1、This document is restricted and may not be sent outside Navistar Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar Inc. FEBRUARY 2009 Page 1 of 17 NAVISTAR INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER:
2、TMS-6900 TITLE: Structural Adhesives Part 1 and Part 2 CURRENT REV No.: 0902 DATE: February 2009 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. H-1 August 2004 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may i
3、nvolve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to use. Cha
4、nge Notice: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; added CEMS B-50 requirement; test method changes; addition of fiberglass constricted layer option; inclusion of newly approved sources; editorial changes. Reference: File 30-1 Keywords: a
5、dhesive, adhesive bonding, structural bonding, structural adhesive Part 1 General, Property, and Performance Requirements 1.0 APPLICATION Part 1 of this specification covers structural adhesive systems used for bonding parts in the construction of truck and tractor cabs and components, such as: hood
6、 and fender assemblies, body panels, roof components, air conditioning components, and other parts used in truck manufacture. Part 2 covers the production process requirements for structural bonding systems. 2.0 SCOPE This specification covers the material properties, performance requirements, produ
7、ction quality and process control, suppliers responsibility, source approval and quality control, general information, and sources for the approved adhesive systems. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comp
8、ly with the requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards applies. The following specifications, standards, and regulations are referenced herein. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS
9、-7133 ASTM D2240 CFR-Title 29, Section 1910 NAVISTAR TMS-9522 ASTM D2294 NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR TMS-9543 ASTM D1002 NAVISTAR Eng. Design Std. A-16 GM 9037P ASTM D2919 NAVISTAR CEMS GT-7E WSB M18P11-A2 ASTM D3163 NAVISTAR CEMS A-6 SAE J243 ASTM D5041 NAVISTAR CEMS C-10 SAE J1523
10、 ASTM B117 NAVISTAR CEMS D-22 SAE J1525 ASTM E132 NAVISTAR CEMS D-28 SAE J1553 ASTM D638 NAVISTAR CEMS G-5, Parts II & V SAE J2334 NAVISTAR CEMS B-50 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without li
11、cense from IHS-,-,-NUMBER: TMS-6900 TITLE Structural Adhesives Part 1 and Part 2 REVISION: 0902 Part 1 (contd) This document is restricted and may not be sent outside Navistar Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liabil
12、ity. 2009 by Navistar Inc. FEBRUARY 2009 Page 2 of 17 3.1 Description of Adhesive Resin Types 3.1.1 Type I One-part, pumpable, heat cured epoxy 3.1.2 Type II One-part, extruded, heat cured epoxy with or without fiberglass layer 3.1.3 Type III Two-part epoxy 3.1.4 Type IV Two-part urethane 3.1.5 Type
13、 V Two-part acrylic 3.1.6 Type VI Two-part methacrylate 3.1.7 Type VII Hot Melt 4.0 GENERAL REQUIREMENTS Adhesive materials supplied to this specification shall bond the intended substrates to produce a permanent and structural bond. The general properties of as received materials, in the uncured st
14、ate, are listed in Table 4. Adhesive materials supplied to this specification shall be compatible with all subsequent cleaning, pre-treat and paint operations used in the Assembly Plant(s) and with current production materials for which the new adhesive approval is sought. 4.1 General Properties Pro
15、perties are provided for reference only. Properties shall be reported on submitted test reports and will be included in Table 4. 4.1.1 Uncured Properties Specific requirements are to be determined between the material supplier, equipment supplier and the applicator. 4.1.1.2 Solids: 4.1.1.2.1 Method:
16、 SAE J243 Procedure ADS-7, Method A 4.1.1.2.1 Requirement: Report 4.1.1.3 Viscosity: 4.1.1.3.1 Method A: SAE J243, Procedure ADS-1, Agitated - Conditioning Method C, Pressure Flow Method 275 kPa (40 psi), 25 1C (77 2F), 20 g. 4.1.1.3.2 Method B: SAE J243, Procedure ADS-1, Agitated - Conditioning Met
17、hod C, Test 2.2 Brookfield, spindle 7, 50 RPM 4.1.1.3.3 Requirement: Report 4.1.1.4 Aged Viscosity: 4.1.1.4.1 Method: Age sample at 43 1C (110 2F) for 72 hours. Test per corresponding method on section 4.1.3. 4.1.1.4.2 Required: Report 4.1.1.5 Process Compatibility: Uncured adhesive shall remain in
