1、ABN 84 006 893 232 GM Holden Limited Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : HN 2413 1 of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE, BODY SHOP, WELD-THROUGH, NON-EXPANDING/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUST NOT BE REPRODUCED. IF U
2、SED IN RELATION TO THE COMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. FORM : I:MaterialsEngineeringStandardForms MaterialSpecificationMatspec.doc 1. SCOPE This specification details the requirements of a high bake, non-paintable, fuel resistant, wel
3、d through sealer capable of being pumped at ambient temperatures. This material must have excellent adhesion to oily metal and resist wash-off through phosphate and E-coat. This expandable sealer is intended for use in the body shop to seal body joints against water, dust and air intrusion. The seal
4、er must exhibit very even and controlled expansion characteristics and must not accelerate corrosion of the metal substrate over which it is applied. The material must be a smooth and homogeneous mixture free of air, lumps, unmixed particles and foreign materials. It must be capable of being dispens
5、ed with standard production pumping equipment. Type 1 defines a non-expanding sealer (0% Expansion) Type 2 defines an expanding sealer with (65% Expansion) 2. REFERENCES HN 1000 ASTM B117 GM9832P HN 0017 GMW3059 GM9021P GM9037 HN 0234 HN 0142 HN 0214 HN 0019 ASTM D1475 3. REQUIREMENTS 3.1 Specific G
6、ravity 1.2 1.7 3.2 Solids Content (ASTM D1475) 95% min 3.3 Flash point (ASTM D1475) 200C 3.4 Viscosity (GM9021P) Orifice 2.6 mm Pressure 60 psi Sample Weight 40 g Seconds 80 - 100 A temperature vs viscosity plot shall be submitted at the time of approval. Temperature range should be 10C t 60C. ABN 8
7、4 006 893 232 GM Holden Limited Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : HN 2413 2 of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE, BODY SHOP, WELD-THROUGH, NON-EXPANDING/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUST NOT BE REPRODUCED. IF USED I
8、N RELATION TO THE COMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. FORM : I:MaterialsEngineeringStandardForms MaterialSpecificationMatspec.doc 3. REQUIREMENTS (continued) 3.5 Toxicity The toxicity shall be disclosed in kind and magnitude, as required
9、by the GM Holden Material Safety Data Sheet. In addition, the material must have full approval of the appropriate medical department prior to production use. 3.6 Expansion (GM9037) Type 2 only- The sealer must expand 65% +/- 10% when baked at 180C for 20 min. 3.7 Odour (GM9832P) The sealer must not
10、have an objectionable odour in either cured or uncured condition. 3.8 Colour Type 1 = Black Type 2 = Any colour apart from black. 4. PERFORMANCE REQUIREMENTS 4.1 Adhesion The sealer must adhere to oily CRS (Cold Rolled Steel), Zn-Ni, Zn, and Zn-Fe panels (oiled with 3 g/m2 representative body shop p
11、ressing oil). Panels are to be prepared as per HN 0234 and baked as per: i) Low ELPO bake = 20 min 160C + 40 min 130C (Low Paint bake) ii) Nominal ELPO bake = 30 min 180C + 50 min 140C (Nominal Paint bake) iii) High ELPO bake = 60 min 200C+ 50 min 140C (Nominal Paint bake) 4.1.1 Initially the sealer
12、 material must not crack or lose adhesion to the panel during or after bake. ABN 84 006 893 232 GM Holden Limited Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : HN 2413 3 of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE, BODY SHOP, WELD-THROUGH, NON-EXPANDING
13、/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THE COMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. FORM : I:MaterialsEngineeringStandardForms MaterialSpecificationMatspec.doc 4. PERFORMANCE REQUIREMENT
14、S (continued) 4.1 Adhesion (continued) 4.1.2 Heat Ageing- panel from 4.1 shall be baked for 2 weeks 70C. There shall be no cracking or loss of adhesion. Sealer must exhibit cohesive failure after heat ageing. 4.2 Corrosion Resistance Prepare panel assembly by taking two 0.8mm x 300mm x 100mm plain s
