PRODUCT SPECIFICATIONS

45 - 71 - 000 / - - C

MATERIALS FOR REINFORCING THE

METAL WORKS CHAIN STRUCTURE

Normalisation Renault Automobiles

DMI / Service 65810
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This document is to be considered as a whole; its parts can not be separated.

© RENAULT 2007.
No duplication is permitted without the approval of the issuing department.
No circulation is permitted without the approval of RENAULT.

DATE OF ISSUE

June 1999 --- This issue originates from Draft NC 1999 0246 / - - A.

MODIFICATIONS

August 2001 - - A Complete revision

This issue originates from Draft NC 2001 0269 / - - A
October 2001 - - B Modification of compression percentages after ageing in paragraph
5.5.2.1. Modification of loss percentage after ageing in paragraph
5.2.2.2. Modification of water uptake percentage in paragraph 5.2.3.
Addition of mention (inner vehicle) in the denomination of function
R100 184 071 in paragraph 6.
This issue originates from Draft NC 20010810 / - - -
September 2007 - - C Addition of the function of highly expansible reinforcing part.
Addition of contents in resistance to traction-shearing and tearing
with sets between metal sheet and preformed/pretwisted.
Displacement of the following characteristics in the tables
Compression and Corrosion; Implementation; Effect on the baths;
Behavior during surface treatments
This issue originates from Draft NC 2007 0646 / - - -

REFERENCED DOCUMENTS

Standards : 00-10-050.
Product Specifications : 45-00-201, 45-71-000.
Test Method : D17 1686, D17 2028, D41 1108, D41 1950, D45 1148, D45 1333, D47
1165, D55 1209, D57 1180, D59 1336, D59 2033.

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CONTENTS

Page

1. OBJECTIVE 4
2. GENERAL CONDITIONS 4
2.1. RESPONSIBILITY OF THE SUPPLIER 4
2.2. TOXICITY 4
2.3. APPROVAL 4
2.4. QUALITY FOLLOW-UP 4
2.5. INDICATIONS ON THE PLANS 5
3. CONDITIONS OF DELIVERY 5
3.1. CONDITIONING AND PACKAGING 5
3.2. MARKING 5
3.3. STORAGE 5
4. SUPPORTS 5
5. REQUIRED FEATURES 6
5.1. FUNCTIONAL FEATURES 6
5.1.1. Compressive strength 6
5.1.2. Traction-shearing resistance 7
5.1.3. Traction-shearing resistance as per the assembly sets 8
5.1.4. Tearing strength (cross test) pending on the assembly sets. 9
5.1.5. Other features 10
5.2. CHARACTERISTICS OF MECHANICAL WORK 11
5.2.1. Operating temperature 12
5.2.2. Baking Temperature 12
5.3. IDENTIFICATION CHARACTERISTICS 13
6. CORRELATION BETWEEN THE CODING OF THE FUNCTION AND THE NAME 144
7. OTHER REQUIREMENTS 14

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1. OBJECTIVE

The present specification book has as main objective the definition of the requirements concerning the
material of the expansible reinforcing items and of the injected reinforcing products. They are
particularly meant to assure the functional rigidity to shock of some void bodies.

Several technical solutions may be taken into account in order to fulfil this functionality, for instance:

- an expansible preformed material,

- a metal or plastic or composite core surrounded by an expansible material,

- an injected product (single component or double component).

The expansible reinforcement items are generally introduced in the metal work chain before closing
the void bodies, while the injected reinforced items are introduced after the operations of surface
treatment.

In order to be valid, this specification book must be accompanied by the specification book 45-00-201
“Linkage, waterproofing, chipping, damping, anticorrosion, stiffening products – General
requirements”.

The paragraphs below, refer, complete, modify or cancel the paragraphs of the same numbers of the
specification book 45-00-201 previously quoted.

2. GENERAL CONDITIONS

2.1. RESPONSIBILITY OF THE SUPPLIER

Refer to the specification book 45-00-201.

2.2. TOXICITY

Refer to the specification book 45-00-201.

The products must be free of solvents or diluents.

Whether when using them, possibly welding, baking and ageing on the vehicle, there must not be any
clearance, any toxic steam, any odour susceptible of disturbing the users.

Besides, the "materials for reinforcing the structure – chain of metal works" must comply with the norm
00-10-050 "Substances with banned or restricted usages – list and modality of declarations".

