1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirelyvoluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefro
2、m, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243TO PLACE A DOCUMENT
3、 ORDER; (724) 776-4970 FAX: (724) 776-0790SAE WEB ADDRESS http:/www.sae.orgCopyright 1995 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.SURFACEVEHICLE400 Commonwealth Drive, Warrendale, PA 15096-0001STANDARDSubmitted for recognition as an American National StandardJ2253I
4、SSUEDDEC95Issued 1995-12TEST PROCEDURES FOR AUTOMOTIVE STRUCTURAL COMPOSITE MATERIALSForewordThis Document has not changed other than to put it into the new SAE Technical Standards BoardFormat.TABLE OF CONTENTS1. Scope . 42. References . 42.1 Applicable Publications. 42.1.1 SAE Publication 42.1.2 AS
5、TM Publications . 42.1.3 GM Publication . 52.1.4 Conflicts 53. Definitions. 53.1 Structural Polymer Composite 53.2 Planar Isotropic Composites. 53.3 Orthotropic Composites 53.4 Special Reinforced Composites . 53.5 Ambient Conditions 54. General Requirements . 54.1 Calibrations. 54.2 Equivalence 64.3
6、 Responsibility for Quality 64.4 Data Reporting . 65. Panel Fabrication 65.1 General Panel Requirements . 65.1.1 Number of Panels. 65.1.2 Constituent Materials 65.1.3 Preform/Mold Charge Lay-up . 65.1.4 Panel Quality 65.1.5 Panel Dimensions. 65.1.6 Panel Thickness . 65.2 Panel Molding. 6COPYRIGHT So
7、ciety of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J2253 Issued DEC95-2-5.2.1 Liquid Composite Molding 75.2.2 SMC Molding 75.2.3 Thermoplastic Compression Molding .75.3 Planar Isotropic Composites. 75.3.1 Panel Test Orientation. 75.3.2 Fiber Content 75.4 Orthotropic Comp
8、osites 75.4.1 Fiber Orientation .75.4.2 Fiber Content 76. Material Sampling .76.1 Sampling Procedure .76.2 Specimen Layout 77. Specimen Preparation 97.1 General .97.2 Rough Cutting.97.3 Surface Edge Finishing. 97.4 Specimen Conditioning. 98. Physical Test Methods 98.1 General .98.2 Specific Gravity.
9、98.3 Resin Content .98.4 Filler Content 98.5 Fiber Content 98.6 Panel Thickness98.7 Crystallinity .98.8 Molecular Weight 109. Thermal Test Methods 109.1 General .109.2 DMA Test Method .109.2.1 Instrumentation .109.2.2 Sample Preparation 109.2.3 Sample Dimensions109.2.4 Test Temperature Range.109.2.5
10、 Heating Rate.109.2.6 Frequency .109.2.7 Other Test Parameters109.2.8 Glass Transition Temperature .109.2.9 Report.109.3 Coefficient of Linear Thermal Expansion (CLTE)119.3.1 CLTE Testing.119.3.2 Instrumentation .119.3.3 Sample Dimensions119.3.4 Sample Preparation 119.3.5 Procedure .119.3.6 Report.1
11、110. Tensile Testing 1110.1 General Description 1110.2 Apparatus1110.3 Test Specimen 12COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J2253 Issued DEC95-3-10.3.1 Specimen Dimensions 1210.3.2 Specimen Preparation 1210.3.3 Specimen Tabbing 1210.4 Procedure
12、.1310.4.1 Setup 1310.4.2 Replicates .1310.4.3 Acceptable Failures.1310.5 Calculations 1310.6 Report.1310.7 Resin Tensile Properties .1311. Compression Testing 1311.1 General Description 1311.2 Compression Test Fixture .1311.3 Test Specimen 1411.3.1 Specimen Dimensions 1411.3.2 Specimen Preparation 1
13、411.3.3 Specimen Tabbing 1411.4 Procedure .1411.4.1 Setup 1411.4.2 Replicates .1411.4.3 Strain Measurement1411.4.4 Chord Modulus .1411.5 Calculations 1411.6 Report.1412. Shear Testing1412.1 General Description 1412.2 Shear Test Fixture.1512.3 Test Specimen 1512.3.1 Specimen Dimensions 1512.3.2 Speci
14、men Preparation 1512.3.3 Specimen Tabbing 1512.4 Procedure .1512.4.1 Dimensions .1512.4.2 Mounting .1512.4.3 Loading .1512.4.4 Replicates .1512.5 Calculation 1512.5.1 Shear Strength1512.5.2 Shear Modulus1612.5.3 Assessing Failure Modes1612.6 Report.1713. Statistical Analysis Methods .1813.1 Mean Cal
15、culation 1813.2 Standard Deviation Calculation.1814. Constituent Content Conversions .1814.1 Weight Percent to Volume Percent .1814.2 Volume Percent to Weight Percent .1814.3 Specific Gravity Estimation .1915. Material Characterization Summary .19COPYRIGHT Society of Automotive Engineers, Inc.Licens
