1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 05 08 Revised Table 1 A. Reaume 2002 08 15 Revised Updated and renumbered 1999 12 08 Activated A. Reaume Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 19 COOLANT CONCENTRATE, HYBRID ORGANIC ACID W
2、ITH WSS-M97B51-A1 SILICATES AND NITRITES 1. SCOPE 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. These materials are for initial fill and service fill. 2. A
3、PPLICATION WSS-M97B51-A1 was originally released for passenger car, light truck and commercial truck applications. 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
4、 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 furnish to the affected Materials Engineering activity a completed and certified copy of the attached supplements A and C and t
5、est reports demonstrating full compliance with all the requirements of this specification along with full formulation and manufacturing limits that apply to the material upon which approval is requested. Suppliers must provide full disclosure of their material formulation to, and be approved by, Mat
6、erials Engineering. All tests must be certified by a qualified and authorized representative of the test facility. 3.2.2 Approval of a new supplier to an approved formulation Supplier must furnish to the affected Materials Engineering activity a completed and certified copy of the attached supplemen
7、ts A and C and test reports demonstrating full compliance with paragraphs 3.1, 3.3, 3.4, 3.5.1-3.5.4, 3.6, and 3.8-3.11, of this specification (or as directed by Materials Engineering). All tests must be certified by a qualified and authorized representative of the test facility. ENGINEERING MATERIA
8、L SPECIFICATIONWSS-M97B51-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 19 3.2.3 Supplying an approved formulation from concentrate Supplier must furnish to the affected Materials Engineering activity a completed and certified copy of the attached supplem
9、ents A and C and test reports demonstrating full compliance with paragraphs 3.1, 3.3, 3.4, 3.5.1, 3.6 (Aluminum water pump cavitation and MTU cavitation chamber tests only),and 3.8-3.11, of this specification (or as directed by Materials Engineering). All tests must be certified by a qualified and a
10、uthorized representative of the test facility. 3.3 COOLANT COMPOSITION Coolants supplied to this specification must adhere to the following: . Minimum of 85% monoethylene glycol (75% virgin). . Anions ASTM D 5927 Chlorides at 25 ppm max Sulfates at 30 ppm max Phosphates at 15 ppm max (measured by Io
11、n Chromatography only) Glycolate at 10 ppm max . Metals, 5 ppm max, each metal ASTM D 6130 Aluminum Calcium Copper Iron Lead Magnesium 3.4 RECYCLED CONTENT Any redistilled (recycled) coolant, up to 10%, supplied to this specification must be pre-approved by Materials Engineering and include full doc
12、umentation of the process including feedstock of used coolant, control plans, FMEA, and compositional limits. Suppliers must certify full compliance with all the requirements of this specification. 3.5 LABORATORY MATERIAL PERFORMANCE 3.5.1 The chemical and physical properties of coolant candidates s
13、hall meet the requirements of the tests listed below. Table 1 requirements are screening tests to determine if candidate coolants qualify for the more intensive evaluations in para 3.7 (Fleet Test). ENGINEERING MATERIAL SPECIFICATIONWSS-M97B51-A1 Printed copies are uncontrolled Copyright 2007, Ford
14、Global Technologies, LLC Page 3 of 19 TABLE 1 TEST DESCRIPTION TEST METHOD TEST DESCRIPTION TEST LIMITS Color Visual Yellow (polymeric dye) Suspended Matter Visual None Relative Density ASTM D 1122/ D 5931 15.5/15.5 C 1.110 - 1.145 Water ASTM D 1123 5% max Freezing point ASTM D 1177/ D 3321/D 6660 5
15、0% by vol -37 C (-34 if measured in F) PH ASTM D 1287 50% by vol 7-9 Silicates ASTM D 6130 Inductively Coupled Plasma Spectroscopy(ICP) 200 ppm, min Reserve Alkalinity ASTM D 1121 10 mL, min Nitrites (as NO2) FLTM AM 107-01 % by weight 0.21 0.26 Foaming Characteristics ASTM D 1881 Foam height Break
16、time 150 mL, max 3 sec, max Effect on automotive finish FLTM BI 113-01 Use 30% coolant/water in place of liquid soap. No effect greater than DI water. Viscosity ASTM D445 20 C Information only Electrical Conductivity ASTM D 1125 20 C, 50% by vol, Information only Thermal Conductivity ASTM D 2717 or
17、Report 20 C, 50% by vol 0.4184 mW/cm C Information only Glassware Corrosion Test ASTM D 1384 Cast iron, steel, brass and copper weight loss per coupon Cast aluminum, low lead solder weight loss per coupon High lead solder weight loss per coupon Average of 3 determinations 10 mg,max 10 mg, max Report
18、 Hot surface corrosion test ASTM D 4340 . Initial qualification - Average of 2 determinations . After FLTM 102-02 - Average of 2 determinations mg/cm2/week, max 1.0 mg/cm2 /week, max Galvano-static pitting test FLTM BL 105-01 Pitting potential, mV vs. SCR -400 mv 3.5.2 Compatibility with Other Coola