The Supplier must guarantee that no substance from the black list is present in the chemical products
and preparations supplied to RENAULT. To do so, the supplier shall make available the exact
chemical composition of the product using the model included in annex 2 of the norm 00-10-050.

2.3. APPROVAL

Refer to the specification book 45-00-201.

2.4. QUALITY FOLLOW-UP

Refer to the specification book 45-00-201.

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2.5. INDICATIONS ON THE PLANS

As an example, the following information "Expansible reinforcing item or injected reinforcing product
R100 184 071 or R100 437 337 according to the specification book 45-71-000” must be reported in
the plan as shown below:

Pièce de renfort expansible

ou produit de renfort injecté
R100 184 071 selon
cahier des charges 45-71-000

Expansible reinforcing item or injected reinforcing item

R100 184 071 according to the specification book 45-71-000

Besides, on the functional plan, the combustibility requirement, measured according to the test method
D45 1333 (see § 5.3) must be mentioned.

3. CONDITIONS OF DELIVERY

3.1. CONDITIONING AND PACKAGING

Refer to the specification book 45-00-201.

3.2. MARKING

Refer to the specification book 45-00-201.

3.3. STORAGE

Refer to the specification book 45-00-201.

The possible transportation of the material must not alter its features.

In case of unstable materials, a specific packaging must guarantee the stability of the contained
material. This requirement is controlled by subjecting the materials to a humid ageing according to the
test method D47 1165-T-21 followed by the series of tests required in the present specification book.

4. SUPPORTS

- Thick sheets of steel,

- Thick electro-galvanized sheets (pure zinc and alloyed zinc),

- cataphoresis coated sheets,

- thick galvanised sheets, (zinc and alloyed zinc),

- thick sheets of aluminium (aluminium protected by the product of the aluminium supplier then
protected by the oil used by RENAULT) and/or pickled (RENAULT commits to provide the
production range of these test specimens),

- TOC sheets (coated with a Thin Organic Coating).

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5. REQUIRED FEATURES

5.1. FUNCTIONAL FEATURES

The functional features of the expansible material or of the injected reinforcing product are defined in the tables below.

5.1.1. Compressive strength

FUNCTION FUNCTION

FEATURES R100 184 071R100 437 337

At - 40 °C ± 2 °C * *
Compressive At 23 °C ± 2 °C ≥ 20 ≥ 8 (3)
strength At 60 °C ± 2 °C * *
in MPa At 85 °C ± 2 °C * *
INITIAL Loss in % :
CONDITION
- between 23 and -40 °C : [ (σ23 °C - σ-40 °C) x 100 / σ23 °C] ≤ 20 % ≤ 40 %
H0
- between 23 and 60 °C : [ (σ23 °C - σ60 °C) x 100 / σ23 °C] ≤ 20 % ≤ 40 %
COMPRESSIVE
After M.E. D47 1165-H-7 à 23 °C * *
STRESS
(speed : 10
After M.E. D47 1165-T-21 à 23 °C * *
mm/min)
AFTER
After M.E. D47 1165-T-21 + M.E. D47 1165-H-7 à 23 °C * *
AGEINGS
Loss in % after M.E. D47 1165-H-7 : [(σi - σf) × 100/σi] (2) ≤ 40 % ≤ 40 %

Loss in % after M.E. D47 1165-T-21 + D47 1165-H-7 : [(σi - σf) × 100/σi] (2) ≤ 40 % ≤ 40 %

RUPTURE STRESS in MPa, after immersion in anticorrosion product void bodies agreed by RENAULT, for 3 hours at a ≥ 20 ≥ 8 (3)
temperature of 23 °C ± 2 °C, followed by a drying period of 24 hours at 23 °C ± 2 °C.

The compressive strength of the expansible material or of the injected reinforcing product is determined in cylindrical test specimens of 35 mm diameter
and 30 mm height. The test specimens are made with an aluminium cylindrical mould of 2 mm thickness, with the inner diameter of 35 mm and the height
of 30 mm.

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Place the PTFE (teflon) sheet inside the mould so to facilitate the stripping.

(1) This test must be carried out on products subject to maximal and minimal baking conditions.

(2) σi : Rupture stress measured in the initial phase, that is before the ageing according to M.E. D47 1165-H-7.

