1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev. 12010 06 16 Revised See Summary of Revisions M. Mehandru, FNA W. Janitschke, FOE 1995 07 13 Activated W. Curtiss G. Molnar Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 5 DUPLEX SEALER, VINYL BASE
2、D, NON-YELLOWING, PUMPABLE WSS-M4G359-A OR AIRLESS, SPRAYABLE HEAT CURING, PAINTABLE, INTERIOR AND EXTERIOR 1. SCOPE The material defined by this specification is a vinyl based, pumpable, or airless sprayable, paintable, heat curing sealer which is non-yellowing. 2. APPLICATION This specification wa
3、s released originally for sealing interior and exterior body seams, including door hem flanges, USB and Roof Ditch Sealing. The material is intended for use in the paint shop and applied over freshly baked electrocoat. Acceptable paintability is achieved with or without primer surfacer. The material
4、 has been formulated to prevent topcoat yellowing and allow topcoat cure in low airflow conditions. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3
5、.2 RHEOLOGY Suppliers must submit flow 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 ap
6、parent activation energy for yield stress. This data constitutes the reference standard and shall be kept on file at the designated material laboratory. 3.3 SOLIDS, min 96% (ASTM D 2834, except heat at 102 +/- 1 C for 3 h in a mechanical convectional oven. Save sample for next test, para 3.4) 3.4 AS
7、H (Based on solids weight), (ISO 3491, Method A, 760 +/- 30 C) The ash content tolerance for any one supplier shall be +/- 5% based on the recorded ash content for their originally approved production sample. See paragraph 4.4. 3.5 WEIGHT PER VOLUME (ASTM D 816) The weight tolerance for any one supp
8、lier shall be +/- 0.05 kg/L, based on the recorded weight of their original approved production sample. See paragraph 4.5. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 11 3.6 FLASHPOINT 100 C (ASTM D 93, Method
9、A) Note: If testing at higher temperatures is not feasible because of gelling of test material, the supplier must certify in writing that each separate volatile ingredient has a flash point 100 C. 3.7 VISCOSITY at 23 C (SAE J1524, VIS-2, 1.32 mm orifice, 280 kPa) Final approval of a specific materia
10、l viscosity for production shipments shall be made by the affected manufacturing activity. In all cases, the viscosity shall be within process limits as identified on the material control plan. The viscosity tolerance for any one supplier shall be +/- 10%, based on the recorded viscosity of the orig
11、inal approved production sample. Reference para 4.7. 3.7.1 As Received +/- 10% (Conditioning Method A) 3.7.2 Aged, max Original + 50% (Material aged in closed container for 168 h at 40 +/- 1 C, conditioning Method A) 3.7.3 90 Day Storage Stability at 23 +/-2 C and 32 +/- 2 C The supplier shall provi
12、de a viscosity profile versus time from initial through 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 on the Approved Source List. 3.8 SAG RESISTANCE 3.8.1 Horizontal, max 6.4 m
13、m 3.8.2 Vertical, max 6.4 mm 3.8.3 Inverted No loss of material Test Method: Apply a 3 x 30 x 200 mm ribbon of material along the center line of two of the three electrocoated panels prepared per para 4.2 Scribe panels to mark the initial material location. Position the panels with the material in t
14、he attitude above for 1 h at RT. Immediately after conditioning, place panels in an oven to cure material at the minimum bake schedule per para 4.3. Maintain panels in the specified attitude during baking and cooling. Allow the panel to cool to 23 +/- 2 C. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G35
15、9-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 11 Determine the sag by measuring the material movement below the scribe mark. Repeat the test using the second set of panels at the maximum bake per para 4.3 3.9 BRIDGING, max 6.4 mm Test Method: Apply a 13 m
16、m diameter material bead over the 6.4 mm diameter holes shown in sketch below. Condition the test fixture with material bead for 15 minutes at 23 +/- 2 C, then bake fixture at the minimum bake schedule acc. to FLTM BV 150-05 for each region to be used. Measure the amount of material sag through hole
17、. Max. 3 mm according to para 3.8 BRIDGING TEST FIXTURE 3.10 ADHESION Shall not be peeled off in a continuous film at any thickness. Test Method: Apply 6.4 - 0 mm tapered material ribbon on two electrocoated panels. See sketch below. Subject one test panel, to the minimum bake schedule and the other
