1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0.0 2017 10 27 Released J. Herl, FOE Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 1 of 4 EXTRUDEABLE PELLETS, SEALER, ANTI-FLUTTER, EXPANDING WSS-M4G371-A1 1 SCOPE The materials defined by this speci
2、fication are extrudable (delivered in pellet form) ethylene copolymer based materials which can be heat bonded to cleaned steel or aluminum using an extrusion process. The beads applied with this extrusion process are used for sealing and vibration dampening purpose. 2 APPLICATION This specification
3、 was released originally for material that comes to Ford in pellet form. These pellets are extruded on cleaned, dry, not oily, preheated metal sheets. Before curing (ecoat oven process) the beads are solvent free, “dry to the touch” and they dont wash out in the successive baths of the e-coat proces
4、s. After curing (ecoat oven process) the extruded beads can function as sealer, NVH or anti-flutter material. 3 REQUIREMENTS 3.1 SYSTEM COMPATIBILITY Initial approval was based on a specific material system which included the substrate, stamping lubricants and sealer. Substrate choice, stamping lubr
5、icants, stamping plant processing conditions, assembly processing condition may affect sealer performance. If any of these parameters are changed, the sealer performance must be validated using these parameters. The material shall work with all the plant processes (cleaning operations, phosphating p
6、rocess, welding operations, etc.) and shall not deteriorate the performance of phosphating, electrocoat primer or other materials applications. 3.2 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used
7、 when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. 3.3 COMPOSITION Ethylene copolymer filled with inert fillers and reactive expanding + curing agents. 3.4
8、 RAW MATERIAL PROPERTIES BEFORE EXTRUSION 3.4.1 Color, Shape Grey pellets average grain size 2.5 - 5 mm. 3.4.2 Solids (FLTM BV 150-10) 98%min (ASTM D2834, except heat at 100 +/- 2 C for 3 h in a mechanical convection oven. Save sample for next test, para 3.4.3) 3.4.3 ASH 70% max (ISO 3491, Method A,
9、 760 +/- 30 C based on the solids weight) ENGINEERING MATERIAL SPECIFICATION WSS-M4G371-A1 Copyright 2017, Ford Global Technologies, LLC Page 2 of 4 3.4.4 Density +/- 10% (ISO 845) The density variation for any one supplier shall be +/- 10%, based on the recorded density of their original approved p
10、roduction sample. 3.4.5 Storage Stability Heat and moisture will accelerate aging. The materials shall be stored in sealed packages (if recommended by the supplier) away from all sources of heat and moisture. The shelf life of the material shall be 6 months from date of manufacture when stored at te
11、mperatures below 32 C. Ambient plant conditions may fluctuate between 15 C and 38 C. Materials shall be evaluated for local plants conditions to determine plant specific requirements for temperatures in excess of 32 C. Deviations from the shelf life requirement shall be identified and concurred upon
12、 by the plant and noted in the supplier control plan. When materials are stored at temperatures below 23 C, they shall be conditioned at room temperature for a minimum of 24 hours prior to application. pellets from date of manufacturing 6 months pellets from date of delivery 3 months extruded beads
13、3 months 3.4.6 Volatile Organic Compounds (VOC) Content +/- 0.05 kg/L (EPA Method 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. 3.5 CURE AND EXTRUSION REQUIREMENTS REPORT (Define the p
14、rocess cure window for material cure, Report minimum and maximum time at temperature requirements to define performance boundaries) Critical performance characteristics shall include, but are not limited to, the following: Volume Expansion, Adhesion, 3.5.1 Operating condition substrate + material bu
15、lk temperature The following features are guide lines. Depending on the material applied, the substrate nature and geometry, the temperature ranges may be extended. It is the responsibility of the person who makes the changes to validate that they dont alter the material properties. Pellet Melt temp
16、erature (C) Pellet Melt temperature (C) 95-105 C Substrate temperature (C) 95 115 C Test procedure The substrate temperature must be measured using a contact thermocouple applied at the surface of the substrate, at the time when the substrate reaches the extruder. The pellet melt (bulk) temperature
