FORD WSS-M99P32-E4-2017 PERFORMANCE ACOUSTICAL UNDERBODY ENGINE SHIELDS TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M99P32-E2).pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 00 2017 03 15 Released K. Mueller, NA Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 1 of 11 PERFORMANCE, ACOUSTICAL WHEEL ARCH/WELL LINERS WSS-M99P32-E2 PERFORMANCE, ACOUSTICAL HEAVY DUTY WHEEL ARCH/WE

2、LL LINERS WSS-M99P32-E3 PERFORMANCE, ACOUSTICAL UNDERBODY/ENGINE SHIELDS WSS-M99P32-E4 PERFORMANCE, ACOUSTICAL HEAVY DUTY UNDERBODY/ENGINE SHIELDS WSS-M99P32-E5 1. SCOPE This specification defines the minimum durability requirements of composite acoustical underbody and under-engine shields, includi

3、ng wheel arch/well liners, where various materials may be combined to provide acoustical (sound absorption/barrier/insulation) features. Examples include PET nonwoven fabric, Glass/PP fiber nonwoven fabric, Glass/PP wet laid nonwoven composite. Materials are also called Light Weight Reinforced Therm

4、oplastic (LWRT). 2. APPLICATION This specification is released for materials used to make functional parts such as under-engine shields, underbody aero/NVH shields, and wheel arch/well liners. There are four subsets of the standard (E2, E3, E4 Report N, min Testing speed: 100 mm/min, samples at maxi

5、mum And minimum thicknesses) OR (ASTM D5034, 100 mm between clamps, Report N, min speed 25mm/min, sample size 25mm x 150mm, at maximum and minimum thicknesses) Report Method, MD/CMD, thickness of samples 3.3.10.1 Change After Humidity Aging -30% max (48 h at 38 +/- 2 C and 95 +/- 2% R.H.; 1 h at roo

6、m 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 After Immersion In Water -30% max (48 h in dist

7、illed water at room temperature) (Test after exposure) 3.3.11 Flexural Modulus Report MPa, min (ISO 178, Method A, Include specimen sizes 12.7mm/min compression rate) Report Method, MD/CMD, thickness of samples 3.3.11.1 Change After Humidity Ageing -30% max (48 h at 38 +/- 2 C and 95 +/- 2% R.H.; 1

8、h at room temperature) 3.3.11.2 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) 3.3.11.3 Change After Immersion In Water -30% max (48 h

9、 in distilled water at room temperature) (Test after exposure) 3.3.12 Peel Strength (Laminates only w/ bonded, non-needled attachment) 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 ENGINEE

10、RING MATERIAL SPECIFICATION WSS-M99P32-E2/E3/E4/E5 Copyright 2017, Ford Global Technologies, LLC Page 5 of 11 3.3.13 Resistance to Water Wicking 25 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

11、Method B, N and Method B (In-Plane), 5 specimens/method) 3.3.15 Environmental Testing After the test, shall exhibit no visible and objectionable appearance such as: . Wrinkling . Distortion . Blistering . Delamination . Expansion, shrinkage or warpage which will interfere with normal function or cau

12、se objectionable and unsightly gaps. In addition, any objectionable appearance observed during the test should be reported. Test Method: Mount the composite on an actual or simulated production support foundation with the approved retention methods. Confirm with the affected Materials Engineering Ac

13、tivity 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).Maximum temperature of exposure will be dependent on location of the component. The values below are

14、 estimates; 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 3.3.15.1 Short Term

15、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 3.3.15.2 Long Term Heat Exposure In addition to no visible and objectionable appearance after the te

16、st requirements listed above, materials shall not crack, flame, glow, smolder, degrade, develop an objectionable odor or exhibit any exothermic reaction when tested at the maximum vehicle use temperature as determined from applicable vehicle tests. Test previously unexposed composite to the followin

17、g (as applicable): 7 days at 150 C: Components exposed to engine fluids or bolted to the engine. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-E2/E3/E4/E5 Copyright 2017, Ford Global Technologies, LLC Page 6 of 11 7 days at 120 C: Components not directly bolted to engine (as agreed by engineering).

