1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 02 12 Revised Revised 3.2.7, 3.2.9, 3.2.10, 3.2.12, 3.2.14, 3.2.17 Inserted 3.3.1, 3.3.1.1, 3.3.1.2 & 3.3.1.3 W.Janitschke/B. trecht2006 10 12 Activated W. Janitschke/B. trecht Printed copies are uncontrolled Copyright 2007, Ford Global T
2、echnologies, LLC Page 1 of 8 SEALER, HOT APPLIED, HEAT CURING, LOW EXPANDING (50% - 100%) WSS-M4G525-A1 SEALER, HOT APPLIED, HEAT CURING, EXPANDING (150% - 250%) WSS-M4G525-A2 SEALER, HOT APPLIED, HEAT CURING, HIGH EXPANDING (300% - 400%) WSS-M4G525-A3 1. SCOPE The materials defined by these specifi
3、cations are hot applied, touch dry at RT after application, heat curing, heat expanding sealers. 2. APPLICATION These specifications were released originally to glue roof bows to laser brazed roof. The material has to form a tack free surface after cooling down, because the roof is initially laid on
4、 the roof bows and then lifted and adjusted to its final position for brazing. The Sealer expands in the e-coat oven. The materials 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. 3.3). Note: Car
5、e must be taken to ensure that the local oil film weight in the area of the adhesive/sealer application does not exceed the critical limit. Monitoring of the film thickness, adequate storage of the part and/or cleaning of the surface prior to sealer application is necessary to avoid critical film th
6、ickness values, which would then cause malfunction of the sealer/adhesive. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys
7、Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 PERFORMANCE REQUIREMENTS 3.2.1 Color Black 3.2.2 Solids, %, min 95 (FLTM BV 150-10) 3.2.3 Ash, %, max 45 (FLTM BV 150-10) 3.2.4 Flash Point 56 C (ASTM D 56) ENGINEERING MATERIAL SPECIFICATIONWSS-M4G525-A1/A2/A3 Printed copies are u
8、ncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 8 3.2.5 Density at 20 C 1.0 to 1.6 g/cm3(ASTM D 1475, tolerance +/- 0.05 g/cm3, based on the recorded density of suppliers original approved sample) 3.2.6 Viscosity at 23 C, s (FLTM BV 103-01, line pressure 0.392 MN/m2, nozzle dia.
9、2 mm) 3.2.6.1 As Received 70 200 3.2.6.2 After Ageing, max 200 (14 days at 35 +/- 2 C) Note: Final approval of a specific viscosity of material for production shipments shall be made by affected Manufacturing Division. In all cases, however, the viscosity shall be within the limits specified above a
10、nd shall meet all requirements of this specification (Control Sample Laboratory Report). 3.2.7 Flow Rate, max No flow permitted (FLTM BV 153-01, Method A, except oiled panels acc. para 3.3) 3.2.8 Cold Resistance After Ageing No loss of adhesion, no chipping. Test Method: (a) Apply 250 x 30 x 3 mm ri
11、bbons of material under test to 300 x 100 mm test panels (prepared according to para 3.3). (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 a
12、ir-dry oven at 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
13、angle of 90. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G525-A1/A2/A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 8 3.2.9 Wash-off Resistance No wash-off of sealer, deformation of sealer surface permitted. Test Method: (a) Apply two ribbons of material under
14、test 250 x 30 x 3 mm and 50 mm apart from each other to a 300 x 300 mm oiled panel, prepared acc. to para 3.3). (b) After conditioning 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
15、 distance between the nozzle and test material shall be 300 mm. The water jet shall be applied between the beads for 1 minute. 3.2.10 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
16、.2 mm ribbons of material under test to 250 x 60 mm oiled test panels (prepared according to para 3.3). (2) After conditioning for 2 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
17、 15 minutes at 60 +/- 1 C. B. Cured Material No loss of adhesion, no chipping Test Method: (1) Test specimens as prepared and tested under para 3.2.9 shall be exposed for 20 minutes in a mechanically convected air-dry oven at 100 +/- 2 C, and subsequently subjected to maximum curing cycle according
18、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. 3.2.11 Flammability and Corrosion Self extinguishing (FLTM BV 159-02, Method A) within 5 s, no corrosion Immediately after welding, separate the we
19、lded parts using a test fixture according to FLTM BV 159-01, Fig. 4. Examine after 48 h at 23 +/- 2 C. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G525-A1/A2/A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 8 3.2.12 Wetting Discoloration or (FLTM BV 153-08, Meth
20、od A) staining permitted The paint film (paint materials shall be noted in the Initial Sample Report of the adhesive, see also para 4.3) shall cover the sealer with a continuous film. 3.2.13 Shear Strength (FLTM BV 154-03, Method B after 10 minutes at 23 +/- 2 C minimum and maximum heat curing cycle
21、 to FLTM BV 150-05, Table 2, test at 23 +/- 2 C) Shear Strength, min 3.2.13.1 A3 Vol.-Exp. 300% 0.30 MPa 400% 0.10 MPa A2 Vol.-Exp. 150% 0.50 MPa 250% 0.35 MPa A1 Vol.-Exp. 50% 0.80 MPa 100% 0.60 MPa3.2.13.2 After Heat Aging (500 h at 80 C) max. deviation from original +/- 10% 3.2.14 Resistance to C
22、orrosion No Corrosion, Blisters nor loss of Adhesion The material shall 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
23、. (c) Expose test assemblies according to FLTM BV 150-05, Table 2: min curing and 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
24、 to a Scab Corrosion Test (FLTM BI 123-01) for 50 cycles. (e) Separate welded assemblies using a test fixture according to FLTM BV 159-01, Fig. 4 and examine. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G525-A1/A2/A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of
