1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2017 04 04 Released B2 Revised B1 See summary of Revisions G. Kowalski, NA 2013 07 19 Updated See summary of revisions G. Kowalski, NA 2011 09 21 Activated Released B1 G. Kowalski, FNA Controlled document at www.MATS Copyright 2017 Fo
2、rd Global Technologies, LLC Page 1 of 10 POYLAMIDE (PA) 6 HEAT STABILIZED, IMPACT MODIFIED WSS-M4D578-B1 35% GLASS FIBER REINFORCED MOLDING COMPOUND POYLAMIDE (PA) 6 HEAT STABILIZED, IMPACT MODIFIED WRS-M4D578-B2 35% GLASS FIBER REINFORCED MOLDING COMPOUND 65% RECYCLED MATERIAL BY WEIGHT 1. SCOPE Th
3、e material defined by this specification is a thermoplastic injection molding compound based on impact modified, heat stabilized 35% glass fiber reinforced polyamide 6. Material with recycled content should be used whenever feasible. Type of Material % Material Type by Weight Specification WRS-M4D57
4、8-B2 Recycled Resin PCR/PIR 65 Virgin Resin 0 Glass Fiber 35 Minimum % Recycled Material 65 2. APPLICATION WSS-M4D578-B1 This specification was released originally for material used for oil pans. WRS-M4D578-B2 This specification was released originally for materials used for applications containing
5、post-consumer or postindustrial recycled resin content 2.1 LIMITATIONS This material absorbs and retains moisture. Part design and tolerances must accommodate changes in part dimensions and physical properties due to moisture absorption or loss in the service/assembly environment. This material does
6、 not contain UV stabilizers, long term exposure to direct sunlight will cause chalking and loss of gloss. This material is not suitable for direct long term exposure to engine coolant, or direct exposure to strong acids or bases. It is not suitable for use above 150oC. 3. REQUIREMENTS 3.1 APPROVED S
7、OURCES This specification is part of the Ford Co-Managed Buy (CMB) agreement. Tier 1 molders who are participating under the CMB agreement must use one the following approved sources (deviations require approval from Raw Materials Purchasing and Materials Engineering): ENGINEERING MATERIAL SPECIFICA
8、TION WSS-M4D578-B1 WRS-M4D578-B2 Copyright 2017, Ford Global Technologies, LLC Page 2 of 10 Specification North American Programs European Programs WSS-M4D578-B1 BASF, Ultramid B3ZG7 OSI DuPont, Zytel 73G35 THS BASF, Ultramid B3ZG7 OSI DuPont, Zytel 73G35 THS WRS-M4D578-B2 Wellman, Ecolon GFT3040 TB
9、D Molders not on the CMB program or regions without CMB are required to use materials listed on the Ford Approved Source List (ASL), and are encouraged to use the CMB sources listed above. Only the sources identified on the Approved Source List can be used when this specification is listed on the dr
10、awing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. Approval of new sources requires the completion of the latest version of the FMD template. Data should be submitted at the same time as the specific
11、ation data package. Only one FMD package is required per trade name approved, FMD is not required for each manufacturing site. FMD is required for new site approvals that do not have an existing FMD record 3.2 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material an
12、d specimens with moisture content not exceeding 0.2% except where noted (Moisture Conditioned) (test according to ISO 15512 Method B/ASTM D6869). All test materials have to be sealed in moisture-proof containers and stored at 23 +/- 2 C for at least 24 h immediately after processing. If the moisture
13、 content exceeds 0.2%, condition the material for a minimum of 16 h at 40 50 C at a reduced pressure below 133 KPa. Conduct tests in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5% relative humidity. Individual specimens shall not be removed from closed containers until immediately before testin
14、g 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms from initial material approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. The material supplier shall ensure that all future material supplied to the spec
15、ification shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.4.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicate
16、d that the mean and +/- 3 sigma values were to be reported. The specification minimum, maximum or range was established using 3 sigma data. For 2011 and beyond, refer to Table 1 for number of samples required for each test. 3.4.2 WSS-M4D578-B1 is based on virgin materials. 3.4.3 WRS-M4D578-B2 must c
17、ontain minimum 65% (Post-Consumer Recycled (PCR) and/or Post Industrial Recycled (PIR) content by weight and Renewable Bio-Based, as defined by WRS-M99P42-A1 and WNS-M99P42-A4). Actual percent to be reported as part of the data submission package. ENGINEERING MATERIAL SPECIFICATION WSS-M4D578-B1 WRS
18、-M4D578-B2 Copyright 2017, Ford Global Technologies, LLC Page 3 of 10 3.4.4 The use of regrind is permitted, for economic / environmental reasons. Part manufacturers using this specification must complete DV and PV testing with the maximum allowable amount of regrind and the maximum allowable regrin
