1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 03 2016 07 05 Revised See Summary of Revisions W. Janitschke, EU 2011 08 25 Revised See Summary of Revisions W. Janitschke, EU 2011 03 17 Revised Complete Revision W. Janitschke, EU Controlled document at www.MATS Copyright 2016, Ford Gl
2、obal 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 requirement
3、s 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 roof, floor, si
4、de 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 APPROVED SOURCES These specifications are performance based and do not have app
5、roved sources. 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) There shall be no exposed metal area
6、 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 x 100 mm shall be coated by materi
7、al 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 Copyright 2016, Ford Global Technologie
8、s, LLC Page 2 of 7 After conditioning for 24 h at 23 +/- 2 C determine the abrasion resistance according to ASTM D968, 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 shall be used. GRAVEL: Type “GABBRO“ grain size 5 - 8 mm or equivale
9、nt SUPPLY SOURCE: ODENWALDER HARTSTEIN INDUSTRIE GMBH Erbacher Strasse 62 D-6101 Rossdorf or equivalent 3.4 CORROSION RESISTANCE, LABORATORY CYCLIC CORROSION TEST CETP 00.00-L-467 Test Method: Test panels of 200 x 100 x 0.8 mm shall be coated by material under test centrally 10 mm away from the edge
10、s 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 23 +/- 2 C, expo
11、se samples to CETP 00.00-L-467 as follows: Samples applied to BIW surfaces: 6 weeks Samples applied to e-coated surfaces: 12 weeks 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 ed
12、ges 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 material technologies require total vehicle corrosion testing prior to approval and their introduction. Test details including film t
13、hickness, 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 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)
14、 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 produce the necessary dry thickness which is required to fulfill acoustical requirements. Panels shall be baked for according to the m
15、inimum 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 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 +/
16、- 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 deviation from original. 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
17、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 kg/m ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Copyright 2016, Ford Global Technologies, LLC Page 5 of 7 3.11 ODOR Rating 3 max (FLTM BO 131-03, cured material p
18、er 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 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 mi
19、n cycle time as in FLTM BV 150-05, for each region to be used) 3.14 ALCANE RESTRICTION (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 J
20、1400, 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) 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for question
21、s concerning Engineering Material 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
22、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
23、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
24、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)
25、vs. Dry Film Build (mm) vs. Target Wet Film Build (mm) ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 4.2.4 Generate a separate graph of Composite Loss Factor vs. Temperature with the interpolated data at 200, 400, 800Hz for each dry sur
26、face 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 variation for any one supplier shall be +/- 20%, based on the recorded loss factor of the original approved production sample. The loss
27、 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 under the same conditions 4.3 PRODUCTION DISPENSING APPR
28、OVAL 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 material quality and dis
29、pense 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 include dimensional mea
30、surements (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/manufacture and set up pa
31、rameters 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 based on the properties and per
32、formance 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 minimum and maximum bake times
33、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 times should also be reported for
34、 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. 4.4 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product D
35、evelopment, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples
36、 must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.5 SUPPLIERS ONGOING RESPONSIBILITY All materia
37、ls must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the aff
38、ected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. ENGINEERING MATERIAL SPECIFICATION WSS-M99P31-A1/A2 Copyright 2016, Ford Global Technologi
39、es, LLC Page 7 of 7 For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.6 RESTRICTED SUBSTANCE MAN
40、AGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comp
41、ly with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2016 07 05 Updated Corrosion Resistance Requirements (3.4. Removed WSS-M99P1111-A and moved those requirements directly into this spec. 2011 08 25 Added WSS-M4G449-A1 (Rubber) as an affected Mater
42、ial specification for WSS-M99P31-A1 in section 4.1 2011 03 17 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 Adh
43、esion 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
