FORD WSS-M99P48-A1-2016 FOAM PERFORMANCE (INTERIOR EXTERIOR UNDERHOOD) TO BE USED WITH FORD WSS-M99P1111-A .pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 3 2016 07 25 Revised Released A4. See summary of revisions G. Kowalski, NA 2014 11 21 Editorial See Summary of Revisions D. Murtonen, NA 2014 07 18 Released Released A1, A2, A3 L. Soreide, NA Controlled document at www.MATS Copyright 201

2、6, Ford Global Technologies, LLC Page 1 of 8FOAM PERFORMANCE (INTERIOR, EXTERIOR, UNDERHOOD) WSS-M99P48-A1 FOAM PERFORMANCE, SEWN IN OR LAMINATION (INTERIOR) WSS-M99P48-A2 FOAM PERFORMANCE, PRESSURE SENSITIVE ADHESIVE TAPE WSS-M99P48-A3 (INTERIOR, EXTERIOR, CLIMATE CONTROL AND UNDERHOOD) FOAM PERFOR

3、MANCE, PRESSURE SENSITIVE ADHESIVE TAPE, WSS-M99P48-A4 HIGH TEMPERATURE APPLICATIONS, UNDERHOOD 1. SCOPE These specifications define the minimum durability requirements of foams and foam tapes made of various materials including polyurethane, polypropylene foam and pressure sensitive adhesive tapes.

4、 2. APPLICATIONS WSS-M99P48-A1 - The materials defined by this specification are for interior, exterior or underhood applications not covered by any other specification. The materials are typically but not limited to a flexible polyether polyurethane or polypropylene foam. WSS-M99P48-A2 The material

5、s defined by this specification are for foam laminated or tack sewn in applications in interior applications. The specification includes foams laminated or tack sewn in to vinyl, leather or fabric and are typically but not limited to slab stock flexible polyether polyurethane foams. These must conta

6、in a flame retardant for the flame lamination process. For Lamination Requirements refer to WSS-M8P18-B1/B4 and WSS-M8P3-E1/E3. WSS-M99P48-A3 The materials defined by this specification are foam tapes for interior, exterior and underhood applications not covered by any other specification (excludes

7、tape performance specifications for emblems, badges and body side moldings). The foam may be from the same source as those in WSS-M98P48-A1 with a pressure sensitive adhesive (PSA) applied to one or both surfaces. The PSA must be tested on the intended substrate. The supplier providing the final pro

8、duct will be listed on the Ford Material Database (FMD) though all sub-suppliers must provide data to the requirements below if requested. WSS-M99P48-A4 The materials defined by this specification are for continuous high heat applications to 180 C with excursion to 220 C for a maximum of 100 hours f

9、or the life of the vehicle. These materials are composed of foam tapes for high heat underhood applications not covered by any other specification (excludes tape performance specifications for emblems, badges and body side moldings). The foam may be from the same source as those in WSS-M98P48-A1 wit

10、h a pressure sensitive adhesive (PSA) applied to one or both surfaces. The PSA must be tested on the intended substrate. The supplier providing the final product will be listed on the Ford Material Database (FMD) though all sub-suppliers must provide data to the requirements below if requested. . 2.

11、1 LIMITATIONS WSS-M99D48-A1 Excluded from this specification are headliner (WSS-M15P27-F/latest), instrument panel (WSS-M15P45-C/latest), acoustical and thermal assemblies and energy absorbing (WSS-M99P32-D1/D2/D3/D4/D5/D6/latest), seat cushion (WSS-M15P20-B1/B2/latest), ENGINEERING MATERIAL SPECIFI

12、CATION WSS-M99P48-A1/A2/A3/A4 Copyright 2016, Ford Global Technologies, LLC Page 2 of 8 Small molded foam parts (WSS-M99P50-A1/latest),small foam in place parts WSS-M99P50-A2/latest) or whose performance is specified separately. These foams may not be made of polyurethane polyester foam since they a

13、re not durable when exposed to heat and light. WSS-M99P48-A2 These foams may not be made of polyurethane polyester foam since they are not durable when exposed to heat and light. WSS-M99P48-A3 These foam tapes do not contain a biocide. For applications that require a biocide (i.e. Climate Control),

14、the biocide must be stated on the Engineering Drawing. Excluded from this specification are tape performance for emblems and badges (WSS-M11P65-A/latest and body side moldings (WSS-M11P65-A2/latest) or whose performance is specified separately. WSS-M99P48-A4 Climate Control is excluded from this spe

15、cification. These foams may not be made of polyurethane polyester foam since they are not durable when exposed to heat. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.1.1 Performance Criteria: Parts using this specification shall me

16、et the appropriate component performance specification and must fulfill the applicable SDS/CDS requirements. 3.1.2 Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CoA) containing lot testing requirements which must include, but are not limited to: Density Tear Resi

17、stance Constant Deflection Compression Set Test 3.1.3 See Table 1 at the end of the specification to determine testing needed by application and sample size. 3.2 DURABILITY REQUIREMENTS AND CHARACTERIZATION OF PRODUCTION MATERIALS 3.2.1 Odor (FLTM BO 131-03, see below for Variant) Condition 1 (23 +/

