1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW15932 Epoxy/Epoxide-Carbon Fiber Reinforced Unidirectional Composite Material Copyright 2011 General Motors Company All Rights Reserved October 2011 Originating Department: North American Engineering Standards Page 1 of 6 1 Scope 1.1 Materia
2、l Description. This specification covers the properties of Epoxy/Epoxide resin reinforced with unidirectional carbon fiber. 1.1.1 Adhesive Bonding. The intended production bonding system (substrate and adhesive) shall meet the requirements of the GMW15921 specification when tested in the laboratory.
3、 Production representative parts, and/or assemblies, shall meet the requirements of GMW16185 when tested according to the specification. 1.1.2 Paint. Follow paint testing procedures listed in the GMW14797 exterior plastic and engine compartment painted parts performance requirements. Approved painti
4、ng materials that can be used on the Epoxy/Epoxide substrate are listed in the GM MATSPC database. Use applicable paint materials approved as follows: Primer per 9984804 Primer surfacer per 9984121 Topcoat per 9984836, 9984901 or 9984904 Paint panels both per 9984823 1.2 Symbols. Material abbreviati
5、on per ISO 11469. 1.2.1 Type I: EP-(CF XX%) . 1.2.2 Where XX is the volume percentage of CF reinforcement. 1.3 Typical Applications. Typical applications include the following: fenders, hoods, roofs, etc. 1.4 Remarks. This specification was developed using the autoclave process. 2 References Note: O
6、nly the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM D696 ASTM D3532 ASTM D792 ASTM D4065 ASTM D3039 ASTM D4255 ASTM D3171 ASTM D5229 ASTM D3410 ASTM D5379 ASTM D3518 ASTM D6641 ASTM D3529 ISO 11469 2.2 GM Standards/Specifications.
7、9984121 GMW3059 9984804 GMW3221 9984823 GMW14797 9984836 GMW15921 9984901 GMW16185 9984904 2.3 Additional References. TMC003 Material Safety Data Sheet guidance documents (available at ). 3 Requirements 3.1 Requirements on Test Specimens. Reference GMW3221. 3.2 Sampling. Testing should be carried ou
8、t with laminates molded from three distinct lots (batch) of materials. A lot (batch) is defined as a quantity of material produced at the same time and under the same conditions from a well defined collection of raw materials. The quantity of material must have minimal variation in properties throug
9、hout to be considered a unique lot (batch). For the laminate, a lot (batch) is defined as one lot of fabric and one lot (batch) of resin(s). Sampling should be done on the start and end of rolls and should also be conducted across the full width of the rolls during production trials and qualificatio
10、n. This is intended to capture down-the- length and across-the-with variation introduced in the prepregging process steps. 3.3 Baseline Cure Process. It is recommended that the material supplier establish a baseline cure cycle to be used to produce laminates for the batch acceptance testing. The bas
11、eline cure cycle should be selected based on the end user applications and requirements for the material. Reasonable tolerances on heat up rates and time at temperature should be established and documented. The cure process shall be capable of Provided by IHSNot for ResaleNo reproduction or networki
12、ng permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15932 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 2 of 6 producing cured laminates of consistent, high quality. The following process conditions should be documented for each material used
13、: preform thickness, preform binder, molding technique, molding temperatures and molding pressure, molding time and panel dimensions. The amount of debulking of the preform needs to be documented. Refer to Table 1 for laminate thickness and panel requirements. Table 1: Cured Laminate Thickness and P
14、anel Requirements Unidirectional Materials Layup Test Number of Batches X, Number of Panels X, Number of Tests/Batch/Panels Test Temperature/Moisture Condition -40 C Ambient 23 C Ambient 85 C Ambient 85 C Wet (0)n1 Tensile ASTM D3039 3X2X3 1X2X3 1X2X3 (0)n1 Compression ASTM D6641 or ASTM D3410 3X2X3
15、 1X2X3 1X2X3 (90)n1 Tensile ASTM D3039 3X2X3 1X2X3 1X2X3 (90)n1 Compression ASTM D6641 or ASTM D3410 3X2X3 1X2X3 1X2X3 (0/90/0/90/0/90/0/90/0) 0/90 Tension ASTM D3039 3X2X3 3X2X3 3X2X3 3X2X3 (90/0)ns1 90/0 Compression ASTM D6641 or ASTM D3410 3X2X3 3X2X3 3X2X3 3X2X3 (+45/-45)ns2 In-plane Shear ASTM
16、D3518 or ASTM D5379 or ASTM D4255 3X2X3 3X2X3 3X2X3 3X2X3 Note 1: Select a value of n such that the laminate thickness is approximately 2.54 mm (0.100 in). Note 2: Select a value of n such that the laminate thickness is approximately 1.27 mm (0.050 in). 3.4 Test Specimen Conditioning. The test speci
17、mens shall be conditioned in accordance with Procedure C of Test Method ASTM D5229/D5229M. The specimens should be of 23 1 C (73 1.8 F) and 50 10% relative humidity. 3.5 Test Procedures. Tests shall be conducted using the latest issue of the test methods indicated. Suitable precautions should be tak
18、en to ensure that applicable safe limits are not exceeded when conducting test procedures, processes, and/or handling the materials required by this specification. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW
19、15932 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 3 of 6 3.5.1 Resin/Fiber Content of Prepreg. Use ASTM D3529 test method. Report the resin content by weight percent and fiber content by g/m2. 3.5.2 Gel Time. Use ASTM D3532 test method for gel time of carbon fiber-epo
20、xy prepreg. Use a test temperature of 125 1 C. Report the gel time in seconds. 3.5.3 Resin/Fiber Content of Laminate. Use Method 1, Procedure A, ASTM D3171 test method for constituent composite materials. Report the fiber, resin and void content by percent volume. 3.5.4 Laminate Density. Use Method
21、A ASTM D792 to measure the density. Report the specific gravity at 23 C. 3.5.5 Moisture Content. Use Procedure A ASTM D5229. Report the percentage. 3.5.6 Dynamic Mechanical Properties. Use ASTM D4065. A temperature sweep shall be conducted from 20 to 200 C. The heating rate shall be 5 C per minute.
