FORD WSS-M99P32-D3-2015 PERFORMANCE ACOUSTICAL HEAVY DUTY WHEEL ARCH WELL LINERS TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M99P32-D2).pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 02 2015 11 23 Revised See Summary of Revisions K. Mueller, NA 2014 11 25 Editorial Corrected acoustical spelling in title D. Murtonen, NA 2014 10 16 Released K. Mueller, NA Controlled document at www.MATS Copyright 2015, Ford Global Techn

2、ologies, LLC Page 1 of 13 PERFORMANCE, ACOUSTICAL WHEEL ARCH/WELL LINERS WSS-M99P32-D2 PERFORMANCE, ACOUSTICAL HEAVY DUTY WHEEL ARCH/WELL LINERS WSS-M99P32-D3 PERFORMANCE, ACOUSTICAL UNDERBODY/ENGINE SHIELDS WSS-M99P32-D4 PERFORMANCE, ACOUSTICAL HEAVY DUTY UNDERBODY/ENGINE SHIELDS WSS-M99P32-D5 1. S

3、COPE This specification defines the minimum durability requirements of composite acoustical underbody and under-engine shields, including wheel arch/well liners, where various materials may be combined to provide acoustical (sound absorption/barrier/insulation) features. Examples include PET nonwove

4、n fabric, Glass/PP fiber nonwoven fabric, Glass/PP wet laid nonwoven composite. Materials are also called Light Weight Reinforced Thermoplastic (LWRT). 2. APPLICATION This specification was released originally for NVH absorbers, barriers, or insulators, specific to materials used in the under-engine

5、 and underbody shields, as well as wheel arch/well liner applications. There are four subsets of the standard (D2, D3, D4 Report N, min Testing speed: 100 mm/min, samples at maximum And minimum thicknesses) Report Method, MD/CMD, thickness of samples 3.3.10.1 Change After Humidity Ageing -30% max (4

6、8 h at 38 +/- 2 C and 95 +/- 2% R.H.; 1 h at room temperature) 3.3.10.2 Change After Long Term Heat Exposure -30% max 7 days for: Components exposed to engine fluids or bolted to the engine: 150 C Components not bolted to engine (as agreed by engineering): 120 C (Test after exposure) 3.3.10.3 Change

7、 After Immersion In Water -30% max (48 h in distilled water at room temperature) (Test after exposure) ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5 Copyright 2015, Ford Global Technologies, LLC Page 4 of 13 3.3.11 Flexural Modulus Report MPa, min (ISO 178, Method A, at maximum thickness

8、, Include specimen sizes 12.7mm/min compression rate) 3.3.12 Peel Strength (Laminates only) 20 N/50mm, min (FLTM BN 151-05, 250 mm length or sample, 30 min. immersion). Adhesion of the covering material must exceed cohesive strength of the substrate Each material should be tested to the fluids quote

9、d in 3.3.8.1. 3.3.13 Resistance to Water Wicking 5 mm, max (SAE J913, using solution A, 16 hours) 3.3.14 Resistance to Bolt Pull - Thru Report Method A, N (FLTM BA 116-01, Method A (Out-of-Plane) Report Method B, N and Method B (In-Plane), 5 specimens/method) 3.4 FINISHED COMPOSITE/PART REQUIREMENTS

10、 This material shall be molded and formed to the specific geometry of the wheel arch/well or vehicle underbody or under-engine shield as appropriate. The material shall be a moldable, self-supporting composite with a solid black color (as agreed by engineering), if visible by the customer (D2 these

11、will be highlighted on the Engineering Drawing. 3.4.1 Construction Report Detailed composite construction must be submitted along with test data. Tier 1 Tier 2 Material Supplier Type of part Ford Production Part Example(s) Trade Name Made in-house or purchased Manufacturing process Number of Layers

12、(including scrims) Min, Max. if a component is exposed to a higher temperature based on historical data, use the maximum temperature. Maximum temperature: Components exposed to engine fluids or bolted to the engine: 150 C Components not directly bolted to engine (as agreed by engineering): 120 C 3.4

13、.4.1 Short Term Heat, Humidity and Cold 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. 48 h at Maximum Temperature +/- 2 C 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. . 48 h at Maximum Temperature +/- 2 C 3.4.4.2 Long Term Heat Exposure ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/