18、- 2 C) Rating 3 max Condition 2 (40 +/- 2 C) Rating 3 max Condition 3 (65 +/- 2 C) Rating 3 max WSS-M99P48-A1 and A3: Variant A WSS-M99P48-A2: Variant C Odor is not performed for WSS-M99P48-A4 3.2.2 Fogging Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test condi

19、tioning 16 h) Fog Number 70 min ENGINEERING MATERIAL SPECIFICATION WSS-M99P48-A1/A2/A3/A4 Copyright 2016, Ford Global Technologies, LLC Page 3 of 8 Formation of clear film, droplets or crystals is cause for rejection. 3.2.3 Flammability (ISO 3795/SAE J369) Burn Rate 100 mm/minute max 3.2.4 Resistanc

20、e to Mildew Rating 3 max (FLTM BO 131-03) No visible mildew The material shall exhibit no visible evidence of mildew growth and/or objectionable odor evaluated per the Rating Scale in FLTM BO 131-03 after 7 days exposure in a humidity cabinet maintained at 98 +/- 2% relative humidity and 38 +/- 2 C.

21、 Sample size 100 x 100 mm x part thickness or a part if smaller. 3.2.5 Stress Cracking Test for Plastics No cracking or crazing (FLTM BO 127-03) All foams, tapes or foam tapes containing plasticizers, mineral oil, or solvents must be tested with the intended substrate (such as but not limited to PC,

22、 PC/ABS, ABS, SMA, ASA, PPO) for potential incompatibility. 3.2.6 Accelerated Weathering Resistance Rating 4 min Preferred Method Standard Practice for Xenon Arc Exposure Test with Enhanced Light and Water Exposure for Transportation Coatings (ASTM D7869, 2250 hours, ISO 105-A02 AATCC Eval Procedure

23、 1) or Performance Based Standard for Accelerated Exposure of Automotive Exterior Materials Using Controlled Irradiance Xenon-Arc Apparatus (Boro/Boro, SAE J2527, Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant expos

24、ure monitored at 340 nm, 3750 hours, ISO 105-A02 AATCC Eval Procedure 1) Securely attach a piece of the test specimen to the holder. If testing foam with PSA use the appropriate substrate. Test specimen shall show no surface cracking, delamination, peeling from substrate, tackiness, or other defects

25、 after exposure. 3.2.7 Corrosion No galvanic corrosion(FSMS Test Method 00.00-L-467, 8 weeks, medium corrosivity, evaluate per RQT-18-001101-002492, para. 4.10) ENGINEERING MATERIAL SPECIFICATION WSS-M99P48-A1/A2/A3/A4 Copyright 2016, Ford Global Technologies, LLC Page 4 of 8 3.2.8 Standard Test Met

26、hods for Pressure-Sensitive Adhesive-Coated Tapes Used for Electrical and Electronic Applications - Adhesion Strength to Steel and Backing (ASTM D1000, Section 46-53 except replace the steel panels with the intended substrate, 180 degree peel) Original 0.48 N/mm width min 3.2.8.1 After Heat Aging Ch

27、ange -25%, max Interior Applications: At or Above Beltline: 168 hours, 100 +/- 2 C Below Beltline: 168 hours, 90 +/- 2 C Scuff Plate / Floor Area: 168 hours, 80 +/- 2 C Special Area: 168 hours, (Review with Materials Engineering) All Exterior Applications: 336 hours, 80 +/- 2 C Underhood Application

28、s: Underhood (non-engine): 336 hours, 110 +/- 2 C Underhood (directly on engine): 1000 hours, 125 +/- 2 C High Heat Underhood Applications (WSS-M99P48-A4 only, excludes Climate Control) Heat Age for 1000 h at 180 C followed by 100 h at 220 C 3.2.8.2 After Environmental Cycling Change -25%, max Inter

29、ior Applications: 10 cycles, each cycle shall consist of the following: 4 h at 100 +/- 2 C 4 h at 38 +/- 2 C and 95 - 100% R.H. 16 h at -40 +/- 2 C Exterior Applications: 10 cycles, each cycle shall consist of the following: 4 h at 80 +/- 2 C 4 h at 38 +/- 2 C and 95 - 100% R.H. 16 h at -40 +/- 2 C

30、Underhood Applications: 4 cycles, each cycle shall consist of the following: 1 h at -40 +/- 2 C 1 h at 121 +/- 2 C Test panels shall show no surface cracking, crazing, delamination, peeling from substrate, peeling from substrate tackiness, or other surface defects after exposure to test conditions f

31、or 3.2.8.1 or 3.2.8.2. ENGINEERING MATERIAL SPECIFICATION WSS-M99P48-A1/A2/A3/A4 Copyright 2016, Ford Global Technologies, LLC Page 5 of 8 3.2.9 Resistance of Foam to various Test Reagents (ASTM D893, WSS-M99P48-A3 and -A4 for Underhood Engine applications) Test Method: Immerse a separate specimen i

