1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions Rev. 5 2012 01 26 N Status WSK-M4D906-A1 replaced by WSS-M4D906-B1 A. Pan, APA 2010 01 06 Revised WSK-M4D906-A1 removed N-STATUS per resin strategy. A. Pan, APA 1996 01 19 Activated L. Rodigas Page 1 of 8 AB
2、S, HIGH IMPACT STRENGTH EXTRUSION WSK-M4D905-A1 MOLDING COMPOUND ABS, HIGH IMPACT STRENGTH EXTRUSION NOT TO BE USED FOR NEW DESIGN WSK-M4D905-A2 MOLDING COMPOUND, INTERIOR ABS, HIGH HEAT RESISTANT EXTRUSION WSK-M4D906-A1 MOLDING COMPOUND NOT TO BE USED FOR NEW DESIGN ABS, HIGH HEAT RESISTANT EXTRUSI
3、ON NOT TO BE USED FOR NEW DESIGN WSK-M4D906-A2 MOLDING COMPOUND, INTERIOR 1. SCOPE The materials defined by these specifications are vacuum formable high impact (WSK-M4D905-A1 & -A2) and high heat (WSK-M4D906-A1 & -A2) extrusion molding compounds based on acrylonitrile/butadiene/styrene (ABS). WSK-
4、M4D905-A2 and WSK-M4D906-A2 materials are molded-in-color with low gloss surfaces, and are able to fulfill weathering requirements necessary for visible interior applications. 2. APPLICATION These specifications were released originally for material used for various extruded and/or coextruded interi
5、or body parts such as rear air conditioning duct assemblies, claddigs, door trim and/or quarter trim panels. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used
6、for initial qualification of materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools
7、must be used to analyze process/product data and assure consistent processing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. 3.1
8、.1 All requirements of this specification, identified by symbol (s), shall be met with data representing 3 sigma values. ENGINEERING MATERIAL SPECIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page 2 of 8 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may cond
9、uct 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 standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and the
10、rmograms 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 conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to
11、testing and tested under the same conditions unless otherwise specified. 3.4 MOLDING COMPOUND (s) 3.4.1 Melt Flow Rate (ISO 1133, 220 C, 10 kg) WSK-M4D905-A1 4 - 9 g/10 minutes WSK-M4D905-A2 2 - 5 g/10 minutes WSK-M4D906-A1 & A2 2 - 5 g/10 minutes The material shall be dried for 2 h minimum at 80 -
12、85 C in a mechanical convection oven immediately preceding the test. 3.5 MOLDED TEST SPECIMEN 3.5.1 Preparation of Test Specimens Unless otherwise specified all tests shall be carried out on injection molded one-end gated test specimens. The following dimensions are required: A. 150 minimum x 10 x 4
13、.0 +/- 0.2 mm (ISO 3167, Type 1A) B. 60 x 60 x 2.0 +/- 0.1 mm (ISO/DIS 294-3) C. 355 x 100 x 1.9 +/- 0.1 mm (ISO 3795) Test specimen A shall be molded using molding conditions defined in ISO 3167. Specimens with shorter dimensions shall be cut from the center of the specimen A. No annealing allowed.