18、 test panel to the maximum bake schedule acc. to FLTM BV 150-05 for each region to be used. Condition panels after baking at 23 +/- 2 C for 1 h minimum. Evaluate adhesion by cutting a 25 mm wide strip across the tapered ribbon. Using the tip of a square spatula, lift the material at both the thin an
19、d thick film edges then attempt to had peel material at 90 degrees from substrate. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 11 Save test panels for Heat Resistance Test, para 3.13 and Corrosion Resistance Te
20、st, para 3.14 ENGINEERING MATERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 11 3.11 COLD ADHESION No flaking, no (FLTM BV 151-01, - 40 C, load “A“) loss of adhesion 3.12 WATER ABSORPTION, max 1.5% (FLTM BV 153-07, except bake at
21、 165 +/- 2 C) 3.13 HEAT RESISTANCE TEST No evidence of blistering, cracking, charring or other deleterious effects Test Method: Examine the test material prepared for Adhesion Test, for any of the above conditions. 3.14 CORROSION RESISTANCE TEST No corrosion or 3.14.1 Option 1 adhesion loss (FLTM BI
22、 123-03, 50 cycles The material shall protect the test panel from corrosion for a scap test period of 50 cycles. Prepare test specimen in accordance to paragraph 3.10 Expose specimen for 50 cycles to the scap test Evaluate material adhesion as described in para 3.10 Observe for any evidence of corro
23、sion 10 mm from the strip. Or 3.14.2 Option 2 (CETP 00.00-L-467, 6 weeks) Note: Report the test method used. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 11 3.15 MANDREL BEND TEST No cracking or adhesion (FLTM B
24、V 122-01, material bake, failure schedule per FLTM BV 150-05 material bake schedule for the region , heat age test specimen 14 days at 70 +/- 1 C before test) 3.15.1 Test at 23 +/- 2 C 3.15.2 Test at -20 +/- 1 C 3.16 COMPATIBILITY WITH PRODUCTION PAINTS - INITIAL REQUIREMENTS No tackiness, staining,
25、 discoloration, dulling, softening, paint transfer, significant color shift, difference in orientation of metallic flakes (metallic paints) or other objectionable appearance defects in the paint over the sealer. Note: Evidence of any defects as stated above shall be reviewed with Body and Assembly P
26、aint Operations and Materials Engineering. Test Method: . Prepare test panels per matrix provided by material engineering or paint engineering for that region. Use current production paints as identified by the Paint Engineering. . Condition painted panels at 23 +/- 2 C for 72 h. . After the 72 h co
27、nditioning period, perform the following tests on each panel: . Cross hatch adhesion check - FLTM BI 106-01, Method B. . Resistance to Xylene - Using a back and forth motion, rub surface of enamel 10 times with a small wad of cheesecloth which has been wetted with xylene. Subject panels for each pai
28、nt/bake condition to each exposure listed below. Retain an unexposed panel as control. 3.16.1 Wetability and Staining Test Method: After 24 h at 23 +/- 2 C mask 1/2 of the sealer beads types a) to c) and expose each assembly for 240 h. a) At 23 +/- 2 C, b) At 40 +/- 1 C, c) In the Fluorescent Sunlam
29、p Cabinet (FLTM BU 152-02). Examine the exposed and unexposed portions of the sealer steps of 24 h. 3.16.2 Resistance to Weathering (SAE J 2527) 3.16.2.1 2000 hours Xenon 3.16.2.2 One Year Florida ENGINEERING MATERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Glob
30、al Technologies, LLC Page 7 of 11 Test Method: Expose test specimens in the Miami/Florida area for 6 months and 1 year at 5 degrees facing south. Prior to examination clean specimens using soap (SM1B4) and water. 3.16.3 Determination of Yellowing None (FLTM BV 153-12) Use bake conditions per FLTM BV
31、 150-05 (use the table for the region to used), 3.17 PAINTABILITY CONFINED AREA Uncovered area - No evidence of paint transfer after 10 double rubs with xylene. Covered area - Paint transfer allowed after a minimum of 5 double rubs with xylene. Test Method: . Apply two 3 x 25 x 100 mm ribbons of mat
32、erial to an ecoated panel. . Place a 475 ml can over one of the sealer ribbons. Bake the assembly according to the minimum prime bake (first minimum) condition acc. to FLTM BV 150-05 for each region to be used. . (This will simulate cure of the primer over the sealer in a restricted airflow conditio
33、n.) . Remove the can and paint with production topcoat as indicated by Materials Engineering. Film builds shall be 0.013 mm for basecoat and 0.013 mm for clearcoat. . Return the can to the original position over the sealer. Bake the assembly at the minimum topcoat bake (second minimum) acc. to FLTM
34、BV 150-05 for each region to be used. . After bake, remove the can and cool the panel for 24 h at 23 +/- 2 C . Evaluate the panels visually for any deterioration of the sealer/paint. Perform a solvent resistance test on both surfaces by rubbing the painted sealer 10 times with xylene (10 double rubs