14、D4/D5 Copyright 2015, Ford Global Technologies, LLC Page 6 of 13 In addition to no visible and objectionable appearance after the test requirements listed above, materials shall not crack, flame, glow, smolder, degrade, develop an objectionable odor or exhibit any exothermic reaction when tested at

15、the maximum vehicle use temperature as determined from applicable vehicle tests. Test previously unexposed composite to the following (as applicable): 7 days at 150 C: Components exposed to engine fluids or bolted to the engine. 7 days at 120 C: Components not directly bolted to engine (as agreed by

16、 engineering). 3.4.4.3 Radiant Heat Cycling, if near exhaust or exceed 150 C (SAE J1361, *test at max.temp for specified number of cycles) * The number of heating and cooling cycles and the actual maximum component surface temperatures is to be supplied by the Ford Heat Management Team. Cycle times/

17、temperatures to be specified on the Engineering Drawing. One cycle = 30 minutes at max. temperature and 30 minutes at ambient temperature. Example of radiant heat cycling: 71 hours trailer tow: 71 cycles = (maximum temperature for 30 min. + ambient temperature for 30 min.) x 71 3.4.5 Breaking Force

18、Report, N, min (ASTM D5034, 100 mm between clamps, speed 25mm/min, sample size 25mm x 150mm, at maximum and minimum thicknesses) Or (ISO 527-4 Type 2, Sample size 25 x 250 mm; Report, N, min Testing speed: 100 mm/min, samples at maximum And minimum thicknesses) Report Method, MD/CMD, thickness of sa

19、mples 3.4.6 Flexural Modulus Report MPa, min (ISO 178, Method A, at maximum thickness, Include specimen sizes 12.7mm/min compression rate) 3.4.7 Peel Strength,(Laminates only) 20 N/50 mm, min (FLTM BN 151-05, 250 mm length or sample, 30 min. immersion) Adhesion of the covering material must exceed c

20、ohesive strength of the substrate Each material should be tested to the fluids quoted in 3.3.8.1. 3.4.8 Salt Staining, (Wheel Arch/Well Liners Only D2 & D3) Report ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5 Copyright 2015, Ford Global Technologies, LLC Page 7 of 13 (CETP 00.00-L-467,

21、6 weeks) There shall be no physical deterioration or permanent staining. 3.4.9 Resistance to Car Wash, (Wheel Arch/Well Liners Only D2 & D3) Report (Ford Test Method 01.08-L-2619) 1) Install the composite on vehicle in design position (or simulated vehicle position). 2) Measure and record torque of

22、all attachments. 3) Inspect the components visible surface for dents, cracks, scratches and functionality and document all defects prior of testing. 4) Subject the composite to 10 cycles through a high pressure treatment for pre-cleaning with 10 liters/minute at 10 MPa and 60 +/-1 C for 2 minutes, u

23、sing a jet with an opening angle of 25 degrees applied at the most unfavorable angularity of impingement in a true distance of 300 mm to the critical area. 5) Inspect the visible surfaces after the test for any damage such as dents, cracks and scratches. 6) Measure fasteners torques. 7) Photograph a

24、nd document any damage to the components tested. 3.4.10 Gravelometer, (Mid-rocker Underbody Shields and Report Front Wheel Arch/Well Liners Only) (SAE J400 / ISO 20567-1, 5 cycles of 700g (473ml), at 23 +/- 2 C and -30 +/- 2 C, test specimens size 100 x 305 mm (4 x 12 in), impingement angle at 45 de

25、grees with edge-supported backer plate) There shall be no holes, fuzziness upon approach, separation, or other changes that impact the function or reduce the perceived quality of the vehicle. 3.4.11 Flammability Flammability is affected by the material thickness and density. Conduct testing on the f

26、ull range of material thicknesses and densities on part. 3.4.11.1 All Components (D2, D3, D4, D5) SE/NBR max (ISO 3795/SAE J369) The material shall not glow or smolder after the flame extinguishes. Flame should be applied to the road side of the component. Supplier shall document test conditions in

