1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions REV 01 2011 07 13 Revision See Para 5 for revisions B. Haggart, FNA 2007 05 08 Activated Y. Bankowski Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 1 of 7 ACETAL (POM) COPOLYMER, MOLDED-IN-COLOR, WSS-M4D84
2、0-A5 INTERIOR, LOW GLOSS, MELT FLOW RATE 11 18 g/10 MINUTES 1. SCOPE The material defined by this specification is a molded-in-color, low gloss thermoplastic acetal copolymer based on trioxane for interior use. 2. APPLICATION This specification was released originally for material used for interior
3、trim applications requiring low gloss applications. Achievable gloss levels are in the range of 2 - 4, whereas conventional acetal is in the range of 8 -13 at best. 2.1 LIMITATIONS This material is not intended for painted applications. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERI
4、ALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-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
5、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. 3.1.1 This specification is based on virgin materials, however materials with recycled co
6、ntent as defined by WRS-M99P42-A1 (post-consumer and/or post industrial recyclates and repolymerised recycled materials) should be used whenever technically feasible and following all materials and PV testing required by Ford Materials Engineering. The use of regrind is permitted, for economic / env
7、ironmental reasons, with compliance as indicated in WSS-M99P1111-A. 3.1.2 Materials used in interior applications must meet the requirements outlined in WSS-M99P2222-B1/Latest, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submis
8、sion package. 3.1.3 Performance Criteria: Parts using this specification shall meet the appropriate performance specification, WSS-M15P4-F/Latest for Hard, Interior, Molded-in-Color component performance. ENGINEERING MATERIAL SPECIFICATION WSS-M4D840-A5 Controlled document at www.MATS Copyright 2011
9、, Ford Global Technologies, LLC Page 2 of 7 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 9988-2. Annealing is allowed for unaged s
10、pecimens for property comparison to Heat Aging samples only. See Table 1 for the number of specimens required. Specimens shall be as follows: Specimen 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
11、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 +/- 0.2 mm Specimen I 100 mm x 150 mm, min 3.3 APPEARANCE 3.3.1 Gloss Rating K (FLTM BI 110-01, ASTM D 5
12、23 molded from smooth polished mold, Specimen I) Gloss Description Gloss Code* Gloss Level Very High A 92 min B 76 - 84 High C 66 - 74 D 58 - 66 E 47 - 53 F 33 - 38 Medium G 17 - 23 H 7 - 13 J 4 - 6 Low K 2 - 4 L 0.5 - 2.0 N 1.8-2.4 *A use 20 degree, B-N use 60 degree 3.3.2 Weathering Resistance Rat
13、ing 4 min (FLTM BO 116-01, 2481.6 kJ/m2 exposure Specimen C from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) Every 526.4kJ/m2 remove the samples from the weatherometer and allow them to cool for one hour. Conduct a tactile evaluation and report any tackiness. Visually evaluate
14、and report any spewing or other exudation. After exposure the material shall show no fading or color change in excess of specified AATCC rating. In addition, there shall be no cracking, crazing or other deterioration. Use regional choice colors for initial approval and report color house used. For c
15、olor durability submissions, test all program colors. ENGINEERING MATERIAL SPECIFICATION WSS-M4D840-A5 Controlled document at www.MATS Copyright 2011, Ford Global Technologies, LLC Page 3 of 7 3.4 MATERIAL PROPERTIES 3.4.1 Melt Flow Rate 11 18 g/10 minutes (ISO 1133, 190 C, 2.16 kg) 3.4.2 Density 1.
16、30 1.36 g/cm3 (ISO 1183, Method A) 3.4.3 Tensile Strength at Yield 38 MPa min (ISO 527-1 and ISO 527-2, Specimen A 50 mm/minute test speed) 3.4.4 Elongation at Yield 8 % min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.4.5 Tensile Modulus 1.46 GPa min (ISO 527-1 and ISO 527-2, Sp
17、ecimen A, 1 mm/minute test speed) 3.4.6 Flexural Modulus 1.8 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.4.7 Impact Strength, Notched Izod (ISO 180/1A, Specimen D) 3.4.7.1 At 23 +/- 2 C 3.3 kJ/m2 min Report Break Type 3.4.7.2 At -40 +/- 2 C 2.5 kJ/m2 min Report Break
18、Type The test specimens must be conditioned for min of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box, if not possible, test can be conducted outside, but within 5 seconds. 3.4.8 Heat Deflection Temperature 70 C min (ISO 75-1 an
19、d 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. Unaged specimens shall be annealed at 120 C for 72 hours prior to testing and property values determined at the time of the aged propertie
20、s) 3.4.9.1 Tensile Strength at Yield Change +/- 25% max (Test Method per para 3.4.3) 3.4.9.2 Impact Strength, Notched Izod, Change +/- 25% max (Test Method per para 3.4.7.1, specimens to be notched before Heat Aging) ENGINEERING MATERIAL SPECIFICATION WSS-M4D840-A5 Controlled document at www.MATS Co