18、joints without flow or washout through the spray and immersion stages of pre-treat and E-coat. It shall be the suppliers responsibility to provide evidence of compatibility. 4.1.1.5.1 Method: CEMS GT-24 4.1.1.5.2 Required: Pass Copyright Navistar International Corporation Provided by IHS under licen
19、se with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6900 TITLE Structural Adhesives Part 1 and Part 2 REVISION: 0902 Part 1 (contd) This document is restricted and may not be sent outside Navistar Inc. or reproduced without permission from Cor
20、porate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar Inc. FEBRUARY 2009 Page 3 of 17 4.1.1.6 Fiberglass constricted layer: If specified, die cut materials shall be supplied with a square weave fiberglass constricted layer. There shall be no loose glass
21、fibers after the die cutting operation. 4.1.1.7 Weldability: This requirement is only applicable when designated as a weld-through adhesive. 4.1.1.7.1 Method: SAE J243 Weld-Through Test ADS-3, Method B. 4.1.1.7.2 Required: Shall meet tensile, flashing, electrode life, and electrode pickup, as specif
22、ied. 4.1.2 Cured Material Properties 4.1.2.1 Tensile Strength-Ultimate (for materials which do not exhibit a definite yield point) or Yield Strength (for materials which do exhibit this property). Will be determined by ASTM D638 using the 0.2 percent offset method. Speed of test will be as designate
23、d in the appendices of ASTM D638 or as agreed upon for new materials not listed. 4.1.2.2 Ultimate Elongation. Will be determined by ASTM D638. Speed of test will be as designated in the appendices of ASTM D638 or as agreed upon for new material not listed. 4.1.2.3 Tensile Modulus. ASTM D638 will det
24、ermine tangent modulus of elasticity at 23C. Speed of testing will be as designated in Table 1 of ASTM D638 or as agreed upon for materials not listed. 4.1.2.4 Poissons Ratio Determine per ASTM E132. 4.1.2.5 Shrinkage (Non expanding Pumpables, only) 4.1.2.5.1 Method: Fill a small, flat container 50
25、mm diameter x 6 mm height (2 in diameter x 1/4 in height) with adhesive material and subject leveled product to maximum bake temperatures for 40 minutes. Observe at room temperature. 4.1.2.5.2 Required: Shall show no visible evidence of shrinkage, cracking or overflow. 4.1.2.6 Volume Expansion/Shrin
26、kage 4.1.2.6.1 Method: Test per GM 9037P, or WSB M-18P11-A2 on coupons prepared in 4.2.1 Sample Preparation. Obtain substrate test coupons that are dimensionally capable of supporting the entire part. For sheet stock, extrusions or injection-molded samples, avoid cutting from the edges of the sheet
27、or part. 4.1.2.6.2 Required: Report only, requirements are under development. 4.2 Property And Performance Requirements In the event of material screening the performance test matrix may be truncated to include only shear strength values for initial, 120C hot pull, and 168hr water immersion conditio
28、ns. 4.2.1 Sample Preparation A minimum of five samples shall be prepared for each condition tested. The surface condition tested shall be representative of production conditions and fully described in the test report. The bond line shall be between 0.25 and 1 mm (.010 and .040 inches) thick with an
29、overlap of 12.5 mm (.5 inch) for metal and 25 mm (1 inch) for plastic, unless otherwise directed. The cure conditions shall be described Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IH
30、S-,-,-NUMBER: TMS-6900 TITLE Structural Adhesives Part 1 and Part 2 REVISION: 0902 Part 1 (contd) This document is restricted and may not be sent outside Navistar Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by
31、Navistar Inc. FEBRUARY 2009 Page 4 of 17 fully in the test report and should closely match the production cure conditions. Times and temperatures should represent actual bond line conditions rather than the reported temperatures of the heating elements or the oven air temperature. These cure conditi
32、ons will be listed on the attached tables and shall be reproducible for future testing. Production cure conditions are listed on Table 3. 4.2.1.1 Steel Surface Preparation: Two sets of five samples shall be made for each condition tested. Solvent (acetone) clean samples thoroughly. The first set sha
33、ll be tested clean. The second set shall have a light oil coating, as in steps 5 and 6 listed below, under Aluminum Surface Preparation. 4.2.1.2 Aluminum Surface Preparation: Three sets of five samples of aluminum test samples shall be made for each condition tested. Solvent (acetone) clean samples
