1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2013 09 04 Revised Removed “Not for European use” from title B. Witkowski, NA 2004 05 27 Revised Rev para 2, 3.4.4, 3.5.8, 3.5.9 added paragraph 3.5.12 J. Crist 2002 01 30 Activated C. Lin Printed copies are uncontrolled Copyright 2004, Ford
2、Global Technologies, LLC Page 1 of 10 PERFORMANCE, SPRAYABLE COATING, ACOUSTIC, WSS-M99P30-A2/A3/A4/A5 INTERIOR AND EXTERIOR, BODY PANELS 1. SCOPE The scope of this specification encompasses solvent free, non-dimensional materials which demonstrate good: Noise, vibration, and harshness (NVH) charact
3、eristics Stone-chip protection Corrosion protection Paint compatibility (where needed) 2. APPLICATION The materials released to this specification were originally released for robotic or hand-application to visible and non-visible areas such as: wheel housing, door skins, floor pans, and dash panels
4、. A2 Suffix designates materials, which are applied to electrocoated surfaces (prior to topcoat) A3 Suffix designates materials, which are applied after the body has been painted (post topcoat) A4 Suffix designates materials, which are applied to oily metal substrates (prior to electrocoat) A5 Suffi
5、x designates materials, which are applied to electrocoated metal surfaces (prior to topcoat), for interior applications only. Note: Due to the characteristics (i.e. expansion) of these products the time from application to bake and Pregel oven temperature is critical. NVH materials are required to p
6、erform in a number of applications and closure designs. Each design and/or application has unique requirements. Compliance with this materials specification does not guarantee the damping material will function for all potential applications on a vehicle. Selection of the appropriate material should
7、 therefore be based on jury evaluations or other NVH test procedures as well as the required functional trial. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99
8、P1111-A). ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4/A5 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 2 of 10 3.4 MANUFACTURING PERFORMANCE REQUIREMENTS 3.4.1 Rheology (SAE J1524, rotational rheometer with 40 mm diameter parallel plates, 500 micron ga
9、p, 50 Pa/sec ramp, stress controlled rheometers use stress range 0 - 3500 Pa, strain controlled rheometers use strain range 0 - 100 sec-1, evaluate material to highest stress or strain as the formulation will allow, report material batch/lot number, identify rheometer make and model, for each test c
10、ondition report yield stress and submit plots for shear stress vs. shear rate, submit plot for viscosity vs. temperature at mid-range shear rate. If a two-component material, report each component and mixed) 3.4.1.1 Initial (as received) Test at 23 +/- 2 C If different than ambient, test at applicat
11、ion temperature +/- 2 C Test over range 10 to 50 C at increments of 10 C 3.4.1.2 Accelerated Aging Test and record after 3 days at 54 C 3.4.1.3 Storage, 30, 60 and 90 days Store at 23 +/- 2 C, 50 +/- 5% R.H. The rheology variation for any one supplier shall be +/- 30%, based on the recorded rheology
12、 of the original approved production sample. The flow curves established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce flow curves that correspond to the reference standard when tested under the
13、 same conditions. 3.4.2 Percent Solids, wt and vol % +/- 0.5 (ASTM D 2834) The weight and volume tolerance for any one supplier shall be +/- 0.05, based on the recorded weight of their original approved production sample. Reference Para 5.1.1. 3.4.3 Weight Per Volume, kg/L +/- 0.05 (ASTM D 816) The
14、weight tolerance for any one supplier shall be +/- 0.05 kg/L, based on the recorded weight of their original approved production sample. Reference para 5.1.2. ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4/A5 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page
15、3 of 10 3.4.4 Viscosity at 25 C, % +/- 5 (SAE J 1524, VIS-2, 1.32 mm orifice, 280 kPa) 3.4.4.1 Initial (as received) Test at 16 C, 25 C, and 43 C. 3.4.4.2 Accelerated Aging Test at 25 C after 14 days at 32 C Test at 25 C after 90 days at 23+/-2 C, 50 +/- 5% R.H. The viscosity tolerance for any one s
16、upplier shall be +/- 5 %, based on the recorded viscosity of their original approved production sample. Reference para 5.1.3. 3.4.5 Volatile Organic Content, % +/- 0.05 (EPA Method 24, Method B) The VOC Content tolerance for any one supplier shall be +/- 0.05%, based on the recorded VOC of their ori
17、ginal approved production sample. 3.4.6 Production Dispensing Approval and Materials Process Window The supplier shall perform necessary tests to verify that production-dispensing systems can maintain and control material flow rate and application pattern. A design of experiments (DOE) shall be cond
