (“R” = Report only) Temperature (C) 1 Hz 10 Hz 101 Hz 200 Hz 400 Hz -20 R R R R R -10 R R R 0.5 0.5 0 R R R 0.5 0.5 10 R R R 1 1 20 R R R 1 1 40 R R R 0.5 0,5 60 R R R R R 3.28 CORROSION RESISTANCE (Ford 00.00-L-467, 6 weeks) Test panels of 200 x 100 x 0.8 mm shall be co
48、ated by material under test centrally 10 mm away from the edges to produce the min required dry thickness of 0.75 mm. Panels shall be baked separately for the min and max curing cycles acc. to FLTM BV 150-05 for the applicable region, then condition for 24 h at 23 +/- 2 C. 3.25.1 Test material on ba
49、re substrates (no-ecoat). ENGINEERING MATERIAL SPECIFICATION WSB-M4G348-A WSS-M4G348-A3/A4/A5/A6 Copyright 2015, Ford Global Technologies, LLC Page 8 of 10 3.25.2 Test on e-coated (after applying the sealer) substrates. The material shall protect the test panel from corrosion. Disregard the area 10 mm from the edges of test panel. Under the material and at the border line of material edges there shall be no visible c