18、3.3.15.3 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/temperatures t

19、o 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 3.3.16 Accelerated Cyclic Corrosion

20、 Test (CETP 00.00-L-467, 6 weeks) 3.3.16.1 Water Absorption Report, % change Weigh the specimen nearest to 0.1 g pre and post test 3.3.16.2 Physical Appearance (WSS-M99P32-E2/E3 only) There shall be no physical deterioration or permanent staining. 3.3.17 Flammability Flammability is affected by the

21、material thickness and density. Conduct testing on the minimum and maximum material thicknesses and densities samples. 3.3.17.1 All Components (E2, E3, E4, E5) 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

22、 of the component. Supplier shall document test conditions in their Control Plan (for PV). 3.3.17.2 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 rem

23、oval 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 60695-2-12 Glow wire flammability index (GWFI) test method for materials IEC 60695-2-13 Glow wire ignition temperature (GWIT) test method for materials

24、 ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-E2/E3/E4/E5 Copyright 2017, Ford Global Technologies, LLC Page 7 of 11 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 Contro

25、l Plan (for PV). 3.3.17.3 Under Engine Shields Only SE/NBR max (ISO 3795 / SAE J369) Cut specimens from shield per ISO 3795 / SAE J369. Place two rods spanning top lip of a pan. Suspend specimens (vehicle position) perpendicular to the rods over the pan. Pour 100 mL of engine oil* at room temperatur

26、e over the top surface of the specimen. After 10 minutes suspend specimen in a vertical position and drain oil off for 20 minutes. Specimen should not touch residual oil in the bottom of the pan. Place specimen in sample holder such that the front edge of the sample to be ignited is the drip off end

27、 of the test specimen. 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 doc

28、ument test conditions in their Control Plan (for PV). *Engine oil is SAE 5W-20: WSS-M2C945-A 3.3.18 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 comp

29、osite. 3.4 ADDITIONAL FMD REQUIRED INFORMATION Mechanical Curves: - Breaking Force - Flexural Modulus - Bolt Pull Thru 3.5 NVH, ACOUSTIC REQUIREMENTS 1.00 meter x 1.20 meter formed samples shall be provided to Ford for testing in a Ford Alpha Cabin as follows for each blend of materials planned for

30、use by Ford: For each GSM planned or proposed for Ford programs (in 200 gsm increments if more than a single GSM is possible for a specific blended material) provide formed samples (heated and pressed to production processing conditions) at the following thicknesses: 1. Minimum, typically 2mm planne

31、d for edges or fixing points 2. Midway between minimum and maximum, typically 4 mm 3. Maximum, typically 6mm planned for open areas with no package constraints ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-E2/E3/E4/E5 Copyright 2017, Ford Global Technologies, LLC Page 8 of 11 4. GENERAL INFORMATION

32、The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression

33、 of interest from Purchasing, Design or Product Development, and Materials Engineering. 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 th

34、e Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford.

35、 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specificatio

36、n requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engin

37、eering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulation

38、s or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and

39、or GMAP reporting. 5. SUMMARY OF REVISIONS ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-E2/E3/E4/5 Copyright 2017, Ford Global Technologies, LLC Page 9 of11 TABLE 1 Material Category E2: Wheel Arch/Well Liners E3: Heavy Duty Wheel Arch/Well Liners Design Verification E2: Wheel Arch/Well Liners E3:

40、Heavy Duty Wheel Arch/Well Liners Production Validation E4: Underbody/ Engine Shields E5: Heavy Duty Underbody/ Engine Shields Design Verification E4: Underbody/ Engine Shields E5: Heavy Duty Underbody/ Engine Shields Production Validation Test Method Sample Size: Noted in Table. Surrogate data may

