1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1996 01 25 Revised Activate C3, revised 3.6 DRH1995 08 30 Revised Rev.para 3.4, 3.5.1.1, 3.6, 3.10; New 3.5.1.2 DRH1995 05 12 Activated D. Henrickson LAGWP 3948-a Page 1 of 10 DEADENER, LIGHT WEIGHT, HEAT BONDABL
2、E WSS-M5G44-C1DEADENER, MEDIUM WEIGHT, HEAT BONDABLE WSS-M5G44-C2DEADENER, HEAVY WEIGHT, HEAT BONDABLE WSS-M5G44-C31. SCOPEAll of the materials defined by this specification are acousticaldeadeners. The various kinds of deadeners specified are described in amat erial matrix enclosed herein. Each uni
3、que material described in thematrix is assigned its own specification number.2. APPLICATIONThi s specification was released originally for materials used to dampvib rating body panels. Unique material applications are defined by thematerial matrix incorporated in the specification.Prior to use, the
4、material must be evaluated under the c omponent productionparameters. The choice of substrates, stamping lubricants, plantproces sing conditions and specific design application may affect materialperform ance. Compliance with this specification does not guarantee thematerial will function for all po
5、tential applications on a vehicle.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers and part producers must conform to Quality SystemRequirements, QS-9000. Material specification r equirements are to beused fo r initial qualification of materials. A Control Plan forong oing production
6、 verification is required. This plan must bereviewed and approved b y the relevant Ford Materials activity and/orFor d Supplier Technical Assistance (STA) prior to production partssubmission. Appropriate statistical tools must be used to analyzepr ocess/product data and assure consistent processing
7、of thematerials.Part producers using this material in their products, must use Fordapproved materials and must conform to a process control plan whichhas been approved by STA and/or the relevant Materials Activity.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G44-C1/C2/C3WP 3948-b Page 2 of 10 3.2 INFRARE
8、D SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may conduct infrared and/ortherma l analysis of material/parts supplied to this specification.The IR spectra and thermograms established for i nitial approval shallconst itute the reference standard and shall be kept on fi
9、le at thedesignated material laboratory. All samples sha ll produce IR spectraand thermograms that correspond to the reference standard when testedunder the same conditions.3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on ma terial conditioned ina c ontrolled atmosph
10、ere of 23 +/- 2 EC and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing and tested under thesame conditions unless otherwise specified.3.4 MATERIAL MATRIXThe matrix below provides information on basic material type,manufacturing process location, method of applic ation, and accept
11、ablein-vehicle orientation for each material specification number.Material TypeC1/C2/C3. Asphaltic Based X. Polyvinyl Chloride. Ethylene Vinyl Acetate. Polyvinyl Acetate . Urethane. Butyl. SBR based X (alternate). Saturated Felt. Aluminum Foil . Adhesive . Magnetic. Special Requirement. Release Line
12、r Assembly Location (whereapplied in mfg. process). Stamping Plant or AssyPlant body-in-white. Paint Shop (assy Plant X after E-coat bake). Trim Shop(assembly plant after paint)ENGINEERING MATERIAL SPECIFICATIONWSS-M5G44-C1/C2/C3WP 3948-b Page 3 of 10 C1/C2/C3Method of Application. Spray. Lay by Han
13、d X. Pressurize . Extrude. Special RequirementIn-vehicle Orientation. Horizontal Only X. Vertical or Horizontal . Inverted or Other. Special Requirement3.5 SAMPLE PREPARATION3.5.1 Applying Material to Substrate3.5.1.1 Materials Applied with PressureRoll once (in the forward direction only) with asto
14、c k steel (78 mm min diameter) using a surfaceload o f 2.2 kg/25 mm of sample width (+/- 0.01 kg,+/- 3 mm sample width).3.5.1.2 Cut sampl es to the size specified, +/- 3 mm. Thesample must be flat with no bent edges, no raisededges and no depressed edges.3.5.2 Sample OrientationAll in -vehicle orien
15、tations used should be evaluated (seematerial matrix (para 3.4) for in-vehicle orientations).3.5.3 Processing Temperature BakesTypical manufacturing-process minutes-at-metal-temperatures(MMT) minimums, nominals, and maximums are identified below.All processing sequences encoun tered with the materia
16、l shouldbe eva luated (see material matrix, para 3.4, for processinformation) unless otherwise specified herein.Process Low Bake Nominal High BakeBake (MMT) (MMT) (MMT)E-coat 10 170 EC 10 182 EC 30 205 ECPrimer 8 135 EC 10 150 EC 20 177 ECTopcoat 10 125 EC 10 130 EC 20 165 ECPredelivery 10 100 ECENG
