FORD WSS-M99P32-D6-2015 PERFORMANCE ACOUSTICAL AND THERMAL COMPONENTS AND ASSEMBLIES FOR ENGINE UNDERHOOD AND TUNNEL APPLICATIONS TO BE USED WITH FORD WSS-M99P1111-A .pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2015 02 20 Released C. Kay, G. Kowalski, A. Reaume, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 7 PERFORMANCE, ACOUSTICAL AND THERMAL WSS-M99P32-D6 COMPONENTS AND ASSEMBLIES FOR ENGINE, UN

2、DERHOOD, AND TUNNEL APPLICATIONS 1. SCOPE This specification defines the minimum durability requirements of insulators present in engine side dash, engine compartment foam gasket, tunnel, underhood, and sound absorption/insulation applications, where various materials are combined to provide assembl

3、ies having thermal, acoustical (sound absorption/barrier/insulation), and/or functional features. In addition, ultra high temperature parts exposed to heat from turbochargers, EGR systems, and exhaust pipes are also included. 2. APPLICATION This specification was released originally for materials us

4、ed as engine compartment, hood, and tunnel insulators. The following components are NOT in the scope for this performance specification: Interior/luggage compartment insulators Use WSS-M99P32-D1/latest. Acoustical wheel arch/well liners Use WSS-M99P32-D2-D3/latest. Acoustical underbody/engine shield

5、s Use WSS-M99P32-D4-D5/latest. 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/latest). 3.2 FINISHED PART REQUIREMENTS Detailed part construction must

6、be submitted along with test data for all tests applicable to material approval according to Table 1. Design Verification testing (DV) is done on the material and Production Validation testing (PV) is done on production parts. DV/PV and sample sizes are defined in Table 1. In addition to the followi

7、ng minimum requirements, production assemblies must withstand normal handling during shipping, installation, use, and service, without tearing, breaking, or permanently deforming. Specific sampling areas may be required when highlighted on the Engineering Drawing. 3.3 APPEARANCE (FLTM BI 109-01) All

8、 appearance properties of exposed materials shall meet the requirements of the relevant Engineering Department. 3.4 WEIGHT (FLTM BN 106-01) The fiber/foam weight/density and total weight/density shall be as specified on the Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D6 Copyri

9、ght 2015, Ford Global Technologies, LLC Page 2 of 7 3.5 FLAMMABILITY Flammability is affected by the material thickness and density. Conduct testing on the full range of material thicknesses and densities on part) 3.5.1 All Components (SAE J369/ISO 3795) Burn Rate SE/NBR max The material shall not g

10、low or smolder after the flame extinguishes. Flame should be applied to the exposed side of the component, or both sides, if the A and B surfaces are exposed to high temperatures. Supplier shall document test conditions in their Control Plan (for PV). 3.5.2 Glow Wire (Only applicable when electrical

11、 wiring is going thru or attached to the component) (IEC 60695-2-10, Glow wire temperature: 750 C) Flame shall extinguish within 10 sec. after removal of the wire. IEC 60695-2-10 Glow wire apparatus and common test procedure IEC 60695-2-11 Glow wire flammability test method for end products IEC 6069

12、5-2-12 Glow wire flammability index (GWFI) test method for materials IEC 60695-2-13 Glow wire 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 t

13、est conditions in their Control Plan (for PV). 3.6 CONSTRUCTION PROPERTIES 3.6.1 Resistance to Mildew Test Method Cut specimens from the various thicknesses in the part and/or test all material thicknesses. Specimen size is 200 x 200 mm unless part size is smaller. Expose for 7 days in a humidity ca

14、binet maintained at 98 +/- 2% relative humidity and 38 +/- 2 C. Evaluation Remove the part from the cabinet and evaluate immediately. The part shall exhibit no visible evidence of mildew growth and/or objectionable odor. 3.6.2 Environmental Testing After the test, the component shall exhibit no visi

15、ble or objectionable appearance degradation which will cause unsightly gaps or interfere with normal function, such as distortion, blistering, delamination, expansion, shrinkage, warpage, or mildew growth. Any underhood/engine side dash/tunnel insulator shall not sag vertically or horizontally more

16、than 6 mm at any point. Sagging greater than the 6 mm specification may be approved by the Engineering Supervisor or Technical Specialist. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D6 Copyright 2015, Ford Global Technologies, LLC Page 3 of 7 In addition, any clear objectionable appearance observ

17、ed during the test should be reported. Test Method: Conduct tests using approved surrogate components mounted on an actual or simulated production support foundation with production intent retention methods. The assemblies shall be subjected to the environmental cycles specified in paragraph 3.6.2.1

