1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions REV 02 2011 08 25 Revised See Summary of Revisions W. Janitschke, Eu 2011 03 17 Revised Document completely Revised, See Summary of Revisions W. Janitschke 2004 03 25 Activated W. Scholz, R. Frechen Controlled document at www.MATS Copyright 2
2、011, Ford Global Technologies, LLC Page 1 of 7 PERFORMANCE SPRAYABLE COATING, ACOUSTIC, INTERIOR, WSS-M99P31-A1 BODY PANELS, APPLIED IN BIW PERFORMANCE SPRAYABLE COATING, ACOUSTIC, INTERIOR WSS-M99P31-A2 AND/OR EXTERIOR, BODY PANELS, APPLIED ON EC 1. SCOPE These specifications define the performance
3、 requirements for material with good acoustical efficiency which is applied to body panels either in body-in-white or in the paint shop. 2. APPLICATION These specifications were originally released for materials to be sprayed on or applied with wide slit nozzle in visible or non-visible areas of roo
4、f, floor, side panel, rocker panel, doors, liftgate etc. where body panel damping and/or panel stiffening is required. The materials with different chemical base are applied onto oily surfaces or dry electrocoat. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers a
5、nd part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 FILM THICKNESS Report wet film thickness and dry film thickness (high and low bake) for each application density from 2.5 kg/m to 5.5 kg/m in 0.5 kg/m increments. 3.3 ABRASION RESISTAN
6、CE (only applicable for materials used as underbody coating) There shall be no exposed metal area showing after 370 liters gravel impact. No loss of adhesion on and around the area of stone impact. 3.3.1 Original (24 h after application) 3.3.2 After Ageing (14 d at 90 +/- 2 C, 24 h 23 +/- 2 C) Test
7、Method: Prepare the test panels as follows: Test panels of 300 x 100 mm shall be coated by material under test centrally 10 mm away from the edges. Dry film target thickness is 1 mm. Panels shall be baked separately for the min and max curing cycles according. to FLTM BV 150-05 for the applicable re
8、gion. ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 2 of 7 After conditioning for 24 h at 23 +/- 2 C determine the abrasion resistance according to ASTM D 968, except I.D. of tube 25 mm and at a gravel through p
9、ut rate of 30 - 40 l/h. For each specimen 5 l of fresh gravel shall be used. GRAVEL: Type “GABBRO“ grain size 5 - 8 mm or equivalent SUPPLY SOURCE: ODENWALDER HARTSTEIN INDUSTRIE GMBH Erbacher Strasse 62 D-6101 Rossdorf or equivalent 3.4 CORROSION RESISTANCE Test Method: Test panels of 200 x 100 x 0
10、.8 mm shall be coated by material under test centrally 10 mm away from the edges to produce the min required dry thickness of 0.75 mm. Panels shall be baked separately for the min and max curing cycles acc. to FLTM BV 150-05 for the applicable region, follow appropriate oven conditions for paint sho
11、p applied materials or for BiW. After conditioning for 24 h at 23 +/- 2 C, 3.4.1 Salt Spray Test (For material applied to uncoated steel or iron only) (ASTM B 117, 500 hours) 3.4.2 Scab Corrosion Test (For EC, EG HDG and all Zn coated panels) (FLTM BI 123-03, 50 cycles or CETP 00.00-L-467, 12 weeks)
12、 Report test method used. The material shall protect the test panel from corrosion. Disregard the area 10 mm from the edges of test panel. Under the material and at the border line of material edges there shall be no visible corrosion, flaking, or any evidence of loss of adhesion of the material. 3.
