1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2016 10 03 A3 -N Status No replacement named S. Short, NA 2014 10 07 A1/2 Inactive A1/2 No replacement named L. Sinclair, NA 2006 10 12 Activated W. Janitschke/B. trecht Controlled document at www.MATS Copyright 2016, Ford Global Technologies
2、, LLC Page 1 of 8 SEALER, HOT APPLIED, HEAT CURING, LOW EXPANDING (50% - 100%) INACTIVE WSS-M4G525-A1 SEALER, HOT APPLIED, HEAT CURING, EXPANDING (150% - 250%) INACTIVE WSS-M4G525-A2 SEALER, HOT APPLIED, HEAT CURING, HIGH EXPANDING (300% - 400%) WSS-M4G525-A3 NOT TO BE USED FOR NEW DESIGN 1. SCOPE T
3、he materials defined by these specifications 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,
4、because the roof is initially laid on 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
5、 max 3 g/m, see para. 3.3). 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 critical limit. Monitoring of the film thickness, adequate storage of the part and/or cleaning of the surface prior to sealer application i
6、s necessary to avoid critical film thickness 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 pr
7、oducers must conform to the Companys 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 SPECIFICATION WS
8、S-M4G525-A1/A2/A3 Copyright 2016, 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, nozzl
9、e dia. 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
10、above and 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
11、3 mm ribbons 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 conv
12、ected air-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 thro
13、ugh an angle of 90. ENGINEERING MATERIAL SPECIFICATION WSS-M4G525-A1/A2/A3 Copyright 2016, 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 test 250 x 30 x 3 mm and
14、 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 distance between the no
15、zzle 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 - 0.2 mm ribbons of materia
16、l 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 15 minutes at 60 +/- 1
17、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 to FLTM BV 150-05, Table
18、 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 welded parts using a test
19、fixture according to FLTM BV 159-01, Fig. 4. Examine after 48 h at 23 +/- 2 C. ENGINEERING MATERIAL SPECIFICATION WSS-M4G525-A1/A2/A3 Copyright 2016, Ford Global Technologies, LLC Page 4 of 8 3.2.12 Wetting Discoloration or (FLTM BV 153-08, Method A) staining permitted The paint film (paint material
20、s 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 to FLTM BV 150-05, Table 2, test at 23 +/- 2 C) Shear
21、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 MPa 3.2.13.2 After Heat Aging (500 h at 80 C) max. deviation from original +/- 10% 3.2.14 Resistance to Corrosion No Corrosion, Blisters nor loss of Adhesion T
22、he 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. (c) Expose test assemblies according to FLTM BV 150-
23、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 to a Scab Corrosion Test (FLTM BI 123-01) for 50 cycl
24、es. (e) Separate welded assemblies using a test fixture according to FLTM BV 159-01, Fig. 4 and examine. ENGINEERING MATERIAL SPECIFICATION WSS-M4G525-A1/A2/A3 Copyright 2016, Ford Global Technologies, LLC Page 5 of 8 3.2.15 Water Absorption 3.2.15.1 (FLTM BV 153-07, Method B, max. 1% Curing conditi
25、ons 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. 3.2.16 Volume Expansion, % A1 A2 A3 50 100 150 250 300 - 400 Test Method: (a) Deter
26、mine 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 according to FLTM BV 150-05, Table 2: . minimum curing cycle (165 C, 10 Materials Temp in EC
27、 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 Where: V1 = Volume of test pa
28、nel 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 ENGINEERING MATERIAL SPECIFICATION WS
29、S-M4G525-A1/A2/A3 Copyright 2016, 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 shall not cause dents and damages by lifting the roof and adjusting to its final position. Test-Method: (a) Apply thre
30、e 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 to para 3.3) straight on the sealer-ribbons and weight both with a weight of 200 and 500 gr. separately. (c) After 7
31、2 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 cell structure shall be fine without large voids. Test Method: (a) Preparation of test assemblies according to FLTM
32、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 material technologies require LPG/APG approval prior to their introduction. Test details including film thickness,
33、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 (EUROPEAN APPLICATIONS) All materials released to this specification must be applicable to oiled surfaces, including co
34、rrosion 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 adhesiv
35、e/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 manufacturing engineering. The lab test panels (see para. 3.3.1) must be oiled with maximum permissible oil film thickness.
36、 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 oil film weight is: 1 - 1.5 g/m The maximum permissible oil weight for full adhesive performance is: 3 g/m ENGINEERIN
37、G MATERIAL SPECIFICATION WSS-M4G525-A1/A2/A3 Copyright 2016, Ford Global Technologies, LLC Page 7 of 8 Note: All necessary 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 tr
38、ansport/storage, e.g. door hem flanges or other oil trapping areas. Unacceptable oil collection will require appropriate storage geometries (critical areas 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
39、 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 process 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 Sm
40、all 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 of approx.10% n-hexane/90% reference oil. Prevent evaporation losses by covering the glass beaker with aluminum foil as airtight as possible. Afte
41、r 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 weight 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 clean
42、ed 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. 3.3.1.3 Checking of Oil Coating/Weight A test panel prepared as per 3.9.1.1 is weigh
43、ed 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 specified oil-weight, the panel can be used. Otherwise oil again
44、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 adaptable for application in accordance with the appropriate Ford Motor Company Process Specification and must be compatible with all related materials.
45、3.5 LINE TRIAL 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. Results shall be made available to Materials Engineering prior to material approval and release. ENGINEE
46、RING MATERIAL SPECIFICATION WSS-M4G525-A1/A2/A3 Copyright 2016, Ford Global Technologies, LLC Page 8 of 8 4. GENERAL INFORMATION 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 a
47、t Ford Motor Company) The material must be stable for 6 months during storage in unopened drums out of direct sunlight at 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.
