1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 4 2014 04 22 Revised Electrical Conductivity 3.4.12 req. was report only. A. Reaume, NA 2013 07 26 Revised Completely revised. See Summary of Revisions. M.Ranger; A.Reaume,FNA 2008 03 20 Activated Marcos Rogrio de Souza Controlled docume
2、nt at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 1 of 18 COOLANT, ORGANIC ADDITIVE TECHNOLOGY (OAT), WSS-M97B44-D CONCENTRATE, FOR PASSENGER CAR AND LIGHT TRUCK 1. SCOPE The material defined by this specification is a coolant concentrate composed essentially of virgin monoethylene g
3、lycol and OAT corrosion inhibitors. When mixed 50/50 with water it shall be a satisfactory fluid for vehicle cooling systems that contain aluminum engine components, radiators and heater cores, ferrous metals and copper brass. This material is for initial fill and service fill. 2. APPLICATION This s
4、pecification was released originally for passenger car and light truck and commercial truck applications without the use of nitrites. It should not be mixed with previously approved coolants including silicated coolants per WSS-M97B51-A1. This material is not suitable for use with magnesium based al
5、loys or zinc coatings (e.g. galvanized product). 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 DOCUMENTATION 3.2.1 Approval of a new formulatio
6、n Supplier must provide a completed and certified copy of the attached Supplement A and test reports demonstrating full compliance with all the requirements of this specification. Suppliers must provide full disclosure of their material formulation to, and be approved by, Materials Engineering. This
7、 disclosure is to a list of each additive by name, target wt%, min and max wt% with sub-supplier names for all components, in particular organic acid technology additives, azoles and other corrosion additives, and ethylene glycol. Disclosure to also include production range levels for pH, reserve al
8、kalinity and water content. All tests must be certified by a qualified and authorized representative of the test facility. Supplier must furnish DFMEA, PFMEA, Process Flow Diagram, and Control Plan. 3.2.2 Approval of a new supplier to an approved formulation Same as 3.2.1 with surrogate test data wh
9、ere approved by Ford and testing and documentation, at minimum, in the attached PVP compare current coolant with proposed coolant Coupon metal weight change Current Coolant Current Coolant/ Cleaner Proposed Coolant Proposed Coolant/ Cleaner Cleaner Control ASTM Corrosive Water Al Iron Steel Brass So
10、lder Copper - A negative result indicates a weight gain 3.4.17 Storage Stability Hard water and temperature Supplier must report water quality conditions that may adversely affect the quality of the coolant (inhibitor depletion, lowered life, etc). The coolant concentrate form, quality and chemical
11、composition shall not be adversely affected, changed or impacted by storage up to 5 years under environmental conditions of normal distribution and storage. In-vehicle, the coolant mixed with water shall be stable so as not to change in form, quality or composition to adversely affects heat transfer
12、 or corrosion inhibition. Hard water solution - Prepare hard water by adding 275mg of calcium chloride (CaCl2) to 1 liter synthetic corrosive water described in the test solution section of ASTM D1384. Prepare six 100 ml coolant samples using the test coolant and the hard water solution. Samples are
13、 to have coolant concentrations of 100% (samples 1 and 2), 75% (samples 3 and 4) and 50% (samples 5 and 6). Put all samples in clean, labeled polymethylpentene (PMP) bottles for testing. (French square-type bottle may aid visual check.) All samples must pass hot and cold storage stability testing fo
14、r the coolant to pass. 3.4.17.1 Hot Storage Stability - Samples 1, 3 and 5 are heat storage tested in a circulating air oven at 65 +/- 2 C for 14 days. Remove a 20 ml sample on days 2, 4, 7, 10 and 14. Allow to cool to room temperature. Check for precipitates, deposits, gelation and phase separation
15、. “Fish eyes” on the top (from defoamer) is acceptable. If anything other than “fish eyes” is ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2014, Ford Global Technologies, LLC Page 5 of 18 present, such as gel or material in solution or precipitate, terminate test and write as failure. A
16、nalyze coolant to determine effect. 3.4.17.2 Cold Storage Stability - Samples 2, 4 and 6 are cold storage tested at -40C for 14 days. Remove a 20 ml sample on days 2, 4, 7, 10 and 14. Allow to go to room temperature. Check for precipitates, deposits, gelation and phase separation. “Fish eyes” on the
17、 top (from defoamer) is acceptable. If anything other than “fish eyes” is present, such as gel or material in solution or precipitate, terminate test and consider as a failure. Analyze coolant to determine effect. 3.4.18 Compatibility with Engine Hot Test Fluids (See compatibility method in WSS-M97B
