1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes Ver. 2 2008 08 20 N-STATUS WSK-M4D905-A2, WSK-M4D906-A1/A2 made N-Status, replaced by WSK-M4D905-A1 C. Boese, FNA 1996 01 19 Activated L. Rodigas Page 1 of 8 ABS, HIGH IMPACT STRENGTH EXTRUSION WSK-M4D905-A1 M
2、OLDING COMPOUND ABS, HIGH IMPACT STRENGTH EXTRUSION NOT TO BE USED FOR NEW DESIGN WSK-M4D905-A2 MOLDING COMPOUND, INTERIOR ABS, HIGH HEAT RESISTANT EXTRUSION NOT TO BE USED FOR NEW DESIGN WSK-M4D906-A1 MOLDING COMPOUND ABS, HIGH HEAT RESISTANT EXTRUSION NOT TO BE USED FOR NEW DESIGN WSK-M4D906-A2 MO
3、LDING 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- M4D905-A2 and WSK-M4D906-A2 materials are molded-
4、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 interior body parts such as rear air conditioning duct
5、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 for initial qualification of materials. A Control
6、 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 must be used to analyze process/product data and
7、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. 3.1.1 All requirements of this specification, identi
8、fied 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 conduct infrared and/or thermal analysis of material/
9、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 thermograms that correspond to the reference standar
10、d 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 testing and tested under the same conditions unle
11、ss 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 - 85 C in a mechanical convection oven immediately
12、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 4.0 +/- 0.2 mm (ISO 3167, Type 1A) B. 60 x 60 x 2.
13、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. 3.5.2 Density 1.04 - 1.14 g/cm3 (ISO 1183, Metho
14、d 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-M4D906-A1 & -A2 44 MPa 3.5.3.1 Elongation at Bre
15、ak, 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) WSK-M4D905-A1 & -A2 1.7 GPa WSK-M4D906-A1 & -A2 2.
16、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. Soak time at each temperature interval - 3 minu
17、tes 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 within tolerance range granted on the original materi
18、al 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, 80 x 10 x 4.0 +/- 0.2 mm specimen (use center sect
19、ion 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 & -A2 10 kJ/m2 WSK-M4D906-A1 & -A2 7 kJ/m2 3.5.6.3 At
20、 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 not possible, test may be conducted outside, but w
21、ithin 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 85 C All specimens dry as molded. If not tested im
22、mediately 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 oil, temperature raise 50 +/- 5 C/h. Dial gage r
23、eset 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 silica gel. 3.5.9 Heat Aging Performance (ISO 188, e
24、xcept 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 SPECIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page
25、 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 Formation of a clear film, droplets or crystals is cause
26、 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-M4D906-A2 only) After exposure in accordance with 3.
27、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 chalking will be allowed provided an acceptable appe
28、arance 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 final approval. 3.8.1 Xenon Arc Weatherometer Rating
29、 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 south, under PPG Herculite K, tempered safety glas
30、s, 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 requirements for material and/or manufactured parts shall be
31、 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 materials supplied to this specification must be equi
32、valent 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 specification, whether or not such changes affect the materi
33、als 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 data, test samples and a new code identification ar
34、e 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 MATERIALS Materials defined by this specification mus
35、t 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, the Supplier shall submit to the affected Materi
36、als 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 nominal values), the material designation and code nu
37、mber, 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 will be added to the Engineering Material Approved
38、 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 range - 20 to + 40 C) ENGINEERING MATERIAL SPECIFICAT
39、ION 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 for each test) . After 48 h at 80 C 0.1 - 0.2 % 5.
40、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 - 5 cm3/10 minutes WSK-M4D906-A1 & -A2 2 - 4 cm3
41、/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) WSK-M4D905-A1 & -A2 1.7 GPa WSK-M4D906-A1 & -A2
42、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 SPECIFICATION WSK-M4D905-A1/A2 WSK-M4D906-A1/A2 Page
43、 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 within the cold chamber, if not possible, test may be
44、 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 WSK-M4D905-A1 & -A2 103 C All specimens dry as mol
45、ded. 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 specimen A), flatwise, 0.34 +/- 0.01 mm deflection
46、. 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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