1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1997 04 28 Revised Revised para 3.6 and 3.8 D. W. Whyte1995 09 15 Revised Revised para 3.6 DRH1995 03 10 Activated D. Henrickson LAGWP 3948-a Page 1 of 9 DEADENER, BUTYL/ALUMINUM FOIL LAMINATE, WSS-M5G58-A2CONSTR
2、AINED LAYER1. SCOPEAll of the materials defined by this specification are acousticaldeadener s. The various kinds of deadeners specified are described in themat erial matrix enclosed herein. Each unique material described in thematrix is assigned its own specification number.2. APPLICATIONThi s spec
3、ification was released originally for materials used to dampvib rating body panels. Unique material applications are defined by thematerial matrix incorporated in the specification.Prior to use, the material must be evaluated under the c omponent productionparameters. The choice of substrates, stamp
4、ing lubricants, plantproces sing conditions and specific design application may affect materialperf ormance. Compliance with this specification does not guarantee thematerial will function for all potential applications on a vehicle.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers an
5、d part producers must conform to Quality SystemRequirements, QS-9000. Material specification r equirements are to beused fo r initial qualification of materials. A Control Plan forong oing production verification is required. This plan must bereviewed and approved b y the relevant Ford Materials act
6、ivity and/orFor d Supplier Technical Assistance (STA) prior to production partssubmission. Appropriate statistical tools must be used to analyzepr ocess/product data and assure consistent processing of thematerials.Part producers using this material in their products, must use Fordapproved materials
7、 and must conform to a process control plan whichhas been approved by STA and/or the relevant Materials Activity.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G58-A2WP 3948-b Page 2 of 9 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may conduct infrared and/orthe
8、rma l analysis of material/parts supplied to this specification.The IR spectra and thermograms established for i nitial approval shallconst itute the reference standard and shall be kept on file at thedesignated material laboratory. All samples sha ll produce IR spectraand thermograms that correspon
9、d to the reference standard when testedunder the same conditions.3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on ma terial conditioned ina control led atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under t
10、hesame conditions unless otherwise specified.3.4 MATERIAL MATRIXThe matrix below provides information on basic material type,manufacturing process location, method of applic ation, and acceptablein-vehicle orientation for each material specification number.Material Type. Asphaltic Mastic. Polyvinyl
11、Chloride. Ethylene Vinyl Acetate. Polyvinyl Acetate. Urethane. Butyl X. SBR Based. Saturated Felt. Aluminum Foil X. Adhesive. Magnetic. Special Requirement. Release Liner XAssembly Location (where appliedin manufacturing process). Stamping Plant or Assembly XPlant Body-in-white. Paint Shop (assembly
12、 Xplant after E-coat bake). Trim Shop (assembly Xplant after paint)Method of Application. Spray. Lay by Hand. Pressurize X. Extrude. Special RequirementENGINEERING MATERIAL SPECIFICATIONWSS-M5G58-A2WP 3948-b Page 3 of 9 In-vehicle Orientation. Horizontal Only. Vertical or Horizontal. Inverted or Oth
13、er X. Special Requirement3.5 SAMPLE PREPARATION3.5.1 Applying Material to Substrate3.5.1.1 Materials Applied with PressureRoll once (in the forward direction only) with a2.2 kg roller having an 83 mm diameter.3.5.2 Sample OrientationAl l in-vehicle orientations used should be evaluated (seematerial
14、matrix (para 3.4) for in-vehicle orientations).3.5.3 Processing Temperature BakesTypical manufacturing-process minutes-at-metal-temperatures(MMT) minimums, nominals, and maximums are iden tified below.All processing sequences encountered with the ma terial shouldbe e valuated (see material matrix, p
15、ara 3.4, for processinformation) unless otherwise specified herein.Process Low Bake Nominal High BakeBake (M at MT) (M at MT) (M at MT)E-coat 10 at 170 C 10 at 182 C 30 at 205 CPrimer 8 at 135 C 10 at 150 C 20 at 177 CTopcoat 10 at 125 C 10 at 130 C 20 at 165 CPredelivery 10 at 100 C3.5.4 Production
16、 Representative SubstratesAll metals, oils/draw compounds, coatings, and o ther surfacesused with the material should be evaluated (for typicalsubstrates, oils and coatings see para 3.5.5).3.5.4.1 Mater ials Applied at Metal Stamping or in theAssembly Plant Body Shop (body in white)-allmetals, galva