41、be used as agreed by Ford Design and Release and Ford Materials Engineering Activities. 3.3.1 Thickness (2mm, 4mm, 6mm for DV), Finished Part for PV 3 3 3 3 3.3.2 Area Weight (2mm, 4mm, 6mm for DV), Finished Part for PV 3 3 3 3 3.3.3.1 All construction details must be included on Engineering Drawing

42、 X X X X 3.3.3.2 Color shall be dark grey or black for all Wheel Arch / Wheel Well Liners (D2/D3) show surfaces X X 3.3.4 Resistance to Mildew (2mm, 4mm, 6mm for DV) 3 3 3.3.5 Moisture Absorption (2mm, 4mm, 6mm for DV) 3 3 3.3.6 Gravelometer (Mid-Rocker Underbody Shields and Front Wheel Arch/Well Li

43、ners Only) (2mm, 4mm, 6mm for DV) 3 3 3.3.7 Water and Splash Resistance (2mm, 4mm, 6mm for DV) 3 3 3.3.8 Fluid Resistance (2mm, 4mm, 6mm for DV) 1 1 3.3.8.1 Resistance of Insulators to Various Test Reagents 1 1 3.3.8.2 Fluid Spotting Resistance 1 1 3.3.9 Corrosiveness to Steel 1 1 1 1 3.3.10 Breakin

44、g Force MD (2mm, 4mm, 6mm for DV) 5 5 3.3.10 Breaking Force CMD (2mm, 4mm, 6mm for DV) 5 5 3.3.10.1 Change After Humidity Aging (for all conditions 3.3.10) 5 5 3.3.10.2 Change After Long Term Heat Exposure (for all conditions 3.3.10) 5 5 ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-E2/E3/E4/E5 Copy

45、right 2017, Ford Global Technologies, LLC Page 10 of 11 3.3.10.3 Change After Water Immersion (for all conditions 3.3.10) 5 5 3.3.11 Flexural Modulus MD (2mm, 4mm, 6mm for DV) 5 5 3.3.11 Flexural Modulus CMD (2mm, 4mm, 6mm for DV) 5 5 3.3.11.1 Change After Humidity Aging (for all conditions 3.3.11)

46、5 5 3.3.11.2 Change After Long Term Heat Exposure (for all conditions 3.3.11) 5 5 3.3.11.3 Change After Water Immersion (for all conditions 3.3.11) 5 5 3.3.12 Peel Strength MD (2mm, 4mm, 6mm for DV) 3 3 3.3.12 Peel Strength CMD (2mm, 4mm, 6mm for DV) 3 3 3.3.13 Water Wicking MD (2mm, 4mm, 6mm for DV

47、) 3 3 3.3.13 Water Wicking CMD (2mm, 4mm, 6mm for DV) 3 3 3.3.14 Resistance to Bolt Pull-Thru, Method A (2mm, 4mm, 6mm for DV) 5 5 3.3.14 Resistance to Bolt Pull-Thru , Method B, MD (2mm, 4mm, 6mm for DV) 5 5 3.3.14 Resistance to Bolt Pull-Thru , Method B, CMD (2mm, 4mm, 6mm for DV) 5 5 3.3.15 Envir

48、onmental Cycling 3.3.15.1 Short Term Heat, Humidity, and Cold 1 1 1 1 3.3.15.2 Long Term Heat Exposure 1 1 1 1 3.3.15.3 Radiant Heat Cycling (as applicable) 1 1 1 1 3.3.16.1 Accelerated Cyclic Corrosion Test Water Absorption 5 5 3.3.16.2 Accelerated Cyclic Corrosion Test Physical Appearance 1 3.3.17

49、.1 Flammability 5 5 5 5 3.3.17.2 Glow Wire Flammability (as applicable) 5 5 5 5 3.3.17.3 Under Engine Shields Only - Oil 5 3.3.18 Water Absorption 1 1 ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-E2/E3/E4/E5 Copyright 2017, Ford Global Technologies, LLC Page 11 of 11 3.4 Additional Curves X X X X 3.5 NVH, Acoustic Requirements X X X X