1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Release No. Released 2010 09 10 N-STATUS Replaced by WSS-M4D1051-A1, WSS-M4D1052-A2 WSS-M4D1053-A1, WSS-M4D1053-A2 L. Soreide, NA 1994 06 01 C10348592 Revised para 3.4.1, 3.5.9.2 & 3.9 L. Rodigas 1993 11 02 EP00E10258829000
2、Released L. Rodigas WP 3948-a Page 1 of 8 POLYCARBONATE (PC), HIGH MELT FLOW RATE WSK-M4D761-A2 MOLDING COMPOUND, INTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a high melt flow rate polycarbonate molding compound. 2. APPLICATION This specification was
3、released originally for material used for interior lamp lenses. 3. REQUIREMENTS 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate stat
4、istical tools must be used to analyze process/product data so that variation in the final product is continuously reduced. 3.1.1 All requirements of this specification, identified by symbol (s), shall be met with data representing 3 sigma values. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSI
5、S 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.
6、 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 % relat
7、ive humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A2 WP 3948-b Page 2 of 8 3.4 MOLDING COMPOUND (s) 3.4.1 Melt Flow Rate 15 - 25 g/10 minutes (ISO 1133, 300 C, 1.2 kg) The material shall
8、 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 test specimens. The following dimensions ar
9、e 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 annealing allowed. 3.5.2 Density 1.19 - 1
10、.21 g/cm3(ISO 1183, Method A) (s) 3.5.3 Tensile Strength at Max Load, min 60 MPa (ISO R 527, 150 x 10 x 4.0 +/- 0.2 mm specimen, 50 mm/minute test speed) 3.5.3.1 Elongation at Break, min 80 % (Test Method according to para 3.5.3) (s) 3.5.4 Flexural Modulus, min 2.2 GPa (ISO 178, 80 x 10 x 4.0 +/- 0.
11、2 mm specimen, 2 mm/min test speed, 64 mm support span) 3.5.5 Shear Modulus at 23 C 0.7 - 1.1 GPa (ASTM D 4065, forced constant amplitude, 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 cl
12、amps 35-40 mm. Soak time at each temperature interval - 3 minutes minimum) ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A2 WP 3948-b Page 3 of 8 Additionally, a Shear Modulus versus Temperature curve shall be plotted for - 50 to + 150 C temperature range, at 5 C minimum intervals. The plotted curve
13、 must be within tolerance range shown on page 8. (s) 3.5.6 Impact Strength, Izod, min (ISO 180/1A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C 10 kJ/m23.5.6.2 At - 40 +/- 2 C 8 kJ/m23.5.6.3 At - 10 +/- 2 C 8 kJ/m2The test specimens must be conditioned for min
14、imum of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box. (s) 3.5.7 Heat Deflection Temperature, min 120 C (ISO 75, 120 x 10 x 4.0 +/- 0.2 mm specimen, 0.32 +/- 0.01 mm deflection. At 1.80 MPa) All specimens dry as molded. If not
15、tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. (s) 3.5.8 Vicat Softening Temperature, min 138 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 o
16、f 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. 3.5.9 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. Unaged property val
17、ues shall be determined at the time of the aged properties determination) ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A2 WP 3948-b Page 4 of 8 3.5.9.1 Tensile Strength at Max Load Change, max + 30 % (Test Method per para 3.5.3) 3.5.9.2 Impact Strength, Izod Change, max - 55 % (Test Method per para
18、 3.5.6.1, specimens to be notched before heat aging) 3.6 FOGGING (FLTM BO 116-03) Fog Number, min 90 Formation of a clear film, droplets or crystals is cause for rejection. 3.7 FLAMMABILITY (ISO 3795) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355 x 100 x 1.0 +/
19、- 0.1 mm with a smooth surface. 3.8 WEATHERING 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
20、 deterioration. A slight loss of gloss or chalking 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 expos
21、ure, pending Florida exposure results for final approval. 3.8.1 Xenon Arc Weatherometer Rating 4 (SAE J1885, 150 kJ/m2 exposure 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 deg south, under gla
22、ss, specimen size: 150 x 100 mm, minimum, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A2 WP 3948-b Page 5 of 8 3.9 OPTICAL PROPERTIES 3.9.1 Yellowness Index, max (ASTM D 1925, 3.2 +/- 0.2 mm thick, clear, molded sheet. Test to be performed afte
23、r exposure according to Test Method per para 3.8.1) Before rating, the specimens are to be treated with Ford car polish (auto wax) at permission of the affected Product Development Materials Activity. 3.9.1.1 Unexposed 0.6 % 3.9.1.2 After 150 kJ/m2 exposure 5.5 % 3.9.1.3 After 300 kJ/m2 exposure 10
24、% 3.9.1.4 After 600 kJ/m2 exposure 16 % 3.9.1.5 After 900 kJ/m2 exposure 19 % 3.9.1.6 After 1240 kJ/m2 exposure 22 % 3.10 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or perform
25、ance specifications. All critical areas with respect to these properties shall be clearly designated on the Engineering drawing. 3.11 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally gra
26、nted. 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, the Supplier shall notify Purcha
27、sing, 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 restrictions imposed by law, regulatio
28、ns or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1. ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A2 WP 3948-b Page 6 of 8 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior a
29、pproval by the responsible Materials Engineering 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 Engineerin
30、g activity a completed copy of their laboratory 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
31、 specimens for Ford evaluation. Fords 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.
32、5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements to the specification. 5.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 5 - 7E-5/C (ASTM E 228 or TMA, temperature range - 20 to + 100 C) 5.2 MOLD SHRINKAGE (ISO 2577, approx. 150 x
33、100 x 3.2 +/- 0.2 mm injection molded specimen) 5.2.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.5 - 0.7 % 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 18 - 24 cm3/10 minutes (ISO 1133, 300 C,
34、1.2 kg) The material shall be dried for min of 4 h at 125 - 130 C in a mechanical convection oven immediately preceding the test. ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A2 WP 3948-b Page 7 of 8 5.4 IMPACT STRENGTH, IZOD, min (ISO 180/4A, 63.5 x 12.7 x 3.2 +/- 0.2 mm specimen, 10 specimens for
35、 each test) 5.4.1 At 23 +/- 2 C 60 kJ/m25.4.2 At - 40 +/- 2 C 10 kJ/m25.4.3 At - 10 +/- 2 C tbd The test specimens must be conditioned for minimum of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box. 5.5 HEAT DEFLECTION TEMPERATUR
36、E, min 130 C (ISO 75, 120 x 10 x 4.0 +/- 0.2 mm specimen, 0.32 +/- 0.01 mm deflection. 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. 5.6 RECYCLING CODE PC ENGINEERING MATERIAL SPECIFICATION WSK-M4D761-A2 WP 3948-b Page 8 of 8