35、). Examine the rag for evidence of paint transfer. 3.18 FUMING TEST No evidence of paint peeling. (FLTM BV 130-01) after paint peeling cross hatch test 3.19 CRACK RESISTANCE, min 5000 cycles (FLTM BV 115-01, bake 2 sets of No cracks panels max bake and min bake per FLTM BV 150-05 according to the re
36、gion for use, for normal and aged tests). 3.20 SHEAR ADHESION, min MPa (FLTM BV 154-03, Method B Prepare two sets of panel minimum and maximum bake according to FLTM BV 150-05, for region to be used, bond line thickness, 3 mm, 3 cm overlap, test at a crosshead speed of 25 mm per min.) ENGINEERING MA
37、TERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 8 of 11 Min Bake Max Bake Exposure Exposure 3.20.1 At 23 +/- 2 C, min 0.5 0.5 3.20.2 At 90 +/- 2 C, min 0.2 0.2 3.20.3 At - 40 +/- 2 C, min 0.5 0.5 3.21 PEEL STRENGTH, min N/mm (FLTM BV
38、 154-03, Method C) (Prepare two sets of panel minimum and maximum bake according to FLTM BV 150-05, for region to be used, bond line thickness 3 mm, 10 cm overlap, test at a crosshead speed of 25 mm per min.) Min Bake Max Bake Exposure Exposure 3.21.1 At 23 +/- 2 C, min 5 5 3.21.2 At 90 +/- 2 C, min
39、 2 2 3.21.3 At - 40 +/- 2 C, min 5 5 3.22 HARDNESS, DUROMETER A (ASTM D 2240) The hardness tolerance for any one supplier shall be +/- 5 based on the recorded hardness of their originally approved production sample. See paragraph 4.7 Test Method: . Apply enough material into a container (such as an
40、ointment tin) to give a 6.4 mm thickness slab. . Bake material at minimum curing according to FLTM BV 150-05 for region to be used. . Condition test sample at 23 +/- 2 C for 4 h, then check instantaneous material hardness. 3.23 CURED SEALANT PROPERTIES 3.23.1 Normal Tensile Strength, min 0.9 MPa (AS
41、TM D 412, die C, pulled at 300 mm/min. Minimum 5 samples per bake) Elongation, min 50% Tear Strength, min 4.0 N/mm (ASTM D 624, die C, pulled at 500 mm/min) ENGINEERING MATERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 9 of 11 3.23.2
42、 Aged (Cured samples aged 2 weeks at 90 +/- 2 C) Tensile Strength, min 1.0 MPa (ASTM D 412, die C, pulled at 300 mm/min. Minimum 5 samples per bake) Elongation, min 50% Tear Strength, min 4.0 N/mm (ASTM D 624, Die C, pulled at 500 mm/min) 3.24 ABRASIVES None Test Method: . Dilute a 1 g sample of the
43、 material with 1 g of M14J507 Naptha or equivalent, and mix thoroughly. . Rub a portion of the diluted material 100 times between 2 pieces of flat, clean plate glass. The appearance of scratches on the glass plate shall be considered failure. 3.25 SPRAYABILITY Shall be suitable for use in the airles
44、s spray equipment designated by the Paint Operation Activity. 3.26 ABRASION RESISTANCE (ASTM D 968) There shall be no exposed metal area showing after 300 L gravel impact. No loss of adhesion on and around the area of stone impact. Panel Preparation: Test panels of 300 x 100 mm (prepared according t
45、o FLTM BI 120-01) shall be coated with the material under test in such a manner (airless) that after curing a dry coating thickness of 0.5 - 0.65 mm is obtained. After 10 minutes at 23 +/- 2 C cure test specimens separately according to FLTM BV 150-05 for the individual region a) min curing cycle b)
46、 max curing cycle Condition for 2 h at 23 +/- 2 C and expose in mechanical convection oven maintained at 70 +/- 2 C for 120 h. Test Method: After conditioning for 24 h at 23 +/- 2 C, determine the abrasion resistance according to ASTM D 968, except I.D. of tube 25 mm and at a gravel throughput rate
47、of 30 - 40 liters/h. For each specimen a 5 L volume of fresh gravel shall be used. ENGINEERING MATERIAL SPECIFICATIONWSS-M4G359-APrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 10 of 11 Check for abrasion resistance and loss of adhesion after 300 L gravel impact. C
48、ontinue abrasion test until exposure of metal area and again check for loss of adhesion. Gravel: Type “GABBRO“ grain size 5 - 8 mm Possible Supply Source: ODENWAELDER HARTSTEIN INDUSTRIE GMBH Lise-Meitner-Str. 35 D 63457 Hanau 3.27 RESISTANCE TO DRIPPING The material must not fall off or show eviden
49、ce of dripping. Test Method: Prepare 300 x 300 mm test panels according to paragraph 3.27, except wet film thickness of material under test 1.0 - 1.5 mm. After conditioning for 5 minutes at 23 +/- 2 C, place specimens in an inverted position in a mechanical convection oven and subject to the “Min Curing Cycle“ according to FLTM BV 150-05 for region to be used. 3.28 ODOR, max Rating 3 (FLTM BO 131-03, for interior application only) 3.29 FOGGING (SAE J 1756, 3 h at 100 C heating, 21 C coo