17、nize coatings, oils/draw compound s andothe r surfaces used with the material should beevaluated.3.5.4.2 Materials Applied in the Assembly Plant Paint Shop(af ter E-coat bake)-all E-coats, primers, andothe r surfaces used with the material should beevaluated.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G
18、58-A2WP 3948-b Page 4 of 9 3.5.4.3 Materials Applied in the Assembly Plant Trim Shop(after paint)-all topcoats and other surfaces usedwith the material should be evaluated.3.5.5 SYSTEM PROCESS COMPATIBILITYInitia l material approval was based on specific materialsystems which included the substrate,
19、 stamping l ubricants anddeadener system. The originally approved materi al system wasprocessed and cured using specific production processparam eters. Substrate choice, stamping lubricants, andasse mbly plant processing conditions may affect adhesiveperformance. If any of these parameters are chan
20、ged, materialperformance must be validated using the new parameters.3.6 TEST MATRIXThe test matrix below and more detailed requirements referenced inthis specification identify the testing requirements for eachmaterial specification.Total Thickness, mm As Specified on(ASTM D 461, w/o release liner)
21、Engineering DrawingTotal Mass, kg/m2, min 2.29(ASTM D 461,w/o release liner)Damping Loss Factor, min(ASTM E 756, 200 hz). At 0 C 0.12. At 15 C 0.17. At 30 C 0.14. At 45 C 0.08. At 60 C 0.05Peel Adhesion, N, min. No Bake, 1 h dwell 8. No Bake, 24 h dwell 20. No Bake, 250 h dwell 20. Bake and 250 h at
22、 88 C 25. Bake and 250 h at 38 C and 100 % R.H. 25Sustained Heat and Sag XCold Adhesion X(FLTM BV 101-02)E-Coat Compatibility X(FLTM BV 119-01)Wash Resistance X(FLTM BV 116-01)Severe Wash Resistance X(FLTM BV 116-02)Foil Thickness, mm As Specified on(ASTM D 461) Engineering DrawingFlammability, mm/m
23、inute, max 100(ISO 3795/SAE J369)Fogging (FLTM BO 116-03), min 70Odor (SAE J1351), max 2ENGINEERING MATERIAL SPECIFICATIONWSS-M5G58-A2WP 3948-b Page 5 of 9 Note: X = Requirement is specified in the appropriate paragraphs of thisspecification which follow.3.7 DAMPING LOSS FACTOR As specified in(ASTM
24、E 756, average of 5 beams, at each TEST MATRIXtemperature, 200 Hz, 15 C increments from0 - 60 C)Test Conditions (unless otherwise specified):. 320 x 20 x 0.8 mm clean cold rolled steel Oberst bar. Oberst bar damped one side only. 40 mm root length undamped, 280 mm free length damped. Mass of damping
25、 material as specified in test matrix. Cure temperature and time as specified by the Materials EngineeringActivity. Report the composite bar loss factor only.Note: The calculated value at 200 Hz is obtained by linear inter-polation between the loss facto r values of the resonances directlyon either
26、side of 200 Hz.3.8 PEEL ADHESION As specified inTEST MATRIXTest Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information): Apply 25 x 125 mm length strips of material toproduction representative substrate panels. The material may have tobe back ed with mylar or duct tape for
27、 reinforcement during peel.Suspend panels as oriented in-vehicle during dwell periods and bakecycling. Use low bake and high bake schedules f or materials that areprocessed through Body and Assembly paint process. Use predeliverybake and no bake schedules (oriented as in-vehicle) only, forma terials
28、 applied at Body and Assembly Division after paintprocessing. “No bake“ schedules should be used o n substrates (metals/oils) used in pre-paint process applications to establish productionsuit ability. Pull ninety degrees to surface at a rate of 305 mm/minute. The peel value reported must be that ob
29、t ained for the averageload.3.9 SUSTAINED HEAT AND SAG No sagging ormaterial degradationTest Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information): This requirement is for materials that arepro cessed through Body and Assembly paint process only. Apply,orient, and bake (
30、high bake only) 150 x 150 mm test samples toproduction representative substrate panels. Suspend panels asorien ted in-vehicle during the bake cycle. No smoking, materialdegradation, or sag of the material is allowed.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G58-A2WP 3948-b Page 6 of 9 3.10 COLD ADHESI
31、ON No loss(FLTM BV 101-02) of adhesionTest Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information): Apply 150 x 150 mm test samples to productionrepresentative substrate panels. Conduct cold slam procedure afterlow bake and after high bake for materials that are processed
