1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2010 01 07 N-STATUS No replacement named J. Crist, NA Released WP 3948-a Page 1 of 5 PC/PBT ALLOY, RUBBER MODIFIED MOLDING COMPOUND ESB-M4D442-A3 - PAINTABLE NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material
2、 defined by this specification is a rubber modified polycarbonate-polybutylene terephthalate (PC/PBT) alloy molding compound formulated for low temperature impact and solvent resistance. 2. APPLICATION This specification was released originally for material used for painted plastic bumpers. 3. REQUI
3、REMENTS 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to analyze process/product data so that varia
4、tion in the final product is continuously reduced. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval
5、shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicate
6、d herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5% relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 MOLDING COMPOUND 3.4.1 Color Black 3.4.2 Melt Flow Rate 11.5-14.0 g/10 min
7、(ASTM D 1238, Procedure A, 250 C, 5.0 kg) ENGINEERING MATERIAL SPECIFICATION ESB-M4D442-A3 WP 3948-b Page 2 of 5 3.4.3 Rubber Content The rubber level of the material will be monitored by a proprietary FTIR procedure provided by the supplier and will be kept on file for future reference as a composi
8、tional fingerprint. 3.5 MOLDED TEST SPECIMENS 3.5.1 Preparation of Test Specimens All test specimens shall be injection molded in accordance with ASTM D 1897. The values of this specification are based on injection molded specimens unless otherwise specified. 3.5.2 Density 1.18-1.21 g/cm3 (ASTM D 79
9、2) 3.5.3 Tensile Strength at Yield, min 45 MPa (ASTM D 638, Type I specimen, 3.2 mm thick, 50 mm/min test speed) 3.5.3.1 Elongation at Break, min 120% 3.5.4 Flexural Modulus 1.6-2.2 GPa (ASTM D 790, Method I, Procedure A, 6.4 x 12.7 x 127 mm specimen, 2.5 mm/min test speed) 3.5.5 Flexural Strength 6
10、2-82 MPa (ASTM D 790, Method I, Procedure A, 6.4 x 12.7 x 127 mm specimen, 2.5 mm/min test speed) 3.5.6 Impact Strength, Izod, min (ASTM D 256, Method A, 6.4 x 12.7 x 63.5 mm specimen, 10 specimens minimum) 3.5.6.1 At -29 +/- 1 C 300 J/m 3.5.7 Heat Deflection Temperature, min 90 C (ASTM D 648, 6.4 x
11、 12.7 x 127 mm specimen, 1.82 MPa) 3.5.8 Instrumented Impact Strength at -29 C Ductile (ASTM D 3763) Test Method: An impact tester (Dynatup Model 8250 or equivalent) equipped with a 13 mm diameter impact head and a 76 mm diameter base shall be used. Test speed will be 12 km/h. Test specimens 100 x 1
12、00 x 3.2 +/- 0.2 mm with a centrally located molded-in rib (1.6(W) x 41(L) x 3.2(H) +/- 0.2 mm) will be conditioned at the specified temperature for 24 h, min and will be impacted within 5 s after removal from the cold chamber. ENGINEERING MATERIAL SPECIFICATION ESB-M4D442-A3 WP 3948-b Page 3 of 5 A
13、ny specimen that exhibits no fracture or a punch through ductile tear within the 13 mm impact area will be defined as a pass. Any specimen that exhibits a brittle or shatter type crack beyond the impact area will be defined as a failure. A minimumm of 10 specimens must be impacted. 3.5.9 Environment
14、al Stress Crack Resistance Elongation, Change from Original, max -50% Test Method: Mount Type I tensile specimens on the fixture bars at 0.7% surface strain level. Immerse the assembly for 5 min at 23 +/- 2 C in Reagent Grade Reference Fuel B plus 15% toluene by volume. Release the strain from the t
15、est bars immediately upon removal from the fuel and allow to air dry. Mount on the tensile machine fixture. Determine the elongation at break. 3.5.10 Heat Aging Performance (1000 h at 90 +/- 2 C) 3.5.10.1 Tensile Strength Change, max +10% (Test Method per para 3.5.3) 3.5.10.2 Elongation Change, max
16、-50% (Test Method per para 3.5.3) 3.5.10.3 Impact Strength, Izod Change, max -10% (Test Method per para 3.5.6) 3.6 FLAMMABILITY Burn Rate, max 100 mm/min (FLTM BN 24-2, without the lot sampling plan) In addition, the test specimen shall not exhibit any flashing or sudden flaming on either surface in
17、 excess of the above max value. 3.7 ADDITIONAL REQUIREMENTS Specific requirements for physical properties of molded or extruded parts shall be specified on the engineering drawing and/or engineering part specification. All critical areas with respect to these properties shall be clearly designated o
18、n the engineering drawing. 3.8 REGRIND AND/OR BLENDED MATERIAL Must meet Q-101 Appendix D or limits as specified on the engineering drawing and/or engineering part specification. ENGINEERING MATERIAL SPECIFICATION ESB-M4D442-A3 WP 3948-b Page 4 of 5 3.9 PAINTABILITY The material when painted must me
19、et the requirements of engineering performance specifications shown on the engineering drawing, using coating materials approved by the responsible product materials engineering office. 3.10 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristi
20、cs to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the spe
21、cification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the
22、request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1, unless a different suffix (e.g., A2 or A3) is specified on the engineering document for the appl
23、ication. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Enginee
24、ring activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity its own laboratory report to the specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Upon approval, the material will
25、be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information given below is provided for assistance and clarification and does not represent requirements to this specification. 5.1 MOLD SHRINKAGE 0.009-0.011 (ASTM D 955, after 48 h, injection molded sample) 5.2 C
26、OEFFICIENT OF LINEAR THERMAL EXPANSION 9.0 x 10-5/C (ASTM D 696) ENGINEERING MATERIAL SPECIFICATION ESB-M4D442-A3 WP 3948-b Page 5 of 5 5.3 FLEXURAL MODULUS (ASTM D 790, Method I, Procedure A, 6.4 x 12.7 x 127 mm specimen, 2.5 mm/min test speed) At 50 +/- 1 C 1.4-1.7 GPa At -24 +/- 1 C 2.2-2.6 GPa 5.4 IMPACT STRENGTH, IZOD No break (ASTM D 256, Method A, 6.4 x 12.7 x 63.5 mm specimen, 10 specimens for each test) 5.4.1 Notched 600 J/m 5.4.2 Unnotched No break 5.5 HEAT DEFLECTION TEMPERATURE, min 112 C (ASTM D 648, 6.4 x 12.7 x 127 mm specimen, 0.45 MPa)
