1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2016 11 23 Released C.Zhou, AP Controlled document at www.MATS Copyright 2016 Ford Global Technologies, LLC Page 1 of 7 THERMOPLASTIC POLYOLEFIN ELASTOMER (TEO), UNFILLED WRS-M4D952-A4 MOLDING COMPOUND, 75% RECYCLED MATERIAL BY WEIGHT
2、1. SCOPE The material defined by this specification is a thermoplastic impact modified injection molding compound based on 75% recycled thermoplastic polyolefin elastomer, for general purpose and non-visible exterior use. Type of Material % of Material by Weight Recycled Resin PCR/PIR 75 Virgin Resi
3、n 25 Minimum % Recycled Material 75 2. APPLICATION This specification was released originally for materials used for underbody shields, wheel liners, and/or other non visible applications and containing post consumer or post industrial recycled resin content 2.1 LIMITATIONS This material does not co
4、ntain UV stabilizers, therefore long term exposure to direct sunlight could cause chalking and loss of gloss, and must not be used for visible (mold-in-color or painted) applications. These materials should not be used for interior applications and have not been tested to meet Vehicle Interior Envir
5、onment Quality Material/component Performance Requirements (WSS-M99P2222-D1). 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing,
6、 CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. 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
7、 of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.3.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which
8、indicated 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. 3.3.2 The use of regrind is permitted, for economic / environmental
9、reasons. Part manufacturers ENGINEERING MATERIAL SPECIFICATION WRS-M4D952-A4 Copyright 2016, Ford Global Technologies, LLC Page 2 of 7 using this specification must complete DV and PV testing with the allowable amount of regrind and the maximum allowable regrind content must be specified on the engi
10、neering 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). 3.3.3 This material must contain a minimum of 75% Post Consumer Recycled (PCR) and/or Post
11、 Industrial Recycled (PIR) content as defined by WRS-M99P42-A1. Actual % to be reported as part of the data submission pack. 3.3.4 Performance Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS- M15P50-B/Latest. Parts must fulfill applicable SDS/CDS r
12、equirements. 3.3.5 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: Melt Flow Rate Impact Strength, Notched Charpy at 23C Flexural Modulus 3.4 SAMPLE PREPARATION All tests shall
13、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 shall be carried out on injection molded, one-end gated test specimens. Th
14、e 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 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
15、.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 Specimen H 50 +/- 1 mm diameter x 3.2 +/- 0.2 mm Specimen I 100 mm x 150 mm, min
16、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. 3.5 MATERIAL PROPERTIES 3.5.1 Density 0.89 0.91 g/cm3 (ISO 1183, Method A) 3.5.2 Hardness, Durometer D 53 - 5
17、7 (ISO 868, 15 s dwell) 3.5.3 Tensile Strength at Yield 14 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WRS-M4D952-A4 Copyright 2016, Ford Global Technologies, LLC Page 3 of 7 3.5.4 Elongation at Yield 5% min (ISO 527-1 and ISO 527-2, Spec
18、imen A, 50 mm/minute test speed) 3.5.5 Tensile Modulus 800 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.5.6 Flexural Modulus 800 MPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.5.7 Impact Strength, Notched Izod (ISO 180/1A, Specimen D) 3.5.7.1 A
19、t 23 +/- 2 C 32 kJ/m2 min 100% Partial Break 3.5.7.2 At 10 +/- 2 C 100% Partial Break 3.5.7.3 At 0 +/- 2 C 13 kJ/m2 min Report Break Type 3.5.7.4 At -40 +/- 2 C 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 impa
20、ct test. Low temperature testing 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. 3.5.8 Heat Deflection Temperature 45 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silico
21、ne oil, 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. 3.5.9 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 120+/- 2 C. After h
22、eat 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) 3.5.9.1 Tensile Strength at Yield, Change +/- 25% max (Test Method per para 3.5.3) 3.5.9.2 Impact Strength, Notched I
23、zod, Change +/- 25% max (Test Method per para 3.5.7.1, specimens to be notched before Heat Aging) ENGINEERING MATERIAL SPECIFICATION WRS-M4D952-A4 Copyright 2016, Ford Global Technologies, LLC Page 4 of 7 3.5.10 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max
