1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW16680 Sealers, Paint Shop, Pumpable, for Waterborne/2K, 3-Wet, Non-Compressed, Compact Painting Process Generic Qualification Copyright 2012 General Motors Company All Rights Reserved June 2012 Originating Department: North American Engineer
2、ing Standards Page 1 of 12 1 Scope This specification details the performance requirements of a family of sealers designed to be compatible with the 3-wet compact painting process which uses waterborne Basecoat + 2K Clearcoat topcoat systems. The materials are applied in paint shop after the E-Coat
3、bake. They must be capable of being either manually or robotically applied. The materials are intended to seal interior and exterior body joints against water, dust, air intrusion and corrosion. The family of materials include: High Appearance Paintable, Ultralight and Abrasion Resistant Rocker Anti
4、chip/Under Body Sealer/Under Body Coating sealers. 1.1 Material Description. The materials must be a smooth and homogeneous mixture free of air, lumps, unmixed particles or foreign materials. 1.1.1 The materials must be capable of being dispensed with approved and validated production displacement p
5、umping and application equipment including (depending upon material type and application): single/multi - point streaming, flat stream, automated hem sealing and airless fan spray and airless spray with rotary masking. Dispense testing shall be conducted through production Manufacturing System Quali
6、fication (MSQ) validated application equipment appropriate for the type of sealer material and application process. 1.1.2 Must not have a noxious or toxic odor in either the uncured or cured state. 1.1.3 In addition, the materials must not adversely affect those personnel handling them. 1.1.4 The ma
7、terials must adhere to all approved production E-Coats. They must not have corrosion causing ingredients. 1.2 Symbols. Not applicable. 1.3 Typical Applications. The materials validated and approved under this specification are formulated to be compatible with the 3-wet non-compressed sealer and topc
8、oat bakes, painting process and topcoat materials. The placement of application on the vehicle is determined by the type of material. The abrasion resistant materials are typically used as rocker anti-chip and/or underbody coating. The ultralight material is typically used for all interior and under
9、body seam sealing. And the high appearance paintable material is typically used to seal “appearance” joints that receive subsequent finessing/skiving. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM D412 AST
10、M D2369 EPA Method 24 SAE J1960 ASTM D634 ASTM E1428 ISO 3219 Z4 DIN ASTM D1475 ASTM G21 SAE J1524 ASTM D2196 DIN 53203 SAE J1864 2.2 GM Standards/Specifications. 9984515 GMW3019 GMW14124 GMW15634 9986347 GMW3022 GMW14729 GMW16124 9986348 GMW3025 GMW14829 GMW16695 9986351 GMW3059 GMW14873 GMW16701 9
11、986369 GMW3205 GMW15481 GMW3016 GMW3235 GMW15487 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16680 Copyright 2012 General Motors Comp
12、any All Rights Reserved June 2012 Page 2 of 12 2.3 Additional References. TMC003 Material Safety Data Sheet guidance documents (available at ). 3 Requirements 3.1 Requirements on Delivery. 3.1.1 Specific Gravity (ASTM D1475). 9986347 (Abrasion Resistant Material): Typically 1.4 g/cc 0.2 g/cc. 998635
13、1 (Ultralight Material): 0.85 g/cc maximum. 9986348 (High Appearance Paintable Material): Typically 1.4 g/cc 0.2 g/cc. 9986369 (Exposed Roof Ditch Sealer): Typically 1.4 g/cc 0.2 g/cc. 3.1.2 Interior Odor (GMW3205-A-1) for 9986351 and 9986348. Prepare a cured film of sealer that is 3 mm 0.5 mm thick
14、 baked at the appropriate nominal bake conditions in Table 4. Cut test specimens from this cured film of material, then condition for 7 days at 23 C 5 C before initiating test procedure. Evaluate using the Wet Condition Coding A and volume ratio Coding 5 from Table 1 found in the GMW3205 test proced
15、ure. The material shall have a tolerable or better odor; minimum rating of 6. 3.1.3 Fogging (GMW3235AY3T290% Minimum) for 9986348 and 9986351 Only. Prepare a cured film of sealer that is 3 mm 0.5 mm thick baked at the appropriate nominal bake conditions in Table 2. Cut test specimens from this cured
16、 film of material, then condition for 7 days at 23 C 5 C before initiating test procedure. Evaluate using Photometric Method Method A. 3.1.4 Volatile and Semi-Volatile Organic Compounds (SVOC) from Interior Materials (GMW15634) for 9986348 and 9986351 Only. Prepare a cured film of sealer that is 3 m