16、ed by Information Handling ServicesSAE J2253 Issued DEC95-4-Figure 1 Specimen Location .8Figure 2 Storage Modulus Diagram 12Figure 3 Typical Shear Load-Deflection Curves17Figure 4 Characterization Test MatrixTest MatrixPlanar Isotropic or Orthotropic CompositesMinimum Requirement20Appendix A Supplem
17、ental Data Reporting Package (SDRP) 21Figure A1 Constituent Materials/process Data Sheet .21Figure A2 Material Properties0 Direction Summary Sheet 25Figure A3 material Properties90 Direction Summary Sheet 26Figure A4 QA properties Data.27Figure A5 Thermal Properties Data 28Figure A6 Panel Thickness
18、Data .28Figure A7 Mechanical Properties Data SheetTensile Strength29Figure A8 Mechanical Properties Data SheetTensile Modulus30Figure A9 Mechanical Properties Data SheetPoissons Ratio .31Figure A10 Mechanical Properties Data SheetTensile Strain to Failure 32Figure A11 Mechanical Properties Data Shee
19、tTensile Energy to Failure 33Figure A12 Mechanical Properties Data SheetCompressive Strength 34Figure A13 Mechanical Properties Data SheetCompressive Modulus 35Figure A14 Mechanical Properties Data SheetCompressive Strain to Failure 36Figure A15 Mechanical Properties Data SheetCompressive Energy to
20、Failure.37Figure A16 Mechanical Properties Data SheetShear Strength .38Figure A17 Mechanical Properties Data SheetShear Modulus .39Appendix B SDRP Data Reporting Program40B.1 General .40B.2 Setup 40B.3 Installation.41B.4 Running the SDRP Program.41B.4.1 Main Menu 41B.4.2 Help Screens 41B.4.3 Data En
21、try Screen 41B.4.4 Error Messages 41B.4.5 Data Files42B.4.6 Printing a Summary Report 42B.4.7 Material File Utility 42B.4.8 Exit to DOS .421. ScopeThis SAE Standard is intended to serve as a guide for the collection of physical, mechanical, andthermal properties of fiber-reinforced polymer composite
22、 materials for automotive structural applications. Thisdocument attempts to utilize test methods applicable to the widest range of structural materials and processeswithout compromising the integrity of the data being sought. A summary of the material characterization isshown in Section 15.2. Refere
23、nces2.1 Applicable PublicationsThe following publications form a part of the specification to the extent specifiedherein. Unless otherwise indicated the latest revision of SAE publications shall apply.2.1.1 SAE PUBLICATIONAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.SAE EA-2
24、253SDRP Data Reporting ProgramCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J2253 Issued DEC95-5-2.1.2 ASTM PUBLICATIONSAvailable from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.ASTM D 618Conditioning Plastics and Electrical Insulating
25、 Materials for TestingASTM D 638Tensile Properties of PlasticsASTM D 696Coefficient of Linear Thermal Expansion of PlasticsASTM D 792Specific Gravity and Density of Plastics by DisplacementASTM D 2584Ignition Loss of Cured Reinforced ResinsASTM D 3039Tensile Properties of Fiber CompositesASTM D 3410
26、Compression Properties of Fiber CompositesASTM D 3417Heats of Fusion and Crystallization of Polymers by Thermal AnalysisASTM D 3593Molecular Weight Averages and Distribution of Polymers by GPC MethodASTM D 4065Practice for Determining and Reporting Dynamic Mechanical Properties of PlasticsASTM D 508
27、3Tensile Properties of Reinforced Thermosetting Plastics Using Straight Sided SpecimensASTMD5296Molecular Weight Averages and Molecular Weight Distribution of Polystyrene by HighPerformance Size-Exclusion ChromatographyASTM D 5379Shear Properties of Composite Materials by the V-notched Beam Method2.
28、1.3 GENERAL MOTORS PUBLICATIONAvailable from Boise Cascade, 13301 Stephens Road, Warren, MI 48089.GM Std 9077-PDetermination of Filler Content2.1.4 CONFLICTSIn the event of a conflict between the text of this document and the references cited herein, thetext of this document shall take precedence.3.
