1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 07 31 Activated J. Crist/N. Lindsay-Merte Printed copies are uncontrolled Page 1 of 12 Copyright 2002, Ford Global Technologies, Inc. STRUCTURAL FOAM PERFORMANCE, CAVITY REINFORCING, WSS-M99P35-A TWO CO
2、MPONENT PUMPABLE, ROOM TEMPERATURE CURING 1. SCOPE This specification defines the material performance requirements for cavity reinforcing two component, room temperature curing structural foam materials applied after paint prior to the trim shop. These materials are used to improve localized joint
3、stiffness and torsional rigidity. 2. APPLICATION The specification was originally released for the two component, room temperature curing structural foam materials applied after paint prior to the trim shop. The materials are used to improve localized joint stiffness and torsional rigidity in applic
4、ations such as pillar to roof, pillar to rocker, and rocker sections. Special consideration is required when evaluating the use of these materials in crash or crush sensitive locations. The Manufacturing Properties and Engineering Performance requirements defined in these specifications are based on
5、 laboratory sample testing and define the minimum acceptance criteria for material performance. The function and design requirements for the specific application are defined by the component SDS (Sub-system Design Specification), key life test requirements, or vehicle program requirements. The final
6、 performance of these materials is dependent on the processing parameters in the assembly plant. Prior to use, the materials must be evaluated under the intended application processing parameters. The choice of substrates, stamping and assembly plant processing conditions, dispensing system, and spe
7、cific design application may affect engineered part performance. Compliance with this specification does not guarantee the materials will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers mus
8、t conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATION WSS-M99P35-A Page 2 of 12 3.2 SYSTEM COMPATIBILITY Initial material approval was based on a specific material system, which included the substrate, paint systems and material
9、. The originally approved material system was room temperature cured using specific production process parameters. The choice of substrates, paint systems, stamping and assembly plant processing conditions, dispensing system and specific design application may affect the material performance. If any
10、 of these parameters are changed, the material performance must be validated using the new parameters. 3.3 ENGINEERING APPLICATION Each application for these materials is unique to a specific design. The engineering drawing shall define the specific location, volume, compressive modulus, tensile mod
11、ulus, compressive yield stress, ultimate tensile strength, and/or other parameters critical for the given application. The materials approved to this specification are initially flowable and may require baffles, plugs, and other engineered parts to contain the foam in the desired location until the
12、material is gelled or fully cured. These baffles, plugs, and other engineered parts shall also be specified on the engineering drawing. Compatibility, functional testing, and manufacturing feasibility for the materials, baffles, plugs, and other engineered parts for each application shall be accesse
13、d and validated prior to production release by the releasing activity. A signed functional report shall be supplied to materials engineering for each application. 3.4 MATERIAL PROPERTIES All testing is conducted at maximum free volume expansion unless otherwise stated. Testing should be reported for
14、 each component and mixed material at agreed upon mix ratio. 3.4.1 Density Report (ISO 845/ASTM D 3574, Test A, interior density) The density variation for any one supplier shall be +/- 10 kg/m3, based on the recorded density of their original approved production sample. Aged density on each compone
15、nt shall not vary more that +/- 10 % when compared to initial density. Report for each component at 23 +/-2 C and aged for 7 days at 40C. Report for mixed material sample cured for 24 hours at 23 +/- 2 C. Reference para 4.3. ENGINEERING MATERIAL SPECIFICATION WSS-M99P35-A Page 3 of 12 3.4.2 Viscosit
16、y Report (SAE J1524, 2.64mm) The viscosity variation for any one supplier shall be +/- 10 kg/m3, based on the recorded viscosity of their original approved production sample. Aged viscosity on each component shall not vary more that +/- 10 % when compared to initial density. Report for each componen
17、t at 23 +/-2 C and aged for 7 days at 40 C. Report for mixed material sample cured for 24 hours at 23 +/- 2 C. Reference para 4.4. 3.4.3 Free Volume Expansion Report (Experimental Design) Report the relationship between free volume expansion, cured material density, mass and material dispense temper
