1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 4 2014 05 29 Revised See Summary of Revisions, Released A4 A. Weatherhead, FoE 2011 04 06 Activated A2 Re-activated for use K. Mueller, NA 1991 03 01 EP00E0108948 Released P. Kuntze ontrolled document at www.MATS Copyright 2014, Ford Glo
2、bal Technologies, LLC Page 1 of 7 POLYCARBONATE + POLYBUTYLENE TEREPHTHALATE WSK-M4D762-A2 BLEND (PC+PBT), MODIFIED MOLDING COMPOUND, HIGH IMPACT PAINTABLE POLYCARBONATE + POLYBUTYLENE TEREPHTHALATE WRS-M4D762-A4 BLEND (PC+PBT), MOLDING COMPOUND, NON-VISIBLE, RECYCLED, 35% PCR/PIR CONTENT 1. SCOPE T
3、he material defined by these specifications are polycarbonate and polybutylene terephthalate blended molding compounds. 2. APPLICATION WSK-M4D762-A2 This specification was released originally for material used for painted plastic bumper. WRS-M4D762-A4 This specification was released originally for m
4、aterial used for energy absorber applications and contains recycled content. 2.1 LIMITATIONS Materials approved to WRS-M4D762-A4 are not UV stabilized and should not be used in long term exposure to direct sunlight. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material supplier
5、s and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.1.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicated that the mean and 3 sigma values were to be reported. The specific
6、ation 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. 3.1.2 WSK-M4D762-A2 is based on virgin materials. 3.1.3 WRS-M4D762-A4 must contain 35% recycled content as defined by WRS-M99P42-A1 (post-consumer a
7、nd/or post industrial recyclates and repolymerised recycled materials). The remaining portion of the material can come from virgin sources. 3.1.4 The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in WSS-M99P1111-A. 3.1.5 Performance Criteria: Parts u
8、sing this specification shall meet the appropriate SDS requirements. 3.1.6 As specified in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CoA) containing lot testing requirements which must include, but are not limited to: ENGINEERIN
9、G MATERIAL SPECIFICATION WSK-M4D762-A2 / WRS-M4D762-A4 Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 2 of 7 Melt Flow Rate Impact Strength, Notched Charpy at 23C Flexural Modulus 3.2 SAMPLE PREPARATION Unless otherwise specified all tests shall be carried out on
10、injection molded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defined in ISO 2580-2. 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
11、, 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 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 +
12、/- 0.2 mm Specimen I 100 mm x 150 mm, min 3.3 MATERIAL PROPERTIES 3.3.1 Density 1.18 - 1.22 g/cm3 (ISO 1183, Method A) 3.3.2 Melt Flow Rate 11-15 g/10 minute (ISO 1133, 250 C, 5 kg) The material shall be dried for 2 h minimum at 120 C in a mechanical convection oven immediately preceding the test. 3
13、.3.3 Tensile Strength at Yield 47 MPa min (ISO 527-1 & ISO 527-2, Specimen A, 50mm/minute test speed) 3.3.3.1 Elongation at Yield 3 % min (ISO 527-1 & ISO 527-2, Specimen A, 50mm/minute test speed) 3.3.4 Flexural Modulus 1.8 GPa min (ISO 178, Specimen D, 64mm support span, 2 mm/minute test speed) EN
14、GINEERING MATERIAL SPECIFICATION WSK-M4D762-A2 / WRS-M4D762-A4 Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 3 of 7 3.3.5 Impact Strength, Notched Izod (ISO 180, Specimen D) 3.3.5.1 At 23 2 C 45 kJ/m2 min 3.3.5.2 At -30 2 C 30 kJ/m2 min 3.3.5.3 At -40 2 C 25 kJ/m
15、2min The test specimen must be conditioned for a minimum of 6 hours at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 3.3.6 Heat Deflection Temperature 68C min
