1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 10 14 Activated Initial release for B2 parameters B.Witkowski FNA/ T.Reilly FoE Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 6 ANTI-FLUTTER, VISCOELASTIC EXPANDING PERFORMANCE WSS-18P11-B2 REQUIR
2、EMENT, HEAT CURING 1. SCOPE This material defines the performance requirements for a die cut or extruded sealer that expands upon exposure to heat. This material can be supplied with or without a pressure sensitive adhesive coating (PSA) or a release liner. 2. APPLICATION The specification was relea
3、sed originally for materials used in the body shop area as an anti-flutter material for roof bow and closure applications. The materials utilized are viscoelastic in nature and provide additional damping over traditional anti-flutter materials commonly used in closure applications. This material can
4、 be supplied with or without an aggressive pressure sensitive adhesive which promotes adhesion to oily, uncleaned cold rolled and galvanized steel. This material expands during the electrocoat bake schedules per para. 3.4.5. Material cure is critical to long term material performance. It is recommen
5、ded that time/temperature data packs be placed on a vehicle in the intended locations to determine the time at temperature requirements for a given application prior to release. The on-vehicle material time at electrocoat oven temperatures must fall within the cure window for the approved material.
6、After release, periodic follow up time/temperature checks are recommended to insure cure performance is maintained. The Manufacturing Properties and Engineering Performance requirements defined in this specification are based on laboratory sample testing and define the minimum acceptance criteria fo
7、r adhesive/polymer material performance. The function and design requirements for the engineered part are defined by the component SDS (Sub-system Design Specification), key life test requirements, or vehicle program requirements. Prior to use, the engineered part must be evaluated under the intende
8、d application processing parameters. The choice of substrates, stamping lubricants, stamping and assembly plant processing conditions and specific design application may affect engineered part performance. Compliance with this specification does not guarantee the engineered part will function for al
9、l potential applications on a vehicle. Selection of the appropriate material should therefore be based on jury evaluations or other NVH test procedures (such as door slam) as well as the required functional trial. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers
10、and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPATIBILITY Initial material approval was based on a specific material system which included the substrate, stamping lubricants and adhesive/polymer. The originally approved
11、material system was oven cured using specific production process parameters. The choice of substrates, stamping lubricants, stamping and assembly plant processing conditions and specific design application may affect adhesive /polymer / engineered part performance. If any of these parameters are cha
12、nged, the material performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATIONWSS-M18P11-B2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 6 3.3 DIMENSIONS As specified on the engineering drawing. 3.4 MATERIAL PROPERTIES 3.4.1 D
13、ensity +/- 0.1 kg/m3 (ISO 845/ASTM D 3574,Test A, interior density) The density variation for any one supplier shall be +/- 0.1 kg/m3, based on the recorded density of their original approved production sample. 3.4.2 Water Absorption, max 5% (FLTM BV 117-01, Method A, 8 h soak time, cure material pe
14、r paragraph 3.4.5) 3.4.3 Volume Expansion, Min 300% Max 700% (FLTM BV 108-02) The volume change variation for any one supplier shall be +/- 10%, based on the recorded volume change of their original approved production sample. 3.4.4 Volatile Organic Compounds (VOC) Content +/- 0.05 kg/L (EPA Method
15、24, Procedure B) The VOC Content variation for any one supplier shall be +/- 10%, based on the recorded VOC Content of their original approved production sample. 3.4.5 MATERIAL CURE SCHEDULE (FLTM BV 150-05, Min and Max cure cycles, per respective region). Record chosen cycle in the Intial Sample Re
16、port. Critical performance characteristics shall include, but are not limited to, the following: Volume Expansion, para 3.4.3 Adhesion, para 3.5.6 3.5 MANUFACTURING PROPERTIES 3.5.1 Differential Scanning Calorimetry Report (20 +/- 1 mg sample size, 5 C/min heating rate, 25 - 250 C Temperature range,
17、 submit Heat Flow vs. Temperature curve) Report onset of reaction 3.5.2 Bridging, max 3 mm (SAE J243, ADS-9, Section 3.3, Method D, non-flow fixture, substrates per para 4.1, bake conditions per para 3.4.5) 3.5.3 Phosphate Wash Resistance (For PSA/Tacky only) Pass (FLTM BV 116-03, 2000psi, 23 C, sub
