1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 01 25 Revised Completely Revised V. Cerato and Global Material Team1994 09 01 Revised Completely revised EP00E10348605000 L. Rodigas 1990 06 01 Released EP00E01031536000 P. Kuntze Printed copies are uncontrolled Copyright 2010, Ford Globa
2、l Technologies, LLC Page 1 of 12 EXTERIOR PLASTICS LAMP ASSEMBLY PERFORMANCE WSK-M98P10-A 1. SCOPE This specification defines the performance requirements for exterior lamp assemblies. 2. APPLICATION This specification was released originally to define the materials performance requirements for exte
3、rior lamp assemblies such as front and rear lamps and licence plate lamps. 2.1 LIMITATIONS All painted exterior components shall meet the requirements of WSS-M2P180-latest for rigid substrates, WSS-M2P181-latest for flexible substrates and WSS-M1P83-latest for chrome plated rigid substrates. All cle
4、ar protective top coating for transparent plastic parts shall meet, WSS-M80J6-latest. When specific properties of a coated substrate are not covered by these referenced performance specifications, test methods within this specification may be applied for exterior lamp assembly only. 2.1.1 Materials
5、used in all systems shall withstand a paint repair surface temperature of 115C for 20 minutes without deformation, functional damage or loss of appearance or other specified physical characteristics. If material cannot meet this requirement it must be capable of being protected, e.g., with shielding
6、, during repair processing of the vehicle. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Produc
7、tion Materials (WSS-M99P1111-A). This specification was developed using virgin material properties, however materials with recycled content as defined by WSS-M99P42-A (post-consumer and/or post industrial recyclates and repolymerised recycled materials) should be used whenever technically feasible a
8、nd following all materials and PV testing required by Ford Materials Engineering. The use of regrind is permitted, for economic/environmental reasons, with compliance as indicated in WSS-M99P1111-A. ENGINEERING MATERIAL SPECIFICATIONWSK-M98P10-A Printed copies are uncontrolled Copyright 2010, Ford G
9、lobal Technologies, LLC Page 2 of 12 3.2 FINISHED PARTS Unless otherwise indicated, testing must be done on actual production parts or a section of the part whenever possible. Where part dimensions limit equipment access, representative panels or plaques may be substituted for production parts. Test
10、ing must be conducted at Design Verification (DV) and Product Validation (PV) per Table 1.0, unless otherwise agreed to by Ford Materials Engineering. Tests according to para 3.6, 3.8, 3.9, 3.10, 3.13, 3.17, 3.25 shall be carried out on the finished part mounted as assembled in the vehicle in a suit
11、able device. 3.3 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to analyse process/product data so that
12、variation in the final product is continuously reduced. 3.4 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared spectroscopy (IR) and/or thermal analysis (TGA) of material/parts supplied to this specification. The IR spectra and thermograms esta
13、blished 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 standard when tested under the same conditions. 3.5 CONDITIONING AND TEST CONDIT
14、IONS The part shall be conditioned for a minimum of 24 h at 23 +/- 2 C and 50 +/- 5% relative humidity prior to test and tested under the same conditions unless otherwise specified. Painted parts shall be aged 16 h at 45 +/- 2 C or 72 h at 23 +/- 2 C prior to above conditioning unless otherwise spec
15、ified. 3.6 ADHESION (For painted, hot stamped, laminated and metallised areas on the finished part) Adhesion shall be tested on the original part and 15 to 30 min after the relevant ageing tests according to para 3.7, 3.8, 3.10, 3.14, 3.18, 3.23. Test Methods: One of the following test conditions sh
16、all be defined according to the application and shown on the Engineering Drawing. 3.6.1 Coating Adhesion No chipping (FLTM BI 106-01, Method C) 3.6.2 Peel Strength, min 15 N/25 mm (ASTM D 1000, Method A) 3.6.3 Visual Evaluation The finished part shall show no evidence of blisters or delamination. EN
17、GINEERING MATERIAL SPECIFICATIONWSK-M98P10-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 12 3.7 HEAT AGING The finished part shall show no visible evidence of warpage, deformation, cracks, delamination or other failures to an extent that would affect its u
18、se in the ultimate assembly. There shall be no local shrinkage where the part has been gated which would interfere with assembly to related parts, or affect its appearance. The finished part shall show no change in appearance when compared with the original part. In addition, there shall be no chang
19、e in light reflectance and transmittance as specified on the Engineering Drawing. Test Methods: One of the following test conditions shall be defined according to the application and shown on the Engineering Drawing. 3.7.1 Short 3.7.1.1 Condition A Mount the finished part according to vehicle instal
20、lation on a suitable fixture and place it in car position in a mechanical convection oven maintained at 95 +/-2 C for 3 hrs. After heat exposure allow samples to cool to 23 +/-2 C for a minimum of 1 hr prior to evaluation. 3.7.1.2 Condition B As under para 3.7.1.1, except use the unmounted part. 3.7
21、.1.3 Condition C As under para 3.7.1.1, except maintain part at test temperature as specified on the Engineering Drawing. 3.7.1.4 Condition D As under para 3.7.1.1, except maintain the unmounted part at test temperature as specified on the Engineering Drawing. 3.7.2 Extended 3.7.2.1 Condition A Moun
22、t the finished part according to vehicle installation on a suitable fixture and place it in car position in a mechanical convection oven maintained at 80 +/- 2 C for 7 days. Evaluate after conditioning for 24 h at 23 +/- 2 C. 3.7.2.2 Condition B As under para 3.7.2.1, except use the unmounted part.