24、 3.6 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.6.1 Percent Recycled Resin Content (PIR/PCR) Report Value, % 3.6.2 Melt Flow Rate Report Value (ISO 1133 230 C, 2.16 kg) g/10 minutes 3.6.3 Molding Shrinkage (Report method used, sample size and value) After 48 h
25、 at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.6.4 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 3.6.5 Impact Strengh, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.6.5.1 At 23
26、+/- 2 C Report Value, kJ/m2 Report Break Type 3.6.5.2 At 0 +/- 2 C Report Value, kJ/m2 Report Break Type 3.6.5.3 At -40 +/- 2 C Report Value, kJ/m2 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
27、testing 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. 3.6.6 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.6.7 Supplemental Informatio
28、n The following curves are to be submitted with the data packages: FTIR TGA DSC first and second heat CLTE Engineering Stress/Strain at 23 C ENGINEERING MATERIAL SPECIFICATION WRS-M4D952-A4 Copyright 2016, Ford Global Technologies, LLC Page 5 of 7 4. GENERAL INFORMATION The information given below i
29、s provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.6 Para. Test Typical Value Units 3.6.1 Recycled Resin Content 75 % 3.6.2 Melt Flow R
30、ate Report Value g/10 minutes 3.6.3 Molding Shrinkage (Report method used, sample size and value) - After 48 h at 23 +/- 2 C Flow Cross Flow 0.9 1.0 1.0 1.3 % % 3.6.4 Coefficient of Linear Thermal Expansion Flow Cross Flow 9.5 10.1 10.2 13.3 E-5 mm/mm/ C E-5 mm/mm/ C 3.6.5 3.6.5.1 3.6.5.2 3.6.5.3 Im
31、pact Strengh, Notched Charpy At 23 +/- 2 C At 0 +/- 2 C At -40 +/- 2 C Report Value Report Value Report Value kJ/m2 kJ/m2 kJ/m2 3.6.6 Poissons Ratio Report Value N/A 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PP+EPDM (ISO 1043/11469/18064) ENGINEERING MATERIAL SPECIFICATION WRS-M4D95
32、2-A4 Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 Table 1: Minimum Sample Size Initial Approval and/or Initial Approval in a New Region and New Manufacturing Location Approval for Recycled Materials Para. Test Minimum Lots Specimens per Lot Total Test Specimens 3.3.4 WSS-M15P50-B Refere
33、nce the Performance Specification 3.3.5 Thermoplastic Property Determination For CAE WSS-M99D68-A1 Reference the Performance Specification 3.5.1 Density 1 3 3 3.5.2 Hardness, Durometer D 1 5 measurements 1 3.5.3 Tensile Strength at Yield* 3 5 15 3.5.4 Elongation at Yield* 3 5 15 3.5.5 Tensile Modulu
34、s 1 10 10 3.5.6 Flexural Modulus* 3 10 30 3.5.7 Impact Strength Notched Izod (per condition)* 3 10 30 3.5.8 Heat Deflection Temperature (per condition)* 3 2 6 3.5.9 Heat Aging Performance 3.5.9.1 Tensile Strength at Yield, Change 1 5 5 3.5.9.2 Impact Strength, Notched Izod, Change 1 10 10 3.5.10 Fla
35、mmability 1 5 5 3.6.1 Percent Recycled Content 1 1 1 3.6.2 Melt Flow Rate 3 1 3 3.6.3 Mold Shrinkage 1 5 5 3.6.4 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.6.5 Impact Strength, Notched Charpy (per condition) 1 10 10 3.6.6 Poissons Ratio 1 2 2 3.6.7 Curves - IR - TGA - DSC (first
36、 and second heat) - CLTE (3 flow and 3 cross flow) - 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. 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interes
37、t from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representativeof the test facility, demonstrating full compliance with all the requirements of the Material S
38、pecification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. ENGINEERING
39、 MATERIAL SPECIFICATION WRS-M4D952-A4 Copyright 2016, Ford Global Technologies, LLC Page 7 of 7 4.4 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material origina
40、lly 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 changes (with reasons) by submission of a comple
41、ted 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 Approval Process (PPAP) sign off must be kept until J
42、ob 1. 4.5 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 WSS-M99P9999-A1 which is updated yearly. It is th
43、e suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 4.6 ADDITIONAL REQUIREMENTS Requirements beyond those explicitly stated in this document and the material specification may be specified on the Engineering drawing, Engineering specification (ES), performance specification,System Design Specification (SDS) and/or Attribute Requirement List (ARL). 5. SUMMARY OF REVISIONS