19、nts Prepare samples of containing 10%/90%, 30%/70%, 50%/50%, 70%/30% and 90%/10% of test coolant and each coolant currently supplied to the market in which the coolant is to be used for both initial fill and after market applications. Samples are then tested to the following tests. Glassware Corrosi
20、on Test (ASTM D1384) - Same test limits as in Table 1. Hot Surface Corrosion Test (ASTM D4340) - Same test limits as in Table 1. ENGINEERING MATERIAL SPECIFICATIONWSS-M97B51-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 19 3.5.3 Storage Stability Prepare
21、hard water by adding 275 mg of calcium chloride (CaCl2) to 1 liter synthetic corrosive water described in ASTM D1384 (Test Solutions section). Prepare six coolant samples of around 100 ml using the test coolant and the hard water solution. Samples are to have coolant concentrations of 100% (samples
22、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 for the coolant to pass. Hot Storage Stability - Sa
23、mples 1, 3 and 5 are heat storage tested in a circulating air oven at 65 +/- 2 C for 14 days. Remove samples on days 2, 4, 7, 10 and 14. Allow to cool to room temperature. Check for precipitates, deposits, gelation and phase separation. “Fish eyes” on the top (from defoamer) is acceptable. If anythi
24、ng other than “fish eyes” is present, terminate test and write as failure. Cold Storage Stability - Samples 2, 4 and 6 are cold storage tested at -40 C for 14 days. Remove the samples on days 2, 4, 7, 10 and 14. Allow to go to room temperature. Check for precipitates, deposits, gelation and phase se
25、paration. “Fish eyes” on the top (from defoamer) is acceptable. If anything other than “fish eyes” is present, terminate test and write as failure. 3.5.4 Compatibility with Engine Hot Test Fluids (Producto Chemical Procedure dated 2-15-96) Prepare 5 samples, of about 100 ml volume, of 50% coolant co
26、ncentrate and 50% deionized water (ASTM D 1193, Type IV minimum water to simulate factory fill usage). Label sample bottles 1, 2, 3, 4 and 5. Add 1, 2, 3 and 4% by volume of engine hot test fluid to samples 1, 2, 3 and 4; leave sample 5 as is. Allow samples to sit for period of one month at ambient
27、temperature. Observe the samples weekly for any change in appearance, such as gelling, precipitation, phase separation. (French square-type bottle may aid visual check.) Any changes, other than “fish eyes” deem the hot test fluid incompatible with the coolant. ENGINEERING MATERIAL SPECIFICATIONWSS-M
28、97B51-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 19 3.5.5 Compatibility with Polymeric Materials Testing shall be performed using currently approved coolant and proposed coolant. A comparison shall be made between the results for both coolants. Results
29、 of the testing must be reported to the responsible Materials Engineer. Testing will be completed by the polymer supplier under the direction of Materials Engineering. Elastomer Testing For currently approved materials for hoses (tube materials only), o-rings, and gaskets contact the responsible Mat
30、erials Engineer. Immersion in Engine Coolant (FLTM BO 130-01, 1000 h at 125 +/- 2 C) 3.5.5.1 Hardness change Rate and Report 3.5.5.2 Tensile Strength Change, max Rate and Report 3.5.5.3 Elongation at Break Change, max Rate and Report 3.5.5.4 Volume Change Rate and Report 3.5.5.5 Compression Stress R
31、elaxation (o-rings and seals only) (ASTM D 6147, 25 % compression) Test Method: Measure the initial back-force (Fo) after 30 minutes at 23 +/- 2 C. Age at 125 +/- 2 C and take back-force (Ft) measurements at 23 +/- 2 C after 24, 48, 96, 168 h and thereafter every 168 h until a total elapsed test tim
32、e of 1000 h has been completed. Plot F against log 10 time in hours F3.5.5.5.1 Heat Aged (Test Method per Conditioning 8 HR, NON-CIRCULATING AT ROOM temp. Total time 60 days (1440 hrs). System pressure: No externally applied pressure. System pressure not to exceed 110 Kpa (16 PSIG). Metal coupons: N
33、o metal test coupons. Radiator position: Tested in vehicle position. Product Engineering Office approval of the test system is required prior to test initiation at a new facility. Report rating per Appendix I. Leak test: The radiator shall not exceed a total leak rate of 5.0 cc/min when pressurized
34、to 21 psig and tested submerged in water at 22 +/- 1C. Internal Corrosion Damage: Cut apart core and examine susceptible areas with a microscope for evidence of crevice attack, pitting attack and erosion-corrosion. Corrosion pits, d crevices, etc. depths are to be established with metallographic cro
35、ss-sections. Report corrosion on the core tubes or headers exceeding 10% of the material thickness. ENGINEERING MATERIAL SPECIFICATIONWSS-M97B51-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 9 of 19 Heater Core Internal Erosion- Corrosion Test Modified ASTM D2
36、570 Exceptions to D2570: Coolant Concentration: 15% Aggressive Ion Concentration: None Test Component: Visteon heater core, Part Number F65H-18476-AA. Coolant Flow Rate: 35.7 L/min. Time/Temperature Cycle: 16 hr, circulating at 107 C; 8 hr, non-circulating at room temp. Total time 8 weeks(1344 hrs).
