1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2010 09 10 N-STATUS Replaced by WSS-M4D1051-A1, WSS-M4D1052-A2, WSS-M4D1053-A1, WSS-M4D1053-A2 L. Soreide, NA 1999 01 21 Revised Revised para 3.5.4, 3.5.7; updated L. Graham 1992 08 03 EP00E10176303000 Release
2、d P. Kuntze WP 3948-a Page 1 of 7 POLYCARBONATE (PC) MEDIUM MELT FLOW RATE WSK-M4D761-A MOLDING COMPOUND, INTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a medium melt flow rate polycarbonate molding compound. 2. APPLICATION This specification was releas
3、ed originally for material used for interior lamp lenses. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for initial qualification of materials. A Control P
4、lan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to analyze process/product data and as
5、sure consistent processing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS
6、 Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory.
7、All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relati
8、ve humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A Material Name Specification Number WP 3948-b Page 2 of 7 3.4 MOLDING COMPOUND 3.4.1 Melt Flow Rate 6 - 15 g/10 minutes (ISO 1133/ASTM D
9、 1238, 300 C, 1.2 kg) The material shall be dried for min of 2 h at 125 - 130 C in a mechanical convection oven immediately preceding the test. 3.5 MOLDED TEST SPECIMEN 3.5.1 Preparation of Test Specimens Unless otherwise specified all tests shall be carried out on injection molded one-end gated tes
10、t specimens. The following dimensions are required: A. 150 min x 10 x 4.0 +/- 0.2 mm (Tensile Bar, ISO 3167) B. 120 x 10 x 4.0 +/- 0.2 mm Specimens with shorter dimensions shall be cut from the center portion of the test specimen A and/or B. The specimens shall be prepared according to ISO 294. No a
11、nnealing allowed. 3.5.2 Density 1.18 - 1.22 g/cm3(ISO 1183, Method A/ASTM D 792, Method A1) 3.5.3 Tensile Strength at Yield, min 60 MPa (ISO R 527/ASTM D 638M, 150 x 10 x 4.0 +/- 0.2 mm specimen, 50 mm/minute) 3.5.3.1 Elongation at Break, min 90 % (Test Method according to para 3.5.3) 3.5.4 Flexural
12、 Modulus, min 2.0 GPa (ISO 178/ASTM D 790M, Method I, Procedure A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 2 mm/min test speed, 64 mm support span, the radius of the loading nose 5.0 +/- 0.1 mm and of the supports 2.0 +/- 0.2 mm) 3.5.5 Shear Modulus at 23 C 750 - 1300 MPa (ASTM D 4065, forced constant am
13、plitude, fixed frequency of 1 Hz +/- 15 %, strain level below 1 %. Specimen approx. 60 x 10 x 4.0 +/- 0.2 mm cut from the center of specimen A. Specimen length between clamps 35 - 40 mm soak time at each temperature interval: 3 minutes minimum) ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A Materia
14、l Name Specification Number WP 3948-b Page 3 of 7 Additionally, a Shear Modulus vs. Temperature curve shall be plotted for - 50 to + 150 C temperature range, at 5 C minimum intervals. The plotted curve must be within tolerance range shown on page 7. 3.5.6 Impact Strength, Izod, min (ISO 180, Method
15、A/ASTM D 256, Method A 63.5 x 10 x 3.2 +/- 0.2 mm specimen, 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C 70 kJ/m23.5.6.2 At - 10 +/- 2 C 70 kJ/m23.5.6.3 At - 40 +/- 2 C 12 kJ/m2The test specimens must be conditioned for minimum of 6 h at the above specified temperature prior to impact test. Low
16、 temperature testing shall be done within the cold box, if not possible, test can be conducted outside, but within 5 s. 3.5.7 Heat Deflection Temperature, min 120 C (ISO 75/ASTM D 648, 120 x 10 x 4.0 +/- 0.2 mm specimen, at standard deflection of 0.32 +/- 0.01 mm. At 1.80 MPa) 3.5.8 Vicat Softening
17、Temperature, min 140 C (ISO 306, 10 x 10 x 4.0 +/- 0.2 mm specimens. Bath - silicone oil, temp. raise 50 +/- 5 C/h. Dial gage reset to O after addition of 5 kg weight. At 49.0 N load) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture
18、-proof container filled with silica gel. 3.5.9 Heat Aging Performance (ISO 188/ASTM D 573, 150 +/- 50 air changes/h, 1000 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 Max + 30 % Load Change, max (Test Metho
19、d per para 3.5.3) 3.5.9.2 Impact Strength, Izod tbe % Change, max (Test Method per para 3.5.6.1, specimens to be notched before heat aging) ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A Material Name Specification Number WP 3948-b Page 4 of 7 3.6 FLAMMABILITY (ISO 3795) Burn Rate, max 100 mm/minut
20、e The specimen size required for material approval is 355 x 100 x 1.0 +/- 0.1 mm with a smooth surface. 3.7 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h) Fog Number, min 95 Formation of clear film, droplets or crystals is cause for rejection. 3.8 WEATHERIN
21、G RESISTANCE After exposure in accordance with 3.8.1 and 3.8.2 the material shall show no fading or color change in excess of specified Gray Scale rating (AATCC Evaluation Procedure 1/ISO 105-A02). In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss or cha
22、lking will be allowed provided an acceptable appearance can be achieved by washing with mild detergents and water (ratio 5:95 by volume), or equivalent, after the Florida exposure. All initial approvals will be based on the preliminary Weatherometer exposure, pending Florida exposure results for fin
23、al approval. 3.8.1 Xenon Arc Weatherometer Rating 4 (SAE J1885, 150 kJ/m2exposure minimum, specimen size: 150 x 100 mm minimum, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) 3.8.2 12 months Florida Rating 4 (FLTM BI 160-01, 5 south, under glass, specimen size: 150 x 100 mm, minimum, 3.2 +/-
24、0.2 mm thick, molded in smooth polished mold) 3.9 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or performance specifications. All critical areas with respect to these properties
25、 shall be clearly designated on the Engineering drawing. ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A Material Name Specification Number WP 3948-b Page 5 of 7 3.10 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon
26、which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements,
27、 the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restr
28、ictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The regulations are defined in Engineering Materials Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials E
29、ngineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their l
30、aboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords
31、engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information
32、 given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 6 - 7E-5/C (ASTM D 696) 5.2 MOLD SHRINKAGE (ISO 2577, approx. 150 x 100 x 3.2 +/- 0.2 mm injection molded specimen) 5.2.1 Molding Shrinkage . After
33、 48 h at 23 +/- 2 C 0.6 - 0.8 % ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A Material Name Specification Number WP 3948-b Page 6 of 7 5.2.2 Post Shrinkage (Separate specimens required for each test) . After 48 h at 80 C 0.05 % . After 30 minutes at 120 C 0.1 % 5.3 MELT VOLUME RATE 5.5 - 14 cm3/10
34、 minutes (ISO 1133/ASTM D 1238, 300 C, 1.2 kg) The material shall be dried for min of 2 h at 125 - 130 C in a mechanical convection oven immediately preceding the test. 5.4 HEAT DEFLECTION TEMPERATURE, min 135 C (ISO 75/ASTM D 648, 120 x 10 x 4.0 +/- 0.2 mm specimen, at standard deflection of 0.32 +
35、/- 0.01 mm. 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. 5.5 RECYCLING CODE SAE or PC OPTIONAL PC ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A Material Name Specification Number WP 3948-b Page 7 of 7
