FORD WSS-M2G410-A-2018 ADHESIVE WELDABLE RIVETABLE THERMAL CURE STRUCTURAL ALUMINUM TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 04 2018 06 11 Editorial See Summary of Revisions B. Witkowski, NA 2017 10 19 Revised See Summary of Revisions B. Witkowski, NA 2003 01 23 Activated N. Lindsay-Merte/J. Crist, NA Controlled document at www.MATS Copyright 2017, Ford Global

2、 Technologies, Inc. Page 1 of 17 ADHESIVE, WELDABLE, RIVETABLE, THERMAL CURE, WSS-M2G410-A STRUCTURAL, ALUMINUM 1. SCOPE The material defined by this specification is pumpable, one component, thermal curing, weldable or rivetable structural adhesives for aluminum. 2. APPLICATION This specification w

3、as released originally for materials used to structurally bond body components such as top rails, rear sills, and cross members to floor pans and inners to outers in a wheel house. This adhesive can be used to bond oily, unclean mill finish and pretreated aluminum sheet, castings and extrusions for

4、body-in white applications. The use of pretreated aluminum sheet, castings and extrusions provide optimal adhesion performance for long term durability. Optimal adhesion strengths are achieved with adhesive bondlines of 0.25 mm. The material is cured in the electrocoat oven. The Manufacturing Proper

5、ties and Engineering Performance requirements defined in this specification are based on laboratory sample testing and define the minimum acceptance criteria for adhesive performance. The function and design requirements for the application are defined by the Sub-system Design Specification (SDS), k

6、ey life test requirements, or vehicle program requirements. Prior to use, the adhesive must be evaluated under the production parameters. The choice of substrates, stamping lubricants, stamping plant processing conditions, assembly plant processing conditions and specific design application may affe

7、ct adhesive performance. Compliance with this specification does not guarantee the adhesive will function for all potential applications on a vehicle. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source

8、 List (ASL) can be used 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. 3.2 SYSTEM COMPATIBILITY Initial adhesive approval was based on a specific materi

9、al system which included the substrate, stamping lubricants and adhesive. The material system was oven cured using specific production process parameters. Substrate choice, stamping lubricants, stamping plant processing conditions and assembly plant processing conditions may affect adhesive performa

10、nce. If any of these parameters are changed, the adhesive performance must be validated using the new parameters. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 2 of 17 3.3 MATERIAL PROPERTIES 3.3.1 Weight Per Volume +/- 0.02 (ASTM D816) The weigh

11、t tolerance for any one supplier shall be +/- 0.02 kg/L, based on the recorded weight of their original approved production sample. Reference para 4.1. 3.3.2 Volatile Organic Compounds (VOC) Content +/- 10% (EPA Method 24, Procedure B) The VOC Content variation for any one supplier shall be +/- 10%,

12、 based on the recorded VOC Content of their original approved production sample. Reference para 4.2. 3.3.3 Cure Requirements Report minimum and maximum cure conditions, must meet requirements in this paragraph. (Define the process cure window for material cure, report minimum and maximum time at tem

13、perature requirements to define performance boundaries). Critical performance characteristics shall include, but are not limited to, the following Lap-Shear, para 3.5.1 Stress Durability, para 3.5.2 Fracture Toughness, para 3.5.4 Fatigue, para 3.5.5 Tensile Properties, para 3.5.7 Peel Resistance, pa

14、ra 3.5.3 Minimum and maximum cure conditions to be proven by the supplier. A cured material is one which will meet all minimum properties required in this specification. The cure conditions required for this specification for e-coat bake are: Minimum cure 10 minutes metal temperature (maximum 20 min

15、utes in oven) at 160 C Maximum cure 30 minutes metal temperature (minimum 40 minutes in oven) at 205 C 3.4 MANUFACTURING PROPERTIES 3.4.1 Rheology Report (SAE J1524, rotational rheometer with 40 mm diameter parallel plates, 500 micron gap, 50 Pa/sec ramp, stress controlled rheometers use stress rang

16、e 0 - 3500 Pa, strain controlled rheometers use strain range 0 - 100 sec-1, evaluate material to highest stress or strain as the formulation will allow, report material batch/lot number, identify rheometer make and model, for each test condition report yield stress and submit plots for shear stress

17、vs shear rate, submit plot for viscosity vs temperature at mid-range shear rate) Initial (as received) Test at 23 +/- 1 C Test at application temperature +/- 2 C Test over range 10 to 50 C at increments of 10 C Aged (age then test at 23 C and application temperature) 7 days at 40 +/- 1 C 90 days at

18、32 +/- 1 C ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 3 of 17 72 hours at 45 +/- 1 C The rheology variation for any one supplier shall be +/- 10 %, based on the recorded rheology of the original approved production sample. The flow curves esta