37、 System pressure: No externally applied pressure. Metal coupons: No metal test coupons. Heater core position: Tested in vehicle position. Product Engineering Office approval of the test system is required prior to test initiation at a new facility. Report rating per Appendix I. Leak test: The heater
38、 core assembly shall not exceed a total leak rate of 1.0 cc/min when pressurized to 241 kPa (35 psig) at 21 +/- 3 C. Conditions shall be met in air and submerged in water for 20 sec. Internal Corrosion Damage: Cut apart core and examine susceptible areas with a microscope for evidence of crevice att
39、ack, pitting attack and erosion-corrosion. Pit and crevice depths are to be established with metallographic cross-sections. No corrosion site on the core tubes, tanks, headers or connector tubes shall exceed 15% of the material thickness. Note: Ends of the core tubes and connectors may exhibit “knif
40、e edge” attack. The depth measurement should be made at least 3mm away from the tube end. ENGINEERING MATERIAL SPECIFICATIONWSS-M97B51-A1 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 10 of 19 Heater Core Internal corrosion test Modified ASTM D2570 Exceptions to
41、D2570: Coolant concentration: 45% Aggressive Ion Concentration: 100 ppm of chloride, sulfate and bicarbonate (use sodium salts) in the final mixture. Coolant Flow Rate 28 +/- 1 L/min/heater core, maximum of 2 cores (connected in parallel) per test stand. Time/Temperature Cycle: 16 hr, circulating at
42、 107 C; 8 hr, non-circulating at room temp. Total time 8 weeks (1344 hrs). 5. System pressure: not to exceed 172 kPa (25 psig). No externally applied pressure. Metal coupons: No metal test coupons. Heater core position: Tested in vehicle position. Product Engineering Office approval of the test syst
43、em is required prior to test initiation at a new facility. Leak test: The heater core assembly shall not exceed a total leak rate of 1.0 cc/min when pressurized to 35 psig at 21 +/- 2 C. Conditions shall be met in air and submerged in water for 20 sec. Internal Corrosion Damage: Cut apart core and e
44、xamine susceptible areas with a microscope for evidence of crevice attack, pitting attack and erosion-corrosion. Pit and crevice depths are to be established with metallographic cross-sections. No corrosion site on the core tubes, tanks, headers or connector tubes shall exceed 15% of the material th
45、ickness. Heater Hose Durability Testing ES-E9LH-18K580-AA Test Procedure a. Assemble hose and clamp components and evaluate integrity under vacuum 61 kPa (18 in. Hg.) and pressure 345 kPa (50 psig) - with 80/20 coolant-water mixture. b. Mount hose and clamp assembly to vibration fixture with opposit
46、e end of hose rigidly apart from fixture and place in an environmental chamber. Assembly shall have 2 feet of free length hose. Raise the chamber temperature from ambient to 127 C (approx. 1 - 2 C per minute) then stabilize. Heat coolant to 104 C Vibrate each hose assembly with a sinusoidal sweep ov
47、er the frequency range of 10 to 60 Hz with a fixed displacement of 0.124244 cm peak to peak (0.25g at 10 Hz, 9g at 60 Hz) at a logarithmic sweep rate of 0.862 octave/minute during the entire sequence. Pressure cycle each hose assembly from 0 to 207 to 0 kPa* at a rate of 4-10 cycles per minute. Hold
48、 for minimum of 2 seconds at each extreme pressure. (Note: *=flow induced pressure, not to exceed 35 kPa). Acceptance Criteria: Test Assemblies must complete 28,000 pressure cycles with no noticable coolant leakage. ENGINEERING MATERIAL SPECIFICATIONWSS-M97B51-A1 Printed copies are uncontrolled Copy
49、right 2007, Ford Global Technologies, LLC Page 11 of 19 Total time should be approximately 1 hour At 127 C temperature, continue pressure cycling test. Maintain coolant temp at 104 C. Continue vibrating hose assembly. Continue pressure cycling. Total sequence is 60 pressure cycles. Reduce chamber temperature to -40 C (approximately 1 - 2 C per minute) and stabilize. Coolant should be not circulating. Vibration system should not be on. Pressure cycling should not be on. Total time should be approximately 80 minutes. At -40 C tem