15、teel panels (CRS), placing a 250mm x 3mm bead of sealer centrally on one of them and placing the second panel directly over the first. Spotweld the panels together by placing 5 spotwelds uniformly spaced along the centre line of the panels through the sealer bead. Panel assembly is then put through
16、production phosphate and ELPO paint system. Expose the panels to 1000h salt spray exposure as per ASTM B117. After completion of the corrosion cycle, remove test panels and immediately rinse with warm water. Drill out the spot welds and pry panels apart. Carefully remove sealer with scraper and exam
17、ine panel condition for rust below the sealer bead. Upon conclusion of test, there must be no rust beneath the sealer bead and the sealer must exhibit cohesive failure. ABN 84 006 893 232 GM Holden Limited Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : HN 2413 4
18、of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE, BODY SHOP, WELD-THROUGH, NON-EXPANDING/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THE COMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. FORM : I:M
19、aterialsEngineeringStandardForms MaterialSpecificationMatspec.doc 4. PERFORMANCE REQUIREMENTS (continued) 4.3 Cold slam The material must withstand two 1.69 Joule impacts at -30C. Prepare panels as described in HN 0234 Clause 3.4 and bake panels at 185C for 30 minutes. Perform impact test as describ
20、ed in HN 0142. 4.4 Wash-off resistance A 80mm x 10mm open bead of adhesive shall be applied to 100mm x 300mm CRS and Zinc coated steel panels. Panels (2x2) shall pass through GM Holdens ELPO system and bake oven. There shall be no loss of material or distortion of bead. This test may only be conduct
21、ed after a pass in the ELPO compatibility test has been received. 4.5 Scab Corrosion Prepare panels (in duplicate) as per 4.2. Expose panels to 20 cycles of the Scab Corrosion Test as outlined in HN 0214. After completion of the corrosion cycle, remove test panels and immediately rinse with warm wat
22、er. Drill out the spot welds and pry panels apart. Carefully remove sealer with scraper and examine panel condition for rust below the sealer bead. Upon conclusion of test, there must be no rust beneath the sealer bead and the sealer must exhibit cohesive failure. ABN 84 006 893 232 GM Holden Limite
23、d Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : HN 2413 5 of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE, BODY SHOP, WELD-THROUGH, NON-EXPANDING/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THE COMPANYS PRO
24、DUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. FORM : I:MaterialsEngineeringStandardForms MaterialSpecificationMatspec.doc 4. PERFORMANCE REQUIREMENTS (continued) 4.6 Long term corrosion performance and durability (for final approval) Assemblies supplied by ven
25、dors must be subjected to vehicle corrosion testing at Lang Lang (or other corrosion test as defined by GM Holden Materials Engineering). Parts must be fitted to their in car position during testing. Parts shall show no significant corrosion at the conclusion of testing. 5. PROCESS REQUIREMENTS 5.1
26、Sag 5mm Max The material shall be stirred with a spatula for 1 minute. Place a single bead of sealer as described in HN 0234 Clause 3.1 on to an oily panel (3 g/m2). Position the panel vertically with the bead horizontal for 30 minutes at: i) 10C ii) 40C Measure and report the distance that the bead
27、 has sagged after this time. 5.2 Pressure Stability The material must be capable of withstanding pumping pressure of 22,400 kPa for 3 days without its viscosity or other characteristics being adversely affected. 5.3 Smoke The material shall not smoke (Visual Observation) when exposed to a temperatur
28、e of 200C. 5.4 Welding The material must not cause excessive flashing, must not be detrimental to electrode tip life, and must meet the weld requirements as outlined in HN 0019. ABN 84 006 893 232 GM Holden Limited Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : H
