1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 1 2011 10 25 Revised See Summary of Revisions V.Cerato, FoE 2009 02 11 Activated K. Mueller, FNA Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 1 of 7 POLYPROPYLENE (PP) COPOLYMER, 22% MINERAL WSS-M4D5
2、56-A8 FILLED MOLDING COMPOUND, EXTERIOR 1. SCOPE The material defined by this specification is a 22% mineral filled thermoplastic injection molding compound based on polypropylene copolymer, with added UV stabilization and scratch additives for exterior use. 2. APPLICATION This specification was rel
3、eased originally for material used in mold-in-color exterior applications, specifically for cowl top ventilator grills. Any color additives need to be reviewed and approved by the raw material supplier and Ford Materials Engineering. The UV/process/heat stabilizers must be in the base resin from the
4、 material supplier, not in the color concentrate, specifically for mold-in-color applications at the press. 2.1 LIMITATIONS This material should not be used for painted applications since it contains performance additives that negatively affect paint adhesion. Production level materials must be used
5、 in preparing test parts / panels. The use of improper sample prep materials can influence test results. 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-
6、A). Note: Many 4D resin specifications prior to 2011, identified certain requirements 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 values. For 2011 and beyond, refer to Table 1
7、 for number of samples required for each test to establish specification limits. 3.1.1 This specification is based on virgin materials, however materials with recycled content as defined by WRS-M99P42-A1 (post-consumer and/or post industrial recyclates and repolymerised recycled materials) should be
8、 used whenever technically feasible and 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. 3.1.2 Performance Criteria Parts using this specification shal
9、l meet the appropriate performance specifications WSS-M98P13-C / Latest. 3.2 SAMPLE PREPARATION 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 1873-2. No a
10、nnealing is allowed. See Tables 1 and 2 for the number of samples required. ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A8 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 2 of 7 Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-
11、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 200 mm Specimen H 50 +/- 1 mm diameter x 3.2
12、+/- 0.2 mm Specimen I 100 mm x 150 mm, min 3.3 APPEARANCE 3.3.1 Weathering Resistance Rating 4 min (SAE J2527 Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure monitored at 340 nm, 3000 h total exposure or as o
13、therwise defined, Specimen C, from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) For color durability submissions, test all program colors. 3.3.2 1 and 2 year Florida Rating 4 min Initial Qualification for new resin technology (SAE J1976, 5 south, direct weathering inland, Specim
14、en C from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) After exposure the material shall show no color change in excess of the specified AATCC Rating. In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss or chalking will be allowed prov
15、ided an acceptable appearance can be achieved as specified below by washing with mild detergents and water (ratio 5:95 by volume) or equivalent after the outdoor exposure only. All initial approvals may be based on the accelerated weathering exposure, pending real world outdoor exposure results for
16、final approval. 3.3.3 Resistance to Scratch and Mar (FLTM BO 162-01, Specimen I) Scratch Rating 2 at 2 N, max Whitening/Color Change Rating 1 at 7 N, max Marring Rating 2 at 2 N, max These values are derived from colored and grained samples in agreement with Materials Engineering. Details regarding
17、color house, let down ratio, colors, grain, etc can be found in the approval package. ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A8 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 3 of 7 3.4 MATERIALS PROPERTIES 3.4.1 Filler Content 20-24 % (ISO 3451-1, Method A
18、, 1h at 850 +/-50C, test portion 2 to 2.5g) 3.4.2 Density 1.02-1.10 g/cm3(ISO 1183, Method A) 3.4.3 Tensile Strength at Yield 20 MPa, min (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A, test speed: 50 mm/minute as noted below) 3.4.5 Tensile Modulus 1.9 GPa, min (ISO 527-1 & ISO
19、 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A test speed: 1 mm/min) 3.4.6 Flexural Modulus 1.9 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.4.7 Impact Strength, Notched Izod (ISO 179-1/2, Specimen D) 3.4.7.1 At 23 +/- 2 C 4.0 kJ/m2min Report Break Type 3.4.7.2 A
20、t -40 +/- 2 C 1.8 kJ/m2min Report Break Type 3.4.8 Heat Deflection Temperature 53C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.4.9 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. After heat aging test specimens are to