14、 3.5.2 Density 1.04 - 1.14 g/cm3 (ISO 1183, Method A) ENGINEERING MATERIAL SPECIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page 3 of 8 (s) 3.5.3 Tensile Strength at Yield, min (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen, test speed: 50 mm/minute) WSK-M4D905-A1 & -A2 32 MPa WSK
15、-M4D906-A1 & -A2 44 MPa 3.5.3.1 Elongation at Break, min (Test Method according to para 3.5.3) WSK-M4D905-A1 & -A2 50 % WSK-M4D906-A1 & -A2 40 % (s) 3.5.4 Flexural Modulus, min (ISO 178, 80 x 10 x 4.0 +/- 0.2 mm specimen, (use center section of specimen A), 2 mm/min test speed, 64 mm support span) W
16、SK-M4D905-A1 & -A2 1.7 GPa WSK-M4D906-A1 & -A2 2.2 GPa 3.5.5 Shear Modulus at 23 C (ASTM D 5279, forced constant amplitude, fixed frequency of 1 Hz +/- 15 %, strain level below 1 %. Specimen approx. 60 x 10 x 4.0 +/- 0.2 mm cut from the center of specimen A. Specimen length between clamps 35 - 40 mm
17、. Soak time at each temperature interval - 3 minutes minimum) WSK-M4D905-A1 & -A2 0.57 - 0.73 GPa WSK-M4D906-A1 & -A2 0.8 - 1.20 GPa Additionally, shear modulus versus temperature curves shall be plotted for - 50 to + 120 C temperature range, at 5 C minimum intervals. The plotted curves must be with
18、in tolerance range granted on the original material approval and it shall constitute the reference standards for materials supplied to these specifications and shall be kept on file at the designated material laboratory and be available on request. (s) 3.5.6 Impact Strength, Izod, min (ISO 180/1A, 8
19、0 x 10 x 4.0 +/- 0.2 mm specimen (use center section of specimen A), 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C WSK-M4D905-A1 & -A2 30 kJ/m2 WSK-M4D906-A1 & -A2 20 kJ/m2 ENGINEERING MATERIAL SPECIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page 4 of 8 3.5.6.2 At - 40 +/- 2 C WSK-M4D905-A1 & -A
20、2 10 kJ/m2 WSK-M4D906-A1 & -A2 7 kJ/m2 3.5.6.3 At 0 +/- 2 C WSK-M4D905-A1 & -A2 22 kJ/m2 WSK-M4D906-A1 & -A2 10 kJ/m2 The 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 chamber, if n
21、ot possible, test may be conducted outside, but within 5 seconds. (s) 3.5.7 Heat Deflection Temperature, min (ISO 75-1 & ISO 75-2, 120 x 10 x 4.0 +/- 0.2 mm specimen (use center section of specimen A), edgewise, 0.32 +/- 0.01 mm deflection. At 1.80 MPa) WSK-M4D905-A1 & -A2 70 C WSK-M4D906-A1 & -A2 8
22、5 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 (ISO 306, 10 x 10 x 4.0 +/- 0.2 mm specimens (use center section of specimen A). Bath - silicone
23、 oil, temperature raise 50 +/- 5 C/h. Dial gage reset to 0 after addition 5 kg weight. At 50 N load) WSK-M4D905-A1 & -A2 89 C WSK-M4D906-A1 & -A2 105 C All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with sil
24、ica gel. 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, Change +/- 20 % (Test Method per para 3.5.3) ENGINEERING MATERIAL SPE
25、CIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page 5 of 8 3.5.9.2 Impact Strength, Izod Change, max - 35 % (Test Method per para 3.5.6.1, specimens to be notched before heat aging) 3.6 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h) Fog Number, min 90 Formati
26、on of a clear film, droplets or crystals is cause for rejection. 3.7 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355 x 100 x 1.9 +/- 0.1 mm (use specimen C) with a smooth surface. 3.8 WEATHERING RESISTANCE (WSK-M4D905-A2 & WSK-M4D
27、906-A2 only) After exposure in accordance with 3.8.1 and 3.8.2 the material shall show no fading or 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 cha
28、lking will be allowed provided an acceptable appearance can be achieved by washing with mild detergents and water (ratio 5:95 by volume), or equivalent, after the Florida exposure. All initial approvals will be based on the preliminary Weatherometer exposure, pending Florida exposure results for fin