29、N 2413 6 of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE, BODY SHOP, WELD-THROUGH, NON-EXPANDING/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THE COMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. F
30、ORM : I:MaterialsEngineeringStandardForms MaterialSpecificationMatspec.doc 5. PROCESS REQUIREMENTS (continued) 5.5 Production Approval Assemblies supplied by vendors must be subjected to mule processing through GM Holden E-coat & NEPS followed by assessment by PQAD/SQA. 5.6 Flame Resistance (HN 0017
31、) The sealer shall be self extinguishing for 50 passes of the Fisher Burner Flame. 5.7 Stability Requirements Material conditional as described below must be able to pass all requirements of this specification. 5.7.1 Elevated Temperature Stability The sealer as shipped must be capable of withstandin
32、g 3 days at 40C. 5.7.2 Storage Stability The shelf life of the material shall be 60 days at 35 C. The shelf life of the material commences from receipt of the material from the manufacturer. 6. APPROVAL, INSPECTION AND REJECTION Refer HN 1000, Clauses A, C and G (Line Trial). 7. HAZARDOUS MATERIALS
33、Refer HN 1000, Clause H. ABN 84 006 893 232 GM Holden Limited Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : HN 2413 7 of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE, BODY SHOP, WELD-THROUGH, NON-EXPANDING/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUS
34、T NOT BE REPRODUCED. IF USED IN RELATION TO THE COMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. FORM : I:MaterialsEngineeringStandardForms MaterialSpecificationMatspec.doc 8. RESTRICTED AND REPORTABLE SUBSTANCES (i) All substances and parts must meet
35、 the compositional requirements of GMW3059. (ii) All chemical components present in materials supplied to this specification must comply with Australian NICNAS (National Industrial Chemicals Notification and Assessment Scheme) obligations. 9. APPROVED SUPPLIERS AND MATERIALS Material known to meet t
36、he full requirements of this specification: APPROVED SUPPLIER APPROVED MATERIALS TO TYPE 1 Henkel Australia Terostat 3200H-13 Orbseal Australia 17004 10. REVISIONS August, 2003 - Correction of a numbering error. In the June 2003 release of HN 2413, there were two sections incorrectly numbered 3.4. T
37、o correct this problem, section 3.4 (Odour) in the June 2003 version has been re-numbered section 3.7 (Odour). - Section 3.5 (Toxicity) has been revised. - Section 3.7 (Odour) has been revised. - Section 3.8 (Colour) has been added. - Correction made to section 4.1.2 (Heat Ageing). The panel from se
38、ction 4.1 should be referenced in this section (not the panel from section 3.3.1). - Section 4.2 (Corrosion Resistance) has been revised. - Deleted section 4.5 (Salt Spray resistance). Replaced with section 4.5 (Scab Corrosion). - Added section 4.6 (Long term corrosion performance and durability (fo
39、r final approval). - Deleted section 5.5 (Before Bake Characteristics). - Added section 5.5 (Production Approval). ABN 84 006 893 232 GM Holden Limited Engineering Department MATERIAL SPECIFICATION NUMBER SHEET RELEASE REVISION : : : : HN 2413 8 of 8 June, 2003 November, 2006 NAME: SEALER-PUMPABLE,
40、BODY SHOP, WELD-THROUGH, NON-EXPANDING/EXPANDING, HIGH WASHOUT RESISTANT THIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THE COMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THE DOCUMENT ISSUE DATE IS STILL VALID. FORM : I:MaterialsEngineeringStandardForms MaterialSpecification
41、Matspec.doc 10. REVISIONS (continued) November, 2003 - Section 9 (APPROVED SUPPLIERS AND MATERIALS) added. Orbseal 17004 added to approved materials. November, 2006 - Section “3.REQUIREMENTS”, “3.4 Viscosity” - revised “pressure”, “sample weight” and “Seconds” - Revised section “8.RESTRICTED AND REPORTABLE SUBSTANCES” to directly reference GMW3059 and NICNAS requirements. - Section “9.APPROVED SUPPLIERS AND MATERIALS” - added approved material Terostat 3200H-13 Prepared By: Y. Zia
