1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2004 10 26 Revised Inserted 3.0; Deleted 3.1, 3.2, 3.3, 3.6, 3.7 & 4 1986 12 09 Revised & Retyped CA01-RD161116 1978 09 11 Released AJ1-6000-41 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 1 of 4 POLYESTER
2、 RESIN, GLASS FIBER REINFORCED - ESB-M3D127-A INJECTION MOLDING COMPOUND 1. SCOPE The material defined by this specification is a glass fiber reinforced polyester resin injection molding compound with good mechanical and thermal resistance properties, excellent moldability and first surface paintabi
3、lity. 2. APPLICATION This specification was released originally for material used to manufacture grille opening panels. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials
4、 (WSS-M99P1111-A). 3.1.1 Process Potential and Capability Short-term process potential study must be conducted using 25 subgroups from one lot, and submitted to the Product Materials Engineering Office prior to production start-up. Long-term process capability study must be conducted using a sample
5、made up of one subgroup from each of 25 production lots, and submitted to the Product Materials Engineering Office. 3.1.2 Standard Deviation Estimate Using the existing sample size, estimate the process standard deviation (the estimate is known as “sigma hat“), found by dividing the average of the s
6、ubgroup ranges (for periods with the ranges in control) by a constant d2 varying by sample size, as shown in the partial table below: n 6 7 8 9 10 d2 2.53 2.70 2.85 2.97 3.08 ENGINEERING MATERIAL SPECIFICATIONESB-M3D127-APrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC P
7、age 2 of 4 3.4 MOLDED TEST SPECIMENS 3.4.1 Preparation of Test Specimens 3.4.1.1 Preparation of Test Specimens for Short-term Process Potential Study All test specimens shall be prepared from injection molded plaques with a thickness of 2.54 +/- 0.25 mm. Prepared specimens must show no evidence of f
8、iber tear or loose fiber strands protruding from the specimens. In each of the following tests (para 3.4.10, 3.4.11, 3.4.12 and 3.4.13) a minimum of 6 specimens are to be evaluated. Three of the specimens are to be oriented in any one direction with the other three perpendicular to the first set. Th
9、e numerical average of the 6 specimens shall meet the minimum average 3.4.1.2 Preparation of Test Specimens for Long-term Process Capability Study All test specimens shall be prepared from injection molded production parts or from injection molded plaques formed in the mold with the production part.
10、 When tests are required on molded production parts, the location from which test specimens are to be taken will be shown on the engineering drawing. When no location for testing is specified, test specimens shall be taken from random locations on the part where the dimensions, shape and size permit
11、 fabrication of test specimens for evaluation by the specified method. A minimum of 6 specimens are to be evaluated in each subgroup to meet the requirements of 3.4.10 (Tensile Strength). 3.4.2 Color Natural or as specified on the engineering drawing. 3.4.3 Glass Fiber Content, by weight, 20% Averag
12、e min Test Method: Weigh each of three 645 mm2test specimens randomly selected from different locations (at least 150 mm apart) on the test plaque or part. Place the specimens in tared crucibles and ignite in a muffle furnace maintained at 425 +/- 5 C for 30 min. Increase temperature to 650 +/- 28 C
13、 for 60 min. Cool slowly to 23 +/- 2 C and weigh the residues. Boil the glass fibers and filler residue in a 5% by volume hydrochloric acid solution for 15 min. If the hydrochloric acid solution does not completely dissolve the filler residue, alternate reagents should be used until all fillers are
14、removed. Rinse the glass fibers several times with distilled water before drying in an oven for 2 h at 120 +/- 2 C. After cooling, weigh the crucibles and calculate the percent fiberglass as follows: Wt. % Glass Fbr. = wt. of washed glass fibers residue x 100 original wt. of specimen Note: Those sup
15、pliers who determine percent glass fiber content by volume must convert this value to percent by weight. ENGINEERING MATERIAL SPECIFICATIONESB-M3D127-APrinted copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 3 of 4 3.4.4 Glass Fiber Length, min 9.6 mm 3.4.5 Filler Content,
16、by weight, max 50% Test Method: Conduct on specimens used in glass fiber content determination (para 3.4.3). 3.4.6 Specific Gravity, max 1.8 (ASTM D 792) 3.4.7 Water Absorption, max 1.3% (ASTM D 570, 24 h immersion) 3.4.8 Hardness, Rockwell M, min 55 (ASTM D 785) 3.4.9 Hardness, Barcol, min 35 (ASTM
17、 D 2583) 3.4.10 Tensile Strength, Subgroup Average, min 9.2 MPa (ASTM D 638, 5 mm/min test speed) 3.4.11 Flexural Modulus, Subgroup Average, min 6.3 GPa (ASTM D 790, tangent, 25 mm specimen width) 3.4.12 Flexural Strength, Subgroup Average, min 55 MPa (ASTM D 790, 25 mm specimen width) 3.4.13 Impact
18、 Strength, Izod, Subgroup Average, min (ASTM D 256, Method A) 3.4.13.1 Notched 29 J/m 3.4.13.2 Unnotched 28 J/m (No notch on either side) 3.5 MOLDED PARTS The following test requirements are applicable to full size molded parts and/or test specimens cut from molded parts. All critical areas with res
19、pect to these properties shall be clearly designated on the engineering drawing. If no specific test location is indicated, the requirement shall apply to any area of the finished part, and test specimens with suitable dimensions to conduct the specified test shall be randomly selected, and must mee
20、t the minimum requirements indicated. 3.5.1 Paintability Molded parts shall be processed in keeping with the best commercial practice to insure good paintability, i.e., “as molded“ surface shall be free of contaminants which would affect paint adhesion, when painted in accordance with released Ford
21、Motor Company specifications for painting fiberglass reinforced polyester plastics. Exterior, highly visible parts which are furnished primed, or fully painted shall conform to the requirements of Engineering Performance Specifications ESB-M2P7-B1. ENGINEERING MATERIAL SPECIFICATIONESB-M3D127-APrint
22、ed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 4 of 4 3.5.2 Heat Resistance Test Method: Expose samples in a mechanical convection oven to achieve a surface temperature of 204 C for 30 min. 3.5.2.1 Unpainted Parts Shall not exhibit any surface imperfections such as bli
23、sters, pits, dry spots or cracks, etc. Surface imperfections shall be determined using a red concentrate dye in oil suspension (Magnaflux Corporation No. 9CM or equivalent). 3.5.2.2 Painted Parts Shall not exhibit any surface cracking, pitting, warpage or blistering of any type. 5. GENERAL INFORMATI
24、ON The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 SPECIFICATION REFERENCE ESB-M2P7-B1 - “Paint Performance - High Visibility Plastic Parts - Exterior“ 5.2 COEFFICIENT OF LINEAR THERMAL EXPANSION 1.8 - 3.2 x 10-5/ C (AST
25、M D 696) 5.3 MOLD SHRINKAGE 0.000 (ASTM D 955) 5.4 TARGET VALUE Target Value indicates the single value of the characteristic that is expected to yield the best downstream results, considering both processing needs and end-item customer satisfaction. The numbers represented below signify a reasonabl
26、e achievable goal for the supplier to strive for in an effort to maintain or improve on the quality of the product. 5.4.1 Tensile Strength, Target Value 25 MPa (ASTM D 638, 5 mm/min test speed) 5.4.2 Flexural Strength, Target Value 74 MPa (ASTM D 790, 25 mm specimen width) 5.4.3 Impact Strength, Izod, Target Value (ASTM D 256, Method A) 5.4.3.1 Notched 158 J/m 5.4.3.2 Unnotched 157 J/m (No notch on either side)
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