σf : Rupture stress measured in the final phase, that is after the ageing according to M.E. D47 1165-H-7 and/or M.E. D47 1165-T-21.

"H0" condition of the material before accelerated ageing: initial condition

"H7" condition of the material after accelerated ageing according to M.E. D47 1165-H-7.

(*) No particular requirement; it must be in agreement with the agreed sample.

(3) Conformity in mini and maxi baking. The controls shall be done according to the baking cycles to which the item was subjected to on the production
site.

5.1.2. Traction-shearing resistance

FUNCTION FUNCTION

FEATURES R100 184 071 R100 437 337

Geometry of joint described in M.E. D41 1108 Figure 2 of annex 1 to Figure 2 of annex 1 to
M.E. M.E.

TRACTION - INITIAL CONDITION RUPTURE STRESS (MPa) at 23 °C

(H0)
All except AR and CRP All except AR and CRP
M.E D41 1108 FACIES ≥ 20 % (*) ≥ 20 % (*)

SHEAR CONDITION RUPTURE STRESS (MPa) after M.E. D47 1165-H-7 at 23 °C ≥2 ≥ 1,5

(M.E. D41 1108) FACIES All except AR and CRP All except AR and CRP
AFTER

AGEING ≤ 20 % (*) ≤ 20 % (*)

(M.E. D47 1165) Loss in % after M.E. D47 1165-H-7 : [(σi - σf) × 100/σi] at 23 °C (1) ≤ 40 % ≤ 50 %

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(1) σi : Rupture stress measured in the initial condition, that is before the ageing, according to M.E. D47 1165-H-7.

σf : Rupture stress measured in the final condition, that is after the ageing, according to M.E. D47 1165-H-7 and/or M.E. D47 1165-T-21.

. "H0" condition of the material before accelerated ageing: initial condition

. "H7" condition of the material after accelerated ageing, according to M.E. D47 1165-H-7.

(*) AR means "Adhesive Rupture"; CRP means "Cohesive Rupture with Peeling”

5.1.3. Traction-shearing resistance as per the assembly sets

FUNCTION FUNCTION

FEATURES R100 184 071 R100 437 337

TRACTION – SHEAR Geometry of the joint described in M.E. D41 1108 according to Figure 2 of annex 1 Adjustment between
the perform and metal
Support and dimensions (1) ; Baking (2)
(expansible reinforcing sheet of 1 to 5 mm
product)

Holding with adjusting Dimensions of the preformed L X l X e 25 X 20 X 4 mm

mechanism

H0 RUPTURE STRESS (MPa) at 23 °C (3)

(1) Support, galvanized non-deformable coated metal sheet. Example: HE450M 1,8mm thickness or equivalent of dimensions 125mm X38mm

(2) Baking to be done according to the most critical cycles seen by the vehicle in the area. (if the cycle is not known please consider the reference cycles
C30+C40+C50)

(3) The minimal holding before failure, pending on the thickness of the preform and on the adjustment to cope with, must be in accordance with the initial
samples (note of product conformity) and to the validation tests on the vehicle. For information : the holding with a 5mm adjustment (critical threshold) must be ≥
to 0,3 MPa.
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5.1.4. Tearing strength (cross test) pending on the assembly sets.

FUNCTION FUNCTION

FEATURES R100 184 071 R100 437 337

Cross test Geometry of the joint described in the European According to chapter 7,2
Norm XP A 89-422 (without welded pt) of the norm
(expansible reinforcing product) with an adjustment between the
Support (1) and baking (2)
perform and the metal sheet
varying from 1 to 5 mm

Holding at tearing Dimensions of the perform L X l X e 38 X 17 X 4 mm

European Norm XP A 89-422 H0 RUPTURE STRESS (MPa) at 23 °C Graph according to the

adjustment (4)
Adjustment between the preformed and the
metal sheet 5 mm (3) (4)

(1) Support, galvanized non-deformable coated metal sheet. Example: HE450M 1,8mm thickness or equivalent of dimensions 125mm X38mm

(2) Baking to be done according to the most critical cycles seen by the vehicle in the area. (if the cycle is not known please consider the reference cycles
C30+C40+C50)

(3) Minimal reference expected base hold of bulging while baking 140%

(4) The minimal resistance before failure must be in accordance with the initial samples (note of product conformity) and to the validation tests on the vehicle.

