1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2010 01 13 N-STATUS No replacement named J. Crist, NA 1993 11 02 EP00E10258829000 Completely Revised L. Rodigas 1990 09 03 EP00E01031530000 Released P. Kuntze WP 3948-a Page 1 of 8 POLYCARBONATE + POLYBUTYLENE
2、 TEREPHTHALATE WSK-M4D763-A2 BLEND (PC+PBT), MODIFIED, EASY FLOW MOLDING COMPOUND, EXTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a UV stabilized, cold impact and gasoline resistant easy flow polycarbonate + polybutylene terephthalate blend molding comp
3、ound for exterior use. 2. APPLICATION This specification was released originally for material used for self- colored bumper shells. 3. REQUIREMENTS 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as describe
4、d therein is required for material/source approval. Appropriate statistical tools must be used to analyze process/product data so that variation in the final product is continuously reduced. 3.1.1 All requirements of this specification, identified by symbol (s), shall be met with data representing 3
5、 sigma values. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference stand
6、ard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material condi
7、tioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. ENGINEERING MATERIAL SPECIFICATION WSK-M4D763-A2 WP 3948-b Page 2 of 8 3.4 MOLDING COMPOUND (s) 3.4.1 Melt Flow Ra
8、te (ISO 1133) 3.4.1.1 250 C, 5 kg 26 - 45 g/10 minutes 3.4.1.2 250 C, 2.16 kg 9 - 16 g/10 minutes The material shall be dried for 2 h minimum at 120 - 125 C in a mechanical convection oven immediately preceding the test. 3.5 MOLDED TEST SPECIMEN 3.5.1 Preparation of Test Specimens Unless otherwise s
9、pecified all tests shall be carried out on injection molded one-end gated test specimens. The following dimensions are required: A. 150 min x 10 x 4.0 +/- 0.2 mm (Tensile Bar, ISO 3167) B. 120 x 10 x 4.0 +/- 0.2 mm Specimens with shorter dimensions shall be cut from the center portion of the test sp
10、ecimen A and/or B. The specimens shall be prepared according to ISO 294. No annealing allowed. 3.5.2 Density 1.20 - 1.28 g/cm3(ISO 1183, Method A) (s) 3.5.3 Tensile Strength at Yield, min 48 MPa (ISO R 527, 150 min x 10 x 4.0 +/- 0.2 mm specimen, 50 mm/minute) 3.5.3.1 Elongation at Break, min 65 % (
11、Test Method according to para 3.5.3) (s) 3.5.4 Flexural Modulus, min 1.9 GPa (ISO 178, 80 x 10 x 4.0 +/- 0.2 mm specimen, 64 mm support span) 3.5.5 Shear Modulus at 23 C 0.53 - 1.1 GPa (ASTM D 4065, forced constant amplitude, fixed frequency of 1 Hz +/- 15 %, strain level below 1 %. Specimen approx.
12、 60 x 10 x 4.0 +/- 0.2 mm cut from the center of specimen A. Specimen length between clamps 35-40 mm. Soak time at each temperature interval - 3 minutes minimum) Additionally, a Shear Modulus vs. Temperature curve shall be plotted for - 50 to + 160 C temperature range, at 5 C minimum intervals. The
13、plotted curve must be within tolerance range shown on page 8. ENGINEERING MATERIAL SPECIFICATION WSK-M4D763-A2 WP 3948-b Page 3 of 8 (s) 3.5.6 Impact Strength, Izod, min (ISO 180/1A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C 36 kJ/m23.5.6.2 At - 40 +/- 2 C
14、12 kJ/m23.5.6.3 At 0 +/- 2 C 32 kJ/m2The test specimens must be conditioned for minimum of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box. (s) 3.5.7 Heat Deflection Temperature, min (ISO 75, 120 x 10 x 4.0 +/- 0.2 mm specimen, 0
15、.32 +/- 0.01 mm deflection) 3.5.7.1 At 1.80 MPa 65 C 3.5.7.2 At 0.45 MPa 100 C All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. (s) 3.5.8 Vicat Softening Temperature, min 117 C (ISO 306, 10 x
16、10 x 4.0 +/- 0.2 mm specimens. Bath - silicone oil, temp. raise 50 +/- 5 C/h. Dial gage reset to 0 after addition of 5 kg weight. At 50 N load) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel.