18、ucted establishing the process window for material quality and dispense equipment controls. Factors included in DOE are material viscosity range (initial and after aging), assembly plant temperature variations (16 - 43 C), production application thickness, and application attitude (horizontal, verti
19、cal, inverted). Responses to the DOE shall include dimensional measurements (width/thickness) on the applied material pattern, dispensed weight/volume, and material movement after application (subject to plant conditions). A formal report shall be submitted to materials and manufacturing activity. T
20、his report shall describe equipment type/manufacture and set up parameters including dispensing tip, applied distance/angle, material flow rate, dispensed velocity, and system pressures. 3.4.7 Wash Resistance (A4 matls only) No wash off (FLTM BV 116-03, Direct and Indirect, 2000psi Report Weight Los
21、s.) 3.4.8 E-coat compatibility Shall not contaminate (A4 matls only) primer bath or cause (FLTM BV 119-01) e-coat film irregularities ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4/A5 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 4 of 10 3.4.9 Sag Resista
22、nce, maximum 4 mm Test Method: Application area should be sprayed per recommended equipment from dispensing company. Apply a 5 x 50 x 200 mm (h x w x l) bead of material along the center line of three panels prepared per para 5.2. Scribe panels to mark the initial location Age unbaked panels for 3 d
23、ays 40 +/- 2 C, 50 +/- 5% R.H. uncured. Age in inverted, vertical, and horizontal positions. Immediately after conditioning, place one panel in an oven to cure the material at the minimum bake schedule per para 5.3 (no bake required for -A3 materials) Allow the panel to cool to 23 +/- 2 C Determine
24、the sag by measuring the material movement below the scribe. Repeat the test using the second panel at the maximum bake per para 5.3. 3.5 Engineering Requirements 3.5.1 Abrasion Resistance (For Underbody Applications Only, A2, A3) 3.5.1.1 SAE J 400 Less than 5% average material loss per test area pe
25、r panel and less than 5 average rust points per test panel after 72 h. Test Method: Spray apply sealer to dry film thickness of 0.5 mm to 3 mm, 100 x 300 x 0.8 mm electrocoated CRLC panels: A2: E-coated substrates per para 5.2.1.1 A3: Painted substrates per para 5.2.1.2 A2 panels should be baked acc
26、ording to the minimum bake schedule per para 5.3. A3 materials should be cured for 24h 23 +/- 2 C, 50 +/- 5% RH, minimum. Subject the bottom portion of the panels to 4.75 L of stones total, 0.475 L at a time. Use 7 gauge aluminum backing plate. Manually remove (without rubbing or abrading) all loose
27、 and/or blistered material. Report percentage of material lost (per panel and average over all panels). Ignore any material loss within 5 mm of panel edges. After abrasion testing is completed, condition the panels in an environmental chamber. Use APGE testing per FLTM BI 023-01: A2, A3: 30 cycles R
28、emove the panels and carefully scrape off remaining sealer with spatula. Record the number of rust spots per panel. Report the average number of rust spots over the 5 panels. Also perform abrasion at - 40 +/- 2 C. Report material loss. ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4/A5 Printe
29、d copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 5 of 10 3.5.2 Acoustic Efficiency, Oberst (SAE J 1637, 2.4 kg/m2, 200Hz, SAE bar, bake per para 5.3) A2 - A4 A5 Composite Loss Factor, min 0.1 0.2 Conditioning: Original (24 h after application) Different bar configurations
30、 (e.g.: coated one-side; sandwich, etc.) may be necessary to get the material loss factor in the glass transition region. Correlation equations to calculate composite loss factor/material loss factor may be used. Each supplier being considered must indicate whether correlation equations between test
31、ing and material performance was used and report reported correlation values for such calculations. The following must be reported for all testing: Bar weight, final material weight, final dry film thickness of material, record of % wt. Solids and % volume solids for the batch of material tested. Re
32、port: 3.5.2.1 Composite Loss Factor/Composite Modulus (per SAE J 1637) at -10, 10, 25, 40 and 60 C for each mode and interpolated to 200, 400, and 800 Hz (measured at 2.4, 3.7, and 4.9 kg/m2 dry surface wts.) 3.5.2.2 Material Loss Factor/Material Modulus (per ASTM E 756) at -10, 10, 25, 40 and 60 C
33、for each mode and interpolated to 200, 400, and 800 Hz (measured at 2.4, 3.7, and 4.9 kg/m2 dry surface wts.) 3.5.2.3 Generate a table of Dry Surface Wt (kg/m2) vs. Dry Film Build (mm) vs. Target Wet Film Build (mm) 3.5.2.4 Generate a separate graph of Composite Loss Factor vs. Temperature with the