32、throughBody an d Assembly paint process. Suspend panels as oriented in-vehicle during the bake cycle. Conduct cold sla m procedure on panelswithout bake also, for materials applied at Metal Stamping Division.Conduct cold slam procedure on panels without ba ke and on panels withpredelivery bake (orie
33、nted as in-vehicle) only, for materials appliedat Body and Assembly Division after paint processing.3.11 E-Coat Compatibility No film irregularities or (FLTM BV 119-01) material incompatibilities 3.12 Wash Resistance Shall remain unaffected (FLTM BV 116-01) No edge loss or displacement3.13 Severe Wa
34、sh Resistance Shall remain unaffected (FLTM BV 116-02) No edge loss or displacement3.14 FLAMMABILITY(ISO 3795/SAE J369)Burn Rate, max 100 mm/minute3.15 FOGGING(SAE J1756, 3 h at 100 C heating, 21 C coolingplate, post test conditioning 1 h)Fog Number, min As specified intest matrixFormation of clear
35、film, droplets or crystals is cause for rejection.The material shall be evaluated after exposure to normal processingconditions.3.16 ODOR, max As specified in(SAE J1351) test matrixThe material shall be evaluated after exposure to normal processingconditions.3.17 FUNCTIONAL APPROVALMaterials being e
36、valuated for approval to this s pecification shall besubject ed to a production trial. Functional trial results must beapproved by the affected assembly operation and Design Engineering.Results shall be made available to Materials Engineering prior tomaterial approval and release.ENGINEERING MATERIA
37、L SPECIFICATIONWSS-M5G58-A2WP 3948-b Page 7 of 9 3.18 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manufa ctured parts shall bespecified on the Engineering drawing, Engineerin g parts specificationand/or performance specification. All critical areas with respect tothese propertie
38、s shall be clearly designated on the engineeringdrawing.3.19 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to making any change in the properties, composition,constr ucti
39、on, color, processing or labeling of the materialorig inally approved under this specification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the Supplier shall notify Purchasing, Toxicology andthe affected Materials Engineering activity of the prop
40、osed changesand obtain the written approval of the Materials Engineeringactivity. Test data, t est samples and a new code identification areto be submitted with the request.Substance restrictions imposed by law, regulations or Ford, apply tothe materials addressed by this document. The restrictions
41、aredefined in Engineering Materials Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSMat erials defined by this specification must have prior approval by theresponsible Materials Engineeri ng activity. Suppliers desiring approval ofthe ir materials shall first obtain an expression of interest f
42、rom theaffec ted Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity a completed copy of their laboratory test reports, signed by aqualified and authorized representative of the test faci lity, demonstratingful l
43、 compliance with all the requirements of this specification (testresults, not nominal values), the material designation a nd code number, andtes t specimens for Ford evaluation. Fords engineering approval of amateri al will be based on its performance to this specification and on anassessment of sui
44、tability for intended processes and/or applications. Uponapprov al, the material will be added to the Engineering Material ApprovedSource List.5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting the requirements of this specification.ENGINEERING M
45、ATERIAL SPECIFICATIONWSS-M5G58-A2WP 3948-b Page 8 of 9 5.1 MATERIAL TEST DATA FORMSelected testing from t he list below, mutually agreed to between thesupplier and the respon sible Materials Engineering Activity, must besubmitted prior to init ial material approval. Selected tests, whichare inc lude
46、d in the material control plan should be updated asreferenced on the control plan.Specification_ _Supplier_ _GSDB Code_Product Code_ _Manufacturing Plant Location_ _Physical/Chemical Properties Selected Test Results Product LimitsTest (Mean, Std Dev, (99.994 % ofsample size) production)Total Thickne
47、ss, mm _ _ _(ASTM D 461, w/o release liner)Total Mass, Kg/m2 _ _ _(ASTM D 461, w/o release liner)Damping Loss Factor(ASTM E 756, 200 hz). At 0 C _ _ _. At 15 C _ _ _. At 30 C _ _ _. At 45 C _ _ _. At 60 C _ _ _Peel Adhesion, N, min. No bake, 1 h dwell _ _ _. No bake, 24 h dwell _ _ _. No bake, 250 h dwell _ _ _. Bake and 250 h at 88 C _ _ _. Bake and 250 h at 38 C _ _ _and 100 % R.H.Sustained Heat and Sag _ _ _Cold Adhesion _ _ _(FLTM BV 101-02)