13、5 CORROSION RESISTANCE, PROVING GROUND (CETP 00.00-R-343) New material technologies require total vehicle corrosion testing prior to approval and their introduction. Test details including film thickness, method of application, number of test cycles, etc. for the individual vehicles are defined by M
14、aterials Engineering, PV steel For min according to DIN EN 10083, hardness code requirements CK75, panel size 240 x (+/- 0.3) 10(+/- 0.3) x see Table 1 1 (+/- 0.02) mm, material size 216 x 10 mm) Or (SAE J 1637, SAE B bar, bake per FLTM BV 150-05 use applicable region) Preparation and Curing of Spec
15、imens: Test panels shall be coated by material under test to produce the necessary dry thickness which is required to fulfill acoustical requirements. Panels shall be baked for according to the minimum curing conditions per FLTM BV 150-05 for each applicable region for BiW or Paint Shop. 3.10.1 Orig
16、inal (24 h after application) 3.10.2 After Environmental Cycling Test Method: Samples must be exposed 16 times to the following cycle in the sequence indicated below: 16 h at 38 +/- 2 C and 98 +/- 2% RH 4 h at - 40 +/- 1 C 4 h at 80 +/- 2 C After each four cycles specimens to be stored at 23 +/- 2 C
17、 for 72 h before continuing or testing. After ageing no deviation from original. ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 5 of 7 LOST FACTORS (OBERST) Table 1 Test Temperature 2.5 3.0 3.5 4.0 5.5 - 20 C 0.0
18、28 0.030 0.033 0.038 0.055 0 C 0.079 0.086 0.099 0.113 0.121 20 C 0.104 0.125 0.146 0.174 0.215 40 C 0.061 0.076 0.088 0.103 0.122 60 C 0.020 0.023 0.028 0.032 0.042 3.11 ODOR Rating 3 max (FLTM BO 131-03, cured material per min cycle time as in FLTM BV 150-05, for each region to be used) 3.12 FOGGI
19、NG 2000 max ppm (VDA 278 (Thermodesorption), cured material per min cycle time as in FLTM BV 150-05, for each region to be used) 3.13 VOLATILE ORGANIC CONTENT 1500 max ppm (VDA 278 (Thermodesorption), cured material per min cycle time as in FLTM BV 150-05, for each region to be used) 3.14 ALCANE RES
20、TRICTION (VDA 278 (Thermodesorption) The supplied material shall not contain Alcanes (n-Aliphates as C10H22 thru C16H34) based on VOC test method and requirements (para 3.12). 3.15 Sound Transmission Loss Report dBL (SAE J1400, 2.5 & 5.0 kg/m2, 25 C, 125 8000Hz, 1/3 octave band, bake minimum/maximum
21、 conditions per FLTM BV 150-05 use applicable region) kg/m ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 6 of 7 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in
22、meeting the requirements of these specifications. 4.1 AFFECTED MATERIAL SPECIFICATIONS WSS-M99P31-A1 relates to WSS-M4G449-A1 (Rubber) WSS-M99P31-A2 relates to WSS-M4G443-A1 (Rubber) WSS-M99P31-A2 relates to WSS-M4G446-A1 (Waterbased Acrylic) 4.2 CORRELATION EQUATIONS Correlation equations to calcul
23、ate 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 correlation values for such calculations. The following must be reported for all testing: Bar w
24、eight, final material weight, final dry film thickness of material, record of % wt. Solids and % volume solids for the batch of material tested. Report: 4.2.1 Composite Loss Factor/Composite Modulus (per SAE J 1637) at -20, 0, 20, 40 and 60 C for each mode and interpolated to 200, 400, and 800 Hz (m
25、easured at 2.5, 3.5, and 5.5 kg/m2 dry surface wts.) 4.2.2 Material Loss Factor/Material Modulus (per ASTM E 756) at -20, 0, 20, 40 and 60 C for each mode and interpolated to 200, 400, and 800 Hz (measured at 2.5, 3.5, and 5.5 kg/m2 dry surface wts.) 4.2.3 Generate a table of Dry Surface Wt (kg/m2)
26、vs. Dry Film Build (mm) vs. Target Wet Film Build (mm) 4.2.4 Generate a separate graph of Composite Loss Factor vs. Temperature with the interpolated data at 200, 400, 800Hz for each dry surface wt. 2.5, 3.5, and 5.5 kg/m2) 4.2.5 Provide raw data of material loss factor and modulus vs. temperature (
27、-20, 0, 20, 40 and 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) established for initial approval shall constitute the reference standard and shall be kept on file
28、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-M99P31-A1/A2 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 7 of
29、7 4.3 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 conducted establishing the process win
30、dow 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, vertical, inverted). Responses to the D
31、OE 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. This report shall describe equipmen
32、t type/manufacture and set up parameters including dispensing tip, applied distance/angle, material flow rate, dispensed velocity, and system pressures. The supplier shall provide at minimum the following DOE to aid in NVH and process qualification. Further DOE and functional trials may be necessary
33、 based on the properties and performance of the initial DOE. This DOE, involves reporting the Composite Loss Factor at 2.5 and 5.5kg/m2 dry surface weights for the following simulated conditions: pre-gel oven, prime oven, and paint oven. The minimum and maximum temperatures should be tested with the
34、 minimum and maximum bake times for each condition. (Example: for the pre-gel oven, the following combination should be run for each surface weight, short time with low temperature, short time with high temperature, long time with low temperature, and long time with high temperature.) Maximum open t
35、imes should also be reported for the material and how they affect the CLF, reporting 1,3, and 7 day open times vs bake conditions would be beneficial in defining this parameter. 5. SUMMARY OF REVISIONS 8/25/2011 1. Added WSS-M4G449-A1 (Rubber) as an affected Material specification for WSS-M99P31-A1
36、in section 4.1 3/17/2011 1. WSS-M99P31-A3 requirements deleted 2. Types A D deleted 3. Film Thickness revised 4. Abrasion Resistance revised 5. Corrosion resistance modified 6. Cold Slam Resistance added 7. Peel Resistance deleted 8. Staining deleted 9. Paint Adhesion modified 10. Panel Sink Marks d
37、eleted 11. Volume Expansion modified 12. Acoustic Efficiency Lost Factor (Oberst) modified 13. Odor modified 14. Fogging modified 15. VOC modified 16. Sound Transmission Loss added 17. Affected Material Specs modified 18. Complete Spec renumbered 19. Change APG to MPG 20. Production Dispensing Approval and Materials Process Window added 21. Correlation equations added