17、INEERING MATERIAL SPECIFICATIONWSS-M5G44-C1/C2/C3WP 3948-b Page 4 of 10 3.5.4 Production Representative SubstratesAll metals, oils/draw compounds , coatings, and other surfacesused wi th the material should be evaluated (for typicalsubstrates, oils and coatings see para 3.5.5).3.5.4.1 Materials Appl
18、ied at Metal Stamping or in theAssem bly Plant Body Shop (body in white)-allmetals, galvanize coatings, oil s/draw compounds andother surfaces used with the material should beevaluated.3.5.4.2 Materi als Applied in the Assembly Plant Paint Shop(aft er E-coat bake)-all E-coats, primers, andother surf
19、aces used with the material should beevaluated.3.5.4.3 Mater ials Applied in the Assembly Plant Trim Shop(after paint)-all topcoats and other surfaces usedwith the material should be evaluated.3.5.5 SYSTEM PROCESS COMPATIBILITYInitial material approval was based on specific material systems whichinc
20、luded the substrate, stampin g lubricants and deadener system. Theorigi nally approved material system was processed and cured usingspeci fic production process parameters. Substrate choice, stampinglubricants, and assembly plant processing conditions may affectadhesive performance. If any of these
21、parameters are changed,material performance must be validated using the new parameters.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G44-C1/C2/C3WP 3948-b Page 5 of 10 3.6 TEST MATRIXThe test matrix below and more detailed requirements referenced inthis specification identify the testing requirements for
22、each materialspecification.C1 C2 C3Total Thickness, mm As Specified on Engineering Drawing(ASTM D 461)Total Mass, kg/m2, +/- 10 % 2.45 3.65 4.88(ASTM D 461)Damping Loss Factor, min(ASTM E 756, 200 hz). At 0 EC 0.08 0.09 0.10. At 15 EC 0.11 0.15 0.20. At 30 EC 0.15 0.19 0.21. At 45 EC 0.06 0.12 0.24.
23、 At 60 EC 0.03 0.06 0.18Peel Adhesion, N, min. No Bake, 1 h dwell. No Bake, 24 h dwell. No Bake, 250 h dwell. Bake & 250 h 88 EC 20 or cohesive failure. Bake & 250 h 38 EC & 100 % RH 10 or cohesive failureSustained Heat and Sag X X XCold Adhesion (FLTM BV 101-02)E-Coat Compatibility(FLTM BV 119-01)W
24、ash Resistance(FLTM BV 116-01)Severe Wash Resistance(FLTM BV 116-02)Foil Thickness, mm(ASTM D 461)C1 C2 C3Flammability X X X(ISO 3795/SAE J369)Fogging (FLTM BO 116-03), min 60 60 60Odor (SAE J1351), max 2 2 2(or no worse than materialcurrently approved)Note: X = Requirement is specified in the appro
25、priate paragraphs of thisspecification which follow.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G44-C1/C2/C3WP 3948-b Page 6 of 10 3.7 DAMPING LOSS FACTOR As specified in TEST MATRIX(ASTM E 756, avg of 5 beams,at each temperature, 200 Hz,15 EC increments from 0 - 60 EC)Test Conditions (unless otherwise
26、specified):. 320 x 20 x 0.8 mm clean cold rolled steel Oberst bar. Oberst bar damped one side only. 40 mm root length undamped, 280 mm free length damped. Mass of damping material as specified in test matrix. Cure temp and time as specified by the Matls. Engrg. Activity. Report the composite bar los
27、s factor only.Note: The calculated value at 200 Hz is obtained by linearinter polation between the loss factor values of the resonancesdirectly on either side of 200 Hz.3.8 PEEL ADHESION As specified in TEST MATRIXTest Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information
28、): Apply 25 x 125 mm length strips of materialto production representative substrate panels. The material may haveto be backed with mylar or duct tape for reinforcement during peel.Suspend panels as oriented in-vehicle during dwell periods and bakecycling. Use low bake and high bake schedules only f
29、or materialsth at are processed thru Body and Assembly paint process. Usepredelivery bake and no bake schedules (oriente d as in-vehicle) only,for materials applied at Body and Assembly Division after paintprocessing. Pull ninety degrees to surface at a rate of 305mm/minut e. The peel value reported
30、 must be that obtained for theaverage load.3.9 SUSTAINED HEAT AND SAG No sag ging or material degradationTest Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information): This requirement is for materials that areprocessed thru Body an d Assembly paint process only. Apply, ori
31、ent,and bake (high bake only) 150 x 150 mm test samples to productionrepr esentative substrate panels. Suspend panels as oriented in-vehicle during the bak e cycle. No smoking, material degradation, orsag of the material is allowed.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G44-C1/C2/C3WP 3948-b Page 7
32、 of 10 3.10 COLD ADHESION No loss of adhesion(FLTM BV 101-02, Steps 9 - 12,Four (4) cycles)Test Me thod (also see SAMPLE PREPARATION paragraph above for moredetailed information): Apply 75 x 150 mm test samples to productionrepres entative substrate panels. Conduct cold slam procedure afterlow b ake