16、(ISO 75-1 & ISO 75-2 Specimen D, flatwise, 0.34 +/- 0.1 mm deflection 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. 3.3.7 Vicat Softening Temperature 117 C min (ISO 306, Specim
17、en D, Bath - silicone oil, temperature raise 50 5 C/h. Dial gage reset to O after addition of 5 kg weight, at 50 N load) 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. 3.3.8 Heat Aging Perfo
18、rmance (ISO 188, except 150 50 air changes/h, 1000 h at 85 2 C. After heat aging test specimens are to be conditioned in a desiccator for 3 - 5 h at 23 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.3.8.1 Tensile Strength Change 20% max (Test meth
19、od per para 3.3.3) 3.3.8.2 Impact Strength, Notched Izod Change 25% max (Test Method per para 3.3.6.1, specimens to be notched before heat aging) 3.4 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.4.1 Melt Volume Rate (ISO 1133) 3.4.1.1 250C, 5kg Report Value, cm3
20、/10 minutes ENGINEERING MATERIAL SPECIFICATION WSK-M4D762-A2 / WRS-M4D762-A4 Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 4 of 7 3.4.1.2 250C, 2.16kg Report Value, cm3/10 minutes The material shall be dried for 2 h minimum at 122 +/- 2 C in a mechanical convecti
21、on oven immediately preceding the test. 3.4.2 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 oC to Tg, Tg to 100 +/- 2 oC) Plaque size is 100 x 150 minimum at 3.2 +/- 0.2 mm thickness. Plaque to be fan or edge gated. Specimens to be water jet or die cut from the center of plaque, mi
22、nimum of three samples each direction. (Test specimen preparation is very important here, if the test specimens are not prepared as described you will get incorrect CLTE values affecting part design.) Conditioning procedure consists of steps 1-4. Start at 23 C. 1. Ramp 5 C/minute to -40 C 2. Isother
23、mal hold for 5 minutes 3. Ramp 5 C/minute to 110 C 4. Isothermal hold for 10 minutes Leave the test specimen in the equipment and run steps 5-7 5. Ramp 5 C/minute to -40 C 6. Isothermal hold for 10 minutes 7. Ramp 5 C/minute to 110 C Report CLTE value after Step 4 (un-annealed value) for both Flow a
24、nd Cross Flow directions. Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C Report CLTE value again after Step 7 (annealed value) for both Flow and Cross Flow directions. Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.4.3 Mold Shrinkage (Report method use
25、d, sample size and value) After 48 h at 23 +/- 2 oC Flow Report Value, % Cross Flow Report Value, % 3.4.4 Post Shrinkage for WSK-M4D762-A2 only (Separate specimens required for each test) After 48 h at 80 oC Flow Report Value, % Cross Flow Report Value, % After 30 min at 120 oC Flow Report Value, %
26、Cross Flow Report Value, % ENGINEERING MATERIAL SPECIFICATION WSK-M4D762-A2 / WRS-M4D762-A4 Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 5 of 7 3.4.5 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.4.5.1 At 23 2 C Report Value, kJ/m2 min Report Bre
27、ak Type 3.4.5.2 At -30 2 C Report Value, kJ/m2 min Report Break Type 3.4.5.3 At -40 2 C Report Value kJ/m2minReport Break Type The test specimen must be conditioned for a minimum of 6 hours at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold
28、 chamber, if not possible, test may be conducted outside, but within 5 seconds. 3.4.6 Heat Deflection Temperature Report Value, oC (ISO 75-1 & ISO 75-2 Specimen D, flatwise, 0.34 +/- 0.1 mm deflection at 0.45 MPa) All specimens dry as molded. If not tested immediately after molding, specimens must b
