1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev. 03 2016 08 03 Revised Corrected specification suffix from WSS to WSK. 2016 05 31 Released Re-activated in updated format T.Nover, EU 1993 12 01 Released EP00E1025883 3000 L. RodigasControlled document at www.MATS Copyright 2016 Ford Globa
2、l Technologies, LLC Page 1 of 7 POLYPROPYLENE (PP) COPOLYMER, 20% MINERAL WSK-M4D783-A2 FILLED MOLDING COMPOUND 1. SCOPE The material defined by this specification is a 20% mineral filled injection molding compound based on polypropylene copolymer. 2. APPLICATION This specification was released orig
3、inally for material used for non visible interior trim parts in low to medium impact zones 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
4、 the drawing, 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 controlle
5、d environment 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 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms from initial material approval shall constitute the reference sta
6、ndard and shall be kept on file at the designated material laboratory. The material supplier shall ensure that all future material supplied to the specification shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 STANDARD REQU
7、IREMENTS FOR PRODUCTION MATERIALS 3.4.1 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 specification minimum, maximum or range was established using 3 sigma data. For 2011
8、and beyond, refer to Table 1 for number of samples required for each test. 3.4.2 This specification is based on virgin material and does not allow the addition of recycled content (PIR/PCR). 3.4.3 The use of regrind is permitted, for economic / environmental reasons. Part manufacturers using this sp
9、ecification must complete DV and PV testing with the allowable amount of regrind and the maximum allowable regrind content must 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 Engi
10、neering through the formal Ford Motor Company process (SREA). ENGINEERING MATERIAL SPECIFICATIONWSK-M4D783-A2 Copyright 2016, Ford Global Technologies, LLC Page 2 of 7 3.4.4 Materials used in interior applications must meet the requirements outlined in WSS-M99P2222- D1/Latest, Performance, Vehicle I
11、nterior Environment Quality Material/Component Requirements. Data must be included in material submission package. 3.4.5 Performance Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS- M15P4-G/Latest. 3.4.6 Ford Materials Engineering may request a Con
12、trol Plan and Certificate of Analysis (C of A) containing lot testing requirements which must include, but are not limited to: Melt Flow Rate (not for filled materials) Filler Content Impact Strength, Notched Charpy at 23C Flexural Modulus 3.5 SAMPLE PREPARATION All tests shall be carried out on pro
13、duction 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. The test specimens A an
14、d D shall be molded using molding conditions defined in ISO 1873- 2. No additional annealing is allowed. See Tables 1 and 2 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 +/- 0.1
15、 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 3.
16、6 MATERIAL PROPERTIES 3.6.1 Determination of Ash, talc filler 18 - 23 % (ISO 3451-1, Method A, at 800C +/- 50C) 3.6.2 Density 1.03 - 1.07 g/cm3(ISO 1183, Method A) 3.6.3 Tensile Strength at Yield 22.0 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.6.4 Elongation at Yield 2.
17、5 % min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.6.5 Tensile Modulus 1.8 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATIONWSK-M4D783-A2 Copyright 2016, Ford Global Technologies, LLC Page 3 of 7 3.6.6 Flexural Modulus 2.0
18、GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.6.7 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.6.7.1 At 23 +/- 2 C 4.5 kJ/m2min Report Break Type 3.6.7.1 At -40 +/- 2 C 1.0 kJ/m2min Report Break Type The test specimen must be conditioned for minimum of
19、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. Test specimens must be reviewed by Materials Engineering. 3.6.8 Heat Deflection Temperature (ISO 75-1
20、and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection. At 1.80 MPa 55 C min At 0.45 MPa 100 C min 3.6.9 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 120+/- 2 C. After heat aging test specimens are to be conditioned in a desiccator for 3 - 5 h at 23
21、 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.6.9.1 Tensile Strength at Yield, Change +/- 25% max (Test Method per para 3.6.3) 3.6.9.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per para 3.6.7.1, specimens to be notched
22、 before Heat Aging) 3.6.10 Interior Odor Test (FLTM BO 131-03, Variant C, Specimen G) Condition 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.6.11 Determination of the Fogging Characteristics of Interior Automotive Materials Photometric (SAE J1756, Specimen F, 3 h at 100 C heati
23、ng, 21 C cooling plate, post test conditioning 16 h) ENGINEERING MATERIAL SPECIFICATIONWSK-M4D783-A2 Copyright 2016, Ford Global Technologies, LLC Page 4 of 7 Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. 3.6.12 Flammability (ISO 3795/SAE J369, Specimen B, s
24、mooth surface) Burn Rate 100 mm/minute max 3.7 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.7.1 Melt Flow Rate Report MFR (ISO 1133 230 C, 2.16 kg) 3.7.2 Molding Shrinkage Report Shrinkage (Report method used, sample size and value) 3.7.3 Coefficient of Linear T
25、hermal Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 100 +/- 2 C) Flow Report Value, E-5mm/mm/ C Cross Flow Report Value, E-5mm/mm/ C 3.7.4 Impact Strength, Notched Izod Report Value kJ/m2 (ISO 180-1/1eA, Specimen D, 23 +/- 2 C) Report Break Type The test specimen must be conditioned for minimum
26、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. 3.7.5 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7
27、.6 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC first and second heat Engineering Stress/Strain at 23 C ENGINEERING MATERIAL SPECIFICATIONWSK-M4D783-A2 Copyright 2016, Ford Global Technologies, LLC Page 5 of 7 4. GENERAL INFORMATION The infor
28、mation given below is 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 3.8 P Test Typical Value Units 3.7.1 Melt Flow Rate 13-19 g/10 min
29、utes 3.7.2 Molding Shrinkage Flow Cross Flow 1.0 1.2 1.0 1.2 % % 3.7.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 8 - 10 8 - 10 E-5mm/mm/ C E-5mm/mm/ C 3.7.4 Impact Strength, Notched Izod At 23 +/- 2 C At - 40 +/- 2 C 3,0 2.0 kJ/m2 kJ/m2 3.7.5 Poissons Ratio 0.34 N/A 4.2 GENERIC IDENTIF
30、ICATION AND MARKING OF PLASTIC PRODUCTS PP-TD20 (ISO 1043/11469) 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy
31、 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 Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upo
32、n request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.4 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval w
33、as originally granted. Prior to making any changes to the material originally 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 a
34、ctivities of the proposed changes (with reasons) by submission of a completed 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)
35、 and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.4 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 Subst
36、ance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. ENGINEERING MATERIAL SPECIFICATIONWSK-M4D783-A2 Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 4.5 AD
37、DITIONAL 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. SUMM
38、ARY OF REVISIONS 2016 08 03 Corrected specification suffix from WSS to WSK and added Summary of Revisions. 2016 05 31 Re-Activated and updated to latest format. 2011 03 17 N Status with No Replacement Named 2006 02 14 Released Inserted 3.0; Deleted 3.1, 3.2, 3.3, 3.8, 3.9 Deleted 3.1, 3.2, 3.3, 3.8, 3.9 & 4