34、interpolated data at 200, 400, 800Hz for each dry surface wt. (2.4, 3.7, and 4.9kg/m2) 3.5.2.5 Provide raw data of material loss factor and modulus vs. temperature (- 10, 10, 25, 40, 60 C) vs. frequency The loss factor variation for any one supplier shall be +/- 20%, based on the recorded loss facto
35、r of the original approved production sample. The loss factor(s) established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce loss factor(s) that correspond to the reference standard when tested un
36、der the same conditions. ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4/A5 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 6 of 10 3.5.3 Sound Transmission Loss, dBL Report (SAE J1400, 2.4 & 4.9 kg/m2, 25 C, 125 8000Hz, 1/3 octave band, bake per para 5.3) 3
37、.5.4 Fogging, minimum (Interior Applications Only) (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 70 Formation of clear film, droplets or crystals is cause for rejection. 3.5.5 Odor The material shall be free from objectionable odors, both
38、as received, after storage, and after cure, as determined by the manufacturing facility. 3.5.6 Sealer Fume Test (A2 material only) (FLTM BV 130-01) No evidence of paint peeling after cross-hatch adhesion test 3.5.7 Condensing Water Vapor Test No blisters (FLTM BI 104-02, Method A, 72 h panels swelli
39、ng, no per para 3.5.1) loss of adhesion no re-dispersion 3.5.8 Peel Resistance (substrates per para 5.2 for applicable specification) The material at all ranges of coating thickness must not be peeled off in a coherent film. Test Method: Coat 300 x 100 mm test panels, prepared according to FLTM BI 1
40、20-01 in such a manner (airless) that after the cure cycles in para 5.3, a dry coating thickness of nominally 2.0 mm beginning at one edge of the test panel and tapering to zero at the other is obtained. After 24h at 23 +/- 2 C make two cuts through the coating along the 300 mm length of the test pa
41、nel and 30 mm apart and try to peel off coating starting at the edge with the lowest film thickness. 3.5.9 Compatibility with Production Paints Initial Requirements A2, A4 & A5 materials which are not covered by trim only and where high appearance is necessary No tackiness, staining, paint transfer
42、or other objectionable appearance defects in the paint over the sealer. ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4/A5 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 7 of 10 Note: Evidence of any defects as stated above shall be reviewed with Vehicle Op
43、erations and Materials Engineering. Test Method: Prepare test panels per matrix in Table 1. Use current production paints as identified by materials Engineering. (Panels shall be kept horizontal prior to baking, during the painting operation and during cure. Use gas-fired oven for paint cure.) Evalu
44、ate After Initial Heat Aging 72 hours at 70 C. 3.5.11 Water Absorption Test, %, max. 5.0 (FLTM BV 117-01, Method A, 8 h soak time) 3.5.12 Cold Slam Resistance (For Closure Applications only, A4) (FLTM BV 101-02, Procedure E, 300 x 300 mm panel substrate per para 5.2.1.3, 4 mm cured material thicknes
45、s, condition for 4 h minimum at -29 +/- 2 C prior to testing, test at - 29 C for 10 slams) Initial Test after 30 days at 50 +/- 2 C and 90 +/- 5% relative humidity Test after 30 cycles APGE (FLTM BI 123-01, modified cycle, 30 cycles) One APGE cycle: 15 min salt water immersion (5% salt solution), pl
46、us 1 h and 45 min drip dry at RT 22 h at 50 +/- 2 C and 90 +/- 5% RH Samples are to remain in the 50 +/- 2 C and 90% +/- 5% environment over the weekends and holidays. Sample preparation: Apply a 150 x 150 mm piece of material on a 300 x 300 mm panel. Cure materials per paragraph 5.3. 5. GENERAL INF
47、ORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 TYPICAL PROPERTIES 5.1.1 Percent Solids, wt and vol% 65.0 - 99.9 (ASTM D 2834) 5.1.2 Weight Per Volume, kg/L 1.3 - 2.0 (ASTM D 816) ENGINEERING MATERIAL SPECIFICAT
48、ION WSS-M99P30-A2/A3/A4/A5 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 8 of 10 5.1.3 Viscosity at 25 C, seconds 30 - 60 (SAE J 1524, VIS-2, 1.32 mm orifice, 280 kPa) 5.1.5 Tensile Strength (Only for materials which are being used to replace interior seam sealer
49、s) 5.1.5.1 Normal Tensile Strength, min 0.9 MPa ASTM D 412, Die C Pull rate: 300 mm/min. 5 samples minimum Bake per Para 5.3 Elongation, min 50% Tear Strength, min 4.0 N/mm ASTM D 624, die C Pulled at 500 mm/min. Bake per Para 5.3. 5.1.5.2 Aged 2 weeks at 90 +/- 2 C Tensile Strength, min 1.0 MPa ASTM D 412, Die C Pull rate: 300 mm/min. 5 samples minimum Bake per Para 5.3 Elongation, min 50% Tear Strength, min 4.0 N/mm ASTM D 624, die C Pulled
