1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2016 07 05 N Status Replaced by WSS-M18P20-A1 B. Witkowski, NA 1998 05 11 Activated W. Curtiss W. Scholz WP 3948-a Page 1 of 13 SEALER/TAPE, DUAL LAYER, HEAT CURING, WSS-M4G362-A PAINTABLE NOT TO BE USED FOR N
2、EW DESIGN 1. SCOPE The material defined by this specification is a heat curing dual layer sealer/tape; the top layer is a paintable, non-tacky, non-flowing film and the bottom layer is a flowable, thermosetting sealer. 2. APPLICATION This specification was released originally for material used to se
3、al the roof ditch joint and provide a smooth surface for adhesively bonding a roof ditch molding. The material is applied on the sealer deck after vehicle electrocoat. The film portion of the sealer/tape is paintable and is suitable for use on non-visible exterior surfaces. The sealer portion of the
4、 tape has flow properties providing a seal for the metal edge and any potential weld burn throughs. Note: Flow properties of this material may be adjusted depending on the application and plant conditions. The 45 degree flow must be specified on the engineering drawing. Material performance limits l
5、isted herein are representative of the sealer/tape released for the original application. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for initial qualifi
6、cation of materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to ana
7、lyze process/product data and assure consistent processing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. ENGINEERING MATERIAL S
8、PECIFICATION WSS-M4G362-A WP 3948-b Page 2 of 13 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval sh
9、all constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated
10、herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 DIMENSIONS As specified on engineering drawing and/or in Trim and Sealer man
11、ual 3.5 MATERIAL PROPERTIES 3.5.1 Solids (without film), min 98 % (ASTM D 2834, except heat at 102 +/- 3 C for 3 h in a mechanical convection oven) 3.5.2 Ash (based on solids weight) (ISO 3491, Method A, 760 +/- 30 C, reference para 5.2) The ash content tolerance for any one supplier shall be +/- 5
12、% based on the recorded ash content for their originally approved production sample. 3.5.3 Specific Gravity (uncured material - with film) (ASTM D 297, water displacement method: reference para 5.3) The specific gravity tolerance for any one supplier shall be +/- 0.1 based on the recorded specific g
13、ravity of their originally approved production sample. ENGINEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 3 of 13 3.5.4 Shelf Life 90 Day Storage Stability at 23 +/- 2 C and 32 +/- 2 C. The supplier shall provide flow properties and cured adhesion data from initial through 90 days storag
14、e at 23 +/- 2 C and 32 +/- 2 C. Measurements shall be taken at monthly intervals. Data shall be made available to Materials Engineering prior to addition to the Approved Source List. Note: Heat greatly accelerates aging. Storage conditions for materials conforming to the requirements of this specifi
15、cation may vary depending on the individual product chemistry. In all cases, shelf life at 23 +/- 2 C shall be a min of 45 d. 3.6 MANUFACTURING PROPERTIES (with and without polyester film) 3.6.1 Flow Properties Horizontal 45 degree 2 - 7 mm * Test Method: Horizontal Panels - Apply a section of seale
16、r/tape (with film) 150 x 25 +/- 0.1 to three 300 x 100 x 0.80 mm electrocoated steel panels per para 5.5. 45 Degree Panel - Apply a 3.7 cm2 section of sealer/tape (without film) to the center of three 300 x 100 x 0.80 mm electrocoated panels. Horizontal and 45 Degree Test - Preheat the panels for 15
17、 minutes at 110 +/- 2 C prior to sealer application. This will heat stake the sealer to the panel. Allow the panels to cool at 23 +/- 2 C for 30 minutes. Scribe the original location of the samples prior to baking. Horizontal Panels - Bake the panels flat per the min bake schedule in para 5.4. Repea
18、t this procedure for the max bake schedule. 45 Degree Panels - Bake the panels at a 45 degree orientation per the min bake schedule in para 5.4. Repeat this procedure for the max bake schedule. Remove panels from oven, cool, and measure material flow from original scribe. Save panels for para 3.7.4.
19、 *45 degree flow will be specified on the engineering drawing and on the part/material control plan. ENGINEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 4 of 13 3.6.2 Curl Test No curl allowed after 2 rebakes. Test Method: Apply a section of sealer/tape (with film) 150 x 25 +/- 0.1 to thr
20、ee 300 x 100 x 0.80 mm electrocoated steel panels per para 5.5. Preheat the panels for 15 minutes at 110 +/- 2 C prior to sealer application. This will heat stake the sealer to the panel. Allow the panels to cool at 23 +/- 2 C for 30 minutes. Prepare test panels per matrix in Table 1, process number
21、 2. Use current production paint as identified by the appropriate engineering office. Record any curling of the film after initial paint application. Using a razor blade, cut through the paint film at one side edge and the top edge of each sample. The cut shall be made approximately 1 mm away from t
22、he polyester film. Do not cut the polyester film. Subject the panel to an additional basecoat/clearcoat bake. Remove from oven and observe for evidence of curling. Repeat this procedure once more for a total of 3 basecoat/clearcoat bakes. Report any evidence of curling and the paint system used. ENG
23、INEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 5 of 13 3.6.3 Bridging 3.6.3.1 Overlap Joint Test Method: Prepare two test fixtures using 0.8 x 100 x 300 mm electrocoated panels prepared per para 5.5 as shown in Figure 1. FIGURE 1 BRIDGING TEST FIXTURE PREPARATION ENGINEERING MATERIAL SP
24、ECIFICATION WSS-M4G362-A WP 3948-b Page 6 of 13 Apply a 25 x 200 mm ribbon of material (with film) to each test fixture as shown in Figure 2. FIGURE 2 SEALER APPLICATION . Position ribbon such that it is centered over the seam. . Cure one test fixture at the min bake schedule per para 5.4. Subject t