25、 8 3.2.15 Water Absorption 3.2.15.1 (FLTM BV 153-07, Method B, max. 1% Curing conditions acc. to FLTM BV 150-05 Table 2 min. curing 10 Min. 175 C) 3.2.15.2 After Heat Aging (500 h at 80 C) max. deviation from original +/- 10% After heat aging the sealer must meet the requirements of paragraph 3.2.18
26、. 3.2.16 Volume Expansion, % A1 A2 A3 50 100 150 250 300 - 400 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 (see sketch in FLTM BV 153-07) and determine volume V2. (c) Expose test assemblies separately accordi
27、ng to FLTM BV 150-05, Table 2: . minimum curing cycle (165 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 a
28、s follows: % Volume Expansion = V3 - V2 - x 100 V2 - V1 Where: 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
29、to 140 C)”. This has to be mentioned in the PSW ENGINEERING MATERIAL SPECIFICATIONWSS-M4G525-A1/A2/A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 6 of 8 3.2.17 Tack-Free Behavior The sealer must show a tack-free surface after application and cooling down and sh
30、all not cause dents and damages by lifting the roof and adjusting to its final position. Test-Method: (a) Apply three 250 x 5 x 5 mm ribbons of material to 300 x 100 mm test panels (prepared according to para 3.3). (b) After cooling down to RT put another 300 x 100 mm test panel (prepared according
31、to para 3.3) straight on the sealer-ribbons and weight both with a weight of 200 and 500 gr. separately. (c) After 72 h remove the above panel. There should be no adhesion between the above panel and sealer. 3.2.18 Structure of Curing The sealer shall form a closed skin after heat curing. The inner
32、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 examined visually. 3.2.19 Corrosion Resistance, Proving Ground (European Production) New
33、 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 Engineering, Body & Materials Engineering. 3.3 OIL COMPATIBILITY & REFERENCE OIL (EU
34、ROPEAN APPLICATIONS) All materials released to this specification must be applicable to oiled surfaces, including corrosion 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
35、 source list (contact materials engineering for details). The supplier must confirm the compatibility of the adhesive/sealer 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 manufac
36、turing engineering. The lab test panels (see para. 3.3.1) must be oiled with maximum permissible oil film thickness. Reference 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 o
37、il film weight is: 1 - 1.5 g/m The maximum permissible oil weight for full adhesive performance is: 3 g/m ENGINEERING MATERIAL SPECIFICATIONWSS-M4G525-A1/A2/A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 7 of 8 Note: All necessary actions must be taken to preve
38、nt 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 appropriate storage geometries (critical are
39、as turned to top) or in-process cleaning operations prior to sealer/adhesive application. 3.3.1 Oiling-Method of Lab Test Panels 3.3.1.1 Test-Panel Cleaning Clean the test-panel with the lint-free cloth soaked with the solvent n-hexane. Rinse both sides of the test panel with n-hexane until no proce
40、ss traces remain on the surface. Allow to dry at ambient-temperature until the n-hexane has completely evaporated. 3.3.1.2 Oiling the Test-Panel Small panels (Tensil-, Shear-, Peel-Adhesion): Immediately after air drying, immerse the panel in a 250 ml glass beaker, filled up to 200 ml with a mixture
41、 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 ambient temperature. Check the oil w
42、eight of the above mixture after the first panel. 30 panels can be oiled, then check the oil weight again. 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 eve
43、n over the panel with a lint-free cloth. Check the oil-weight. 3.3.1.3 Checking of Oil Coating/Weight A test panel prepared as per 3.9.1.1 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 w
44、ith the panel-dimensions. If the oil-weight deviates approx. +/- 0.3 g/m from the specified oil-weight, the panel can be used. Otherwise oil again or re-adjust the above mixture. 3.4 QUALITY The adhesive shall be a smooth, homogeneous mixture, free from foreign materials. The material must be adapta
45、ble for application in accordance with the appropriate Ford Motor Company Process Specification and must be compatible with all related materials. 3.5 LINE TRIAL Materials being evaluated for approval to this specification shall be subjected to a production trial. Functional trial results must be ap
46、proved by the affected assembly operation. Results shall be made available to Materials Engineering prior to material approval and release. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G525-A1/A2/A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 8 of 8 4. GENERAL INFOR
47、MATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. 4.1 STORAGE STABILITY (From date of receipt at Ford Motor Company) The material must be stable for 6 months during storage in unopened drums out of direct sunlight at
48、temperatures between 5 C and 32 C. 4.2 OPEN ASSEMBLY TIME As specified by the supplier (At the required operation temperature) Open assembly time is the maximum time interval from initial application of the sealer to the completion of the part assembly for bonding. 4.3 MATERIAL REFERENCE All related materials used for approval of sealers according to this specification, e.g. paint materials or metallic substrates, shall be noted in the Initial Sample Report of the sealer.