18、strates per para 4.1) Panel Preparation: Cut a 100 x 150 strip at production thickness of and apply a 300 x 300 mm panels prepared for each substrate per para 4.1. Pass a 2.2 kg roller over samples per ASTM D1000. Condition at 23 +/- 2 C for 1 hour prior to performing wash test. ENGINEERING MATERIAL
19、 SPECIFICATIONWSS-M18P11-B2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 6 3.5.4 Electrocoat Compatibility Pass (FLTM BV 119-01, use current production paints as identified by Materials Engineering) Shall not contaminate electrocoat primer bath or cause ele
20、ctrocoat film irregularities. 3.5.5 Uncured Adhesion Pass Test Method: Prepare four panels for each substrate per para 5.1. Cut four 100 x 150 x 4 mm strips of the material and apply to four 300 x 300 mm panels prepared for each substrate per para 5.1. Pass a 2.2 kg roller over samples per ASTM D 10
21、00. Invert two panels immediately after material application and condition for 72 h at 40 C. Observe for peeling or lifting of adhesive/polymer from panel or slump or sag between attachments, as appropriate. Stand the remaining two panels vertically immediately after material application and conditi
22、on for 72 h at 40 C. Observe for peeling or lifting of material from panel or slump or sag between attachments, as appropriate. 3.5.6 Adhesion Characteristics Pass Test Method: Apply two 200 mm length ribbons of material to each of two 0.89 x 100 x 300 mm steel per para 4.1 and condition panels at 2
23、3 +/-2 C for 1 h. Bake on panel at min and max bake per para 3.4.5. Position panels in a horizontal attitude during bake. After bake, condition panels at 23 +/-2 C for 4 h min. Evaluate adhesion by inserting the top of a sharp spatula under the end of the material strip. Grasp the tab of sealer and
24、attempt to peel 180. The material shall not be removable in a continuous coherent film. Observe for any indication that the material fails to adhere to the substrate or is brittle. 3.5.7 Release Paper Adherence and Removal Pass (Pressure Sensitive/Tacky Materials only) The release paper must remain
25、attached to the adhesive/polymer surface during shipment and handling. It must be easily removed from the adhesive/ polymer without part distortion or paper tear at ambient plant conditions (7 to 38 C). Final approval for the release paper may be part and plant specific. Release paper information sh
26、all be noted in the supplier control plan. 3.5.8 Odor Pass Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.5.9 Storage Stability 6 Months Heat and moisture will accelerate aging. The materials shall be stored in sealed package
27、s (if so recommended by the supplier) away from all sources of heat and moisture. The self life of the material shall be 6 months from date of manufacture. Ambient plant conditions may fluctuate. Materials shall be evaluated for local plants conditions to determine plant specific requirements for te
28、mperatures and supplier shall provide testing of plant conditions within their control plan. 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 15 C, they shall be cond
29、itioned at room temperature and checked for acceptable green state adhesion prior to use . Application properties are optimized with adequate conditioning of the material. Supplier shall demonstrate minimum green state adhesion (if applicable for PSA) and note minimum storage temperature. ENGINEERIN
30、G MATERIAL SPECIFICATIONWSS-M18P11-B2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 6 Critical performance characteristics to evaluate for shelf life stability shall include, but are not limited to, the following: Volume Expansion, para 3.4.3 Uncured Adhesio
31、n, para 3.5.5 Adhesion Characteristics, para 3.5.6 Release Paper Adherence and Removal, para 3.5.7 - Cold slam resistance (3.6.3) on uncured material. 3.6 ENGINEERING REQUIREMENTS 3.6.1 Vertical Expansion, min (Ramp Expansion, SAE J1918, Method #3, cure material per para 3.4.5) 3.6.1.1 Minimum bake
32、10 3.6.1.2 Maximum bake 10 3.6.2 Corrosion Resistance Test Method: Place a 39 cm2 area section of production material on each of two 150 x 75 mm steelpanels, substrates per para. 4.1. Cover the material with an identical steel panel and clamp in position for close contact. Cure test panels in a mech
33、anical convection oven for prior to e-coat requirements per FLTM BV 150-05, one for min and one for max bake. Remove clamps and subject the cured assemblies to the following exposure then separate assemblies and evaluate: After APGE cycles (FLTM BI 123-03) There shall be no corrosion beneath origina
34、l material contact area Report after 10, 20 and 30 cycles One APGE cycle: 15 min salt water immersion (5% salt solution) 3 hrs drip dry at 23 +/- 2 C 20 hrs and 45 mins 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.