29、 Definitions3.1 Structural Polymer CompositeAutomotive structural polymer composites are considered to be thosehaving a tensile modulus greater than 7 GPa and a tensile strength greater than 100 MPa.3.2 Planar Isotropic CompositesThese materials are defined as being comprised of randomly oriented fi
30、bersthat will result in properties that are nearly the same in all directions in-plane, but different in the thicknessdirection. Examples of such materials include liquid molded composites reinforced with continuous strandmats, chopped strand mats, or directed fiber preforms; random fiber sheet mold
31、ed composites (SMC) andrandom fiber reinforced thermoplastic composites.3.3 Orthotropic CompositesThese materials do not have the same x, y, and z directional properties. Suchmaterials include liquid molded composites reinforced with unidirectional and bidirectional stitched mats,woven fabrics, knit
32、ted fabrics, and directionally reinforced SMC and thermoplastic composites.3.4 Special Reinforced CompositesSome reinforcements create different symmetry than planar isotropic ororthotropic reinforcements. Examples include some triaxial woven preforms, braided mats, or mixed lay-ups.Test specimen la
33、yout definition for these reinforcements is beyond the scope of this document. Sampling ofthese materials should be done with the prior approval of the customer.3.5 Ambient ConditionsThese are room temperature laboratory conditions, which are assumed to be 23 C 2C and 50% 5% RH.4. General Requiremen
34、ts4.1 CalibrationsAll measuring equipment for determining or controlling physical, mechanical, or thermalcharacteristics shall be calibrated and certified with traceability to the National Institute of Standards andTechnology.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Han
35、dling ServicesSAE J2253 Issued DEC95-6-4.2 EquivalenceAny substitution of supposed equivalent items, where “or equivalent” is specified herein, mustfirst be approved by the customer.4.3 Responsibility for QualityUnless otherwise specified, the supplier is responsible for all quality inspectionand fo
36、r meeting all of the test requirements specified herein. The supplier may use internal testing facilities orany other qualified test agencies.4.4 Data ReportingAll physical, thermal, and mechanical data and information on the constituent materials andpanel molding shall be submitted to the customer
37、using the Supplemental Data Reporting Package (SDRP).All data requested herein shall be manually recorded onto the SDRP forms or entered into the electronic SDRPprogram for output and transmittal to the customer. Graphs or other requested traces shall also be packagedand sent with the SDRP to the cu
38、stomer.The SDRP Data Reporting Program (EA-2253) available from SAE as a 3-1/2 in or a 5-1/4 in diskette, is amenu-driven program, which facilitates data entry and reporting using an IBM-compatible personal computer.This program is the preferred method for reporting data.The SDRP reporting forms are
39、 found in Appendix A. These include a “Constituent Materials/Process DataSheet” (A3-A5) for the raw materials and processing data. This form may be modified as required to provideadditional relevant information.5. Panel Fabrication5.1 General Panel Requirements5.1.1 NUMBER OF PANELSSix panels shall
40、be tested for any given material (a material is defined here as anyparticular combination of resin, reinforcement, and filler). Sufficient panels should be molded to assure thatsix panels are available after potential rejections cited in 5.1.4, 5.1.6, 5.3.2, or 5.4.2.5.1.2 CONSTITUENT MATERIALSAll o
41、f the panels shall be from a single production lot of composite using singlebatches of resin, fiber, filler, and additives. The resin type, all matrix constituents and fibers used in moldingare to be clearly defined. RECORD IN SDRP.5.1.3 PREFORM/MOLD CHARGE LAY-UPTo allow for a direct comparison to
42、be made among material systems, allplies shall be aligned in the same direction. Every ply in a given plaque shall also be the same reinforcementform and product code. Mixed lay-ups may be considered for submittal, but should be discussed with thecustomer prior to panel fabrication. If multiple plie
43、s are used, the plies must be aligned and directionallyindicated. The number of plies must also be indicated. RECORD IN SDRP.5.1.4 PANEL QUALITYEvidence of a flawed or an improperly prepared test panel shall be cause for discarding thepanel prior to testing and fabrication of a replacement panel. Su
44、ch causes include incorrect lay-upsequence, incorrect cure cycle, incorrect fiber content, fiber misalignment, nonfilling of mold cavity, blisters,excessive porosity, excessive void content, severe panel warpage, resin rich surfaces, thickness variationacross the plaque, or compression of the prefor
45、m towards the surface.5.1.5 PANEL DIMENSIONSNominal panel dimensions shall be 610 mm x 610 mm.5.1.6 PANEL THICKNESSPanel thickness shall be 3.2 mm 0.2 mm with maximum thickness run out of 0.2 mm.5.2 Panel MoldingMolding conditions such as injection time, mold temperature, and postcure schedules must
46、be reported. Reaction conditions for the material must be representative of conditions which would be utilizedto mold an actual production part and should be reported in complete detail. Panels may be fixtured duringpostcure if warpage is likely to occur. RECORD IN SDRP.COPYRIGHT Society of Automoti
47、ve Engineers, Inc.Licensed by Information Handling ServicesSAE J2253 Issued DEC95-7-5.2.1 LIQUID COMPOSITE MOLDINGThermoplastic or thermoset binders in the preform shall be “set” prior tomolding. All panels shall be molded in a center-gated mold. Following the cure, care should be taken toavoid unne
48、cessary flexing of the plaque during demolding. Postcure is permissible, but should be noted inthe SDRP.5.2.2 SMC MOLDINGThe structural SMC molding charge must be prepared in a manner consistent withproduction molding practice. If the material will be used with 80% mold coverage, a similar coverage
49、shouldbe used in the fabrication of test plaques. Using 80% as an example, the charge should consist of one ormore plies cut to a square configuration and placed over the central 430 mm x 430 mm area of the mold.The charge should be from properly matured material and should be thermally equilibrated to ambienttemperature prior to molding. Following cure, care should be taken to avoid unnecessary flexing of theplaque during demolding. Postcure is permissible but should be noted in the SDRP.5.2.3 THERMOPLASTIC COMPRESSION MOLDING
