1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions REV. 00 2015 10 01 Released B. Haggart, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 6 POLYPROPYLENE (PP) MOLDING COMPOUND, WRS-M4D1058-A1 HOMOPOLYMER, HEAT STABILIZED, 35% GLASS FIBER/MINERAL REI
2、NFORCED, 100% PCR/PIR RESIN CONTENT, 65% RECYCLED MATERIAL BY WEIGHT, NON-VISIBLE APPLICATIONS 1. SCOPE The material defined by this specification is based on a 25% glass fiber and 10% mineral reinforced thermoplastic injection molding compound, with 100% recycled resin. 2. APPLICATION This specific
3、ation was released originally for material used for hidden structural components in floor console. 2.1 LIMITATIONS This material is not intended for visible or decorated (wrapped, painted, etc) applications. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources
4、. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. The approved source for
5、this specification is TMG Optipro CP2510GM. 3.2 CONDITIONING AND TEST CONDITIONS All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioni
6、ng environment or soon after removal. 3.3 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.3.1 Materials approved to these specifications require testing to WSS-M99P2222-D1/latest Performance, Vehicle Interior Environment Quality Material/Component Requirements. If collective parts exceed 100 cm2 or
7、 100 g then testing will be required per the appropriate performance specification. 3.3.2 Materials requiring High Strain Rate, Creep or fiber oriented Tensile Modulus must test to the requirements of WSS-M99D68-A1/Latest, Thermoplastic Property Determination. For CAE, High Strain Rate Tensile, Cree
8、p and Tensile Modulus. Data must be included in the material submission package. ENGINEERING MATERIAL SPECIFICATION WRS-M4D1058-A1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 6 3.3.3 Performance Criteria: Parts using this specification shall meet the appropriate performance specification
9、, WSS-M15P4-F/Latest for Hard, Interior, Molded-in-Color component performance. 3.4 SAMPLE PREPARATION Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defined in ISO 1873-
10、2. No annealing is allowed. See Table 1 for the number of specimens required. Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, Specimen Type 1A) Specimen B 355 x 100 x 1.0 +/- 0.1 mm (ISO 3795) Specimen C 145 x 60 x 3.2 +/- 0.2 mm Specimen D Center of Specimen
11、A. 80 x 10 x 4.0 +/- 0.2 mm Specimen E 100 mm diameter x 3.2 mm Specimen F 80 mm diameter x 3.2 mm Specimen G 90 mm x 200 mm Specimen H 50 +/- 1 mm diameter x 3.2 +/- 0.2 mm Specimen I 100 mm x 150 mm, min 3.5 MATERIAL PROPERTIES 3.5.1 Filler Content 30 - 37 % (ISO 3451-1, Method A, 1h at 700 +/- 25
12、 C, Test portion 2 - 2.5 g) 3.5.2 Density 1.14 1.19 g/cm3 (ISO 1183, Method A) 3.5.3 Tensile Strength at Yield 52 MPa min (ISO 527-1 & ISO 527-2, Specimen A, 50 mm/minute test speed) 3.5.4 Elongation at Break 4.5 % min (ISO 527-1 & ISO 527-2, Specimen A, 50 mm/minute test speed) 3.5.5 Tensile Modulu
13、s 3.4 GPa min (ISO 527-1 & ISO 527-2, Specimen A, 1 mm/minute test speed) 3.5.6 Flexural Modulus 3.6 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.5.7 Impact Strength, Notched Charpy (ISO 179-1/eA, Specimen D) 3.5.7.1 At 23 +/- 2 C 9.5 kJ/m2 min Report Break Type 3.5.7.