23、ENGINEERING MATERIAL SPECIFICATIONWSK-M98P10-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 12 3.7.2.3 Condition C As under para 3.7.2.1, except maintain part at test temperature as specified on the Engineering Drawing. 3.7.2.4 Condition D As under para 3.7
24、.2.1, except maintain the unmounted part at test temperature as specified on the Engineering Drawing. 3.8 ENVIRONMENTAL CYCLING (FLTM BQ 104-07) The finished part shall show no visible evidence of warpage, deformation, cracks, delamination or other failures to an extent that would affect its use in
25、the ultimate assembly. The finished part shall show no changes in appearance when compared with the original finished part. Unless otherwise noted, the cycled part shall show no color change in excess of Grey Scale rating 4 (AATCC Evaluation Procedure 1/ISO 105-A02) when compared with the original p
26、art. (A color tone shift to the yellow direction is allowed up to Grey Scale rating 4. No other tone change (e.g. pink) is allowed. No visible cracks, blisters, softening, dulling, or evidence of material degradation when observed with the unaided eye from a distance of 300 +/- 30 mm. In addition th
27、ere shall be no change in light reflectance and transmittance as specified on the Engineering Drawing. The adhesion of the individual surface coating shall meet the requirements of para 3.6. Test Methods: One of the following test conditions shall be defined according to the application and shown on
28、 the Engineering Drawing. 3.8.1 Condition A (FLTM BQ 104-07, Procedure 1) The finished part shall be mounted as assembled in the vehicle in a suitable device before testing. For examination disregard the area of the reflex - reflector. 3.8.2 Condition B Same as para 3.9.1, except temperature as spec
29、ified on Engineering drawing. 3.9 RESISTANCE TO COLD IMPACT After test the finished part shall show no breaks, cracks, delamination or other failures. Test Methods: One of the following test conditions shall be defined according to the application and shown on the Engineering Drawing. ENGINEERING MA
30、TERIAL SPECIFICATIONWSK-M98P10-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 12 3.9.1 Condition A The finished part shall be mounted as assembled in the vehicle in a suitable device and stored for 16 h at - 40 +/- 2 C . Remove part from cold box and within
31、 5 s after removal drop a steel ball of 225 +/- 5 g and approximately 38 mm in diameter onto the test sample from a height of 300 mm. The impact shall be carried out on areas regarded as most vulnerable. Examination shall be done after conditioning to 23 +/- 2 C. 3.9.2 Condition B Same as para 3.10.
