1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2012 02 06 Activated New Global Coolant Specification M. Ranger, A. Reaume, FNA Controlled document at www.MATS Copyright 2012, Ford Global Technologies, LLC Page 1 of 17 COOLANT, ORGANIC ADDITIVE TECHNOLOGY (OAT), WSS-M97B44-E1 CONCEN
2、TRATE, FOR PASSENGER CAR AND LIGHT TRUCK 1. SCOPE The material defined by this specification is a coolant concentrate composed essentially of virgin monoethylene glycol and OAT corrosion inhibitors. When mixed 50/50 with water it shall be a satisfactory fluid for vehicle cooling systems that contain
3、 aluminum engine components, radiators and heater cores, ferrous metals and copper brass. This material is for initial fill and service fill. 2. APPLICATION This specification was released originally for passenger car and light truck and commercial truck applications without the use of nitrites. It
4、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 alloys or zinc coatings (e.g. galvanized product). 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers an
5、d 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 formulation Supplier must provide a completed and certified copy of the attached Supplement A and test reports demonstrating full compliance with a
6、ll the requirements of this specification. Suppliers must provide full disclosure of their material formulation to, and be approved by, Materials Engineering. This 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
7、organic acid technology additives, azoles and other corrosion additives, and ethylene glycol 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
8、an approved formulation Same as 3.2.1 with surrogate test data where 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/ Cl
9、eaner Cleaner Control ASTM Corrosive Water Al Iron Steel Brass Solder 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, lowere
10、d life, etc). The coolant concentrate form, quality and chemical 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 i
11、n form, quality or composition to adversely affects heat transfer 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 sample
12、s using the test coolant and the hard water solution. Samples are 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.
13、) All samples must pass hot and cold storage stability testing for 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
14、. Check for precipitates, deposits, gelation and phase separation. “Fish eyes” on the top (from defoamer) is acceptable. If anything other than “fish eyes” is ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-E1 Copyright 2012, Ford Global Technologies, LLC Page 5 of 17 present, such as gel or material
15、in solution or precipitate, terminate test and write as failure. Analyze 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 precipi
16、tates, deposits, gelation and phase separation. “Fish eyes” on the 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
17、 with Engine Hot Test Fluids (See compatibility method in WSS-M97B56-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,
18、load 120 C 25 % compression, 50/50 v/v coolant/water, 3024 hours) (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 vess
19、el; completely immerse CSR fixtures in coolant. Lubricate both ends 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. Bes
20、ides the initial readings, take readings at 24 hours, 1 week, 3 weeks, 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
21、 Materials (FLTM BO 130-01, 1000 h at 125 +/- 2 C) (Materials identified 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 use
22、d in continuous contact with coolant). Test new coolant with approved 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 MATER
23、IAL SPECIFICATION WSS-M97B44-E1 Copyright 2012, Ford Global Technologies, LLC Page 6 of 17 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-
24、A1 -A2 -A3 WSS-M96D34-A4/A5 All hose diameters -28 -10 -45 -28 3.4.21.2 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, whi
25、ch can be extracted by engine coolant and re-deposit elsewhere in the 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 co
26、oling system based on a standard sample size. Equipment and Materials 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
27、 Three filter papers for Buchner funnel One 500 ml filter flask with 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 / di
28、stilled water mixture Convection oven capable of 100C Procedure 1. 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 / w
29、ater mixture. Plug and clamp the open end. Verify no leakage. Bake 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 d
30、istilled water to seal the paper to the funnel. 5. Remove a plug from 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 i
31、n the hose, repeat rinse as necessary. 6. Using distilled water in a squeeze bottle, wash any solid residue away from the sides of the funnel to the filter paper surface. ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-E1 Copyright 2012, Ford Global Technologies, LLC Page 7 of 17 7. Tare the watch gla
32、ss. Carefully remove the filter paper, place on watch glass, and if 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. Acce
33、ptance criteria Weight of extractables on the filter paper must weigh 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 fail
34、ures are to be evaluated via the Global 8D problem solving process. 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 ambie
35、nt for 60 days. Evaluate the color after test and determine pH. Report 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,
36、brass and copper 10 mg, max Cast aluminum, low lead solder 20 mg, max 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,
37、min (QCBTU Method) 85 % of original 3.5.4.2 Heater Core Deposit Weight 1.0 mg/cm2 max 3.5.4.3 Water Pump Evaluation Rating #9 min ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-E1 Copyright 2012, Ford Global Technologies, LLC Page 8 of 17 (Rate per ASTM D2809) 3.5.4.4 Test Coupon Weight Loss At the e
38、nd of the test, the average weight loss of the 7 similar metal coupons 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
39、all coupons of each type that were tested for 96 h. The sum of the 96 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 d
40、epending on coolant supplier. Test method must be reviewed by and agreed 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
41、% coolant 25 mg/coupon, max Overall coolant rating 90/100, minimum All 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)
42、3.5.6.1 ASTM D4340 after stagnant and solubility testing. 1 mg/cm2/wk, 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
43、 No adverse effect on (ASTM D1123, D1287, D5827, D6130) coolant inhibitors 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-E1 Copyright 2012, Ford Gl
44、obal Technologies, LLC Page 9 of 17 3.5.7 Radiator Internal Corrosion 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
45、 radiators are to be tested and analyzed post-test. 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. Corrosion pits, crevices, etc. depths are to be established
46、 with metallographic cross-sections. If there are no apparent sites of 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 t
47、hickness. 3.5.7.2 Provide 250 ml coolant samples from pre-test, 5 min 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
48、Climate Control. Test method to be provided by PTI Cooling PD , Heater 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 wi
49、th 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 metallographic cross-sections. If there are no apparent sites of corrosion attack or corrosion build-up, six(6) tubes sections and one(1) header section from both headers is to be metallurgically examined (-0. No erosion, corrosi