14、2 At -40 +/- 2 C 4.5 kJ/m2 min Report Break Type ENGINEERING MATERIAL SPECIFICATION WRS-M4D1058-A1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 6 The test specimens must be conditioned for min of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be
15、 done within the cold box, if not possible, test can be conducted outside, but within 5 seconds. 3.5.8 Heat Deflection Temperature 120 C min (ISO 75-1 & ISO 75-2, Specimen D flatwise, 0.34 +/- 0.1 mm deflection, at 1.80 MPa) 3.5.9 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 100
16、0 h at 120 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.5.9.1 Tensile Strength at Yield Change +/- 25% max (Test Method per para 3.5.3) 3.5.9.2 Impact Strength, Notched Charpy Change +/- 25% max (Test Method per para 3.5.7.1, specimens to be
17、 notched before heat aging) 3.5.10 Odor (FLTM BO 131-03, Specimen G, Variant C) Condition 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.5.11 Fogging Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min Forma
18、tion of clear film, droplets or crystals is cause for rejection. 3.5.12 Flammability (ISO 3795/SAE J369 Specimen B smooth surface) Burn Rate 100 mm/minute max 3.6 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Material Database . 3.6.1 Percent Recycled Resin Content (PCR/PIR) Report 3.6
19、.2 Melt Flow Rate Report g/10 minutes (ISO 1133, 230 C, 2.16 kg) 3.6.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 C to 100 +/- 2 C) Flow Report E-5 mm/mm/ C ENGINEERING MATERIAL SPECIFICATION WRS-M4D1058-A1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 6 Cross Flow Report E-
20、5 mm/mm/ C 3.6.4 Mold Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Range, % Cross Flow Report Range, % 3.6.5 Poissons Ratio Report Ratio (ISO 527-1/2, Specimen A, test speed 1 mm/minute) 3.6.6 Supplemental Information The following curves are to be submi
21、tted with the data packages: FTIR TGA DSC CLTE Engineering Stress/Strain at 23 C 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. 4
22、.1 TYPICAL PROPERTIES USING TEST METHODS IN SECTION 3.4 Para. Test Typical Values Units 3.6.1 Percent Recycled Resin Content (PCR/PIR) 100 % 3.6.2 Melt Flow Rate 4 - 10 g/10 minutes 3.6.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 1.54 25.7 E-5 mm/mm/ C E-5 mm/mm/ C 3.6.4 Mold Shrinkage
23、 After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering) Flow Cross Flow 0.1 0.4 % % 3.6.5 Poissons Ratio 0.4 N/A 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PP(GF+TD)35 (ISO 1043/11469) 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their mater
24、ials shall first obtain an expression of interest from ENGINEERING MATERIAL SPECIFICATION WRS-M4D1058-A1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 6 Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test
25、 reports, signed by a qualified and authorized representativeof the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier w
26、ill review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.4 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Pr
27、ior to making 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
28、 changes (with 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 Appr
29、oval Process (PPAP) sign off must be kept until Job 1. 4.4 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
30、WSS-M99P9999-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. ENGINEERING MATERIAL SPECIFICATION WRS-M4D1058-A1 Copyright 2015, Ford Global Technologies, LLC Page 6 of 6 Table 1: Number of Specimens
31、Required Initial Approval Para. Test Minimum Lots Specimens per lot Total Test Specimens 3.3.1 WSS-M99P2222-D1 Total Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See below for odor and fogging) 1 1 1 per test 3.3.2 WSS-M99D68-A1 See Specification 3.3.3 WSS-M15P4-F See Perfo
32、rmance Specification 3.5.1 Filler Content* 3 1 3 3.5.2 Density 1 3 3 3.5.3 Tensile Strength at Yield* 3 5 15 3.5.4 Elongation at Break* 3 5 15 3.5.5 Tensile Modulus 1 10 10 3.5.6 Flexural Modulus* 3 10 30 3.5.7 Impact Strength, Notched Charpy (per condition)* 3 10 30 3.5.8 Heat Deflection Temperatur
33、e* 3 2 6 3.5.9 Heat Aged Properties 3.5.9.1 Tensile Strength at Yield Change 1 5 5 3.5.9.2 Impact Strength, Notched Charpy Change 1 10 10 3.5.10 Odor 1 9 9 3.5.11 Fogging Photometric 1 3 3 3.5.12 Flammability 1 5 5 3.6.1 Percent Recycled Resin Content (PCR/PIR) 1 1 1 3.6.2 Melt Flow Rate 3 1 3 3.6.3 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.6.4 Mold Shrinkage 1 5 5 3.6.5 Poissons Ratio 1 5 5 3.6.6 Curves - FTIR - TGA - DSC - CLTE Stress/Strain Curves 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements.