35、3.6.3 Cold Slam Resistance (FLTM BV 101-02, Procedure E, 300 x 300 mm panel for each substrate per para 4.1, 4 mm cured material thickness, condition for 4 h minimum at -40 +/- 2 C prior to testing, test at -40 C for 10 slams) Sample preparation: Apply a 150 x 150 mm piece of material on a 300 x 300
36、 mm panel. Material thickness to be determine by minimum expansion assumption used for engineering part design. Pass a 2.2 kg roller per ASTM D 1000 over sample within 15 minutes of patch application. Cure between aluminum plates lined with release paper or in a fixture to maintain a 4 mm cured mate
37、rial thickness. Initial Test after 30 days at 50 +/- 2 C and 90 +/- 5% relative humidity Test after 30 cycles APGE (FLTM BI 123-03, manual cycle, report after 10, 20 and 30 cycles) ENGINEERING MATERIAL SPECIFICATIONWSS-M18P11-B2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologie
38、s, LLC Page 5 of 6 3.6.4 Peel Adhesion, min 0.5 N/ mm (ASTM D 1876, substrates per para 4.1, material cure per para 4.2, 76.2 mm overlap, 2.0 +/- 0.4 mm adhesive bondline, condition for 30 minutes at specified 23 +/- 2 C prior to test.) All materials shall show 100% cohesive failure; report failure
39、mode. 254 mm/min. pull rate. Report load between 25 and 75 mm cross-head travel. 3.7 SPONGE AND CELL STRUCTURE AFTER CURE Pass Shall exhibit uniform cell structure with no large voids. A natural skin formation shall result from the cure cycle. The sponge shall have good resilience under finger press
40、ure. Test Method: Cross sectional observation of the sponge shall be made by cutting through the skin and sponge mass of a cured specimen. The sponge system shall be visually examined. 3.8 MATERIAL CONSISTENCY Pass Shall be a smooth, homogeneous mixture free from foreign materials and properties det
41、rimental to normal production operations. 3.9 PACKAGING Supplier shall be responsible advising on any packaging related issues to this material, including but not limited to any concerns for nesting, compression of material, etc. Plant shall review suppliers control plan to address this issue. 3.10
42、FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material a
43、pproval and release. This functional approval shall validate at a minimum effectiveness of the material damping 3.11 DAMPING PROPERTIES (ISO 6721-4) Supplier shall furnish report demonstrating loss factor vs frequency and Youngs modulus vs frequency at target bake conditions. Minimum Damping Loss Fa
44、ctor Targets Temperature (C) 1Hz 10Hz 101Hz -20 0.1 0.1 0.1 -10 0.2 0.2 0.2 0 0.6 0.4 0.2 10 1.0 1.0 0.6 20 0.5 0.8 1.0 40 0.2 0.3 0.6 60 0.2 0.15 0.3 3.12 FOGGING Fog Number, min 70 (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Formation of clear film, droplets
45、or crystals is cause for rejection. ENGINEERING MATERIAL SPECIFICATIONWSS-M18P11-B2 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 6 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of
46、 this specification. 4.1 SUBSTRATES Cold rolled steel as specified on engineering drawing. Panel thickness: 0.8 mm unless otherwise specified. Note: If any other steel, such as precoated with Zn, Zn/Ni, Duplex, galvanized, galvanealed, etc. is used for manufacturing, the adhesive has to be tested ac
47、cording to this specification on these substrates Currently released HD, EG, and CRS materials, 0.8mm thickness. Reference specifications WSD-M1A333-A2,WSD-M1A333-A2, nominal 0.8 mm thickness, coated per WSS-M1P94-A to coating weight 50G50G-EL and 50G50G-HD, panels Electrocoated steel panels prepare
48、d per WSS-M3P1-D using current production paints as specified by Materials Engineering, materials to be tested at lower coating weights as applicable. All related materials used for approval of adhesive/polymer according to this specification, eg. Paint materials or metallic substrates, shall be not
49、ed in the initial sample report of the adhesive/polymer/ part. 4.2 OIL COMPATIBILITY & REFERENCE OIL All materials released to this specification must be applicable to oiled surfaces, including corrosion protection oil, wash oils, pre-lubricants, draw oils, hot melts etc. The approved products for use are listed in the applicable approved source list (contact local materials engineering for details). The supplier must confirm the compatibility of the adhesive/sealer material to these specific coating materials in the appropriat