19、d content must be specified on the engineering drawing. Any changes to what is specified on the drawing (no specific amount implies zero regrind) must be approved by Materials and PD Engineering through the formal Ford Motor Company process (SREA). 3.4.5 Performance Criteria: Parts using this specif
20、ication shall meet the appropriate performance specifications, WSS-M15P50-C1/C2/Latest 3.4.6 Ford Materials Engineering may request a Control Plan and Certificate of Analysis (C of A) containing lot testing requirements which must include, but are not limited to: Filler Content Impact Strength, Notc
21、hed Charpy at 23C Flexural Modulus 3.5 SAMPLE PREPARATION All tests shall be carried out on production materials manufactured from the production process unless correlation to a non-production process has been reviewed and approved by Ford Materials Engineering. Unless otherwise specified all tests
22、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 1874-2. No annealing is allowed. See Table 1 for the number of samples required. Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0
23、 +/- 0.2 mm (ISO 527-2, Specimen Type 1A) Specimen B 355 x 100 x 1.0 +/- 0.1 mm Specimen C 145 x 60 x 3.2 +/- 0.2 mm Specimen D 80 x 10 x 4.0 +/- 0.2 mm (may be cut from the center of Specimen A) 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 Specime
24、n H 50 +/- 1 mm diameter x 3.2 +/- 0.2 mm Specimen I 100 mm x 150 mm, min For Appearance Testing: Use an ungrained, non-polished, tool to prepare specimens for C through N gloss surfaces. Use a smooth, polished tool to prepare specimens for A and B gloss surfaces. 3.6 MATERIAL PROPERTIES 3.6.1 Melt
25、Temperature 215 - 225C (ISO 11357, 10 C/min heating rate) 3.6.2 Determination of Ash (Glass Fiber) 32.5 37.0 % (ISO 3451-4, Method A, test temperature 600 +/- 25 oC, test portion 2 to 2.5g) 3.6.3 Density 1.35 - 1.42 g/cm3 (ISO 1183, Method A) ENGINEERING MATERIAL SPECIFICATION WSS-M4D578-B1 WRS-M4D5
26、78-B2 Copyright 2017, Ford Global Technologies, LLC Page 4 of 10 B1 B2 3.6.4 Tensile Strength at Break 145 MPa min 109 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 5 mm/minute test speed) 3.6.5 Tensile Modulus 8.2 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.6.6 Impact St
27、rength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.6.6.1 At 23 +/- 2 C 17 kJ/m2 min Report Break Type 3.6.6.2 At -40 +/- 2 C 11 kJ/m2 min Report Break Type The test specimen must be conditioned for minimum of 6 hours at the above specified temperature prior to impact test. Low temperature testing
28、shall be done within the cold chamber. If not possible, test may be conducted outside, but within 5 seconds. Test specimens must be reviewed by Materials Engineering. 3.6.7 Heat Deflection Temperature 188 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflecti
29、on. At 1.80 MPa) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.6.8 Heat Aging Performance (1000 h at 140+/- 2 C. After heat aging test specimens are to be conditioned in a desiccator for
30、3 - 5 h at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) B1 B2 3.6.8.1 Tensile Strength at Break, Change +/- 25% max +/- 25% max 3.6.8.2 Impact Strength, Notched Charpy, Change +/- 25% max +/- 25% max (Test Method per para 3.6.6.1, specimens
31、 to be notched before Heat Aging) ENGINEERING MATERIAL SPECIFICATION WSS-M4D578-B1 WRS-M4D578-B2 Copyright 2017, Ford Global Technologies, LLC Page 5 of 10 3.6.9 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.7 MATERIAL PROPERTIES REPORT ONLY Values are re
32、tained in Ford Materials Database . 3.7.1 Percent Recycled Resin Content (PIR/PCR) by Weight Report % (WRS-M4D578-B2 only) 3.7.2 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % Note: Shrinkage vales are determined
33、 on plaque samples and represent approximate values, part shrinkage can be affected by molding conditions, part thickness and geometry. 3.7.3 Coefficient of Linear Thermal Expansion (ISO 11359-2 TMA) -30 +/- 2 C to 60 +/-2oC Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 60 +/
34、-2oC to 120 +/-oC Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.7.4 Water Absorption Report Value, % (ISO 62, 24 h immersion, Specimen H) 3.7.5 Heat Deflection Temperature Report Value, oC% (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm def
35、lection. At 0.45 MPa) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.7.6 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.7 Flexural Modulus Re
36、port Value, GPa (ISO 178, Specimen D 66 mm support span, 2 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WSS-M4D578-B1 WRS-M4D578-B2 Copyright 2017, Ford Global Technologies, LLC Page 6 of 10 3.7.8 Moisture Conditioned: The specimens shall be conditioned to a moisture content of 1.0 to 2.
