1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes Rev 02 2012 05 04 N Status No usage or replacement N. Benipal, NA 2000 02 28 Editorial no technical change APC 1998 04 16 Activated A. Vallabhanath WP 3948-a Page 1 of 4 VARNISH, HIGH TEMPERATURE POLYESTER RES
2、IN, WSS-M7J40-B2 HIGH SOLIDS 2 PARTS, ELECTRICAL INSULATING NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a high heat distortion type polyester resin, where medium viscosity, fast cure and retention of strength and electrical properties under high temperature c
3、onditions are required. 2. APPLICATION This specification was released originally for coating and impregnating alternator stators and rotors. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specifica
4、tion requirements are to be used for initial qualification 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 submissio
5、n. Appropriate statistical tools must be used to analyze 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
6、 relevant Materials Activity. 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 shall constitute the
7、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. ENGINEERING MATERIAL SPECIFICATION WSS-M7J40-B2 WP 3948-b Page 2 of 4 3.3 CONDITIO
8、NING AND TEST CONDITIONS All test values indicated 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 MIXING RATIO BY WEIGHT Th
9、is material shall be mixed as follows: Polyester Resin 100 Curing Agent - tertiary butyl perbenzoate 1 3.5 SPECIFIC GRAVITY, Part A 1.06 - 1.1 (ASTM D 154 at 23 +/- 2 C) 3.6 VISCOSITY, Part A, s 150 - 200 (FLTM BI 111-01 at 23 +/- 2 C) 3.7 WEIGHT PER VOLUME, Part A, kg/L 5.11 - 5.35 3.8 FLASH POINT,
10、 Part A, C, min 46 (ASTM D 93) 3.9 SOLIDS, Part A, %, by weight, min 100 (FLTM BI 102-01) 3.10 SEDIMENT-CENTRIFUGING, Part A Clear - no (30 minutes at 2400 rpm) sediment 3.11 CURING The material shall completely cure in 20 minutes at 150 C. Test Method: Place 10 g of the catalyzed material in a 64 m
11、m diameter aluminum evaporation dish and bake for 20 minutes at 150 +/- 1 C. Remove from oven, air cool to room temperature and inspect varnish for internal tackiness. 3.12 CHARACTERISTICS AFTER CURING The baked finish shall be hard, adherent and resistant to bending. The finish shall not lose its p
12、hysical or insulating properties when subjected to the long continuous action of heat and electrical stress. The finish shall also be resistant to the action of alkalies, acids, oils and moisture that may be present in its application environment. 3.13 DIELECTRIC STRENGTH S/T, min, V/mil 2,500 (ASTM
13、 D 115, except dip once into catalyzed as received material and test resulting thickness) ENGINEERING MATERIAL SPECIFICATION WSS-M7J40-B2 WP 3948-b Page 3 of 4 3.14 HELICAL COIL BOND STRENGTH, kg, min 23 +/- 2 C 4 149 +/- 3 C 3.6 Test Method: Prepare twisted coils by winding 100 turns of #28 gauge M
14、W35 copper magnet wire on a 57 mm circular shape coil into oval and twisted 2 1/4 turns per ASTM D 4882 and place 12 of the 57 mm coils on a fixture. Dip into the varnish with 2 % tetrabutylperoxide and withdraw at rate of 100 mm/minute. Dip and bake cycle is listed below. 5 minutes: Dip 5 minutes:
15、Drain 30 minutes: Bake at 82 C 10 minutes: Cool Place the samples in a flexural testing type jig such as is available at Rawsonville Quality Control Laboratory. Apply the load in the center of 51 mm span on the coils through a lever system attached to the heating chamber and testing jig. The load is
16、 lead shot poured into a pail attached to the lever. When the testing is performed at 149 C, the sample is placed into the jig and allowed to stand for 15 minutes prior to load application to bring sample up to the temperature. 3.15 ROOM TEMPERATURE CURE WITH 1.0 % MEKP 20 - 30 minutes 3.16 SUPPLIER
17、S RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approv
18、ed under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engi
19、neering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The regulations are defined in Engineering Materials Specification WSS-M99P9999
20、A1. ENGINEERING MATERIAL SPECIFICATION WSS-M7J40-B2 WP 3948-b Page 4 of 4 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of i
21、nterest 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, signed by a qualified and authorized representative of the test facility, demonst
22、rating 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 of a material will be based on its performance to this specification and on an asses
23、sment 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 provided for clarification and assistance in meeting the requirements of this specificati
24、on. 5.1 SHELF LIFE, min 3 months (Unopened - from the date of shipment) 5.2 FLAMMABILITY This material represents a potential fire hazard. The Manufacturing Engineering Department shall notify both the security and the safety units of its presence in the plant. The location in which it is used or stored shall be included in the notification.