32、1, except at 23 +/- 2 C and a height of 200 mm. 3.9.3 Condition C Same as para 3.10.1, except height as specified on the Engineering Drawing. 3.10 SHOCK TEST The finished part shall show no breaks, cracks or other failures. The adhesion of the individual surface coating shall meet the requirements o
33、f para 3.6. Test Method: The finished part or a section of it shall be maintained at - 40 +/- 2 C for 16 h. Then immediately immerse part in water at 70 +/- 2 C for 5 minutes. Evaluate after conditioning to 23 +/- 2 C/ 3.11 SALT SPRAY RESISTANCE (for metallised areas only) (ASTM D 117, 240 h or as s
34、pecified on the Engineering Drawing) The part shall not show any surface changes, loss of gloss or adhesion. The adhesion of the individual surface shall meet the requirements of para 3.6. 3.12 HUMIDITY (ASTM D 2247, 3 cycles) 1 cycle consists of the following: 8 h at 38 +/- 2 C and 98 +/- 2% relati
35、ve humidity 16 h at 23 +/- 2 C The adhesion of the individual surface coating shall meet the requirements of para 3.6. 3.13 RESISTANCE TO HEAT WARPAGE (applicable to finished assembly to be stored or shipped) The finished part shall be mounted in a text fixture on its seating plane in its design ope
36、rating condition and design mounting position and then expose to 1 cycle as detailed: 2h at 70 +/- 2 C 500h at 60 +/- 2C and 90 +/- 2% relative humidity ENGINEERING MATERIAL SPECIFICATIONWSK-M98P10-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 12 The finis
37、hed part shall show no visible evidence of warpage, deformation, cracks, delamination or other failures to an extent that would affect its use in the ultimate assembly. There shall be no local shrinkage where the part has been gated which would interfere with assembly to related parts, or affect its
38、 appearance. The finished part shall show no change in appearance when compared with the original part. In addition, there shall be no change in light reflectance and transmittance as specified on the Engineering Drawing. 3.14 WEATHERING (Applicable to parts using materials without previous weatheri
39、ng approval) After exposure the part shall show no fading or color change in excess of specified AATCC rating (AATCC Gray Scale for Evaluating change in color(Procedure 1 / ISO 105-A02). In addition, there shall be no cracking, crazing or other deterioration. All initial approvals will be based on t
40、he preliminary weatherometer exposure (para 3.14.1), pending natural exposure results for final approval. 3.14.1 Accelerated Xenon Arc Weatherometer Rating 4 (SAE J2527, modified type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant exposure 3000 hrs exposure, specimen size: 60x60 min x0.
41、2 + / - 0.1mm) as defined on Engineering Drawing All colour submissions required. 3.14.2 Natural weathering (Applicable for pigmented materials, laminated, painted or hot stamped areas on the finished part) Rating 4 New resin Technology only 1 and 2 years required (SAE J1976, Procedure A) 3.14.3 The
42、 material must withstand an outdoor exposure in accordance with SAE J576, certified by an approved test laboratory. Applicable to uncoated equipments for signaling operation such as transparent lenses and reflective devices. 3.15 RESISTANCE TO HOT WATER HIGH PRESSURE CLEANING (Applicable to painted,
43、 laminated, hot stamped or metallised areas only) (FLTM BO 160-04) After test the finished part shall show no delamination of surface coating or other surface failures. ENGINEERING MATERIAL SPECIFICATIONWSK-M98P10-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 7
44、 of 12 3.16 RESISTANCE TO STONE CHIPPING Rating 1 (Applicable to painted and coated, laminated hot stamped or metallised areas only) (FLTM BI 157-02, Method B, or as defined on except water immersion shall Eng. Drawing be omitted) 3.17 RESISTANCE TO WATER IMMERSION 240 h (FLTM BI 104-01) or as defin
45、ed on Eng. Drawing The part shall not show any surface changes, loss of gloss or adhesion. The adhesion of the individual surface shall meet the requirements of 3.6. The adhesion of the respective surface coating shall meet the Requirements of clause 3.6.2. 3.18 CHEMICAL RESISTANCE Production repres
46、entative materials specific to the application should be used for the following tests. 3.18.1 Resistance to Incidental Fluid Spotting, Vertical Surfaces Only (FLTM BI 168-01, Method B. Reference Appendix 1.0 for the test fluids to be used per application). No color change in excess of Grey Scale rat
47、ing of 4-5 (AATCC Evaluation procedure1/ISO 105-A02), surface distortion, dulling, or permanent softening permitted. 3.18.2 Resistance to Incidental Fluid Spotting, Horizontal Surfaces Only (FLTM BI 113-01. Reference Appendix 1.0 for the test fluids to be used per application). No color change in ex
48、cess of Grey Scale rating of 4-5 (AATCC Evaluation procedure1/ISO 105-A02), surface distortion, dulling, or permanent softening permitted. 3.19 RESISTANCE TO WAXING AND DEWAXING COMPOUNDS The part shall show no breaks, cracks, blisters, surface changes or other failures. The adhesion of the individu
49、al surface coating shall meet the requirements of para 3.6. Test Methods: One of the following test conditions shall be defined according to application and shown on Engineering Drawing. 3.19.1 FLTM BO 155-01 3.19.2 The finished part shall be mounted as assembled in the vehicle in a suitable device and wetted 3 times in 24 h intervals with the test fluid at 23 +/- 2 C. The test fluid being 86% vol. of dewaxing compound per FLTM BO 155-01 and 14% vol. of an anionic detergent. Examination shall be done 7 days after the last wetting. ENGINEERING MATERIAL SP
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