For information: the tearing resistance must be ≥ to 0,5 MPa.

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5.1.5. Other features

FUNCTION FUNCTION

FEATURES R100 184 071 R100 437 337

CORROSIVE STRENGTH SPECIMEN DESCRIBED IN ME D59 1336 Annex 13 (C) Annex 13 (C)

AFTER 9 CYCLES « 3C » ME D17 1686 (1) FRINGE CORROSION WITHOUT WITHOUT

Or after 9 cycles « ECC1 » ME D17 2028 (1) SUBJACENT CORROSION WITHOUT WITHOUT

Bulging Thickness (mm) 4 4

(M.E. D57 1180) (1) Level in % 60 ≤.....≤ 90 110 ≤.....≤ 210 (1)

Dry extract (M.E. D55 1209) Level in % ≥ 99 ≥ 99

Water retake Thickness (mm) 4 4

(M.E. D45 1148) (1) Level in % < 30 < 30

No expansion must be observed after the material was subject

Temperature at the beginning of the expansion
to heating at 70 °C for 1 hour.

(1) Requirement according to the agreed value, the tolerance must be ±15% within the considered interval

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5.2. CHARACTERISTICS OF MECHANICAL WORK

FUNCTION FUNCTION

CHARACTERISTICS R100 184 071 R100 437 337

CONDITIONS SUPPORTS or ITEMS TEMPERATURE 15°C at 35°C

FOR APPLICATION PRODUCT TEMPERATURES 15°C à 35°C (Items not concerned with)

APPLICATION BAKING CYCLES (SEE CDC 45-00-201) See chapter 5.2.2

EFFECT ON THE BATHS ME D59 2033 (in the project) Conservation of the features after a possible readjustment of the
bathing parameters. No overfloating liquid.

BEHAVIOR DURING THE SURFACE TREATMENTS GEOMETRY OF THE JOINT Annex 13 (a)
DESCRIBED IN ME 1336
AND ELECTRODEPOSITION

ME.D59 1336 LOSS OF MASS IN % ≤ to 10%

(procedure A)

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5.2.1. Operating temperature

This paragraph refers exclusively to the expansible reinforcing items.

The implementation of welding procedures near or on the expansible reinforcing item may locally heat the material for a short while. On heated wall, this
heating may raise up to 130 °C in 1 minute. It must not cause an excessive bulging of the expansible material, making the correct passage of the
phosphate coatings or of the cataphoresis impossible.

5.2.2. Baking temperature

- Unless otherwise instructed, the expansible reinforcing items must be able to undertake the following baking cycles:

. minimal baking cycle 30 + minimal baking cycle 40 + minimal baking cycle 50,

. minimal baking cycle 30 + minimal baking cycle 40 + minimal baking cycle 50.

- Unless otherwise instructed, the injected reinforcing items must be able to undertake the following baking cycles:

. minimal baking cycle 40 + minimal baking cycle 50,

. minimal baking cycle 40 + minimal baking cycle 50.

- A minimal baking cycle 30 different from those required could be asked for pending on the location of the item on the vehicle and the factory baking
conditions.

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5.3. IDENTIFICATION CHARACTERISTICS

FUNCTION FUNCTION

CHARACTERISTICS R100 184 071 R100 437 337

Volume mass at 23 °C Before baking * *

(M.E. 1163) (1) After baking * *

Module at 10 Hz * *

Visco-analysis from - 70 °C toà 150 °C (1) Damping at 10 Hz * *

Glass transition temperature (Tg °C) * *

COLOR * *
Combustibility (M.E. D45 1333) combustion speed(mm/min) ≤ 100 ≤ 100

(1) This test must be carried out on products before being subject to the minimal and maximal baking conditions.

(*) No special requirement; it must be in accordance with the agreed sample.

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6. CORRELATION BETWEEN THE CODING OF THE FUNCTION AND THE NAME

The usage example is defined in the table below:

CODING OF THE NAME

FUNCTION

R100 184 071 Expansible reinforcing item or injected reinforcing product (interior of
the vehicle)

R100 437 337 Highly expansible reinforcing item

7. OTHER REQUIREMENTS

As other requirements might prove to be necessary, RENAULT reserves the right to complete or
modify, at any time, the present specification book.

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