1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 03 2017 03 13 Editorial Separated from A5 S. Short, NA 2013 09 04 Revised Removed “Not for European use” from title B. Witkowski, NA 2002 01 30 Activated C. Lin Copyright 2017, Ford Global Technologies, LLC Page 1 of 10 PERFORMANCE, SPRAY
2、ABLE COATING, ACOUSTIC, WSS-M99P30-A2/A3/A4 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) characteristics Stone-chip protection Corrosion protection Paint c
3、ompatibility (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. A2 Suffix designates materials, which are applied to elec
4、trocoated 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) NVH materials are required to perform in a number of applications a
5、nd 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 therefore be based on jury evaluati
6、ons 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-M99P1111-A). ENGINEERING MATERIAL SPECI
7、FICATION WSS-M99P30-A2/A3/A4 Controlled document at www.MATS Copyright 2017, 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 gap, 50 Pa/sec ramp, stress controlled rh
8、eometers 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 condition report yield stress and submit
9、 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 application temperature +/- 2 C Test over range
10、 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 of the original approved production sa
11、mple. 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 same conditions. 3.4.2 Percent Solids,
12、 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 weight tolerance for any one supplier s
13、hall 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 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 3 of 10 3.4.4 Viscosity at 25 C, % +/- 5 (
14、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 supplier shall be +/- 5 %, based on the rec
15、orded 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 original approved production sample. 3.4.6 Pr
16、oduction 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 conducted establishing the process window for
17、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, vertical, inverted). Responses to the DOE shall
18、 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. This report shall describe equipment type/m
19、anufacture 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 Loss.) 3.4.8 E-coat compatibility Shall not c
20、ontaminate (A4 matls only) primer bath or cause (FLTM BV 119-01) e-coat film irregularities ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 4 of 10 3.4.9 Sag Resistance, maximum 4 mm Test Method: Application ar
21、ea 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 days 40 +/- 2 C, 50 +/- 5% R.H. uncured. Age i
22、n 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 the sag by measuring the material movement be
23、low 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 per panel and less than 5 average rust points p
24、er 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 according to the minimum bake schedule per para
25、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 and/or blistered material. Report percentage
26、 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 Remove the panels and carefully scrape off rem
27、aining 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 Controlled document at www.MATS Copyright 2017, Ford G
28、lobal 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) Composite Loss Factor, min 0.1 Conditioning: Original (24 h after application) Different bar configurations (e.g.: coated one-side; sandwich, etc.) may be necessary to ge
29、t 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 testing and material performance was used and report reported corre
30、lation 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. Report: 3.5.2.1 Composite Loss Factor/Composite Modulus (per SAE
31、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 for each mode and interpolated to 200, 400, and 800 Hz (measure
32、d 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 interpolated data at 200, 400, 800Hz for each dry surface wt. (
33、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 factor of the original approved production sample. The loss factor(s
34、) 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 under the same conditions. ENGINEERING MATERIAL SPECIFICATION WSS
35、-M99P30-A2/A3/A4 Controlled document at www.MATS Copyright 2017, 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) 3.5.4 Fogging, minimum (Interior Applications Only) (SAE J1756, 3 h
36、 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 as received, after storage, and after cure, as determined by the m
37、anufacturing 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 swelling, no per para 3.5.1) loss of adhesion no re-dispersion 3.5.8 Pee
38、l 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 120-01 in such a manner (airless) that after the cure cycles in par
39、a 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 panel and 30 mm apart and try to peel off coating starting at the ed
40、ge with the lowest film thickness. 3.5.9 Compatibility with Production Paints Initial Requirements A2 and A4 materials which are not covered by trim only and where high appearance is necessary No tackiness, staining, paint transfer or other objectionable appearance defects in the paint over the seal
41、er. ENGINEERING MATERIAL SPECIFICATION WSS-M99P30-A2/A3/A4 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 7 of 10 Note: Evidence of any defects as stated above shall be reviewed with Vehicle Operations and Materials Engineering. Test Method: Prepare test panels pe
42、r 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.) Evaluate After Initial Heat Aging 72 hours at 70 C. 3.5.11 Water Absorption
43、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 thickness, condition for 4 h minimum at -29 +/- 2 C prior to testing, test at -
44、 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), plus 1 h and 45 min drip dry at RT 22 h at 50 +/- 2 C and 90 +/- 5% RH Sa
45、mples 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 INFORMATION The information given below is provided for clarification and
46、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 SPECIFICATION WSS-M99P30-A2/A3/A4 Controlled document at www.MATS Copyright 2017,
47、 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 sealers) 5.1.5.1 Normal Tensile Strength, min 0.9 MPa ASTM D 412, Die C Pull rat
48、e: 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
49、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. 5.1.6 Crack Resistance, min 5000 cycles (FLTM BV 115-01, bake 2 sets of No cracks panels per para 5.3 for normal and aged tests. Substrates identified per para 5.2, only for materials which are being used to replace interior seam s