34、thoroughly. The first set shall be tested clean. The second set shall have a light oil coating, as in steps 5 and 6 listed below. The third set shall be prepared in the following manner: 1) Clean samples thoroughly with acetone. 2) Apply Mill Oil (Ashland Tectyl 900) liberally to the bonding surface
35、. 3) Wipe oil off surface with a clean, soft, paper lab towel. A light oil residue should remain. 4) Bake samples for four (4) hours at 200 C (392 F). 5) Apply Drawing lubricant (Quaker 61AUS)* liberally to the bonding surface. 6) Wipe oil off surface with a clean, soft, paper lab towel. A light oil
36、 residue should remain. 7) Prepare test samples as required. * Other lubricants will be used in production. Adhesives and lubricants shall be compatible with each other. Testing compatibility shall be the responsibility of the supplier of the new material. The Plant Metallurgist or QC Manager at the
37、 Navistar Body Plant in Springfield, Ohio maintains a list of approved lubricants. 4.2.1.3 Plastic and Painted Surface Preparation: One set of five samples shall be made for each condition tested. Freshly painted surfaces shall be aged for 72hrs at 49 + 3C (120 + 5F) prior to surface preparation. So
38、lvent (isopropanol) clean samples thoroughly prior to bonding. 4.2.2 Lap Shear Strength 4.2.2.1 Method: Prepare samples as directed in 4.2.1 Sample Preparation. Test per ASTM D3163 or ASTM D1002, as appropriate. Tensile machine jaw separation rate shall be 13 mm (.5 in) per minute. Test overlap shea
39、r at the following specified temperatures after holding at temperature for 30 minutes. Report the average of five tests and their failure modes. 4.2.2.2 Required: See Table 1A. 4.2.3 Cross Peel Test (FRP only) 4.2.3.1 Method: SAE J1553 test method shall be used, with an adhesive thickness of 0.75 mm
40、 (30 mil). 4.2.3.2 Required: See Table 1B, for required values. 4.2.4 Cleavage Fracture Strength 4.2.4.1 Method: Prepare samples as indicated in 4.2.1 Sample Preparation except for the geometry requirements of ASTM D5041. Test per ASTM D5041. Test samples un-aged and after water-immersion. 4.2.4.2 R
41、equired: A minimum of 75% fiber tear is required for FRP samples. Report peak load, failure initiation energy and failure propagation energy. See Table 1A. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted with
42、out license from IHS-,-,-NUMBER: TMS-6900 TITLE Structural Adhesives Part 1 and Part 2 REVISION: 0902 Part 1 (contd) This document is restricted and may not be sent outside Navistar Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent
43、liability. 2009 by Navistar Inc. FEBRUARY 2009 Page 5 of 17 4.2.5 Stress Durability 4.2.5.1 Method: Test per ASTM D2919 using a fixture described in either ASTM D2294 or ASTM D2919. Prepare samples as indicated in 4.2.1 Sample Preparation except for the geometry requirements of ASTM D2919 or D2294.
44、Load samples to 2 MPa (290 psi). Test samples after 6 weeks of exposure per the cycle below. Cycle may be interrupted for weekends and holidays, in which case leave the samples in humidity for that period. 1) 16 hours humidity 2) 2 hours -30 2C (-22 3.6F) 3) 2 hours at ambient conditions 4) 2 hours
45、70 2C (158 3.6F) 4.2.5.2 Required: Report time to failure or residual load per Lap Shear Strength above. 4.2.6 Corrosion 4.2.6.1 Method: Expose coupons prepared as in section 4.2.1 Sample Preparation for shear strength test to 500 hrs of ASTM B117 salt spray. Test residual load per lap shear strengt
46、h above. 4.2.6.2 Required: See Table 1A. 4.2.7 Humidity 4.2.7.1 Method: Test per CEMS GT-7E on coupons prepared in 4.2.1 Sample Preparation for shear strength test for 500 hours. 4.2.7.2 Required: See Table 1A. 4.2.8 Water Immersion 4.2.8.1 Method: Immerse coupons prepared in 4.2.1 Sample Preparatio
47、n for shear strength test and cross peel in distilled water at 25C (77F) 2C (3.6F) for 500 hours. 4.2.8.2 Required: See Table 1A for shear and Table 1B for cross peel. 4.2.9 Over-bake 4.2.9.1 Method: Prepare samples for lap shear as directed in 4.2.1 Sample Preparation and in 4.1.2.5 Shrinkage. Over
48、-bake samples in re-circulating air oven for (4) hours at maximum bake temperatures. Check hardness per ASTM D2240, and residual lap shear strength. 4.2.9.2 Required: 4.2.9.2.1 After Over-baking: 3 points maximum change from original hardness. 4.2.9.2.2 Over-baked material shall not darken substantially or show other evidence of degradation. 4.2.9.2 3. Shall retain 95% of original strength by lap shear. 4.2.10 Heat-Aging 4.3.10.1 Method: Prepare samples for l