18、56-A1) Any changes, other than “fish eyes” deem the hot test fluid incompatible with the coolant. 3.4.19 Compression Stress Relaxation O-rings and Seals Only Report curves and (ASTM D6147, Method B, Automotive Standard (ASD) Fixture, load 120 C 25 % compression, 50/50 v/v coolant/water, 3024 hours)
19、(Materials identified by program; contact Materials Engineering or PTI Core for a list.) Test new coolant with approved coolant for comparison. Test Method exceptions: Use a ratio of 25% coolant mixture to 75% air in the pressure vessel; completely immerse CSR fixtures in coolant. Lubricate both end
20、s of the CSR button with silicone lubricant; wipe with a paper towel to remove all excess oil, only a glossy surface should remain. After compressing the samples take the initial reading between 1 and 2 hours, no less than 1 hour. Besides the initial readings, take readings at 24 hours, 1 week, 3 we
21、eks, 6 weeks, 12 weeks and 18 weeks. Compression level at readings: 0.1 mm max Compression rate at readings: 1mm/minute Number of compression readings per test: 3, report only the third reading. 3.4.20 Compatibility with Thermoplastic Materials (FLTM BO 130-01, 1000 h at 125 +/- 2 C) (Materials iden
22、tified by program; contact Materials Engineering or PTI Core for a list.) 50/50 % coolant/water, 10 test specimens minimum, Unaged property values shall be determined at the time of the aged properties determination. Test plastics used in continuous contact with coolant). Test new coolant with appro
23、ved coolant for comparison. 3.4.20.1 Tensile Strength at Max Load, Report (ISO 527, 5mm/minute test speed) 3.4.20.2 Impact Strength, Charpy, Report (ISO 179, Test specimens to be notched before immersion, 23 +/- 2 C) ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2014, Ford Global Technol
24、ogies, LLC Page 6 of 18 3.4.21 Compatibility with Heater Hose Material 3.4.21.1 Burst Pressure after Wet Heat Aging (ASTM D380, fill hose with 50/50 coolant and deionized water. Heat to 104 +/- 2C for 2000 hours) % Change WSE-M96D34-A1 -A2 -A3 WSS-M96D34-A4/A5 All hose diameters -28 -10 -45 -28 3.4.
25、21.2 EPDM Hose Extraction Test (Zinc/ Zinc Compound Extraction) Sulfur cured EPDM compounds employ zinc oxide and fatty acids such as stearates in their formulations as cure activators. These activators can produce zinc stearate, which can be extracted by engine coolant and re-deposit elsewhere in t
26、he system. Excess amounts of this compound can potentially block coolant passages and cause overheat. The following procedure provides a method to evaluate the potential amount of zinc stearate deposits they may see throughout the cooling system based on a standard sample size. Equipment and Materia
27、ls Three 356mm X 38.1 hose samples Six 25 mm long plugs of ample outer diameter to seal hose, both ends Six worm gear clamps of sufficient size for the hose sample One Buchner funnel, 114 mm top diameter and 95 mm perforated diameter Three filter papers for Buchner funnel One 500 ml filter flask wit
28、h molded rubber stopper Three watch glasses approximately 120 mm diameter One electronic balance capable of weights of 0.001 grams Distilled water in squeeze bottle 70% isopropyl alcohol Approximately 320 ml of 45% / 55% coolant / distilled water mixture Convection oven capable of 100C Procedure 1.
29、Rinse the inside of the hose thoroughly with isopropyl alcohol followed by 2 rinses with distilled water to remove any surface contaminants. 2. Plug 1 end of the hose and apply clamp to seal. Fill hose 305 mm deep full of coolant / water mixture. Plug and clamp the open end. Verify no leakage. Bake
30、at 100C for 24 hours. 3. Prior to removal of the hoses from the oven, dry out the filter paper at 100C for 1 hour, or to constant weight. Record the filter paper weight. 4. Place the filter paper inside the filter funnel, and apply distilled water to seal the paper to the funnel. 5. Remove a plug fr
31、om one end of a hose sample and carefully drain the contents onto the filter paper / vacuum filter set up. Pour a small amount of distilled water into the hose, swirl water, drain and repeat the rinse. In any visual residue remains in the hose, repeat rinse as necessary. 6. Using distilled water in
32、a squeeze bottle, wash any solid residue away from the sides of the funnel to the filter paper surface. ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2014, Ford Global Technologies, LLC Page 7 of 18 7. Tare the watch glass. Carefully remove the filter paper, place on watch glass, and if
33、necessary, use a spatula to collect any additional residue from the funnel sides and add to the filter paper. Bake filter paper at 100C for 24 hours, the compare the pre-test weight and the post-test weight of the filter paper. Acceptance criteria Weight of extractables on the filter paper must weig
34、h less than 1.0 g. 3.4.22 Compatibility with Heater Hose Material and Degas Bottle Material (FLTM BP 108-09, 1000 h at 125 +/- 2 C, 50/50 % coolant/ de-ionized or distilled water, Delta E 21 max 3.5 DURABILITY TESTING Note: All failures are to be evaluated via the Global 8D problem solving process.
