FORD WSS-M4D1052-A3-2013 POLYCARBONATE (PC) OPTICAL GRADE LOW MELT FLOW INTERIOR TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M4D1052-A1).pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2013 04 03 Released K. Waugh, NA Controlled document at www.MATS Copyright 2013, Ford Global Technologies, LLC Page 1 of 6 POLYCARBONATE (PC), OPTICAL GRADE, HIGH MELT FLOW, EXTERIOR WSS-M4D1052-A1 POLYCARBONATE (PC), OPTICAL GRADE, LO

2、W MELT FLOW, EXTERIOR WSS-M4D1052-A2 POLYCARBONATE (PC), OPTICAL GRADE, LOW MELT FLOW, INTERIOR WSS-M4D1052-A3 1. SCOPE The material defined by this specification is a thermoplastic injected molded compound based on polycarbonate. These are non UV-stable materials. 2. APPLICATION WSS-M4D1052-A1 ther

3、efore it requires a UV stable coating for exterior applications. Long term exposure to direct sunlight will cause chalking and loss of gloss. WSS-M4D1052-A1 only: These materials should not be considered for parts with snap-in features or features that are notch-sensitive, as they tend to break in t

4、hese types of applications. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.1.1 Many 4D resin specifications prior to 2011, identified certain requ

5、irements with the symbol (s), which indicated that the mean and +/- 3 sigma values were to be reported. The specification minimum, maximum or range was established using 3 sigma data. For 2011 and beyond, refer to Table 1 for number of samples required for each test to establish specification limits

6、. 3.1.2 This specification is based on virgin materials, however materials with recycled content as defined by WRS-M99P42-A1 (post-consumer and/or postindustrial recyclates and repolymerised recycled materials) should be used whenever technically feasible and following all materials and PV testing r

7、equired by Ford Materials Engineering. 3.1.3 The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in Ford Engineering CAD and Drafting Standard E-4 3.1.4 WSS-M4D1052-A3 only: Materials used in interior applications must meet the requirements outlined in

8、 WSS-M99P2222-D1/Latest, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submission package. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-A1/2/3 Copyright 2013, Ford Global Technologies, LLC Page 2 of 6 3.1.5 Performance Criteria

9、: WSS-M4D1052-A1 & A2: Parts using this specification shall meet the appropriate performance specifications, WSK-M98P10-A/Latest (Exterior Lamp Assembly). WSS-M4D1052-A3: Parts using this specification shall meet the appropriate performance specification, WSS-M15P4-F/Latest. 3.1.6 As specified in WS

10、S-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CoA) containing lot testing requirements which must include, but are not limited to: Melt Flow Rate Filler Content Impact Strength, Notched Charpy at 23C Flexural Modulus 3.2 SAMPLE PREPAR

11、ATION Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defined in ISO 7391-2. See Tables 1 and 2 for the number of samples required. Specimens shall be as follows: Specimen

12、 A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, Specimen Type 1A) Specimen B 355 x 100 x 1.0 +/- 0.1 mm (ISO 3795) Specimen C 145 x 60 x 3.2 +/- 0.2 mm Specimen D Center of Specimen A, 80 x 10 x 4.0 +/- 0.2 mm Specimen E 100 mm diameter x 3.2 mm Specimen F 80 mm diameter x 3.2 mm Specimen G 90 mm x

13、 200 mm Specimen H 50 +/- 1 mm diameter x 3.2 +/- 0.2 mm Specimen I 100 mm x 150 mm, min 3.3 APPEARANCE 3.3.1 Weathering Resistance (WSS-M4D1052-A3 only) Rating 4 min (FLTM BO 116-01, 225.6 kJ/m2 exposure Specimen C from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) After exposur

14、e the material shall show no fading or color change in excess of the specified AATCC rating. In addition, there shall be no cracking, crazing or other deterioration. Use regional choice for initial approval and report the color house used. See Table 2 for additional color durability submission requi

15、rements. 3.4 MATERIAL PROPERTIES A1 A2/A3 3.4.1 Melt Flow Rate, g/10 minutes 14 - 25 9 - 14 (ISO 1133 300 C, 1.2 kg) The material shall be dried for 4hr minimum at 125 C in a mechanical convection oven immediately preceding the test. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-A1/2/3 Copyright 20

16、13, Ford Global Technologies, LLC Page 3 of 6 3.4.2 Density 1.16-1.26 g/cm3 (ISO 1183, Method A) 3.4.3 Tensile Strength at Yield 55 MPa min (ISO 527-1 & ISO 527-2, Specimen A, 50mm/minute test speed) 3.4.4 Elongation at Yield 5% min (ISO 527-1 & 527-2, Specimen A, 50mm/minute test speed) 3.4.5 Tensi

17、le Modulus 2.0 GPa min (ISO 527-1 & ISO 527-2, Specimen A 1mm/min test speed) 3.4.6 Flexural Modulus 2.1 GPa min (ISO 178, Specimen D, 64mm support span, 2mm/min test speed) 3.4.7 Impact Strength Charpy, notched (ISO 179-1/1eA, Specimen D) A1 A2/A3 3.4.7.1 At 23 +/- 2 C 9 kJ/m2, min 58 kJ/m2, min Co

18、mplete Break Partial Break 3.4.7.2 At -40 +/- 2 C 7 kJ/m2, min 6 kJ/m2, min Complete Break Complete Break The test specimen 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 possib

