1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2015 07 02 Released C. Kay, NA, G. Kowalski, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 6 POLYPROPYLENE (PP) HOMOPOLYMER, 33% TALC FILLED, WRS-M4D939-A2 MOLDING COMPOUND, 37% PCR/PIR RESI
2、N CONTENT, 25% RECYCLED MATERIAL BY WEIGHT 1. SCOPE The material defined by this specification is a 33% talc filled injection molding compound based on 25% recycled polypropylene homopolymer from post-consumer sources (PCR) and/or post industrial sources (PIR). 2. APPLICATION This specification was
3、released originally for material used for air-conditioning and heater housing. 2.1 LIMITATIONS This material does not contain UV stabilizers; long term exposure to direct sunlight will cause chalking and gloss loss. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material supplier
4、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 spec
5、ification 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 WRS-M4D939-A2 must contain 25% Post Consumer Recycled (PCR) and/ or post industrial sources (PIR) content as defined by WRS-M99P42-A1. The
6、 remaining portion of the material can come from virgin sources. 3.1.3 The use of regrind is permitted, for economic / environmental reasons. Part manufacturers using this specification must complete DV and PV testing with the allowable amount of regrind and the maximum allowable regrind content mus
7、t 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 Comany process (SREA). 3.1.4 Materials used in interior applications must meet the requi
8、rements outlined in WSS-M99P2222-D1/Latest, Performance,Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submission package. 3.1.5 Performance Criteria: Parts using this specification shall meet the appropriate performance specification, WSS-M15
9、P4-F. ENGINEERING MATERIAL SPECIFICATION WRS-M4D939-A2 Copyright 2015, Ford Global Technologies, LLC Page 2 of 6 3.1.6 As specified in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CofA) containing lot testing requirements which mus
10、t include, but are not limited to: Melt Flow Rate Filler Content Impact Strength, Notched Charpy at 23C Flexural Modulus 3.2 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 revi
11、ewed and approved by Ford Materials Engineering. 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 1873-2. No annealing is allowed. See Table 1 for the number
12、 of samples 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 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
13、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 3.3 MATERIAL PROPERTIES 3.3.1 Determination of Ash 30 - 36% (ISO 3451-1, Method A, 30 min at 550 +/- 50 C, test portion 1 2 g, Mineral) 3.3.
14、2 Density 1.10 - 1.17 g/cm3 (ISO 1183, Method A) 3.3.3 Tensile Strength at Yield 27 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.3.4 Elongation at Yield 3.0% min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.3.5 Tensile Modulus 3.0 GPa min (ISO 527-1 an
15、d ISO 527-2, Specimen A, 1 mm/minute test speed) 3.3.6 Flexural Modulus 2.5 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WRS-M4D939-A2 Copyright 2015, Ford Global Technologies, LLC Page 3 of 6 3.3.7 Impact Strength, Notched Charpy (ISO
16、179-1/1eA, Specimen D) 3.3.7.1 At 23 +/- 2 C 1.7 kJ/m2 min Report Break Type 3.3.7.2 At -40 +/- 2 C 1.3 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 shall be done within the c
17、old chamber, if not possible, test may be conducted outside, but within 5 seconds. Test specimens must be reviewed by Materials Engineering. 3.3.8 Heat Deflection Temperature at 1.80 MPa 67 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection.) 3.3.9 Heat
18、 Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 140 +/- 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) 3.3.9.1 Tensile Strength at Yiel