22、The frequency shall be maintained at 1 Hz for fixed frequency instrumentation. Report the glass transition temperature from the storage modulus data. T-75 (find the maximum storage modulus and report the temperature at which the modulus is 75% of the maximum), Thermograms for either shear moduli (G,
23、 G” and tan ) or Tension, Compression or flexural moduli (E, E”, and tan ) versus temperature shall be submitted. 3.5.7 Tensile. Use ASTM D3039/D3039M. Use a minimum gage length of 127 2.5 mm (5.00 0.1 in). All specimens are to be loaded in tension at a rate of 1.27 mm (0.05 in)/minute until failure
24、. Report the maximum load, stress, modulus, Poissons ratio, and strain to failure. 3.5.8 Compression. Compression tests should be performed using either test method ASTM D6641/D6641M or ASTM D3410/D3410M. All specimens are to be loaded in compression at a rate of 1.27 mm (0.05 in)/minute until failu
25、re. Report maximum load and stress. 3.5.9 In-Plane Shear. In-Plane shear tests should be performed using either test method ASTM D5379/D5379M or ASTM D4255/D4255M or test method ASTM D3518/D3518M. Each specimen is loaded in tension at a rate of 1.27 mm (0.05 in)/minute until failure. Report maximum
26、load, shear stress, shear modulus, and shear strain to failure for all in-plane shear specimens. The shear modulus is reported from the linear portion of the shear stress-shear strain curve. 3.5.10 The Coefficient of Linear Thermal Expansion (CLTE). Use ASTM D696 over the following temperature range
27、s: a. -30 to 30 C. b. 30 to 85 C. Report the CLTE over both ranges, use the specimen original length at -30 C as the zero point for l/l (change in length/original length). 3.6 The specimens shall be tested and the results averaged. The average value is the material property value. This value is comp
28、ared to the required value shown in Table 2: Compound Property Table. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15932 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 4 of 6 Table
29、 2: Compound Property Table Property Type I 23 C Ambient Type II 23 C Ambient Test Method Resin Content Prepreg % Volume 40 to 50 45 to 55 ASTM D3529 Fiber Content Prepreg g/m2 180 to 200 180 to 200 Gel Time s 120 to 600 120 to 600 ASTM D3532 Resin Content Laminate % Volume 40 to 50 45 to 55 ASTM D3
30、171, Procedure A Fiber Content Laminate % Volume 50 to60 45 to 55 Void Content Laminate % volume 2 2 Specific Gravity 1.3 to 1.7 1.3 to 1.7 ASTM D792, Method A Moisture Content % 2.5 2.5 ASTM D5229, Procedure A Tg C 135 130 ASTM D4065, 5 C/minute Tensile Strength MPa (0)n (90)n (0/90/0/90/0/90/0/90/
31、0) 192.7 n=12 5.2 n=12 120 139.9 n=12 5.8 n=12 100 ASTM D3039 Tensile Modulus MPa (0)n (90)n (0/90/0/90/0/90/0/90/0) 18.2 n=12 1.3 n=12 10.4 16 n=12 1.2 n=12 9.6 Poissons Ratio (0)n (90)n (0/90/0/90/0/90/0/90/0) 0.199 n=12 0.048 n=12 0.025 0.198 n=12 0.034 n=12 0.027 Provided by IHSNot for ResaleNo
32、reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15932 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 5 of 6 Property Type I 23 C Ambient Type II 23 C Ambient Test Method Compression Strength MPa (0)n (90)n (90/0)n C
33、ompression Modulus MPa (0)n (90)n (90/0)n 109.2 n=12 18.1 n=12 66.6 n=6 109.2 n=12 18.1 n=12 66.6 n=6 101.8 n=12 19.1 n=12 69.8 n=6 101.8 n=12 19.1 n=12 69.8 n=6 ASTM D6641 or ASTM D3410 Shear Modulus MPa (-45/+45)ns 1.60 n=4 1.35 n=8 ASTM D5379 or ASTM D4255 or ASTM D3518 Coefficient of Linear Ther
34、mal Expansion /C -30 to 30 C (0)n (90)n (90/0)n (45/45)n 30 to 85 C (0)n (90)n (90/0)n (45/45)n 1.02X10-6 n=12 3.38X10-5 n=12 2.86X10-6 n=6 3.23X10-6 n=4 1.14X10-6 n=12 3.89X10-5 n=12 3.20X10-6 n=6 3.50X10-6 n=4 1.28X10-6 n=12 3.65X10-5 n=12 3.75X10-6 n=6 2.97X10-6 n=8 1.41X10-6 n=12 4.40X10-5 n=12
35、3.80X10-6 n=6 3.27X10-6 n=8 ASTM D696 3.7 Compound Properties. Material suppliers must certify molding compound properties to the specific GM Test Sampling Plan approved for their material. 3.7.1 Constituent Materials. Individual specifications for the materials which constitute the Epoxy/Epoxide mo