27、their Control Plan (for PV). 3.4.11.2 Glow Wire Flammability (IEC 60695-2-10, Glow wire temperature: 750 C) Only applicable when electrical wiring is going thru or attached to the component. Flame shall extinguish within 10 sec. after removal of the wire IEC 60695-2-10 Glow wire apparatus and common

28、 test procedure IEC 60695-2-11 Glow wire flammability test method for end products IEC 60695-2-12 Glow wire flammability index (GWFI) test method for materials ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5 Copyright 2015, Ford Global Technologies, LLC Page 8 of 13 IEC 60695-2-13 Glow wir

29、e ignition temperature (GWIT) test method for materials Flame should be applied to the exposed side of the component, which under certain conditions may include inner/outer surfaces. Supplier shall document test conditions in their Control Plan (for PV). 3.4.11.3 Under Engine Shields Only SE/NBR max

30、 (ISO 3795 / SAE J369) Cut specimens from shield per ISO 3795 / SAE J369. Suspend specimens (vehicle position) over a pan to catch flow through oil. Pour 100 mL of engine oil* at room temperature over the top surface of the specimen. After 10 minutes place shield in a vertical position and drain oil

31、 off for 20 minutes. Test ISO 3795/SAE J369 immediately following 20 minute oil drain. The material shall not glow or smolder after the flame extinguishes. Flame should be applied to the road side of the component (at the specimen end where the oil dripped in vertical position). Supplier shall docum

32、ent test conditions in their Control Plan (for PV). *Engine oil is SAE 5W-20: WSS-M2C945-A 3.4.12 Water Absorption +10% max After weighing the production composite, completely immerse it in a 23 C water bath for 1 hour. Place composite in vehicle position for 24 hours. Re-weigh the production compos

33、ite. 3.4.13 Resistance to Bolt Pull Thru Report Method A, N (FLTM BA 116-01, Method A (Out-of-Plane) Report Method B, N and Method B (In-Plane), 5 specimens/method) 3.5 ADDITIONAL FMD REQUIRED INFORMATION Mechanical Curves: - Breaking Force - Flexural Modulus - Bolt Pull Thru (3.3 and 3.4) Material

34、Characterization Curves (3.3): - FTIR - DSC (1st and 2nd heats) - TGA 3.6 FUNCTIONAL REQUIREMENTS Component supplier shall meet the NVH program specific targets as directed by Ford D&R activity through the Request for Quote document. These targets are program dependent and run at Ford NVH facilities

35、. 3.6.1 Sound Absorption: ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5 Copyright 2015, Ford Global Technologies, LLC Page 9 of 13 The component shall meet the Sound Absorption Target Curve in the 400Hz to 10KHz frequency range as specified in the Request for Quote. The measurements shou

36、ld be conducted in the Ford Alpha Cabin. The target curve should be specified on the Engineering Drawing. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering M

37、aterial Specifications. 5. SUMMARY OF REVISIONS 11/23/2015 All 3.3 and 3.4: Clarified unconsolidated and consolidated. Changed to maximum and minimum thicknesses, where applicable. 3.3.8: clarified for test reagents. 3.3.10.2 and 3.3.10.3: clarified testing. 3.4.1: clarified construction requirement

38、s. 3.4.11.3: clarified terminology for test specimen. Table 1: clarified references for above. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/3/4/5 Copyright 2014, Ford Global Technologies, LLC Page 10 of13 TABLE 1: Material and Physical Property Requirements Material Category D2: Wheel Arch/Well

39、Liners D3: Heavy Duty Wheel Arch/Well Liners D4: Underbody/ Engine Shields D5: Heavy Duty Underbody/ Engine Shields Test Method Sample Size: Noted in Table 3.3.1.1 Thickness minimum 3 3 3 3 3.3.1.2 Thickness maximum 3 3 3 3 3.3.2 Area Weight (minimum) 3 3 3 3 3.3.2 Area Weight (maximum) 3 3 3 3 3.3.

