1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2001 04 27 Activated M. Masserant Printed copies are uncontrolled Page 1 of 6 Copyright 2000, Ford Global Technologies, Inc. STYRENE MALEIC ANHYDRIDE COPOLYMER (SMA), WSS-M4D857-A3 RUBBER MODIFIED, 16 % GLAS
2、S FIBER REINFORCED MOLDING COMPOUND 1. SCOPE The material defined by this specification is a rubber modified styrene maleic anhydride copolymer (SMA), reinforced with 16 % glass fiber blended with 0-10% acrylic regrind, 0-20% manufactured regrind or reclaim and 0-2% by weight acid scavenger (CaCO3).
3、 See paragraph 5.4 for definitions of reclaim and regrind. The glass fibers are coated with a non-PVA (polyvinyl acetate) binding agent which can withstand mold temperatures of 315 C, without producing mold corroding by-products. The final material blend (containing 20 % reclaimed SMA) shall not exc
4、eed 0.12 wt % PVC/ABS skin (thermoformed) and 0.1 % polyurethane foam. 2. APPLICATION This specification was released originally for material used for the structural base of instrument panels laminated with soft trim materials on the finished surface. 3. REQUIREMENTS Material specification requireme
5、nts are to be used for initial qualification of materials. 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to the Companys Quality System Requirements. 3.1.1 All requirements of this specification, identified by symbol (s), shall be met with data representing 3 sig
6、ma values. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS 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
7、to the reference standard when tested under the same conditions. ENGINEERING MATERIAL SPECIFICATION WSS-M4D857-A3 Page 2 of 6 Copyright 2000, Ford Global Technologies, Inc. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosph
8、ere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 MOLDING COMPOUND (s) 3.4.1 Melt Flow Rate, range 2.6 - 6.0 g/10 minutes (ISO 1133, 220 C, 10 kg) Note: Melt flow rate is for molding compoun
9、d as supplied. Melt flow on physical blends of compound, reclaim/regrind are not practical because of irregular shape/size of reclaim/regrind and non-uniformity of blend. (s) 3.4.2 Glass Fiber Content, range 14 - 19 % (ISO 3451/1, Method A at 650 C +/- 25 C, test portion 2.5 to 3.0 g) 3.5 MOLDED TES
10、T 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 (Tensile Bar, ISO 3167) B. 120 x 10 x 4.0 +/- 0.2 mm Specimens with s
11、horter dimensions shall be cut from the center portion of the test specimen A and/or B. The specimens shall be prepared according to ISO 294. No annealing allowed. 3.5.2 Density, range 1.15 - 1.20 g/cm3 (ISO 1183, Method A) (s) 3.5.3 Tensile Strength at Maximum Load, min 64.0 MPa (ISO R 527, 150 min
12、 x 10 x 4.0 +/- 0.2 mm specimen 2 mm/minute test speed, 64 mm support span) ENGINEERING MATERIAL SPECIFICATION WSS-M4D857-A3 Page 3 of 6 Copyright 2000, Ford Global Technologies, Inc. (s) 3.5.4 Flexural Modulus, min 4.6 GPa (ISO 178, 80 x 10 x 4.0 +/- 0.2 mm specimen, 2 mm/minute test speed, 64 mm s
13、upport span) 3.5.5 Shear Modulus at 23 C, range 1.2 - 2.5 MPa/GPa (ASTM D 4065, forced constant amplitude, fixed frequency of 1 Hz +/- 15 % strain level below 1 %. Specimen approximately 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
14、at each temperature interval - 3 minutes minimum) Additionally, a Shear Modulus versus Temperature curve shall be plotted for 50 to + 150 C temperature range, at 5 C minimum intervals. The plotted curve must be within the tolerance range shown on page 7. (s) 3.5.6 Impact Strength, Izod, min (ISO 180
15、/1A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C 7.0 kJ/m2 3.5.6.2 At - 40 +/- 1 C 3.5 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 co
16、ld box. (s) 3.5.7 Heat Deflection Temperature, min (ISO 75, 120 x 10 x 4.0 +/- 0.2 mm specimen, edgewise 0.32 +/- 0.1 mm deflection) 3.5.7.1 At 1.80 MPa 114 C All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled w
17、ith silica gel. ENGINEERING MATERIAL SPECIFICATION WSS-M4D857-A3 Page 4 of 6 Copyright 2000, Ford Global Technologies, Inc. 3.5.8 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 100 +/- 2 C. After heat aging test specimens are to be conditioned in a desiccator for 3 - 5 h
