1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions REV 01 2011 03 17 Revised Document completely Revised, See Summary of Revisions W. Janitschke 2004 03 25 Activated W. Scholz, R. Frechen Printed copies are uncontrolled Copyright 2011, Ford Global Technologies, LLC Page 1 of 7 PERFORMANCE SPR
2、AYABLE 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 requirements for material with good acoustical efficiency whi
3、ch 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 roof, floor, side panel, rocker panel, doors, liftgate etc. where
4、 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 and part producers must conform to the Companys Standard Requir
5、ements 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 RESISTANCE (only applicable for materials used as underbody coating) T
6、here 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 Method: Prepare the test panels as follows: Test panels of 300
7、 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 region. ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Prin
8、ted copies are uncontrolled 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 put rate of 30 - 40 l/h. For each specimen 5 l of fresh gravel
9、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 0.8 mm shall be coated by material under test centrally 10 mm a
10、way 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 shop applied materials or for BiW. After conditioning for 24 h at
11、 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) Report test method used. The material shall protect the test
12、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. 3.5 CORROSION RESISTANCE, PROVING GROUND (CETP 00.00-R-343) New
13、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 Materials Engineering, PV steel For min according to DIN EN 100
14、83, 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 Specimens: Test panels shall be coated by material under test to p
15、roduce 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 Original (24 h after application) 3.10.2 After Environmental Cycli
16、ng 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 for 72 h before continuing or testing. After ageing no deviat
17、ion from original. ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Printed copies are uncontrolled 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 0.028 0.030 0.033 0.038 0.055 0 C 0.079 0.086 0.099 0.113 0.121 2
18、0 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 FOGGING 2000 max ppm (VDA 278 (Thermodesorption), cured material pe
19、r 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 RESTRICTION (VDA 278 (Thermodesorption) The supplied material sha
20、ll 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 conditions per FLTM BV 150-05 use applicable region) kg/m ENG
21、INEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Printed copies are uncontrolled Copyright 2011, Ford Global Technologies, LLC Page 6 of 7 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. 4.1 AFFECTED
22、 MATERIAL SPECIFICATIONS WSS-M99P31-A1 relates to WSK-M4GXXX-A (Bitumen) 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 calculate composite loss factor/material loss factor may be used. Ea
23、ch 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 weight, final material weight, final dry film thickness of mate
24、rial, 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 (measured at 2.5, 3.5, and 5.5 kg/m2 dry surface wts.) 4.2.2 Mat
25、erial 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) vs. Dry Film Build (mm) vs. Target Wet Film Build (mm) 4.2.4 G
26、enerate 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 (-20, 0, 20, 40 and 60 C) vs. frequency The loss factor variati
27、on 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 at the designated material laboratory. All samples shall produ
28、ce loss factor(s) that correspond to the reference standard when tested under the same conditions ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Printed copies are uncontrolled Copyright 2011, Ford Global Technologies, LLC Page 7 of 7 4.3 PRODUCTION DISPENSING APPROVAL AND MATERIALS PROCESS WIN
29、DOW 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 material quality and dispense equipment controls. Fact
30、ors 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 include dimensional measurements (width/thickness) on
31、 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/manufacture and set up parameters including dispensing
32、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 based on the properties and performance of the initial DOE. T
33、his 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 minimum and maximum bake times for each condition. (Example:
34、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 times should also be reported for the material and how they aff
35、ect the CLF, reporting 1,3, and 7 day open times vs bake conditions would be beneficial in defining this parameter. 5. SUMMARY OF REVISIONS 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
36、 Cold Slam Resistance added 7. Peel Resistance deleted 8. Staining deleted 9. Paint Adhesion modified 10. Panel Sink Marks deleted 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