17、m 0.5 mm thick baked at the appropriate nominal bake conditions in Table 2 below. Cut test specimens from this cured film of material, then condition for 7 days at 23 C 5 C before initiating test procedure. After this conditioning, packaging is done as described for other test materials. Evaluate SV
18、OC using 60 minutes at 120 C per 4.2.2.1 of GMW15634. 3.1.5 Volatile Organic Compound (VOC) Determination, (Environmental Protection Agency (EPA) Method 24 Section 2.2 Using ASTM D2369 Procedure B), All 4 Materials. Target is 35.9 kg/m3 (0.3 lb/gal) or less. However, the final VOC of the product, in
19、cluding all weights, calculations and runs, are to be identified and reported as data in the submission book. 3.1.5.1 Condensing Volatiles Test (GMW3016), All 4 Materials. Maximum 3% allowed when baked as follows and tested according to GMW3016: High bake materials 20 minutes at 165 C 5 C Low bake m
20、aterials 20 minutes at 130 C 5 C 3.1.6 Viscosity. The viscosity shall be determined using the Pressflow (3.1.6.1), Brookfield (3.1.6.2) and Rheometric (3.1.6.3) methods. 3.1.6.1 Pressflow Viscosity (SAE J1524). Orifice: 1.32 mm (0.052 in) Pressure: 414 kPa (60 psi) Sample Weight: 20 g Test temperatu
21、re is 25 K 0.5 K The viscosity requirements are as follows: Key Product Characteristic (KPC) the viscosity requirement, at 72 h from date of batch manufacture, shall be: 9986348: 60 s 5 s 9986351: 60 s 5 s 9986347: 6.5 s 3.5 s 9986369: 40 s 5 s In addition, when stored in proper conditions, the rate
22、 at which the viscosity increases with age should not exceed the following guidelines: Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16
23、680 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 3 of 12 For 9986348 and 9986351: Viscosity at 30 days 72 h value + 20% Viscosity at 60 days 72 h value + 40% Viscosity at 90 days 72 h value + 60% In no case should the material viscosity exceed 100 s at the end of the 90 d
24、ay shelf life of the material. For 9986347: Viscosity at 90 days 72 h value + 20%. In no case should the material viscosity exceed 13 s at the end of the 90 day shelf life of the material. For 9986369: Viscosity at 90 days shall be 72 h data +35%. In no case should the material viscosity exceed 60 s
25、 at the end of the 90 day shelf life of the material. 3.1.6.1.1 The initial and aging viscosity data shall be provided in both numerical and graphed format in the material submission book. 3.1.6.2 Brookfield Viscosity (ASTM D2196). Spindle: Number 7. Rotational Speed 20 rpm. Take viscosity reading a
26、fter 1 minute. Test temperature is 25 C 0.5 C. The viscosity requirements are as follows: Key Product Characteristic (KPC) Requirement at 72 h from batch manufacture, the viscosity shall be: 9986348: 150 000 cps to 165 000 cps (centipoise) 9986351: 100 000 cps to 115 000 cps 9986347: 55 000 cps to 7
27、0 000 cps 9986369: 25 000 cps to 40 000 cps In addition, when stored in proper conditions, the viscosity increase with age should not exceed: 9986348: 190 000 cps at 90 days 9986351: 140 000 cps at 90 days 9986347: 90 000 cps at 90 days 9986369: 50 000 cps at 90 days 3.1.6.2.1 The initial and aging
28、viscosity data shall be provided in both numerical and graphed format in the material submission book. 3.1.6.3 Rheometric Determination of Viscosity Using a Rotational Viscometer (ISO 3219 using Z4 DIN Cup and Spindle). Rotation Speed 0 1/s to 130 1/s Sample test temperature 23 C 0.5 K Table 1: Visc
29、ometer Program Test Time Start Speed End Speed Wait Period 300 s 0 1/s 0 1/s Ascending 120 s 0 1/s 130 1/s Hold Cycle 180 s 130 1/s 130 1/s Descending 120 s 130 1/s 0 1/s Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networ
30、king permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16680 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 4 of 12 The relative viscosity, descending Bingham viscosity and Yield Point (all KPC requirements) at 72 h after batch manufacture shall b
31、e as follows: Descending Bingham (Pa s) Bingham Yield Stress (Pa) 9986348 13 2 575 125 9986351 7.0 1.0 400 100 9986347 1.75 0.8 380 120 9986369 6.7 0.2 117.5 7.5 In addition, when stored in proper conditions, the viscosity increase with age shall not exceed the following values: Descending Bingham (
32、at 90 days): Variation should not exceed 10% of 72 h data. Yield Stress (at 90 days): Variation should not exceed 20% of 72 h data. 3.1.6.3.1 The measured and calculated data, along with the curves generated, shall be included as data in the submission book. 3.1.7 Particle Size (DIN 53203): 200 m ma
33、ximum. 3.1.8 Color. White or light gray 3.2 Performance Requirements. 3.2.1 Adhesion (GMW3019), All Materials. One full set of test panels (bakes according to Table 2 and Table 3) must be prepared using a major production technology from each GM approved source of Electrocoat. This must also include