18、 at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.5.8.1 Tensile Strength at Max +/- 25 % Load, % change (Per para 3.5.3) 3.5.8.2 Impact Strength, Izod Change +/- 25 % (Test Method per para 3.5.6.1, specimens to be notched before heat aging
19、) 3.6 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 90 Formation of clear film, droplets or crystals is cause for rejection. 3.7 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute The specimen size required for material
20、approval is 355 x 100 x 1.6 +/- 0.1 mm with a smooth surface. 3.8 ADDITIONAL REQUIREMENTS Additional requirements for material and/or manufactured parts may be specified on the Engineering drawing, Engineering parts specification, performance specification, System Design Specification (SDS) and/or C
21、omponent Design Specification (CDS). ENGINEERING MATERIAL SPECIFICATION WSS-M4D857-A3 Page 5 of 6 Copyright 2000, Ford Global Technologies, Inc. 3.9 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was
22、 originally granted. Prior to making any changes to the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify the affected Purchasing, and Materials Engineering activities (wit
23、h reasons) of the proposed changes. Upon notification of the Company, further instructions will be provided. Note: Suppliers should be prepared to provide test data and samples demonstrating compliance to this specification, if requested. Substance restrictions imposed by regulations or Company dire
24、ction applies to the materials addressed by this document. The restrictions are identified in Restricted Substance Management Standard WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification for direct supply to the Company must have prior approval. Certain materials subcon
25、tracted by part suppliers may also require prior approval. These include materials critical to the Companys business for regulatory, safety, environmental or compatibility requirements or contractual agreements. Suppliers desiring approval of their materials shall first obtain an expression of inter
26、est from Purchasing, Design or Materials Engineering activity. Upon request, the Supplier shall submit 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 specific
27、ation. 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 5.6 E-5/C (ASTM E 831 TMA, temperature range - 30 to + 30 C) 5.2 MOLD SHRINKAGE (ISO 294-4, approximat
28、ely 150 x 100 x 3.2 +/- 0.2 mm injection molded specimen) ENGINEERING MATERIAL SPECIFICATION WSS-M4D857-A3 Page 6 of 6 Copyright 2000, Ford Global Technologies, Inc. 5.2.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.25 - 0.45 % 5.2.2 Post Shrinkage (Separate specimens required for each test) . Af
29、ter 48 h at 80 C 0.1 % . After 30 minutes at 120 C 0.3 % 5.3 MULTI AXIAL IMPACT AT MAX LOAD (ASTM D 3763, 100 x 100 x 2.5 +/- 0.2 mm edge gated injection molded specimen) Test velocity at initial contact with the test specimen shall be 6.7 m/s and must not change by more than 10 % during the impact
30、event. Load energy and velocity are to be recorded as a function of displacement. 5.3.1 At 23 C 5.0 J 5.3.2 At - 30 C 4.5 J 5.4 DEFINITIONS REGRIND SMA: Injection molded surface flawed parts, sprues, and runners are granulated. Without any additional processing, this SMA material is blended at 20 %
31、maximum with virgin SMA material as certified by the approved supplier to injection mold parts. RECLAIMED SMA: Injection molded SMA parts are used in conjunction with PVC+ABS (thermoformed) and polyurethane (PUR) foam to manufacture interior components (i.e. instrument panels). These composite panel
32、s, including trimming offal, are granulated, and the SMA extracted from PVC+ABS skins and polyurethane foam. The reclaimed SMA material can contain a maximum of 0.6 wt % PVC+ABS skin and 0.2 wt % polyurethane foam for a total of 0.8 wt % combined PVC+ABS skin/PUR foam. This reclaimed SMA material is
33、 blended at 20 % maximum with virgin SMA material as certified by the approved supplier to injection mold parts. RECYCLATE: Plastic resin recovered from post consumer products. This material salvaged separated/purified by various processes, possible enhanced with additives, and used to injection mold parts. 5.5 RECYCLING CODE SMA-GF16
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