19、le, test may be conducted outside, but within 5 seconds. 3.4.8 Heat Deflection Temperature 114C min (ISO 75-1 & ISO 75-2, Specimen D, Flatwise, 0.34 +/- 0.1mm deflection. At 1.80 MPa) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture

20、-proof container filled with silica gel. 3.4.9 Vicat Softening Temperature 136C min (ISO 306, Specimen D. Bath silicone oil, Temperature raises 50 +/- C/h. Dial gage reset to O after addition of 5 kg weight, at 50 N load) All specimens dry as molded. If not tested immediately after molding, specimen

21、s must be stored in a sealed, moisture-proof container filled with silica gel. 3.4.10 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 90 +/- 2 C. After heat aging test specimens are To be conditioned in a desiccator for 3 5 h at 23 +/- 2 C. Unaged property Values shall be

22、 determined at the time of the aged properties determination) 3.4.10.1 Tensile Strength at Yield, Change +/- 25% max (Test method per para 3.4.3) 3.4.10.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per para 3.4.7, ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-A1/2/3 Copyright

23、2013, Ford Global Technologies, LLC Page 4 of 6 specimens to be notched before heat aging) 3.4.11 Odor (WSS-M4D1052-A3 only) Rating 3 max (FLTM BO 131-03, Variant C, Specimen G) 3.4.12 Fogging Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h)

24、A1/A2 A3 Fog Number 90 min 70 min Formation of clear film, droplets or crystals is cause for rejection. 3.4.13 Flammability (ISO 3795/SAE J369 Specimen B, smooth surface) Burn Rate 100 mm/min max 3.4.14 Luminous Transmittance 88 % min (ASTM D 1003, Specimen H) 3.4.15 Haze 2 % max (ASTM D 1003, Speci

25、men H) 3.4.16 Yellowness Index (WSS-M4D1052-A3 only) 0.5 max (FLTM BO 116-01, Specimen C, Evaluate after 225.6 kJ/m2 exposure, per ASTM E 313) 3.5 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.5.1 Molding Shrinkage (Report method used, sample size and value) Afte

26、r 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.5.2 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 30 +/- 2 C) Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.5.3 Impact Strength, Izod, notched (ISO 180/1A, Specimen D) 3.

27、5.3.1 At 23 +/- 2 C Report kJ/m2 Report Break Type 3.5.3.2 At - 40 +/- 2 C Report kJ/m2 Report Break Type The test specimen 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 possib

28、le, test may be conducted outside, but within 5 seconds. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-A1/2/3 Copyright 2013, Ford Global Technologies, LLC Page 5 of 6 3.5.4 Poissons Ratio Report (ISO 527-1 & ISO 527-2, Specimen A, test speed 1mm/min) 3.5.5 Supplemental Information The following cu

29、rves are to be submitted with the data packages: FTIR TGA DSC CLTE Engineering Stress/Strain at 23 C (additional temperatures required depending on the material and or application) 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirem

30、ents of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.5 Para. Test Typical Value Units 3.5.1 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering)

31、Flow Cross Flow 0.8 0.81 - 0.83 % % 3.5.2 Coefficient of Linear Thermal Expansion Flow Cross Flow 7.1 6.4 6.8 E-5 mm/mm/ C E-5 mm/mm/ C 3.5.3 3.5.3.1 3.5.3.2 Impact Strength, Notched Izod, mean At 23 +/- 2 C At - 40 +/- 2 C A1 A2/A3 35CB 67PB 9CB 11CB kJ/m2/Break Type kJ/m2/Break Type 3.5.4 Poissons

32、 Ratio 0.35 - 0.38 N/A 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PC (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-A1/2/3 Copyright 2013, Ford Global Technologies, LLC Page 6 of 6 Table 1 Initial Approval New Manufacturing Location for Previously Approved Material Para. Tes

33、t Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 3.1.4 WSS-M99P2222-D1/Latest Total Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See below for Odor and Fogging) 1 1 1 per test 3.1.5 WSK-M98P10-A/Latest Refe

34、rence performance specification 3.1.5 WSS-M15P4-F/Latest Reference performance specification 3.3.1 Weathering Resistance 1 1 1 3.4.1 Melt Flow Rate* 3 1 3 1 1 1 3.4.2 Density 1 3 3 1 3 3 3.4.3 Tensile Strength at Yield * 3 5 15 1 5 5 3.4.4 Elongation at Yield * 3 5 15 1 5 5 3.4.5 Tensile Modulus 1 1

35、0 10 3.4.6 Flexural Modulus* 3 10 30 1 10 10 3.4.7 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.4.8 Heat Deflection Temperature* 3 2 6 1 2 2 3.4.9 Vicat Softening Temperature* 3 2 6 1 2 2 3.4.10 Heat Aging Performance 3.4.10.1 Tensile Strength at Yield, Change 1 5 5 3.4.10.2 Imp

36、act Strength, Notched Charpy, Change 1 10 10 3.4.11 Odor 1 9 9 3.4.12 Fogging Photometric 1 3 3 3.4.13 Flammability 1 5 5 3.4.14 Luminous Transmittance 1 3 3 3.4.15 Haze 1 3 3 3.4.16 Yellowness Index 1 3 3 3.5.1 Mold Shrinkage 1 5 5 1 5 5 3.5.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.5.3 Impact Strength, Notched Izod (per condition) 1 10 10 3.5.4 Poissons Ratio 1 2 2 1 2 2 3.5.5 Curves - IR - TGA - DSC - CLTE - Stress/Strain Curves 1 1 1 per test