18、ature. The free volume change variation for any one supplier shall be +/- 5 %, based on the recorded volume change of their original approved production sample. Reference para 4.5. 3.4.4 Volatile Organic Compounds (VOC) Content Report (EPA Method 24) The VOC Content variation for any one supplier sh
19、all be +/- 0.01 kg/L, based on the recorded VOC Content of their original approved production sample. Reference para 4.6. 3.4.5 Material Reactivity (Experimental Design) Report the relationship between material reactivity and material dispense temperature. Specific information with regard to materia
20、l reactivity shall include, but is not limited to, the following: Cure time Peak material exotherm temperature vs mass Material purge requirements 3.4.6 Process Operating Window Report (Experimental Design) Using production level dispensing equipment, conduct a design of experiments to define the op
21、erating parameters required to achieve the vehicle specific targets for compression modulus and volume fill. Requirements for scope of design of experiments as specified by Materials Engineering. ENGINEERING MATERIAL SPECIFICATION WSS-M99P35-A Page 4 of 12 Report parameters used for design of experi
22、ments, measured response, and summarize the effects of each variable. Provide recommended operating parameters to Ford for specific dispensing equipment utilized. 3.4.7 Differential Scanning Calorimetry Report (20 +/- 1 mg sample size, 10 C/min heating rate, 25 - 250 C temperature range, submit Heat
23、 Flow vs. Temperature curve) Report onset of reaction Report glass transition point of cured material at recommended mix ratio 3.5 MANUFACTURING PROPERTIES All testing is conducted at maximum free volume expansion unless otherwise stated. 3.5.1 Material Consistency Shall be a smooth homogenous mixtu
24、re, free from entrapped air, foreign materials and any properties detrimental to normal production operation. 3.5.2 Color Each component is distinctly different in color. The mixed material shall meet manufacturing process control requirements. Final approval of material color for production shipmen
25、ts shall be made by the affected manufacturing activity. The material color for any one supplier shall not visually deviate from the originally approved production samples. Color shall be identified on the supplier control plan. 3.5.3 Odor 3.5.3.1 Odor (North American Production) Shall be free from
26、objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.5.3.2 Odor (European Production), Rating 2 max. (FLTM BO 131-01, cured material per 3.5) ENGINEERING MATERIAL SPECIFICATION WSS-M99P35-A Page 5 of 12 3.5.4 Storage Stability Heat and moisture will
27、accelerate aging. The materials shall be stored in away from all sources of heat and moisture. The self life of the material shall be 3 months from date of manufacture when stored at temperatures below 32 C. Ambient plant conditions may fluctuate between 15 C and 38 C. Materials shall be evaluated f
28、or local plants conditions to determine plant specific requirements for temperatures in excess of 32 C. Deviations from the shelf life requirement shall be identified and concurred upon by the plant and noted in the supplier control plan. When materials are stored at temperatures below 23 C, they sh
29、all be conditioned at room temperature for a minimum of 24 hours prior to application. Application properties are optimized with adequate conditioning of the material. Critical performance characteristics to evaluate for shelf life stability shall include, but are not limited to, the following: Dens
30、ity, para 3.4.1 Viscosity, para 3.4.2 Free Volume Expansion, para 3.4.3 Material Reactivity, para 3.4.5 Elastic Compression Modulus, para 3.6.1 Adhesion, para 3.6.2 Dimension Stability, para 3.6.6 3.6 ENGINEERING REQUIREMENTS All testing is conducted at maximum free volume expansion unless otherwise
31、 stated. 3.6.1 Elastic Compression Modulus, ECOMP, (ASTM D 1621, cylindrical test samples, diameter 30 +/- 5 mm, height 2 x diameter, material cure per para 4.2, record up to a minimum of 25 % over yield point, report compressive modulus, compressive yield point, report, uncured sample volume and we
32、ight, report information for location sampling data at top, center, and bottom. report cured sample density, report temperature at center of sample container and at the outer edge, report sample weight prior to and after environmental exposure, and cured sample dimensions. Submit stress-strain curve
33、. Measure exact sample dimensions for each samples and save for 3.6.6 Dimensional Stability) Sample preparation: ENGINEERING MATERIAL SPECIFICATION WSS-M99P35-A Page 6 of 12 Material sampling shall be at maximum free volume expansion. The material shall be dispensed using production level dispensing