19、d, Change +/- 25% max (Test Method per para 3.3.3) 3.3.9.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per para 3.3.7.1, specimens to be notched before Heat Aging) 3.3.10 Interior Odor Test (FLTM BO 131-03, Variant C, Specimen G) Condition 1 Rating 3 max Condition 2 Rating 3 max
20、 Condition 3 Rating 3 max 3.3.11 Determination of the Fogging Characteristics of Interior Automotive Materials (Photometric, SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, Post-test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for reje
21、ction. For Interior Applications: All materials should be stored in an open environment for 14-28 days after manufacture, and then must be bagged in heat sealed polyethylene (PE) or PE coated aluminum bags until tested. 3.3.12 Flammability (ISO 3795, Specimen B) Burn Rate 100 mm/min max ENGINEERING
22、MATERIAL SPECIFICATION WRS-M4D939-A2 Copyright 2015, Ford Global Technologies, LLC Page 4 of 6 3.4 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.4.1 Melt Flow Rate Report Value, g/10 min (ISO 1133, 230 C, 2.16 kg) 3.4.2 Percent Recycled Resin Content (PIR/PCR) Re
23、port % 3.4.3 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.4.4 Heat Deflection Temperature at 0.45 MPa Report Value, C (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflectio
24、n.) 3.4.5 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2 C) Flow Report Value, E-5 mm/mm/C Cross Flow Report Value, E-5 mm/mm/C 3.4.6 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.4.7 Supplemental Information The following
25、 curves are to be submitted with the data packages: FTIR TGA DSC (first and second heat) CLTE (3 flow and 3 cross flow) Engineering Stress/Strain at 23 C, -40 C ENGINEERING MATERIAL SPECIFICATION WRS-M4D939-A2 Copyright 2015, Ford Global Technologies, LLC Page 5 of 6 4. GENERAL INFORMATION 4.1 TYPIC
26、AL PROPERTIES USING METHODS IN SECTION 3.4 Para. Test Typical Value Units 3.4.1 Melt Flow Rate 11-18 g/10 min 3.4.2 Recycled Content 25 % 3.4.3 Mold Shrinkage - After 48 h at 23 +/- 2 C Flow Cross Flow 0.7-1.3 0.9-1.6 % % 3.4.4 Heat Deflection Temperature (at 0.45 MPa) 121 C 3.4.5 Coefficient of Lin
27、ear Thermal Expansion Flow Cross Flow 5-10 5-10 E-5 mm/mm/ C E-5 mm/mm/ C 3.4.6 Poissons Ratio 0.4 N/A 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS (ISO 1043) PP-TD30 ENGINEERING MATERIAL SPECIFICATION WRS-M4D939-A2 Copyright 2015, Ford Global Technologies, LLC Page 6 of 6 Table 1: Min
28、imum Sample Size Initial Approval and New Manufacturing Location Approval for Recycled Materials Para. Test Minimum Lots Specimens per Lot Total Test Specimens 3.1 WSS-M99P1111-A 3.1.4 WSS-M99P2222-D1/Latest Total Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See below for O
29、dor and Fogging) 1 1 1 per test 3.1.5 Enter Performance Specification number WSS-M15P4-F 3.3.1 Determination of Ash* 3 1 3 3.3.2 Density 1 3 3 3.3.3 Tensile Strength at Yield* 3 5 15 3.3.4 Elongation at Yield 3 5 15 3.3.5 Tensile Modulus 1 10 10 3.3.6 Flexural Modulus* 3 10 30 3.3.7 Impact Strength
30、Notched Charpy (per condition)* 3 10 30 3.3.8 Heat Deflection Temperature (1.8 MPa)* 3 2 6 3.3.9 Heat Aging Performance 3.3.9.1 Tensile Strength at Yield, Change 1 5 5 3.3.9.2 Impact Strength, Notched Charpy, Change 1 10 10 3.3.10 Odor 1 9 9 3.3.11 Fogging, Photometric 1 3 3 3.3.12 Flammability 1 5
31、5 3.4.1 Melt Flow Rate 3 1 3 3.4.3 Mold Shrinkage 1 5 5 3.4.4 Heat Deflection Temperature (0.45 MPa) 3 2 6 3.4.5 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.4.6 Poissons Ratio 1 2 2 3.4.7 Supplemental Information/Curves - IR - TGA - DSC (first and second heat) - CLTE (3 flow and 3 cross flow) - Stress/Strain Curves (23 C, -40 C) 1 1 1 per test 5. SUMMARY OF REVISIONS