18、. Confirm with the affected Materials Engineering Activity for agreement prior to using test chambers with automated programmable test cycles for the listed test conditions below. Ramp speed 1 to 5 C per minute (record actual ramp speed on data sheet). 3.6.2.1 Short Term Heat, Humidity and Cold Maxi

19、mum temperature of exposure will be dependent on location of the component. The values below are estimates; if a component is exposed to a higher temperature based on historical data, use the maximum temperature. Maximum temperature: Components attached to engine (away from exhaust manifold): 150 C

20、Hood/engine side dash/tunnel insulators: 120 C Components attached to power steering or transmission components: 135 C Components attached to coolant components: 120 C Under hood components not directly attached to engine: 120 C 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. 48 h at Maximum Temp

21、erature +/- 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 3.6.2.2 Heat Aging Test one previously unexposed component to one of the following temperatures for 7 days at maximum temperature per component application listed below +/- 2 C. Maximum temperatu

22、re: Components attached to engine (away from exhaust manifold): 150 C Hood/engine side dash/tunnel insulators: 150 C Parts attached to power steering fluid or transmission fluid: 135 C Parts attached to coolant components: 120 C Under hood components not directly attached to engine: 120 C Evaluation

23、 In addition to the post-test requirements listed in 3.6.2, insulation and covering materials shall not crack, flame, glow, smolder, degrade, develop an objectionable odor, or exhibit any exothermic reaction when tested at the maximum use temperature. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D6

24、 Copyright 2015, Ford Global Technologies, LLC Page 4 of 7 3.6.3 Resistance of Insulators to Various Test Reagents (ASTM D896) The finished or surrogate part shall not dissolve, exhibit tackiness or delaminate when immersed in each of the following test reagents for a 4 hour period. Use a separate s

25、pecimen for each test reagent. Test Reagents: 1. Deionized Water 2. 3% (by weight) salt (NaCl) solution in Deionized Water 3. Engine Oil Resistance ASTM SF 105* 4. Brake Fluid FMVSS DOT 3 or 4* 5. Sulfuric Acid (2.5% by weight in Deionized Water) 6. Long Life Coolant WSS-M97B44-D* (50/50% vol. Coola

26、nt/Deionized Water) 7. Transmission/Power Steering Fluid WSS-M2C938-A* 8. Windshield Washer Fluid Resistance WSS-M8B16-A3* *Or currently released equivalent fluid. 3.6.4 Corrosiveness to Steel Rating 4 min (SAE J1389) 3.7 PHYSICAL PROPERTIES 3.7.1 Breaking Strength (non-foam materials only) (ASTM D5

27、034, for test set-up and procedure, exception of speed 25 mm/minute) Specimens to be cut from flat areas of the finished part and distance between clamps at beginning of test should be 100 mm. Report value of the load at which the specimen breaks; include individual values, averages, and % changes i

28、n the data submission package. 3.7.1.1 Original Report Only, N 3.7.1.2 Change After Humidity Aging -30% avg. change (48 h at 38 +/- 2 C and 95 +/- 2% R.H.; 1 h at from original, max room temperature) 3.7.1.3 Change After Heat Aging -30% avg. change (Conditions per para. 3.6.2.2) from original, max 3

29、.7.1.4 Change After Immersion in Water -30% avg. change (48 h in distilled water at room temperature) from original, max 3.7.2 Tear Resistance Test (foam materials only) Report Value, kPa (ASTM D3574, Test F) Specimens to be cut from flat areas of finished parts. Conduct testing on full range of mat

30、erial thicknesses on part. 3.7.3 Compression Force Deflection Test (foam materials only) (ASTM D3574 Test C) Test sample shall not compress more than 70% of the original thickness after loading with 35 kg. Upon removing the load, the material shall recover at least 65% of the compressed distance. EN

31、GINEERING MATERIAL SPECIFICATION WSS-M99P32-D6 Copyright 2015, Ford Global Technologies, LLC Page 5 of 7 3.7.4 Constant Deflection Compression Set Test (foam materials only) 3.7.4.1 Original Report Value, % (ASTM D3574 Test D) 3.7.4.2 Steam Autoclave Aging Exposure +/- 40% max from (ASTM D3574 Test

32、J2, 5 hours at 120 C +/- 5 C, Original Value followed by Constant Deflection Compression Set Test (ASTM D3574 Test D) 3.7.4.3 Dry Heat Aging Exposure +/-10% max from (ASTM D3574 Test K) Original Value 22 hours at 140 C or maximum temperature as mutually agreed between Ford D&R and Materials Engineer