29、al approval. 3.8.1 Xenon Arc Weatherometer Rating 4 (SAE J1885, except Black Panel Temperature at 80 C, 300 kJ/m2 exposure minimum, specimen size: 60 x 60 mm minimum, 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen). 3.8.2 12 months Florida Rating 4 (FLTM BI 160-01, 5 deg s
30、outh, under PPG Herculite K, tempered safety glass, 3 mm thick. Specimen size: 60 x 60 minimum, 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen) ENGINEERING MATERIAL SPECIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page 6 of 8 3.9 ADDITIONAL REQUIREMENTS Specific requirement
31、s for material and/or manufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or performance specification. All critical areas with respect to these properties shall be clearly designated on the engineering drawing. 3.10 SUPPLIERS RESPONSIBILITY All mate
32、rials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specificati
33、on, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test da
34、ta, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Materials Specification WSS-M99P9999-A1. 4. APPROVAL OF MATE
35、RIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request,
36、 the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification (test results, not nomi
37、nal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the material w
38、ill be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 7 - 10E-5/ C (ASTM E 831 TMA, temperature rang
39、e - 20 to + 40 C) ENGINEERING MATERIAL SPECIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page 7 of 8 5.2 MOLD SHRINKAGE (ISO/DIS 294-3, 60 x 60 x 2.0 +/- 0.1 mm injection molded specimen) 5.2.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.5 - 0.8 % 5.2.2 Post Shrinkage (Separate specimens required f
40、or each test) . After 48 h at 80 C 0.1 - 0.2 % 5.3 MELT VOLUME RATE (ISO 1133, 220 C, 10 kg, extrudate volume in cm3/10 minutes) The material shall be dried for 2 h minimum at 80 - 85 C in a mechanical convection oven immediately preceding the test. WSK-M4D905-A1 4 - 9 cm3/10 minutes WSK-M4D905-A2 2
41、 - 5 cm3/10 minutes WSK-M4D906-A1 & -A2 2 - 4 cm3/10 minutes Note: The material shall be dried for 2 h minimum at 80 - 85 C in a mechanical convection oven immediately preceding the test. 5.4 MODULUS OF ELASTICITY (ISO 527-1 & 527-2, 150 minimum x 10 x 4 +/- 0.2 mm specimen, test speed: 1 mm/minute)
42、 WSK-M4D905-A1 & -A2 1.7 GPa WSK-M4D906-A1 & -A2 tbd GPa 5.5 IMPACT STRENGTH, CHARPY (ISO 179/leA, 80 x 10 x 4.0 +/- 0.2 mm specimen (use center section of specimen A), 10 specimens for each test) 5.5.1 At 23 +/- 2 C WSK-M4D905-A1 & -A2 19 kJ/m2 WSK-M4D906-A1 & -A2 tbd kJ/m2 ENGINEERING MATERIAL SPE
43、CIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page 8 of 8 5.5.2 At - 40 +/- 1 C WSK-M4D905-A1 & -A2 tbd kJ/m2 WSK-M4D906-A1 & -A2 tbd kJ/m2 The test specimens must be conditioned for minimum of 6 hours at the above specified temperature prior to impact test. Low temperature testing shall be done with
44、in the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 5.6 HEAT DEFLECTION TEMPERATURE, min (ISO 75-1 & ISO 75-2, 120 x 10 x 4.0 +/- 0.2 mm specimen (use center section of specimen A), edgewise, 0.32 +/- 0.01 mm deflection. At 0.45 MPa) WSK-M4D905-A1 & -A2 100 C W
45、SK-M4D905-A1 & -A2 103 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. 5.7 HEAT DEFLECTION TEMPERATURE, min (ISO 75-1 & ISO 75-2, 120 x 10 x 4.0 +/- 0.2 mm specimen (use center section of s
46、pecimen A), flatwise, 0.34 +/- 0.01 mm deflection. At 1.80 MPa) WSK-M4D905-A1 & -A2 tbd C WSK-M4D906-A1 & -A2 tbd 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. 5.8 GLOSS LEVEL tbd Test method under development. 5.9 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES ABS
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