NAVISTAR MPAPS D-7133-2014 Material Process and Quality Control Requirements for Liquid Composite Molded Parts.pdf

1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 1 of 4 NAVISTAR, INC. Material, Parts, and Process Specificatio

2、ns (MPAPS) NUMBER: MPAPS D-7133 Former Designation: TMS-7133 TITLE: Material, Process and Quality Control Requirements for Liquid Composite Molded Parts CURRENT REV No.: 1412 DATE: Dec. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-7133 Aug. 2006 PR

3、INTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety an

4、d health practices and to determine the applicability of regulatory limits prior to use. Change Notice: Changed to new MPAPS format; editorial changes. 1.0 APPLICATION This specification describes engineering property and quality requirements for the selection of those materials to be utilized in th

5、e Liquid Composite Molding process (LCM). This includes such materials as dicyclopentadiene (DCPD) and urethane. 2.0 SCOPE This specification covers general, material property requirements, tooling requirements, surface appearance, pre-paint requirements, PPAP, quality and quality control, source ap

6、proval, shipping and identification requirements and designation on drawings for parts produced using the LCM process. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 spec

7、ification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 ASTM D790 CFR Title 29, Part 1910 ASTM

8、D638 NAVISTAR Manufacturing Standard MS-D-13 ASTM D570 NAVISTAR MPAPS B-50 ASTM D792 NAVISTAR CEMS Test Method DT-4 SAE J1344 NAVISTAR CEMS Test Method GT-5A Metton Post Molding Guide * NAVISTAR MPAPS G-9005 * The Metton Molding Guide is available from: Metton of America Inc. 3800 Camp Creek Pky. Bu

9、ilding 1800 Suite 126 Atlanta GA 30331 NUMBER: MPAPS D-7133 TITLE: Material, Process and Quality Control Requirements for Liquid Composite Molded Parts REVISION: 1412 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Stan

10、dards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 2 of 4 4.0 GENERAL QUALIFICATION Individual parts of the composite/assembly must meet all of the requirements of the material specification(s) shown on the engineering drawing for the part and/or

11、subassembly in addition to meeting all requirements of this specification. 4.1 Tooling requirements Selection of tooling materials, construction methods and maintenance procedures shall be such that a minimum of 30,000 parts can be produced without deterioration of the surface finish. After the init

12、ial production (30,000 pieces), repair of the molds is restricted to a maximum of 25% of the mold surface and such repair shall not result in degradation of the surface quality of the part. 4.2 Material Properties Property ASTM Method Unless otherwise specified DCPD Requirement Density, max, kg/m3 D

13、 792 1.05 Water absorption (24 hrs), max. D 570 0.5% Tensile Strength, min D 638 6.5 ksi Tensile Modulus, min D 638 250 ksi Flexural Strength, min D 790 10 ksi Flexural Modulus, Tangent, min D 790 250 ksi Gardner Impact, -20C, min CEMS DT-4 8.0 ft-lbs 4.3 Part Marking As an aid to recovery and recyc

14、ling of plastic parts, each part shall be marked to identify the type of polymeric material the part is comprised of. Part marking shall be in accordance with SAE J1344. Each part shall be identified so as to provide traceability to resin lot, molding date, and operator. 4.4 Surface Appearance This

15、requirement applies to parts identified on the drawing by a zone designation as per MPAPS G-9005. Parts such as hoods, fenders, or other highly visible parts are considered to be Zone I as per MPAPS G-9005. The surface is to be uniform, i.e. no areas of discontinuity, blisters, cracks, chips etc., a

16、re allowed. Small defects, such as pinholes, pits and small dirt particles, are to be minimized. No more than 12 of these small defects per part, or 6 within a 3-square inch (1935 mm2) area, is permitted. 4.5 Pre-paint Finish For parts requiring a pre-paint finish, the pre-paint treatment will confo

17、rm to the requirements of MPAPS G-9005. Parts requiring a pre-paint finish should be prepared in accordance with the resin/material suppliers recommended practice, e.g., per the Post Molding Guide for Metton . Surface appearance requirements will be in accordance with the zone descriptions in MPAPS

18、G-9005 for the primed surfaces. The pre-paint finish shall be adherent to the surface such that it will pass the Adhesion of Paint Test as per CEMS Test Method GT-5A. NUMBER: MPAPS D-7133 TITLE: Material, Process and Quality Control Requirements for Liquid Composite Molded Parts REVISION: 1412 This

19、document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 3 of 4 4.6 Molding Process The molder shall submit to Materials Engi

20、neering at NAVISTAR the following information, relating to the production process, as described below. Information provided by the vendor to NAVISTAR shall be considered confidential. When identified by the supplier as “sensitive or proprietary”, such information will be considered confidential and

21、restricted to the appropriate Materials Engineering and Manufacturing Quality Control personnel. 4.6.1 A description of the constituent materials. This will include the molders material identification, level of promoter and system gel/cure times. Process Control limits for these factors should also

22、be included. 4.6.2 If reinforcing materials are used, a drawing of the reinforcement lay-up showing the physical dimensions of coverage. Include the tolerances of for those dimensions with respect to the location in the mold. 4.6.3 A general description of the molding process. This is to include the

23、 basic steps involved in producing the part, such as mold preparation, injection procedure, demolding, and any secondary and finishing operations. 5.0 QUALITY Initial production part samples will be selected and inspected jointly by both the supplier quality group and by product and supplier quality

24、 personnel. Samples will be inspected for cosmetic surface finish, component fit, edge finish and other characteristics as appropriate. These samples will be retained as reference inspection standards at the both vendor and NAVISTAR facilities. These samples will be considered standards of minimum a

25、cceptable finish quality for all future parts and will be maintained as reference standards both at the vendor and International facilities. No changes in the molding materials or production processes will be made after these initial production part samples have been approved. 5.1 Production Part Ap

26、proval Process (PPAP) Before final production approval is granted, sample parts will be submitted to NAVISTAR and to the appropriate NAVISTAR manufacturing plant(s) for approval in accordance with requirements of the Production Part Approval Process (PPAP) manual as per ISO 9001. 6.0 SOURCE APPROVAL

27、 AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and

28、approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent i

29、n all respects to those samples which were approved by the purchaser. No changes in formulation or NUMBER: MPAPS D-7133 TITLE: Material, Process and Quality Control Requirements for Liquid Composite Molded Parts REVISION: 1412 This document is restricted and may not be sent outside Navistar, Inc. or

30、 reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 4 of 4 processing practices are permitted without approval. In the event that changes in material, properties, processing practices, con

31、struction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updat

32、ed Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide s

33、tatistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products.

34、7.0 SHIPPING AND HANDLING Shipping and identification shall be in accordance with NAVISTAR Manufacturing Standard MS-D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. 8.0 DESIGNATION ON DRAWINGS The drawing will reference MPAPS D-7133 for

35、material properties, process and quality requirements. 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/