34、 Electrocoat technologies from all GM regions globally. The electrocoat panels for this testing must be prepared and processed in an actual assembly plant unless otherwise agreed to by the approving GM engineer. The materials must be capable of demonstrating at least a minimum of fine line cohesion
35、performance after the sealer bake oven. Table 2: Bakes for Adhesion (Plant Prepared E-Coat Panels) Sealer Bake Oven 9986347, 9986348, 9986351, 9986369 Minimum Sealer Bake 6 minutes at 130 C Low Limit Sealer Bake 10 minutes at 140 C Target Sealer Bake 10 minutes at 149 C Upper Limit Sealer Bake 20 mi
36、nutes at 163 C Table 3: Bakes for Adhesion Over Baked E-Coat Panels ACT (Applied Coating Technology lab) or Equivalent ELPO Bake Sealer Bake 60 minutes at 190 C All bakes in Table 2 3.2.1.1 The materials, when baked as described in Table 2 and Table 3, must not crack or lose adhesion to the substrat
37、e during or after exposure to the following conditions. In addition, the material must demonstrate cohesive adhesion when peeled from substrate. Initial Adhesion after cooling to ambient temperatures. Exterior Cycle (GMW14124, Cycle F) 12 cycles. Copyright General Motors Company Provided by IHS unde
38、r license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16680 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 5 of 12 3.2.2 Shrinkage/Expansion GMW15481, All 4 Materials. Ma
39、terial baked as described in 3.2.1 Table 2 (maximum bakes only) must exhibit no (0%) expansion and no shrinkage greater than 2%. 3.2.3 Elongation (9986347, 9986351, 9986348) ASTM D412, Method “A”, Using Die “C” Dumbbell. Material baked as described in 3.2.1 Table 2, must not exhibit less than 100% e
40、longation. This applied to all sealer bakes (minimum, lower limit, target, and upper limit). 3.2.3.1 Elongation (For 9986369 only) ASTM D412, Method “A”, Using Die “C” Dumbbell and Crosshead Speed of 300 mm/minute. Minimum Bake: 100% minimum Lower Limit Bake: 100% minimum Target Bake: 150% minimum U
41、pper Limit Bake: 150% minimum 3.2.3.2 Aged Elongation (9986369 Only). A second set of samples shall be prepared according to 3.2.3.1 and then exposed to 70 C for 336 h. Following this exposure the samples are allowed to stabilize to room temperature (25 C) and are then tested for elongation as descr
42、ibed in 3.2.3.1. The samples must again meet the minimum elongation requirements. 3.2.3.3 Tensile Strength (9986347 only), ASTM D412, Method “A”, Using Die “C” Dumbbell and Crosshead Speeds of 50 mm/minute and 500 mm/minute. Material baked as described in 3.2.1 Table 2, must not exhibit less than 0.
43、8 mPa. This applied to all sealer bakes (minimum, lower limit, target, and upper limit) and BOTH crosshead speeds. 3.2.4 Tear Strength (9986369 Only), ASTM D634, Method A, Using Die C and Crosshead Speed of 500 mm/minute. Two (2) sets of samples shall be prepared and baked according to Table 2. 3.2.
44、4.1 Initial Tear Strength. The first set of panels prepared in 3.2.4 shall be temperature stabilized to 25 C and then tested according to 3.2.4. The minimum tear strength requirement is 10 N/mm. 3.2.4.2 Aged Tear Strength. The second set of samples prepared in 3.3.4 shall be exposed to 70 C for 336
45、h. Following this exposure the samples are temperature stabilized to 25 C and then tested according to 3.2.4. The minimum test strength requirement is again 10 N/mm. 3.2.5 Porosity, All Materials. The material must exhibit no signs of trapped air from either an external observation or a cross sectio
46、nal view after being baked according to Table 2 (maximum bakes only). 3.2.6 Degradation Resistance, All Materials. Apply 2 beads of sealer, 3 mm high x 40 mm wide x 200 mm long, to the surface of a phosphated steel panel (inspect the panel first to be sure it is free of surface corrosion). Bake the
47、panel as follows: Bake 1 h at 175 C After baking, remove panel from oven and allow it to cool to room temperature. 3.2.6.1 After Bake. Remove one (1) sealer bead from the panel and inspect the surface of the panel. There must not be any corrosion on the panel surface where the sealer previously exis
48、ted. 3.2.6.2 After Humidity. Expose the panels with the remaining sealer bead to 40 C at 98% humidity for 240 h. 3.2.6.3 After Exposure. Remove the remaining sealer bead and again inspect the panel. There must be no corrosion on the panel surface where the sealer previously existed. 3.2.7 Compatibility with Associated Production Material/Process, All 4 Materials. Compatibility with plant specific materials, such as deadener/damper, primer surfacers, and topcoats, shall be evaluated before introduction to any production facilities. If any plant sp