17、 3.5.9 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 80 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.5.9.1 Tensile Strength at Yield, +/- 20 % Change (Test Method per para 3.5.3) 3.5.9.2 Impact Strength, Izod Ch
18、ange +/- 30 % (Test Method per para 3.5.6.1, specimens to be notched before heat aging) ENGINEERING MATERIAL SPECIFICATION WSK-M4D763-A2 WP 3948-b Page 4 of 8 3.6 CHEMICAL RESISTANCE Conduct all tests according to ISO 4599/SAE J2016, except use specimens A defined in para 3.5.1. Test temperature 23
19、+/- 2 C, 0.7 +/- 0.02 % strain. Minimum of 10 specimens for each test. 3.6.1 Immersion in 85 % Fuel C + 15 % Methanol (Test fluid according to ISO 1817) 3.6.1.1 Elongation at Break, min 65 % Test according to para 3.5.3 after 5 minutes immersion, followed by 25 - 30 minutes waiting period after remo
20、val from the test fluid. 3.6.2 Immersion in Dewaxing Fluid (EAO, applicable if required only) (Test fluid according to U-MB 005-8000 (FOG) and U-MB 005-8001 (FOB) 3.6.2.1 Elongation at Break, min 65 % Test according to 3.6.1, except immersion time 120 minutes; use 2 fluids. 3.7 WEATHERING RESISTANCE
21、 After exposure in accordance with 3.7.1, 3.7.2 and 3.7.3, the material shall show no color change in excess of specified Gray Scale rating (AATCC Evaluation Procedure 1/ISO 105-A02). In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss or chalking will be
22、allowed provided an acceptable appearance can be achieved by washing and/or polishing with Ford car polish (auto wax) after the outdoor exposure, at permission of the affected Product Development Materials Activity. All initial approvals will be based on the preliminary Weatherometer exposure, pendi
23、ng Florida and Arizona exposure results for final approval. 3.8.1 Xenon Arc Weatherometer Rating 4 (SAE J1960, 660 kJ/m2exposure minimum, specimen size: 150 x 100 mm minimum, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) 3.8.2 12 months Florida Rating 4 12 months Arizona (NAAO only) (SAE J19
24、76, 5 south, direct weathering inland, specimen size: 150 x 100 mm, minimum, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) ENGINEERING MATERIAL SPECIFICATION WSK-M4D763-A2 WP 3948-b Page 5 of 8 3.8.3 24 months Florida Rating 3-4 24 months Arizona (NAAO only) (SAE J1976, 5 south, direct weath
25、ering inland, specimen size: 150 x 100 mm, minimum, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) 3.8 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or performance specifi
26、cations. All critical areas with respect to these properties shall be clearly designated on the Engineering drawing. 3.9 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior t
27、o making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicol
28、ogy and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, a
29、pply to the materials addressed by this document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approv
30、al of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified
31、and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be bas
32、ed on its performance to this specification and on an assessment of suitability for intended process and/or application. Upon approval, the material will be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information below is provided for clarification and assistan
33、ce in meeting the requirements to the specification. 5.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 10 - 12E-5/C (ASTM E 228 or TMA, temperature range - 40 to + 100 C) ENGINEERING MATERIAL SPECIFICATION WSK-M4D763-A2 WP 3948-b Page 6 of 8 5.2 MOLD SHRINKAGE (ISO 2577, approx. 150 x 100 x 3.2 +/- 0.2 mm
34、 injection molded specimen) 5.2.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.6 - 1.4 % 5.2.2 Post Shrinkage (Separate specimens required for each test) . After 48 h at 80 C 0.1 - 0.7 % . After 30 min at 120 C 0.6 - 1.1 % 5.3 MELT VOLUME RATE (ISO 1133) 5.3.1 250 C, 5 kg 24 - 43 cm3/10 minutes 5.
35、3.2 250 C, 2.16 kg 8 - 15 cm3/10 minutes Note: The material shall be dried for 2 h minimum at 120 - 125 C in a mechanical convection oven immediately preceding the test. 5.4 MELT VISCOSITY 190 - 270 Pa.s (ASTM D 3035, Capillary Rheometer Capillary 1 mm diameter L/D = 30 temperature: 260 C shear rate
36、: 1.5E3 s-1) The material shall be dried for min 2 h at 120 - 125 C in a mechanical convection oven immediately prior to testing. 5.5 USE OF REGRIND MATERIAL (Property values of regrind material shallbe compared with original virgin material. Regrind: compound of 20 weight % regrind based on single
37、reprocessed material, free of contaminations and 80 weight % virgin material) 5.5.1 Melt Flow Rate Change, max + 30 % (Test method per para 3.4.1.1 and 3.4.1.2) 5.5.2 Tensile Strength at Yield Change +/- 10 % (Test method per para 3.5.3) 5.5.3 Flexural Modulus Change +/- 10 % (Test method per para 3
38、.5.4) 5.5.4 Impact Strength, Izod Change, max - 10 % (Test method per para 3.5.6.1) 5.5.5 Heat Deflection Temperature Change +/- 10 % (Test method per para 3.5.7.1) ENGINEERING MATERIAL SPECIFICATION WSK-M4D763-A2 WP 3948-b Page 7 of 8 5.5.6 Weathering Resistance 5.5.6.1 Xenon Arc Weatherometer Rating 4 (Test method per para 3.8.1) 5.5.6.2 12 Months Florida tbd (Test method per para 3.8.2) 5.5 RECYCLING CODE PC+PBT ENGINEERING MATERIAL SPECIFICATION WSK-M4D763-A2 WP 3948-b Page 8 of 8
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