33、ing, followed by Constant Deflection Compression Set Test (ASTM D3574 Test D) 3.7.5 Peel Strength (All Laminates) (FLTM BN 151-05, 250 mm length sample, 30 min. immersion. Each material should be tested to the fluids quoted in 3.6.3.) Samples must meet at least one of the following requirements: . -

34、 Achieve peel strength value of 6 N/50 mm, min - Adhesion of the covering material must exceed cohesive strength of the substrate 3.7.6 Moisture Absorption 30% max Cut a 200 x 200 +/-10mm specimen from the part to be tested and seal any cut edges, e.g. with wax. Weigh the specimen to the nearest 0.1

35、 g. Condition part/section in suspended position at 38 +/- 2 C and 95 +/- 2% R.H. for 24 h. After 1 h at 23 +/- 2 C and 50 +/- 2% RH weigh the part/section to the nearest 0.1 g and determine increase of weight in percent based on the original weight. 3.8 THERMAL PROPERTIES The surface of the part/ma

36、terial being protected shall not reach its maximum use temperature when tested at the maximum vehicle use temperature as determined from applicable vehicle tests. 3.8.1 Thermal Conductivity (Thermal Insulators Only) Report W/M/K (ASTM C518, ASTM C177) 4. GENERAL INFORMATION The information given bel

37、ow is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 FUNCTIONAL REQUIREMENTS Component supplier shall meet the NVH program specific targets as directed by Ford D&R activity throug

38、h the Request for Quotation (RFQ) document. These targets are program dependent and run at Ford NVH facilities. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D6 Copyright 2015, Ford Global Technologies, LLC Page 6 of 7 4.1.1 Sound Absorption: The component shall meet the Sound Absorption Target Curv

39、e in the 400 Hz to 10 kHz frequency range as specified in the RFQ. The measurements should be conducted in the Ford Alpha Cabin. The target curve should be specified on the Engineering Drawing. 4.1.2 Sound Transmission Loss: The component shall meet the Sound Transmission Loss Target Curve in the 20

40、0 Hz to 10 kHz frequency range as specified in the RFQ. The measurements should be conducted in the Ford Sound Transmission Loss Chamber. The target curve should be specified on the Engineering Drawing. 4.1.3 Sound Insulation: The component shall meet the Sound Insulation Loss Target Curve in the 10

41、0 Hz to 10 kHz frequency range as specified in the RFQ. The measurements should be conducted in the Ford APAMAT Chamber. The target curve should be specified on the Engineering Drawing. 5. SUMMARY OF REVISIONS ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D6 Copyright 2015, Ford Global Technologies,

42、 LLC Page 7 of 7 TABLE 1 Felt/Shoddy PUFoamHighTemperature Foam Nonwoven MineralFiber Glass Fiber Sample size required for DV and PV noted in Table. Test method: 3.4 Weight Substrate and Total Weight 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3.5 Flammability 3.5.1 All Components 5(DV+PV)

43、 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 3.5.2 Glow Wire at 750 C: 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 3.6 Construction Properties 3.6.1 Resistance to Mildew 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 3.6.2 Environmental Testing 3.6.2.1 Short Term Heat, Humidity, an

44、d Cold 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 3.6.2.2 Heat Aging 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 1(DV+PV) 3.6.3 Resistance to Various Test Reagents 1(DV) per reagent 1(DV) per reagent 1(DV) per reagent 1(DV) per reagent 1(DV) per reagent 1(DV) per reagent 3.6.4 Corrosiven

45、ess to Steel 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 3.7 Physical Properties 3.7.1 Breaking Strength 3.7.1.1 Original 5(PV) 5(PV) 5(PV) 5(PV) 3.7.1.2 Change After Humidity Aging 5(PV) 5(PV) 5(PV) 5(PV) 3.7.1.3 Change After Heat Aging 5(PV) 5(PV) 5(PV) 5(PV) 3.7.1.4 Change After Immersion in Water 5(PV)

46、5(PV) 5(PV) 5(PV) 3.7.2 Tear Resistance 5(PV) 5(PV) 3.7.3 Compression Force Deflection Test 1(PV) 1(PV) 3.7.4 Constant Deflection Compression Set Test 3.7.4.1 Original 3(PV) 3(PV) 3.7.4.2 Steam Autoclave Aging Exposure 3(PV) 3(PV) 3.7.4.3 Dry Heat Aging Exposure 3(PV) 3(PV) 3.7.5 Peel Strength (Laminates only) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3.7.6 Moisture Absorption 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 3.8 Thermal properties 3.8.1 Thermal Conductivity 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) 1(DV)