32、n each test reagent for 4 hours. Allow specimens to recover for 24 hours at 23 C before evaluating. Test Reagents: 1. Deionized Water 2. 3% (by weight) salt (NaCl) solution in Deionized Water 3. Engine Oil Resistance to ASTM SF 105* 4. Brake Fluid FMVSS DOT 4* 5. Sulfuric Acid (2.5% by weight in Dei

33、onized Water) 6. Long Life Coolant WSS-M97B44-D* (50/50% vol. Coolant/Deionized Water) 7. Transmission/Power Steering Fluid WSS-M2C938-A* 8. Windshield Washer Fluid Resistance WSS-M8B16-A3* *Or currently released equivalent fluid. Requirement: The specimen shall not dissolve, exhibit tackiness, dela

34、minate, crack, craze, blister, or irreversible show signs of softening (depolymerization) after exposure. 3.3. MATERIAL PROPERTY - REPORT ONLY Standard Test Methods for Flexible Cellular Materials Slab, Bonded and Molded Urethane Foams. Product Engineering Drawing may list specific call outs or requ

35、irements for any property listed below when a specific value is required for part performance. 3.3.1 Tensile Test Report Value, MPa (ASTM D3574 Test E) 3.3.2 Density Report Value, (ASTM D3574 Test A) kg/m3 or lb/ft3 3.3.3 Tear Resistance Test Report Value, MPa (ASTM D3574 Test F) 3.3.4 Constant Defl

36、ection Compression Set Test, Original Report Value, % (ASTM D3574 Test D) 3.3.4.1 Steam Autoclave Aging Exposure +/- 40% max from (ASTM D3574 Test J2, 5 hours at 120 C +/- 5 C Original followed by Constant Deflection Compression Set Test (ASTM D3574 Test D) 3.3.4.2 Dry Heat Aging Exposure +/- 10% ma

37、x from (ASTM D3574 Test K, Original 22 hours at 140 C or maximum temperature as mutually agreed upon, Followed by Constant Deflection Compression Set Test (ASTM D3574 Test D) ENGINEERING MATERIAL SPECIFICATION WSS-M99P48-A1/A2/A3/A4 Copyright 2016, Ford Global Technologies, LLC Page 6 of 8 3.3.5 Ind

38、entation Force Deflection Report Value N (ASTM D3574 Test B1) 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 Material Specifications. Ford Motor Company d

39、rawings and documents should include the appropriate Foam Performance specification, foam density and any additional critical properties as shown in the examples below: WSS-M99P48-A1, Interior WSS-M99P48-A2 Compression Set: 50% max Density: 27-35 kg/m3 (1.7 lb/ft3) WSS-M99P48-A3, Exterior WSS-M99P48

40、-A3, Climate Control Polyether foam with Tape Biocide tested per ES-8G13-19A672-AA WSS-M99P48-A4, Underhood Supplier and Product Code 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to maki

41、ng any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (w

42、ith reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Proces

43、s (PPAP) sign off must be kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P999

44、9-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2016 07 25 Released WSS-M99P48-A4 High temperature applications Added to para 3.2.8.1 Long term heat age at 180 C for 1000 h

45、 followed by short term heat age at 200 C for 100 h. Added para 3.2.9 Resistance to various reagents. Removed WSS-M99P1111-A and added those requirements directly into this specification. Updated Table 1 for A4. Added foam composition limitation to Application section A1. Added section 3.3.5 test pr

46、operty of Indentation Force Deflection ENGINEERING MATERIAL SPECIFICATION WSS-M99P48-A1/A2/A3/A4 Copyright 2016, Ford Global Technologies, LLC Page 7 of 8 2014 11 21 Editorial changes under applications section WSS-M8P3-A changed to WSS-M8P3-E1/3 2014 09 10 Editorial changes made to table 1 only ENG

47、INEERING MATERIAL SPECIFICATION WSS-M99P48-A1/A2/A3/A4 Copyright 2016, Ford Global Technologies, LLC Page 8 of 8 Table 1: Sample Size required for DV and PV unless otherwise agreed upon and documented in FMD *Contact Materials Engineering Material Category Replicates per Test A1: Foam A2: SewInand L

48、aminatedFoamA3: Foam with Pressure Sensitive AdhesiveA4: Foam with Pressure Sensitive Adhesive, HighTemperature Applications Interior ApplicationsExteriorApplications ClimateControl Applications Underhood Applications Test method: Odor (3 conditions) 3 (DV & PV) 3 (DV & PV) 3 (DV & PV) X X Fogging 3

49、 (DV & PV) 3 (DV & PV) 3 (DV & PV) X X . Flammability 5 (DV & PV) 5 (DV & PV) 5 (DV & PV) 5 (DV & PV) X X X X Resistance to Mildew 3 (DV) 3 (DV) 3 (DV) X X Environmental Stress Cracking 3 (DV) 3 (DV) 3 (DV) X X X X Weathering 3 (DV) 3 (DV) X Corrosion 3 (DV) 3 (DV) 3 (DV) X Pressure Sensitive Adhesive Strength As Received 3