35、3.5.1 Dye Stability Test Test Method Make a mixture of 50/50 coolant and deionized water and record pH. Fill an internally fluxed heat exchanger with coolant mixture. Place heat exchanger in oven for 2 weeks at 90C or store at ambient for 60 days. Evaluate the color after test and determine pH. Repo
36、rt change or loss in color. Report pH change. 3.5.2 Aluminum Water Pump Cavitation (ASTM D2809, 3 sample minimum) 3.5.2.1 100 hours 8 min 3.5.2.2 300 hours 8 min 3.5.3 Simulated Service Corrosion Test (ASTM D2570) Cast iron, steel, brass and copper 10 mg, max Cast aluminum, low lead solder 20 mg, ma
37、x High lead solder Report Aluminum radiator rating per Appendix I, (Page 20) Tube pitting 5, min Crevice corrosion 5, min Crevice corrosion 5, min 3.5.4 Engine Dynamometer Test (FLTM BL 102-02) 3.5.4.1 Radiator Heat Rejection Test, min (QCBTU Method) 85 % of original 3.5.4.2 Heater Core Deposit Weig
38、ht 1.0 mg/cm2 max ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2014, Ford Global Technologies, LLC Page 8 of 18 3.5.4.3 Water Pump Evaluation Rating #9 min (Rate per ASTM D2809) 3.5.4.4 Test Coupon Weight Loss At the end of the test, the average weight loss of the 7 similar metal coupon
39、s shall not exceed 10 mg/coupon. The weight loss of any individual coupon in the 7 bundles shall not exceed 30 mg. Determine and report the weight loss for each coupon that was in for the duration of the test. Determine the sum of all coupons of each type that were tested for 96 h. The sum of the 96
40、 h shall compare favorably (25 % variation) to the duration sums. 3.5.5 FVV Dynamic High Temperature Simulated Service Test Or Other High Temperature Simulated Service Test Method (Note: High temperature service test methods vary depending on coolant supplier. Test method must be reviewed by and agr
41、eed upon with PTI Core Engineering prior to testing.) Acceptance Criteria for FVV: Weight loss in cavitation chamber 40% coolant 30 mg/coupon, max 20% coolant 50 mg/coupon, max Weight loss in coupon 40% coolant 15 mg/coupon, max 20% coolant 25 mg/coupon, max Overall coolant rating 90/100, minimum Al
42、l ratings except corrosion Max rating achieved Corrosion rating 30/40, minimum 3.5.6 Stagnant Coolant Solubility and Corrosion Testing (FLTM BL 106-01, Heat exchanger chosen by PTI Core Engineering and Climate Control Engineering) 3.5.6.1 ASTM D4340 after stagnant and solubility testing. 1 mg/cm2/wk
43、, max Compare result from 3.4.10 for unused coolant. Note: 0.25 0.49 mg/cm2/wk is considered marginal. 0.20 to 0.24 mg/cm2/wk is favorable. less than 0.19 mg/cm2/wk is excellent. 3.5.6.2 Coolant Analysis before and after ASTM D4340 No adverse effect on (ASTM D1123, D1287, D5827, D6130) coolant inhib
44、itors or pH or metals in solution 3.5.6.3 Heat Exchanger after stagnation No deposits or precipitates inside heat exchanger as a result of the stagnation test ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2014, Ford Global Technologies, LLC Page 9 of 18 3.5.7 Radiator Internal Corrosion
45、Test (Modified ASTM D2570, Heat exchangers chosen by PTI core engineering Test method to be provided by PTI Cooling PD, Radiator Engineering Specification ES C1BY-8005-AA or latest by program) 3.5.7.1 Internal Corrosion Damage Two radiators are to be tested and analyzed post-test. Cut apart core and
46、 examine susceptible areas with a microscope for evidence of crevice attack, pitting attack and erosion-corrosion. A minimum of 6 tubes and both headers must be examined. Corrosion pits, crevices, etc. depths are to be established with metallographic cross-sections. If there are no apparent sites of
47、 corrosion attack or corrosion build-up, six(6) random tubes sections and one(1) header section from both headers is to be metallurgically examined. No corrosion site on the core tubes or headers shall exceed 10% of the material thickness. 3.5.7.2 Provide 250 ml coolant samples from pre-test, 5 min
48、into test, and post test. Coolant samples are to be analyzed and results reviewed by PTI Core Engineering. 3.5.8 Heater Core Internal Erosion-Corrosion Test (Modified ASTM D2570, Heat exchangers chosen by PTI Core Engineering and Climate Control. Test method to be provided by PTI Cooling PD , Heater
49、 Core Engineering Specification ES 6L24-18476-AA, revision B, or latest by program) Two heater cores are to be tested and analyzed post-test 3.5.8.1 Internal Erosion-Corrosion Damage Cut apart core and examine susceptible areas with a microscope for evidence of crevice attack, pitting attack and erosion-corrosion. A minimum of 6 tubes and both headers must be examined. Erosion-corrosion, corrosion, and crevices, etc. depths are to be established with meta