19、blished for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce flow curves that correspond to the reference standard when tested under the same conditions. Final approval of material rheology for product

20、ion shipments shall be made by the affected manufacturing activity. In all cases, the rheology shall be within the limits as identified on the material control plan. 3.4.2 Pumpability/Dispense Capability Materials being considered for approval to this specification shall be evaluated for processing

21、capability using extrusion, stream and swirl methodologies. The pumpability/dispense capability report must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. Materials shall be a smo

22、oth homogenous mixture, free from entrapped air, foreign materials and properties detrimental to normal production operation. The material shall work with all the plant processes (cleaning operations, phosphating process, welding operations, etc.) and shall not deteriorate the performance of phospha

23、ting, electrocoat primer or other materials applications. 3.4.3 Differential Scanning Calorimetry (20 +/- 1 mg sample size, 5 C/min heating rate, 25 - 250 C temperature range, submit Heat Flow vs. Temperature curve) Onset of reaction 80 C min Glass Transition Temperature Report 3.4.4 Sag Resistance

24、(FLTM BV 118-01, lab caulking gun applied 5 mm diameter bead, substrates per para 4.3, condition for 24 h at 40 C, oven schedule per para 4.4, one panel each bake) Horizontal No measurable movement Vertical No measurable movement Inverted No loss of material 3.4.5 Slump Resistance 3 mm max Assembly

25、aged 30 days at 50 +/- 1 C Test Assembly: Two 25 x 100 mm coupons, prepared per para 4.3, with two 38 x 12 x 3 mm spacers. The spacers are placed at each end of one of the coupons, and sufficient adhesive is applied between the spacers to fill the gap. The second coupon is placed on top of the adhes

26、ive and spacers (Figure 1). Clamp the assembly with spring clips at each end. Remove excess adhesive from all exterior edges with a spatula. Test Method: Prepare three assemblies per substrate and subject to exposure. After exposure, condition assemblies at 23 +/- 2 C for 24 hours, then bake at mini

27、mum bake per para 4.4. ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 4 of 17 Determine the slump by measuring adhesive loss from the bottom of the assembly. Photograph and record observations of any adhesive loss after exposure and after bake. Re

28、peat the above procedures for maximum bake per para 4.4. 3.4.6 Bridging 3 mm max (SAE J243 ADS-9, Section 3.3, Method D, non-flow fixture, substrates per para 4.3, photograph after exposure and after material cure, bake conditions per para 4.4) Assembly aged 30 days at 50 +/- 1 C 3.4.7 Wash Resistan

29、ce (FLTM BV 116-01, Method B, 10.0 x 200.0 mm substrates, per para 4.3) No measurable movement, displacement or wash-off. 3.4.8 Electrocoat Compatibility (FLTM BV 119-01, use current production paints as identified by Material Engineering, substrates per para 4.3) Shall not contaminate electrocoat p

30、rimer bath or cause electrocoat film irregularities. 3.4.9 Welding Acceptance Test Must Pass (FLTM BV 109-01, gun application, 25 coupon assemblies per condition, substrates per para 4.3) As prepared (fresh material) Assembly aged 30 days at 23 +/- 2 C Assembly aged 30 days at 40 +/- 2 C 3.4.10 Flam

31、mability with Continuous Spot Welding (FLTM BV 114-01, substrates per para 4.3) During welding tests, less than 5 % of the welds shall exhibit a flame and all shall be self-extinguishing within 30 seconds. 3.4.11 Rivetability The adhesive shall not cause excess quilting as defined in Figure 2, nor c

32、ause a break through of the sheet metal or buckling of the rivet. Original approval was based on laboratory / plant trials using hydraulic/electric and manual/robotic parameters. New applications shall be validated using the intended production parameters ENGINEERING MATERIAL SPECIFICATION WSS-M2G41

33、0-A Copyright 2017, Ford Global Technologies, Inc. Page 5 of 17 Test Method: Perform rivet tests using methods typical of the production application, e.g. hydraulic/electric, manual/robotic. Using 1.0 x 100 x 400 mm aluminum coupons construct an assembly as defined in Figure 3. A 3 mm bead of adhesi

34、ve shall be applied 9.5 mm from edge of lower coupon prior to mating with the top coupon. Use rivet and type as specified by the application. After riveting, cure adhesive per para 4.4. Examine the assembly. Cross section the assembly through the rivet. A rivetability report must be approved by the

35、affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. 3.4.12 Odor Rating 3 max (FLTM BO 131-03, method D, cure per FLTM BV 150-05, high and low bake per para 4.4) 3.4.13 Material Consistency Shall be a smo

36、oth homogenous mixture, free from entrapped air, foreign materials and any properties detrimental to normal production operation. 3.4.14 Storage Stability Heat greatly accelerates aging. The material shall be stored in closed containers away from all sources of heat. The shelf life of the material s

37、hall be 3 months from date of manufacture when stored below 32 C. When materials are stored at temperatures below 23 C, they shall be conditioned at room temperature 24 hours prior to application. Application properties are optimized with adequate conditioning of the material. Ambient plant conditio

38、ns may fluctuate between 7 C and 38 C. Materials shall be evaluated for local plant conditions to determine plant specific requirements in excess of 32 C. Critical performance characteristics to evaluate for shelf life stability shall include, but are not limited to, the following: Rheology, para 3.