37、0 wt% moisture then place the specimens in standard atmosphere of 23 +/- 2 C and 50 +/- 5% relative humidity for at least 1 h before testing (according to ISO 1110). Moisture content shall be reported to verify the moisture level. 3.7.8.1 Moisture Content Report Value Weight% (ISO 15512, Karl Fisher
38、, or ASTM D756-93) Note: Moisture content must be between 1.0 2.0 wt% before testing para 3.7.7.2, 3.7.7.3, 3.7.7.4, and 3.7.7.5. 3.7.8.2 Tensile Strength at Break Report Value MPa (ISO 527-1 and ISO 527-2, Specimen A, 5 mm/minute test speed, 23 +/- 2oC) 3.7.8.3 Tensile Modulus Report Value GPa (ISO
39、 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.8.4 Impact Strength, Notched Charpy Report Value kJ/m2 (ISO 179-1/1eA, Specimen D, 23 +/- 2 C) Report Break Type 3.7.8.5 Flexural Modulus Report Value GPa (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.7.9 Supplementa
40、l Information The following curves are to be submitted with the data packages: FTIR TGA DSC first and second heat Engineering Stress/Strain at 23 C, -40 C, and 140oC 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this sp
41、ecification. Contact for questions concerning Engineering Material Specifications. ENGINEERING MATERIAL SPECIFICATION WSS-M4D578-B1 WRS-M4D578-B2 Copyright 2017, Ford Global Technologies, LLC Page 7 of 10 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.7 Para. Test Typical Value Units 3.7.1 Recyc
42、led Resin Content by Weight 65 % 3.7.2 Molding Shrinkage (Report method used, sample size and value) - After 48 h at 23 +/- 2 C Flow Cross Flow 0.34 0.50 % % 3.7.3 Coefficient of Linear Thermal Expansion -30 to 60oC Flow Cross Flow 60 to 120oC Flow Cross Flow 2.22 8.48 1.27 1060 E-5 mm/mm/ C E-5 mm/
43、mm/ C E-5 mm/mm/ C E-5 mm/mm/ C 3.7.4 Water Absorption 1.1 % 3.73.5 Heat Deflection Temperature at 0.45 MPa 218 oC 3.7.6 Poissons Ratio 0.40 N/A 3.7.7 Flexural Modulus 8.7 GPa 3.7.8.1 Moisture content 1.0 2.0 % 3.7.8.2 Moisture Conditioned Tensile Strength at Break 112 MPa 3.7.8.3 Moisture Condition
44、ed Tensile Modulus 6.4 GPa 3.7.8.4 Moisture Conditioned Notched Charpy Impact 16 kJ/m2 3.7.8.5 Moisture Conditioned Flexural Modulus 6.1 GPa 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PA6-GF35 (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D578-B1 WRS-M4D578-B2 Copyright 2
45、017, Ford Global Technologies, LLC Page 8 of 10 Table 1: Minimum Sample Size Initial Approval and/or Initial Approval in a New Region and New Manufacturing Location Approval for Recycled Materials Additional Manufacturing Location for Previously Approved Material Para. Test Minimum Lots Specimens pe
46、r Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4.5 WSS-M15P50-C1/C2 Reference the Performance Specification 3.6.1 Melt Temperature 3 1 3 3.6.2 Determination of Ash* 3 1 3 1 1 1 3.6.3 Density 1 3 3 1 3 3 3.6.4 Tensile Strength at Break* 3 5 15 1 5 5 3.6.5 Tensile Modulus 1 1
47、0 10 3.6.6 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.6.7 Heat Deflection Temperature at 1.80 MPa* 3 2 6 1 2 2 3.6.8 Heat Aging Performance 3.6.8.2 Impact Strength, Notched Charpy, Change 1 10 10 3.6.9 Flammability 1 5 5 3.7.1 Percent Recycled Content 1 1 1 3.7.2 Mold Shrinkag
48、e 1 5 5 1 5 5 3.7.3 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.7.4 Water Absorption 1 3 3 3.7.5 Heat Deflection Temperature at 0.45 MPa 3 2 6 1 2 2 3.7.6 Poissons Ratio 1 2 2 1 2 2 3.7.7 Flexural Modulus 1 10 10 3.7.8 Moisture Conditioned 3.7.8.1 Moisture Content 1 1 1 1 1 1 3.7
49、.8.2 Moisture Conditioned Tensile Strength at Break 1 5 5 3.7.8.3 Moisture Conditioned Tensile Modulus 1 10 10 3.7.7.4 Moisture Conditioned Notched Charpy Impact 1 10 10 1 10 10 3.7.8.5 Moisture Conditioned Flexural Modulus 1 10 10 1 10 10 3.7.9 Curves - IR - TGA - DSC (first and second heat) - CLTE (3 flow and 3 cross flow) - Stress/Strain Curves -40, 23, 140oC 1 1 1 per test