33、 and after high bake for materials that are processed thruBody an d Assembly paint process. Suspend panels as oriented in-vehicle during the bake cycle. Conduct cold sl am procedure on panelswithout bake also, for materials applied at Metal Stamping Division.Conduct cold slam procedure on panels wit
34、hout b ake and on panels withpredelivery bake (oriented as in-vehicle) only, for materials appliedat Body and Assembly Division after paint processing.3.11 E-Coat Compatibility No film irregularities(FLTM BV 119-01) or material incompatibilities3.12 Wash Resistance Shall remain unaffected(FLTM BV 11
35、6-01) No edge loss or displacement3.13 Severe Wash Resistance Shall remain unaffected(FLTM BV 116-02) No edge loss or displacement3.14 FLAMMABILITY(ISO 3795/SAE J369)Burn Rate, max 100 mm/minute3.15 FOGGING(FLTM BO 116-03, 3 h at 100 EC)Fog Number, min As specified in test matrixFormati on of a clea
36、r film, droplets or crystals is cause forrejection.Bond to aluminum foil in 135 EC oven for 30 minutes for evaluation.3.16 ODOR, max As specified in test matrix(SAE J1351)The material shall be evaluated after exposure to normal processingconditions.3.17 FUNCTIONAL APPROVALMaterials being evaluated f
37、or approval to this specification shall besubject ed to a production trial. Functional trial results must beapproved by the affected assembly operation and Design Engineering.Results shall be made available to Materials Engineering prior tomaterial approval and release.ENGINEERING MATERIAL SPECIFICA
38、TIONWSS-M5G44-C1/C2/C3WP 3948-b Page 8 of 10 3.18 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manuf actured parts shall bespecified on the Engineering drawing, Engineeri ng parts specificationand/or performance specifications. All critical areas with respectto these properties s
39、hall be clearly designated on the engineeringdrawing.3.19 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon which approval wasoriginally granted.Pri or to making any change in the properties, composition,constr uction,
40、 color, processing or labeling of the materialorig inally approved under this specification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the Supplier shall notify Purchasing, Toxicology andthe affected Materials Engineering activity of the propose
41、d changesand obtain the written approval of the Materials Engineeringactivity. Test data, test samples and a new code identification areto be submitted with the request.Substance restrictions imposed by law, regulations or Ford, apply tothe materials addressed by this document. The restrictions ared
42、efined in Engineering Material Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSMate rials defined by this specification must have prior approval by therespo nsible Materials Engineering activity. Suppliers desiring approvalof their materials shall first obtain an expression of interest from th
43、eaffect ed Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity a completed copy of their laboratory test reports, signed by aqualified and authorized representative of the test faci lity, demonstratingfull compli
44、ance with all the requirements of this specification (testresults, not nominal values), the material designation a nd code number, andtest specimens for Ford evaluation. Fords engineering approval of amateri al will be based on its performance to this specification and on anassessment of suitability
45、 for i ntended processes and/or applications. Uponapprov al, the material will be added to the Engineering Material ApprovedSource List.ENGINEERING MATERIAL SPECIFICATIONWSS-M5G44-C1/C2/C3WP 3948-b Page 9 of 10 5. GENERAL INFORMATIONThe information given below is provided for clarification and assis
46、tancein meeting the requirements of this specification.5.1 MATERIAL TEST DATA FORMSelected testing from the list below, mutually agreed to between thesupplier and the respo nsible Materials Engineering Activity, must besubmitted prior to ini tial material approval. Selected tests, whichare inc luded
47、 in the material control plan should be updated asreferenced on the control plan.Specification Supplier GSDB Code Product Code Manufacturing Plant Location Physical/Chemical Properties Selected Test Results Product LimitsTest (Mean, Std Dev, (99.99 4 % ofsample size) produ ction)Total Thickness, mm
48、(ASTM D 461, w/o release liner)Total Mass, Kg/m 2(ASTM D 461, w/o release liner)Damping Loss Factor(ASTM E 756, 200 hz). At 0 EC _ . At 15 EC . At 30 EC . At 45 EC . At 60 EC Peel Adhesion, N, min. No bake, 1 h dwell _ _ _ _. No bake, 24 h dwell _ _ _ _. No bake, 250 h dwell _ _ _ _. Bake & 250 h at 88 EC _ _ _ _. Bake & 250 h at 38 EC & _ _ _ _100 % r.h.Sustained Heat and Sag Cold Adhesion