39、4.1 Sag Resistance, para 3.4.4 Slump Resistance, para 3.4.5 Rivetability, para 3.4.11 Stress Durability, para 3.5.2 Fracture Toughness, para 3.5.4 Fatigue, para 3.5.5 Tensile Properties, para 3.5.7 3.5 ENGINEERING REQUIREMENTS 3.5.1 Adhesion Strength, min 12.0 MPa, not to exceed (SAE J1523, substrat

40、es per para 4.3, more than 30% reduction 0.25 mm adhesive bondline thickness, of strength after aging or 13 mm length overlap, 13 mm/min pull exposure. rate, oven cure per para 4.4) ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 6 of 17 3.5.1.1 No

41、rmal (Condition for 30 minutes at specified temperature prior to test) Test at 23 +/- 2 C Test at 80 +/- 2 C Test at -40 +/- 2 C 3.5.1.2 Exposed (Condition at 23 +/- 2 C for 1 h, subject to environmental cycle, oven cure per para 4.4, test at 23 C) Environmental cycle: - 40 +/- 1 C for 7 days PLUS 3

42、8 +/- 1 C for 98 +/- 2 % RH for 7 days PLUS 40 +/- 1 C for 7 days PLUS 23 +/- 2 C for 1 day 3.5.1.3 Aged (Oven cure per 4.4, then expose per below, then condition at 23 +/- 2 C for 24 h after exposure, test at 23 +/- 2 C) 3.5.1.3.1 Expose to 10 Thermal Cycles prior to evaluation One Cycle: 90 +/- 1

43、C for 4 h PLUS 38 +/- 1 C and 98 +/- 2 % RH for 4 h PLUS - 40 +/- 1 C for 16 h 3.5.1.3.2 Expose to 10 Moisture Intrusion Cycles prior to evaluation One Cycle: 16 h at 38 +/- 2 C and 95 +/-5 % condensing RH 4 h at -40 +/- 2 C 4 h at 80 +/- 2 C Samples are to be conditioned at 23 +/- 2 C and 50 +/- 5%

44、 RH over weekends and holidays. Time between conditions shall not exceed 5 minutes. 3.5.1.3.2 Corrosion Environment- Expose to (CETP 00.00-L-467, 6 weeks) prior to evaluation 3.5.2 Stress Durability (FLTM BV 101-07, substrates per para 4.3, all coupons from one manufacturers lot, report thickness fo

45、r each coupon and substrate yield strength for manufacturers lot, oven cure para 4.4, two fixtures, cyclic corrosion exposure, report data per test method) Load condition of each tube, 2400N, all coupons tested must exceed 45 cycles without failure. 3.5.3 Peel Resistance (ASTM D1876, 0.25 mm adhesiv

46、e bondline thickness, 76.2 mm overlap, 127 mm/min pull rate, substrates per para 4.3, oven cure per para 4.4, condition for 30 minutes at specified temperature prior to test) ENGINEERING MATERIAL SPECIFICATION WSS-M2G410-A Copyright 2017, Ford Global Technologies, Inc. Page 7 of 17 Test at 23 +/- 2

47、C 5 N/ mm min Test at 80 +/- 2 C 5 N/ mm min Test at - 40 +/- 2 C 5 N/ mm min 3.5.4 Fracture Toughness (FLTM BU 121-01, 0.25 mm bondline thickness, substrates per para 4.3, oven cure per para 4.4, condition at specified temperature 30 minutes prior to test, 2 m/s impact velocity, Report A, h and n f

48、or the characterized metal, report R1 and R2 for each coupon assembly) Test at 23 +/- 2 C 0.5 kJ/m2min Test at 80 +/- 2 C 0.5 kJ/m2min Test at - 40 +/- 2 C 0.5 kJ/m2min 3.5.5 Fatigue Values shall be above the minimum in Figure 4. Test Method: Prepare 36 lap shear coupons as prepared per para 3.5.1,

49、substrates per para 4.3, oven cure per para 4.4. Condition at 23 +/- 2 C for 2 h. Refer to para 3.5.1 Shear Adhesion testing at 23 C to determine average static peak load failure. Determine fatigue resistance in a dynamic tensile testing machine with a sinusoidal cyclic axial load and a frequency of 20 Hz at less than 1E6 cycles and 20 Hz at greater than 1E6 cycles. Maximum tensile loads to range fr