21、pyright 2011, Ford Global Technologies, LLC Page 4 of 7 3.4.10 Odor Rating 3 max (FLTM BO 131-03, Specimen G) 3.4.11 Fogging Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is c
22、ause for rejection. 3.4.12 Fogging Gravimetric 2.5 mg max (SAE J1756, Specimen F, 16 h at 100 C heating, 21 C cooling plate, post test conditioning 4 h) 3.4.13 Flammability (ISO 3795/SAE J369 Specimen B smooth surface) Burn Rate 100 mm/minute max 3.5 MATERIAL PROPERTIES REPORT ONLY Values are retain
23、ed in Ford Material Database . 3.5.1 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 C to 30 +/- 2 C) Flow Report E-5 mm/mm/ C Cross Flow Report E-5 mm/mm/ C 3.5.2 Mold Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Report Range, % 3.5.3 Poissons Ratio Repor
24、t Ratio (ISO 527-1/2, Specimen A, test speed 1 mm/minute) 3.5.4 Water Absorption Report % (ISO 62, 24 h immersion, Specimen H) 3.5.5 Impact Strength, Notched Charpy (ISO 179-1/2, Specimen D) 3.5.5.1 23 +/- 2 C Report Value, kJ/m2 Report Break Type 3.5.5.2 -40 +/- 2 C Report Value, kJ/m2 Report Break
25、 Type The test specimen 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 within 5 seconds. ENGINEERING MATERIAL SPECIFICATION WSS-M4D840-A
26、5 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 clarification and assistance in meeting the requirements of this specification. 4.1 TYPICAL PROPERTIES USING TEST METHODS IN SECTION 3.5 Para
27、. Test Typical Values Units 3.5.1 Coefficient of Linear Thermal Expansion; Flow Cross Flow 13 13 E-5 mm/mm/ C E-5 mm/mm/ C 3.5.2 Mold Shrinkage (Method used: ISO 294-3 & 294-4 / ISO 2577, 48 h at 23 +/- 2 C, 60 x 60 x 2.0 +/- 0.1 mm specimen) 1.5 % 3.5.3 Poissons Ratio 0.46 N/A 3.5.4 Water Absorptio
28、n 0.3 % 3.5.5.1 Impact Strength Charpy, Notched at 23 +/- 2 C 2.4 kJ/m2 3.5.5.2 Impact Strength Charpy, Notched at -40 +/- 2 C 1.7 kJ/m2 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES POM (ISO 1043) ENGINEERING MATERIAL SPECIFICATION WSS-M4D840-A5 Controlled document at www.MATS Copyright 2011,
29、Ford Global Technologies, LLC Page 6 of 7 Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Previously Approved Material Test Lots Specimens per lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 1 1 1 per test 3.1.2 WSS-M99P2222-B1 Tot
30、al Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See below for odor and fogging) 1 1 1 per test 3.3.1 Gloss 1 1 1 3.3.2 Weathering Resistance 1 1 1 3.4.1 Melt Flow Rate* 3 1 3 1 1 1 3.4.2 Density 1 3 3 3.4.3 Tensile Strength at Yield* 3 5 15 1 5 5 3.4.4 Elongation at Yield*
31、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 at Yield Change 1 5 5 3.4.9.2 Impact Strength,
32、Notched Izod Change 1 10 10 3.4.10 Odor 1 9 9 3.4.11 Fogging Photometric 1 3 3 3.4.12 Fogging Gravimetric 1 3 3 3.4.13 Flammability 1 5 5 3.5.1 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.5.2 Mold Shrinkage 1 5 5 3.5.3 Poissons Ratio 1 5 5 3.5.4 Water Absorbtion 1 3 3 3.5.5 Impac
33、t Strength, Notched Charpy (per condition) 1 10 10 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 set the requirement max or min. ENGINEERING MATERIAL SPECIFICATION WSS-M4D840-A5 Controlled document at
34、 www.MATS Copyright 2011, Ford Global Technologies, LLC Page 7 of 7 Table 2: Minimum Color Property Testing 5. SUMMARY OF REVISIONS 2011 07 13 Updated Format Revised Title to include “Melt Flow Rate“ Added Para 3.1.2 for recycled content and regrind Added Para 3.1.3 for VIEQ Added Critical Process P
35、arameters Revised Para 3.2.1 Melt Flow Rate at 190C and 2.16 kg test conditions Added Appearance Para 3.3 and Gloss Rating Para 3.3.1 Revised Para 3.4.1 for Test Specimen size to current M4D template Revised Para 3.4.3.1 to Elongation at “Yield“ Revised Para 3.4.4 Tensile Modulus by removing (s) req
36、uirement Removed Para 3.3.4 Tensile Stress/Strain Curves Revised Para 3.3.6 for Izod Impact by removing “initial qualification“ comment Moved Impact Strength Charpy Notched to General Information Para 5.4 Revised Para 3.4.7 for Heat Deflection Temperature to be consistent with M4D Template Revised P
37、ara 3.5 for fogging by removing 1 h post test conditioning Added Para 3.6 for Odor Removed Para 3.6.1 Xenon Arc Weatherometer (Unfiltered) Removed Para 3.6.2 12 Months Florida Weathering Revised Para 5 General Information to contain new verbiage in M4D Template Revised Para 5.1 CLTE to contain updat
38、ed ISO 11359-2 Method Revised Para 5.2 Mold Shrinkage to use M4D Template verbiage Added Para 5.5 Poissons Ratio Revised Para 5.6 to contain ISO 1043 Removed Para 4.4 Hardness, Rockwell M Para. Test Method Lots Specimens per Lot Total Test Specimens Color Test Direction 3.3.2 Weathering Resistance 1
39、 1 1 Every color 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 3.4.10 Odor 1 9 9 As directed by Materials Engineering 3.4.12 Fogging Gravimetric 1 3 3 As directed by Materials Engineering 3.4.13 Flammability 1 5 5 Every Color 3.5.5.1 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering
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