36、lding compound shall be established by the molder. Incoming materials shall be approved to those specifications by the molders laboratory before release for production. Test results shall be maintained by the molder and be available for General Motors review. 4 Manufacturing Process All shipments of
37、 material or parts under contract or purchase order manufactured to this specification shall be equivalent in every respect to the initial samples approved by Engineering. There shall be no changes in raw material composition or source, formulation, construction, manufacturing or test methods, or lo
38、cation of manufacture without prior notification and approval by the appropriate GM Material Specialist Team. Lack of notification by the supplier constitutes grounds for rejection of any shipment and/or forfeiture of approval. While samples may be taken from incoming shipments and checked for confo
39、rmance to this specification, the supplier shall accept the responsibility for incoming shipments meeting this specification without dependence upon purchasers inspection. 5 Rules and Regulations. 5.1 Legal Regulations. All materials must satisfy applicable laws, rules, regulations and recommendatio
40、ns valid in the country of usage. 5.2 Language. In the event of conflict between the English and domestic language, the English language shall take precedence. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW1593
41、2 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 6 of 6 5.3 Inspection and Rejection. Samples of components or materials released to a GM material specification shall be tested for conformity with the requirements of this material specification and approved by the respon
42、sible Engineering department prior to commencement of delivery of bulk supplies. A new approval must be received for any changes, e.g., properties, manufacturing process, location of manufacture, etc. If not otherwise agreed, all testing and documentation normally required for initial release must b
43、e completed. It is the responsibility of the supplier to inform the customer in a timely manner, without solicitation, and to include documentation of all modifications of materials and/or processes and to apply for a new release. If not otherwise agreed, all release tests shall be repeated and docu
44、mented by the supplier prior to commencement of delivery of non-conforming bulk supplies. In individual cases, a shorter test can be agreed to between the responsible Engineering department and the supplier. 5.4 Initial Source Approval. No shipments shall be made by any supplier until representative
45、 initial production samples have been approved by the appropriate Materials Engineering department(s) as meeting the requirements of this specification. 5.5 Material Safety Data Sheets/Safety Data Sheets (MSDS/SDS). For new product submissions, or when a change in chemical composition of an existing
46、 product has occurred, a complete copy of the Material Safety Data Sheet/Safety Data Sheet must be submitted in compliance with the Globally Harmonized System of Classification and Labeling of Chemicals (GHS) requirements or other country-specific MSDS/SDS requirements. In addition, product MSDS/SDS
47、 submissions must be in compliance with specific country General Motors TMC003 Material Safety Data Sheet/Safety Data Sheet guidance documents where available. 5.6 All materials supplied to this standard must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts. 5.
48、7 The molding compound shall be identified by the specification code, the manufacturers identification code and lot number, along with any additional vehicle group and component division requirements. 6 Approved Sources Engineering qualifications of an approved source are required for this standard.
49、 Only sources listed in the GM Materials File MATSPC under this standard number have been qualified by Engineering as meeting the requirements of this standard. 7 Notes 7.1 Glossary. MATSPC: Global repository of GM approved materials for corresponding GM Engineering Standards. 7.2 Acronyms, Abbreviations, and Symbols. CLTE Coefficient of Linear Thermal E
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