1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 01 31 Revised Para 3.0 inserted ; Para 3.1, 3.2, 3.3, 3.10, 3.11,4 deleted 1996 02 09 Activated N.E. Lindsay G.A. Molar Printed copies are uncontrolled Page 1 of 7 Copyright 2003, Ford Global Technologi
2、es, Inc. ADHESIVE, EPOXY, ONE COMPONENT, INDUCTION HEAT WSS-M2G300-A2 RESPONSIVE, STRUCTURAL, BONDLINE SPACERS 1. SCOPE The material defined by this specification is a pumpable one-component, induction heat responsive, epoxy resin base, structural adhesive with bondline spacers. Full adhesive streng
3、ths are attained after oven cure. 2. APPLICATION This specification was released originally for materials to structurally bond metal-to-metal body components such as the inner and outer panels (hem flange) of decklids, doors and hoods, etc. This adhesive can be used to bond oily, unclean metal subst
4、rates, such as hot dip and electro-galvanized steel. Bondline spacers have been added to the adhesive to maintain a 0.25 mm bondline thickness during the hemming process. Adhesive must be able to be applied using the application processes described in para 5.7. The recommended induction heating proc
5、ess for body components is a minimum 4 second cycle time at metal temperatures of 191 C. Full adhesive strengths are attained after oven cure. Recommended material cure schedules are 171 C metal temperature for 10 minutes minimum and 205 C metal temperature for 30 minutes maximum. Prior to use, the
6、adhesive must be evaluated under the component production parameters. The choice of substrates, stamping lubricants, stamping plant process conditions, assembly plant process conditions and specific design application may affect adhesive performance. Compliance with this specification does not guara
7、ntee the adhesive will function for all potential applications on a vehicle. Note: Material defined by this specification is intended to replace ESB-M2G300-A. The material approved to WSS-M2G300-A2 reflects a minor formulation change to compensate for the addition of bondline spacers over material a
8、pproved to ESB-M2G300-A. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). ENGINEERING MATERIAL SPECIFICATION WSS-M2G300-A2 Page 2 of 7 Copyright 2003,
9、 Ford Global Technologies, Inc. 3.4 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific material system which included the substrate, stamping lubricants and adhesive. The originally approved material system was induction heated and oven cured using specific production process par
10、ameters. Substrate choice, stamping lubricants, stamping plant process conditions and assembly plant process conditions may affect adhesive performance. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. 3.5 RHEOLOGY Suppliers must submit flo
11、w characterization data to Ford Motor Company for flow modeling and process window determination. For a specified temperature range, the requested properties include, but are not limited to, viscosity, yield stress, apparent activation energy for viscosity and apparent activation energy for yield st
12、ress. This data constitutes the reference standard and shall be kept on file at the designated material laboratory. 3.6 MATERIAL CHARACTERISTICS 3.6.1 VISCOSITY (SAE J1524, VIS-2, 2.64 mm orifice, 550 kPa) As Recived +/- 10 s(Conditioning Method B) The viscosity tolerance for any one supplier shall
13、be +/- 10 s, based on the recorded viscosity of the original approved production sample. Reference para 5.1. . Aged, 7 days at 40 +/- 2 C 20 % max increase from initial . 90 day Storage Stability at 23 +/- 2 C and 32 +/- 2 C The supplier shall provide a viscosity profile versus time from initial thr
14、ough 90 days storage at 23 +/- 2 C and 32 +/- 2 C. Measurements shall be taken at weekly intervals. Curves shall be made available to Materials Engineering prior to addition to the Approved Source List. Final approval of a specified material viscosity for production shipments shall be made by the af
15、fected manufacturing activity. In all cases, the viscosity shall be within specification limits as identified on the material control plan. 3.6.2 Solids, min 99 % (ASTM D 2834, except heat for 3 h at 102 +/- 3 C in a mechanical convection oven, test each component and mixed product, save sample for
16、next test) ENGINEERING MATERIAL SPECIFICATION WSS-M2G300-A2 Page 3 of 7 Copyright 2003, Ford Global Technologies, Inc. 3.6.3 ASH, max 40 % (ISO 3491, Method A, 760 +/- 30 C. Based on the solids weight) 3.6.4 Weight Per Volume (ASTM D 816) The weight tolerance for any one supplier shall be +/- 0.02 k
17、g/L, based on the recorded weight of their original approved production sample. Reference para 5.2. 3.6.5 Sag Resistance (FLTM BV 118-01, 6 mm material thickness, substrates per para 5.4, oven cure per para 5.5.2, one panel each bake) . Horizontal 3 mm .Vertical 3 m . Inverted No loss of material 3.