25、he second test fixture to the max bake schedule per para 5.4. . Allow test fixtures to cool for 1 h at 23 +/- 2 C. . Inspection Test Method: . Inspect test fixture to insure that material has satisfactorily bridged raised portion of panel as shown in Figure 2, Section B. Any evidence of tearing will
26、 constitute a failure. ENGINEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 7 of 13 . Inspect test fixture to insure that material has satisfactorily bridged metal-to-metal portion of the panel as shown in Figure 2, Section A. Any evidence of gaping will constitute a failure. 3.7 ENGINEERI
27、NG REQUIREMENTS 3.7.1 Adhesion (with film) Shall not be removed in a continuous coherent film when subjected to the following environments. 3.7.1.1 Normal, 24 h at 23 +/- 2 C 3.7.1.2 Salt Spray, 500 h (ASTM B 117) 3.7.1.3 Thermal Cycle . 4 h at 90 +/- 2 C . 4 h at 38 +/- 1 C and 95 - 100 % relative
28、humidity . 16 h at - 30 +/- 1 C . 4 h at 38 +/- 1 C and 95 - 100 % relative humidity . 4 h at 90 +/- 2 C . 16 h at - 30 +/- 1 C Sample preparation: SAE J1600, Method B, with the following modifications: . Apply a 75 x 200 mm strip of material along the center line of two electrocoated steel panels p
29、repared per para 5.4. . Cure the material per bake schedules in para 5.5. Report failure mode. 3.7.2 Low Temperature Resistance No cracking or (FLTM BV 101-02) loss of adhesion Place the panels prepared in para 3.6.1 in the slamming apparatus. Condition 4 h at - 40 +/- 1 C. The panel shall be slamme
30、d a total of 20 times. ENGINEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 8 of 13 3.7.3 Compatibility with Production Paints - Initial Requirements No tackiness, staining, discoloration, dulling, softening, paint transfer, significant color shift, difference in orientation of metallic fl
31、akes (metallic paints) or other objectionable appearance defects in the paint over the sealer. Note: Evidence of any defects as stated above shall be reviewed with Vehicle Operations and Materials Engineering. Test Method: . Prepare test panels per matrix in Table 1. Use current production paints as
32、 identified by Materials Engineering. (Panels shall be kept horizontal prior to baking, during the painting operation and during cure. Use gas fired oven for paint cure.) . Condition painted panels at 23 +/- 2 C for 4 - 24 h. . After 4 - 24 h at 23 +/- 2 C, perform the following tests on each panel:
33、 . Cross hatch adhesion check - FLTM BI 106-01, Method B. . Resistance to Xylene - using a back and forth motion, rub surface of enamel 10 times with a small wad of cheesecloth which has been wetted with xylene. 3.7.4 Compatibility with Production Paints - Weathering Requirements No tackiness, stain
34、ing, discoloration, chalking, gloss change or other deleterious effects on topcoats when compared to paint not over sealer. Test Method: . Prepare test panels per matrix in Table 2. Use current production paints as identified by the Body Engineering Office. (Panels shall be kept horizontal prior to
35、baking, during the painting operation and during cure.) . Condition painted panels at 23 +/- 2 C for 72 h. ENGINEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 9 of 13 . Subject panels for each paint/bake condition to each exposure listed below. Retain an unexposed panel as control. 3.7.4.
36、1 Heat Age 14 d at 102 C 3.7.4.2 10 Thermal Cycles (as described in para 3.7.1.3) . After exposure, perform the following evaluation on each panel: . Cross hatch adhesion test per FLTM BI 106-01. . Examine test panels and compare to the control panel and to the paint not over sealer side of the pane
37、l for evidence of tackiness, staining, discoloration, gloss change, adhesion loss, or other deleterious effects on top-coats. 3.8 QUALITY Material shall be a homogeneous product. It shall be consistent in color and texture, and free from objectionable odors during normal storage. It shall be suitabl
38、e for the intended application. 3.9 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 to Mater
39、ials Engineering prior to material approval and release. 3.10 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or performance specification. All critical areas with respect to these
40、 properties shall be clearly designated on the engineering drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 10 of 13 3.11 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was ori
41、ginally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall no
42、tify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law
43、, regulations or Ford, apply to the materials addressed by this document. The regulations are defined in Engineering Materials Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. S
44、uppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports
45、, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval o
46、f a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information given below is provid
47、ed for clarification and assistance in meeting the requirements of this specification. 5.1 MECHANICAL CONVECTION OVEN The mechanical convection 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) within 8 - 10 minutes. 5.2 AS
48、H CONTENT, Typical 10 % based on solids weight ENGINEERING MATERIAL SPECIFICATION WSS-M4G362-A WP 3948-b Page 11 of 13 5.3 SPECIFIC GRAVITY, Typical 1.15 5.4 BAKE SCHEDULES First Min Bake: 8 minutes at 135 +/- 1 C metal temperature (15 minutes total oven time max) Second Min Bake: 10 minutes at 130
49、+/- 1 C metal temperature (17 minutes total oven time max) Max Bake: 20 minutes at 177 +/- 1 C metal temperature (not less than 30 minutes total oven time) 5.5 SUBSTRATES Electrocoat primed steel panel 100 x 300 x 0.80 mm prepared per WSS-M2P180-A performance specification. Use current production paints as identified by Materials Engineering. 5.6 HARDNESS, Typical 50 - 60 (ASTM D 2240, Durometer D) 5.7 CURED TENSILE STRENGTH (without film), typical 2.0 - 5.0 MPa (ASTM D 412, Die C, pulled at 500 mm/minute. Cured at min bake schedules per para 5.4. Tested at 23 +/- 2