34、 equipment at optimized parameters as determined by para 3.4.6. The sampling container shall be at least a 3.8 L paint can or larger, if required. Cut samples using a cylindrical core sampling tool with an inside diameter of 30 +/- 5 mm. Trim sample length to a height of 2 x diameter. Confirm the sa
35、mples taken from top, center, and bottom have a consistent compression modulus +/- 10%. If sample data is consistent, samples may be used from any location. If sample data varies more than +/- 10%, choose the sampling location, which yields samples with the lowest compression modulus and use for all
36、 future testing. Monitor material exothermic temperatures using two thermocouple probes. One probe shall be imbedded in the material at the center of the larger sampling container ant the second probe shall be imbedded in the material no more than 3-5 mm just inside the cylinder edge about midway to
37、 container top. Report time/temperature profile for each probe; use DSC to report extent of cure at both thermocouple probe sites. Weigh each sample prior to and after environmental exposure. Measure exact sample dimensions for each sample prior to testing. Save measurements for 3.6.6 dimensional st
38、ability. 3.6.1.1 Normal, min 400 MPa (Condition at 1 h at specified temperature prior to test) Test at - 40, 23, 50 and 80 +/- 2 C 3.6.1.2 Environmentally Aged 80 % Retention of initial modulus at 23 C Test after 30 days at 50 +/- 2 C and 90 +/- 5 % relative humidity Test after 30 cycles APGE (FLTM
39、BI 123-01, modified cycle, report after 10, 20 and 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 ENGINEERING MATERIAL SPECIFICATION WSS-M99P35-A Page 7 of 12 Samples are to remain in the 50 +/- 2 C a
40、nd 90 % +/- 5 % environment over the weekends and holidays. Test after 10 moisture intrusion cycles One cycle: 16 h at 38 +/- 2 C and 95 +/- 5 % condensing RH 4 h at - 40 +/- 2 C 4 h at 80 +/- 2 C Samples are to be conditioned at 23 +/- 2 C and 50 +/- 5% RH over weekends and holidays. Time between c
41、onditions shall not exceed 5 minutes. 3.6.2 Adhesion Sample preparation: Using substrates per para 4.1. Cut five 150 x 150 mm panels. Using heat resistant tape join the four panels to form a box and join the other panel to cap the bottom of the box. Material sampling shall be at maximum free volume
42、expansion. The material shall be dispensed using production level dispensing equipment at optimized parameters as determined by para 3.4.6. Dispense the material into the box constructed above. After 24 hours, remove the bottom cap and trim the top to be flat and even with the top of the box. Condit
43、ion or expose, peel away the box and report failure mode. Surface analysis data is required to support fine layer cohesive failure mode descriptions. 3.6.2.1 Normal, Cohesive failure (Condition at 1 h at specified temperature prior to test) Test at -40, 23, 50 and 80 +/- 2 C ENGINEERING MATERIAL SPE
44、CIFICATION WSS-M99P35-A Page 8 of 12 3.6.2.2 Environmentally Aged Cohesive failure and no more than 12 mm corrosion undercutting at material edge Test after 30 days at 50 +/- 2 C and 90 +/- 5 % relative humidity Test after 30 cycles APGE (FLTM BI 123-01, modified cycle, report after 10, 20 and 30 cy
45、cles) 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 Samples are to remain in the 50 +/- 2 C and 90 % +/- 5 % environment over the weekends and holidays. Test after 10 moisture intrusion cycles One cycle: 16 h a
46、t 38 +/- 2 C and 95 +/- 5 % condensing RH 4 h at -40 +/- 2 C 4 h at 80 +/- 2 C Samples are to be conditioned at 23 +/- 2 C and 50 +/- 5% RH over weekends and holidays. Time between conditions shall not exceed 5 minutes. Test after 500 hr Salt Spray (European Production) (ASTM B 117) Test after 50 cy
47、cles Scab Corrosion (European Production) (FLTM BI 123-01, without scribe) Test after 10 Rounds of VDA 621-415 (European Production) 3.6.3 Corrosion Resistance, Proving Ground (European Production) New material technologies require LPG/APG approval prior to their introduction. Test details including
48、 film thickness, method of application, number of test cycles, etc. for the individual cars are defined by Materials Engineering, PV&T. ENGINEERING MATERIAL SPECIFICATION WSS-M99P35-A Page 9 of 12 3.6.4 Cured Flammability (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute 3.6.5 Fogging (SAE J1756, 3 h
49、 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. 3.6.6 Dimensional Stability, % 5 % max change (ASTM D 2126, using sample measurements from 3.6.1 Compressive Modulus) Test after 30 days at 50 +/- 2 C and 90 +/- 5 % relative humidity Test after 30 cycles APGE (Reference para 3.6.1.3) Test after 10 thermal cycles (Reference para 3.6.1.3) 3.6.7 Tensile Properties (ASTM D 638, Report modulus of elasticity, ultimate t