29、e stored in a sealed, moisture-proof container filled with silica gel. 3.4.7 Stress Cracking Test for Plastics Report evidence of cracking or crazing (FLTM BO 127-03, 1%, specify the contact material(s) 3.4.8 Tensile Strength at Break (ISO 527-1 & ISO 527-2, Specimen A, Report Value,MPa 50mm/minute
30、test speed) 3.4.8.1 Elongation at Break Report Value, % (ISO 527-1 & ISO 527-2, Specimen A, 50mm/minute test speed) 3.4.9 Hydrolytic Stability (ISO 188, humidity aging at 90C /70% RH for 500 h or 80C /70% RH for 1000 h After humidity aging test specimens are to be conditioned for 24 h at 23 +/- 2 C
31、50% RH. Unaged property values shall be determined at the time of the aged properties determination). Report values if material is used in parts for the interior or where high heat and humidity environments exist. Impact Strength, Notched Charpy, Report Value, % (Test Method per para 3.4.5,specimens
32、 to be notched before humidity aging) 3.4.10 Supplemental Information The following are to be submitted with the data packages: FTIR TGA DSC CLTE (3 curves per direction, flow and cross flow) Engineering Stress/Strain at 23 C ENGINEERING MATERIAL SPECIFICATION WSK-M4D762-A2 / WRS-M4D762-A4 Controlle
33、d document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 6 of 7 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
34、.1 TYPICAL PROPERTIES USING TEST METHODS IN SECTION 3.4 Para. Test Typical Values Units 3.4.1 Melt Volume Rate 250oC, 5kg 250oC, 2.16kg 10 14 3.5 6.5 cm3/10 minutes cm3/10 minutes 3.4.2 Coefficient of Linear Thermal Expansion Flow Cross Flow 10.9 11.2 E-5mm/mm/oC E-5mm/mm/oC 3.4.3 Mold Shrinkage (Fo
35、r specific method and Sample Size contact Materials Engineering) After 48 h at 23 2 C After 48 h at 80C After 30 min at 120C 0.5 0.9 0.1 0.3 0.1 0.3 % % % 3.4.5 Izod Impact at 23 2 C at -30 2 C at -40 2 C 45 30 25 kJ/m2 3.4.6 Heat Deflection Temperature at 0.45 MPa 90 C 3.4.7 Stress Cracking Any con
36、tact material No Cracking or crazing 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PC+PBT (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSK-M4D762-A2 / WRS-M4D762-A4 Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 7 of 7 Table 1: Minimum Sample S
37、ize Initial Approval * New Manufacturing Location for Previously Approved Material* Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 3.3.1 Density 1 3 3 3.3.2 Melt Flow Rate 1 1 1 3.3.3 Tensile Strength at Yield* 3 5 15 1 5
38、 5 3.3.3.1 Elongation at Break* 3 5 15 1 5 5 3.3.4 Flexural Modulus* 3 10 30 1 10 10 3.3.5 Impact Strength, Notched Izod, (per condition) 3 10 30 1 10 10 3.3.6 Heat Deflection Temperature (per Condition) 3 2 6 1 2 2 3.3.7 Vicat Softening Temperature 3 2 6 1 2 2 3.3.8 Heat Aging Performance (per cond
39、ition) 1 5 5 3.4.1 Melt Volume Rate (per condition) 1 3 3 3.4.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.4.3 Mold Shrinkage (per condition) 1 5 5 1 5 5 3.4.4 Post Shrinkage (per condition) 1 5 5 3.4.5 Impact Strength, Notched Charpy, (per condition) 1 5 5 3.4.8 Tensile Strengt
40、h at Break* 3 5 15 3.4.8.1 Elongation at Break* 3 5 15 3.4.10 Curves FTIR TGA DSC CLTE (3 curves per direction, flow and cross flow) Engineering Stress/Strain at 23 C 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements. * Recycled resins must
41、always follow the initial approval testing. The new manufacturing location for previously approved materials is not applicable for recycled resins. 5. SUMMARY OF REVISIONS 2013 11 14 Added WRS-M4D762-A4 Updated sections 3.1, 3.3, 3.4 Revised Flex Modulus to reflect historical data package, was 2.0 GPa Removed Immersion in Dewaxing Fluid Updated typical property section Added Table 1