17、shall be measured by plunging a thermocouple in the melt material when it flows out of the extruder. Maximum working conditions Maximum temperature = 110 C (peak temperature), Maximum shear rate in extrusion process = 1000 s-1 ENGINEERING MATERIAL SPECIFICATION WSS-M4G371-A1 Copyright 2017, Ford Glo
18、bal Technologies, LLC Page 3 of 4 3.5.2 Viscosity as a function of shear rate at 85C, 95C, 105C, (report only) measured with oscillating rheometer Shear range = 1 to 100 s-1 Strain = 5%, shear rate = 1 to 100 rad.s-1. Requirements regarding the extrude-ability of the material From a general point of
19、 view, pellets must always be free flowing and able to be fed by a material dispenser provided by the integrator. The integrator is responsible for selecting the pellet size for the application, extruder equipment, and process technology. 3.5.3 Differential Scanning Calorimetry Report onset of react
20、ion (20 +/- 1 mg sample size, 5 C/min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) 3.5.4 Residence time in the extruder How to handle breaks longer than 10 minutes, see 4.3 Bulk material temperature Maximal residence time 80 C 60 minutes 90 C 15 minutes 100 C 1
21、0 minutes Test procedure - Take approx. 5 kg of virgin material pellets, - Set all zone of the extruder to 80 C, - Fill the extruder with the pellets at 50 rpm screw speed, - When the extruder is full, stop it then wait for 1 hour. When the hour is elapsed, extrude a 3 mm strip as long as possible,
22、without feeding with fresh pellets. The extruder must remain ON as long as some material is extruded. - Measure the density and the expansion of the material at the beginning, at the middle and at the end of the strip (expansion = 30 min. at 165 C, 30 min. at 205 C, 5mins at 165 C) - Repeat the test
23、ing at 90 C, and 100 C. 3.6 MATERIAL PROPERTIES AFTER EXTRUSION ACCORDING TO WSS-M18P11-B 3.7 MATERIAL PROPERTIES AFTER CURING (ECOAT OVEN PROCESS) ACCORDING TO WSS-M18P11-B ENGINEERING MATERIAL SPECIFICATION WSS-M4G371-A1 Copyright 2017, Ford Global Technologies, LLC Page 4 of 4 3.8 TESTING REQUIRE
24、MENTS Test Material Approval DV Test Annual Testing Lot Testing 3.4.2 Solids X 3.4.3 Ash X 3.4.4 Density (ISO 845) X X 3.4.5. Storage stability X 3.4.6 VOC Content (EPA Method 24, Procedure B) X 3.5.1 Operating conditions X X 3.5.2 Viscosity X 3.5.3 Extrude-ability X X 3.5.4 DSC X X 3.5.5. residence
25、 time in extruder X X 3.6 surface precoated with lubricants as specified by the Material Engineering Activity. Galvanized Steel 60G/60G-EL, electrogalvanized, clean, unpolished, nominal 0.8 mm thickness; surface precoated with lubricants as specified by the Materials Engineering Activity. Aluminum:
26、6111-T4 alloy, clean, bare, unpolished, nominal 0.9 mm thickness; surface to be precoated with lubricants as specified by the Materials Engineering Activity. 4.2 MANUFACTURING PROCESS - BREAKS LONGER THAN 10 MINUTES Break longer than 10 minutes: purge the “old” material with new one before starting
27、again. 1 hour break: when leaving, the operator will have to purge the material from the extruder, i.e. remove as much material as possible out of the machine without feeding fresh one. When he will be back on line, the operator will have to remove the aged material from the extruder by chasing it w
28、ith fresh material. The operators make sure that the amount of material corresponding to the full volume of the extruder was purged. No need to cool down the extruder during the break, 1 weekend break: when leaving, the operator will have to purge the material from the extruder, i.e. remove as much
29、material as possible out of the machine without feeding fresh one. After the weekend, the operator will have to remove the aged material from the extruder by chasing it with fresh material. They make sure that the amount of material corresponding to the full volume of the extruder was purged. No need to cool down the extruder during the break, but this can be done for cost saving or safety purpose. Supplier shall meet the minimum above requirements and provide process information to manufacturing group if different from above. 5 SUMMARY OF REVISIONS