21、 be conditioned in a desiccator for 3 - 5 h at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.4.9.1 Tensile Strength at Yield, Change +/- 25% max (Test Method per para 3.4.X) 3.4.9.2 Impact Strength, Notched Izod, Change +/- 25% max (Test M
22、ethod per para 3.4.X.X, specimens to be notched before Heat Aging) ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A8 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 4 of 7 3.4.10 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute ma
23、x 3.5 MATERIALS PROPERTIES - REPORT ONLY Values are retained in Ford Materials Database . 3.5.1 Melt Flow Rate Report Value, g/10 minutes (ISO 1133 230 C, 2.16 kg) 3.5.2 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Valu
24、e, % 3.5.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2 C) Flow Report Value, E-5mm/mm/ C Cross Flow Report Value, E-5mm/mm/ C 3.5.4 Impact Strength, Charpy, notched, typical (ISO 180/1A, specimen D) 3.4.7.1 At 23 +/- 2 C Report Value kJ/m2Report Break Type 3.4.7.2
25、At - 40 +/- 2 C Report Value kJ/m2Report Break Type 3.4.7.3 At 0 +/- 2 C Report Value kJ/m2Report Break Type The test specimen must be conditioned for a 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 p
26、ossible, test may be conducted outside, but within 5 seconds. Paragraph 3.3.6.3, test temperature minimum 10 C from glass transition temperature. 3.5.5 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A 1 mm/minute test speed) 3.5.6 Supplemental Information The following curves are to
27、be submitted with the data packages: FTIR TGA DSC CLTE Engineering Stress/Strain at 23 C ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A8 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 5 of 7 4. GENERAL INFORMATION The information given below is provided for clari
28、fication and assistance in meeting the requirements 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 Melt Flow rate 17-27 g/10 min 3.5.2 Molding Shrinkage After 48 h
29、at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering) Flow Cross Flow 0.9 1.2 % % 3.5.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 8.5 9.5 E-5mm/mm/ C E-5mm/mm/ C 3.5.4 Impact Strength Charpy notched At 23C At -40C At 0C 4.0 1.8 2.5 kJ/m2kJ/m2 kJ/m23.5.5 Poi
30、ssons Ratio 0.43 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PP-TD22 (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A8 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 6 of 7 Table 1: Minimum Sample Size Initial Approval New Manufacturing Loca
31、tion for Previously Approved Material Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 3.3.1 Weathering Resistance 1 1 1 3.3.2 1 and 2 year Florida 1 1 1 3.3.3 Scratch Resistance 1 3 3 3.4.1 Filler Content* 3 1 3 1 1 1 3.4.
32、2 Density 1 3 3 3.4.3 Tensile Strength at Yield* 3 5 15 1 5 5 3.4.5 Tensile Modulus 1 10 10 3.4.6 Flexural Modulus* 3 10 30 1 10 10 3.4.7 Impact Strength Notched Izod (per condition)* 3 10 30 1 10 10 3.4.8 Heat Deflection Temperature* 3 2 6 1 2 2 3.4.9 Heat Aging Performance 3.4.9.1 Tensile Strength
33、 at Yield, Change 1 5 5 3.4.9.2 Impact Strength, Notched Izod, Change 1 10 10 3.4.10 Flammability 1 5 5 3.5.1 Melt Flow Rate* 3 1 3 1 1 1 3.5.2 Mold Shrinkage 1 5 5 1 5 5 3.5.3 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.5.4 Impact Strength, Notched Charpy (per condition) 1 10 10
34、 3.5.5 Poissons Ratio 1 5 5 3.5.6 Curves - IR - TGA - DSC - CLTE - Stress/Strain Curves 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A8 Controlled document at www.MATS Copyright 2011, Ford
35、Global Technologies, LLC Page 7 of 7 Table 2: Minimum Color Property Testing 5. SUMMARY OF REVISIONS 10/25/2011 Updated the following sections: Updated Format in line with M4D template Revised scope to specify precise amount of filler Revised Limitation verbiage Para 2.1 Revised Para 3.1.1 to list l
36、atest performance specification Added Para 3.1.2 performance criteria Added Para 3.2 sample preparation Moved Melt Flow Rate to General Information Para 3.5.1 Moved Weathering resistance from special requirements to requirements Para 3.3.1 and 3.3.2 Moved Scratch resistance from General information
37、to requirements 3.3.3 Revised test speed for Tensile Modulus from 5mm/min to 1mm/min and amend min value accordingly Para 3.4.5 Added Impact Strength Charpy notched to General information Para 3.5.4 Revised Para 3.5.2 Mold Shrinkage to use M4D Template verbiage Added Para 3.5.5 Poissons Ratio Added
38、Para 3.5.6 Supplemental Information Added Para 4.1 Typical Properties Using Methods in Section 3.5 Added Table 1: Minimum Sample Size Added Table 2: Minimum Color Property Testing Para. Test Lots Specimens per Lot Total Test Specimens Color Test Direction 3.3.1 Weathering Resistance 1 1 1 Every colo
39、r 3.3.3 Scratch Resistance 1 3 3 As directed by Materials Engineering 3.4.3 Tensile Strength at Yield 1 5 5 As directed by Materials Engineering 3.4.6 Flexural Modulus 1 10 10 As directed by Materials Engineering 3.4.7.1 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering 3.4.10 Flammability 1 5 5 Every color
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