18、6.6 Wash Resistance (FLTM BV 116-01, Method A, 1.5 mm material thickness, substrates per para 5.4) No measurable movement, displacement or wash off. 3.6.7 Electrocoat Compatibility (FLTM BV 119-01, use current production paints as identified by Material Engineering) Shall not contaminate electrocoat
19、 primer bath or cause electrocoat film irregularities. 3.6.8 Expansion No porosity or (Substrates per para 4.4, one panel expansion each substrate) Extrude a 13 x 200 mm adhesive bead onto a 100 x 300 mm panel. Place the test panel in an air circulating oven and bake at 205 +/- 2 C for 30 min. After
20、 bake, condition test panel at 23 +/- 2 C for 1 h minimum. Cut the panel lengthwise through the center of the adhesive. Examine the adhesive for any voids, porosity or expansion caused by entrapped air or internal gassing. ENGINEERING MATERIAL SPECIFICATION WSS-M2G300-A2 Page 4 of 7 Copyright 2003,
21、Ford Global Technologies, Inc. 3.6.9 Odor Shall be free from objectionable odors as determined by the manufacturing facility, both as received and after storage. 3.6.10 Color The material color shall meet manufacturing process control. Final approval of material color for production shipments shall
22、be made by the affected manufacturing activity. The material color for any one supplier shall not visually deviate from the original approved production sample. Reference para 5.3. 3.6.11 Material Consistency Shall be a smooth homogenous mixture, free from entrapped air, foreign materials and any pr
23、operties detrimental to normal production operation. 3.6.12 Cold Adhesion (FLTM BV 101-02, Procedure “E“, 0.51 mm material thickness, substrates per para 5.4, oven cure per para 5.5.2) No cracking or adhesion failure 3.6.13 Storage Stability Heat greatly accelerates aging. The material shall be stor
24、ed in closed containers away from all sources of heat. The shelf life of the material shall be 3 months when stored below 27 C. If stored at 4 C, the shelf life is extended to 6 months. When these materials are stored at temperatures below 23 C, they shall be conditioned at room temperature for 24 h
25、 prior to application. Adequate conditioning permits the material to retain its optimum application properties. 3.7 INDUCTION HEATED MATERIAL PERFORMANCE 3.7.1 Adhesion Strength, min (SAE J1523, substrates per para 5.4, 0.25 mm adhesive bondline thickness, 13 mm length overlap, induction heat per pa
26、ra 5.5.1, 13 mm/min pull rate) 3.7.1.1 Normal (Induction heat, condition at 23 +/- 2 C, and test after designated time) . Test after 15 min 1.4 Mpa . Test after 24 h 1.4 MPa ENGINEERING MATERIAL SPECIFICATION WSS-M2G300-A2 Page 5 of 7 Copyright 2003, Ford Global Technologies, Inc. 3.7.1.2 Aged 1.4 M
27、Pa (Induction heat, condition at 23 +/- 2 C for 24 h, subject to environmental cycle and test at 23 C) Environmental cycle: -30 +/- 1 C for 7 days PLUS 38 +/- 1 C and 98 +/- 2 % RH for 7 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for 1 day 3.8 OVEN CURED MATERIAL PERFORMANCE 3.8.1 Adhesion Stre
28、ngth, min (SAE J 1523, Substrates per para 5.4, 0.25 mm adhesive bondline thickness, 13 mm length overlap, 13 mm/min pull rate, induction heat per para 5.5.1, condition at 23 +/- 2 C for 24 h, oven cure per para 5.5.2) 3.8.1.1 Normal (Condition for 30 minutes at specified temperature prior to test)
29、. Test at 23 +/- 2 C 6.9 MPa . Test at 90 +/- 2 C 5.5 MPa . Test at -30 +/- 2 C 6.9 MPa 3.8.1.2 Aged (Condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2) . 10 Thermal Cycles 5.5 MPa One Cycle: 90 +/- 1 C for 4 h PLUS 38 +/- 1 C and 98 +/- 2 % RH for 4 h PLUS -40 +/- 1 C for 16 h . 500
30、 Salt Spray 5.5 MPa (ASTM B 117) 3.9 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 Mate
31、rials Engineering prior to material approval and release. ENGINEERING MATERIAL SPECIFICATION WSS-M2G300-A2 Page 6 of 7 Copyright 2003, Ford Global Technologies, Inc. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this sp
32、ecification. 5.1 VISCOSITY, Typical as received 10 - 35 s 5.2 WEIGHT PER VOLUME, Typical 1.2 - 1.7 kg/L 5.3 COLOR, Typical green to grey- green 5.4 SUBSTRATES Materials being evaluated for approval to this specification shall be tested with typical lubricants and at applications levels as specified
33、by Materials Engineering. WSB-M1A250-C3, 60G60G-EL, nominal 0.8 mm thickness WSB-M1A250-C3, 60G60G-HD, nominal 0.8 mm thickness 5.5 MATERIAL CURE SCHEDULES 5.5.1 Induction Heat (FLTM BU-119-01) Cycle Time: 1 second ramp to metal temperature with a 3 second hold at metal temperature; not to exceed 4
34、seconds total cycle time Process nominal: 191 +/- 7 C metal temperature 5.5.2 Oven Cure (After bake, condition at 23 +/- 2 C for 1 h minimum, then test) Bake Minimum: 171 C metal temperature for 10 minutes (not to exceed 20 minutes oven time) Bake Maximum: 205 C metal temperature for 30 minutes (not
35、 to be less than 40 minutes oven time) 5.6 TENSILE PROPERTIES (ASTM D 638, 3.0 +/- 0.5 mm thick, material cure for 30 minutes at 180 C adhesive temperature, condition at 23 +/- 2 C for 24 h, test at 23 +/- 2 C, Type I specimen, W = 10 mm, G = 50 mm, 5 mm/min +/- 10 %) . Percent Elongation at Break 2
36、 - 5 % . Modulus of Elasticity (Youngs Modulus) 2.4 - 4.6 GPa ENGINEERING MATERIAL SPECIFICATION WSS-M2G300-A2 Page 7 of 7 Copyright 2003, Ford Global Technologies, Inc. 5.7 APPLICATION PROCESS Adhesive must be able to be applied using flow, stream, spray and swirl application equipment. 5.8 BONDLIN
37、E SPACERS Solid glass spheres are added as bondline spacers to the adhesive to maintain a 0.25 mm bondline thickness in the hem on a closure panel during the hemming process. Nominal size 0.25 +/- 0.04 mm diameter Percent within range 80 % minimum Percent true spheres 85 % minimum Percent loading (by weight) 1.0 +/- 0.2 %