40、3 Fiber Reinforcement (minimum) 1 1 1 1 3.3.3 Fiber Reinforcement (maximum) 1 1 1 1 3.3.4 Resistance to Mildew (minimum) 3 3 3 3 3.3.4 Resistance to Mildew (maximum) 3 3 3 3 3.3.5 Moisture Absorption (minimum) 3 3 3 3 3.3.5 Moisture Absorption (maximum) 3 3 3 3 3.3.6 Gravelometer (Mid-Rocker Underbo

41、dy Shields and Front Wheel Arch/Well Liners Only) (minimum) 3 3 3 3 3.3.6 Gravelometer (Mid-Rocker Underbody Shields and Front Wheel Arch/Well Liners Only) (maximum) 3 3 3 3 3.3.7 Water and Splash Resistance (minimum) 3 3 3 3 3.3.7 Water and Splash Resistance (maximum) 3 3 3 3 3.3.8 Fluid Resistance

42、 (minimum) 1 1 1 1 3.3.8.1 Resistance of Insulators to Various Test Reagents 1 1 1 1 3.3.8.2 Fluid Spotting Resistance 1 1 1 1 3.3.8 Fluid Resistance (maximum) 1 1 1 1 ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/3/4/5 Copyright 2015, Ford Global Technologies, LLC Page 11 of 13 3.3.8.1 Resistanc

43、e of Insulators to Various Test Reagents 1 1 1 1 3.3.8.2 Fluid Spotting Resistance 1 1 1 1 3.3.9 Corrosiveness to Steel 1 1 1 1 3.3.10 Breaking Force MD (minimum) 5 5 5 5 3.3.10 Breaking Force MD (maximum) 5 5 5 5 3.3.10 Breaking Force CMD (minimum) 5 5 5 5 3.3.10 Breaking Force CMD (maximum) 5 5 5

44、5 3.3.10.2 Change After Humidity Aging (for all conditions 3.3.10) 5 5 5 5 3.3.10.3 Change After Long Term Heat Exposure (for all conditions 3.3.10) 5 5 5 5 3.3.10.4 Change After Water Immersion (for all conditions 3.3.10) 5 5 5 5 3.3.11 Flexural Modulus MD (maximum) 5 5 5 5 3.3.11 Flexural Modulus

45、CMD (maximum) 5 5 5 5 3.3.12 Peel Strength MD (minimum) 3 3 3 3 3.3.12 Peel Strength MD (maximum) 3 3 3 3 3.3.12 Peel Strength CMD (minimum) 3 3 3 3 3.3.12 Peel Strength CMD (maximum) 3 3 3 3 3.3.13 Water Wicking MD (minimum) 3 3 3 3 3.3.13 Water Wicking MD (maximum) 3 3 3 3 3.3.13 Water Wicking CMD

46、 (minimum) 3 3 3 3 3.3.13 Water Wicking CMD (maximum) 3 3 3 3 3.3.14 Resistance to Bolt Pull-Thru, Method A (minimum) 5 5 5 5 3.3.14 Resistance to Bolt Pull-Thru , Method B, MD (minimum) 5 5 5 5 3.3.14 Resistance to Bolt Pull-Thru , Method B, CMD (minimum) 5 5 5 5 ENGINEERING MATERIAL SPECIFICATION

47、WSS-M99P32-D2/3/4/5 Copyright 2015, Ford Global Technologies, LLC Page 12 of 13 TABLE 2: Finished Composite/Part Requirements Test Method Sample Size: Noted in Table Material Category D2: Wheel Arch/Well Liners, D3: Heavy Duty Wheel Arch/Well Liners , D4: Underbody/ Engine Shields, D5: Heavy Duty Un

48、derbody/ Engine Shields 3.4.1 Construction Description Tier 1 Tier 2 / Material Supplier Type of Part Ford Production Part (examples) 3.4.1 Construction Description (continued) Trade name Made in house or Purchased Manufacturing Process # of Layers (scrims, etc.) Min, Max, Average, Denier GSM of eac

49、h layer % Recycled Content 3.4.1 Construction Description (continued) Main material Composition(s) for each layer D2: Wheel Arch/Well Liners D3: Heavy Duty Wheel Arch/Well Liners D4: Underbody/ Engine Shields D5: Heavy Duty Underbody/ Engine Shields 3.4.1.1 All construction details must be included on Engineering Drawing X X X X 3.4.1.2 Part Layout CAD for all test specimens in 3.4 X X X X 3.4.1.3 Color shall be dark grey or b