1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2010 09 10 INACTIVE Replaced by WSS-M4D1051-A1, WSS-M4D1052-A2, WSS-M4D1053-A1, WSS-M4D1053-A2 L. Soreide, NA1991 04 02 EP00E10189483000 Released P. Kuntze WP 3948-a Page 1 of 6 POLYCARBONATE (PC), MODIFIED,
2、 HIGH HEAT RESISTANT WSK-M4D796-A1 MOLDING COMPOUND NOT TO BE USED FOR NEW DESIGN 1. SCOPE: The material defined by this specification is a high heat resistant molding compound based on bisphenol A/bisphenol C derived co-polycarbonate. 2. APPLICATION: Thise specification was released originally for
3、material used for lamp reflectors. 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 statistical tools must be used t
4、o analyze process/product data so that variation in the final product is continuously reduced. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and t
5、hermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING
6、AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 MOLDING COMPOUND 3.4.1 Melt Fl
7、ow Rate 4 - 8 g/10 minutes (ISO 1133/ASTM D 1238, 320 C, 2.16 kg) The material shall be dried for 4 h minimum at 130 - 140 C in a mechanical convection oven immediately preceding the test. ENGINEERING MATERIAL SPECIFICATION WSK-M4D796-A1 Page 2 of 6 ENGINEERING MATERIAL SPECIFICATION WSK-M4D796-A1 P
8、age 3 of 6 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 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.
9、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 1.14 - 1.16 g/cm3(ISO 1183, Method A/ASTM D 792, Method A1) 3.5.3 Tensile Strength at Yield, min 65 M
10、Pa (ISO R 527/ASTM D 638M, 150 min x 10 x 4.0 +/- 0.2 mm specimen, 50 mm/min test speed) 3.5.3.1 Elongation at Break, min 60 % (Test Method according to para 3.5.3) 3.5.4 Flexural Modulus, min 2.0 GPa (ISO 178/ASTM D 790M, Method I, Procedure A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 64 mm support span)
11、 3.5.5 Shear Modulus at 23 C 740 - 1100 MPa (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 clamps 35 - 40 mm. Soak time at each temperature interva
12、l - 3 minutes minimum) Additionally, a Shear Modulus vs. Temperature curve shall be plotted for - 50 to + 195 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 A/ASTM D 256, Method A, 80
13、x 10 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C 7 kJ/m2ENGINEERING MATERIAL SPECIFICATION WSK-M4D796-A1 Page 4 of 6 3.5.6.2 At - 40 +/- 2 C 4 kJ/m2The test specimens must be conditioned for minimum of 6 h at the above specified temperature prior to impact test. Low
14、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 (ISO 75/ASTM D 648, 120 x 10 x 4.0 +/- 0.2 mm specimen) 3.5.7.1 At 1.82 MPa 154 C 3.5.7.2 At 0.45 MPa 171 C All specimens dry as molded. If no
15、t tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.5.8 Vicat Softening Temperature, min 180 C (ISO 306, 10 x 10 x 4.0 +/- 0.2 mm specimens. Bath - silicone oil, temperature raise 50 +/- 5 C/h. Dial gage reset to 0 after additi
16、on 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-proof container filled with silica gel. 3.5.9 Heat Aging Performance (ISO 188/ASTM D 573, 150 +/0 50 air changes/h, 1000 h at 140 +/- 2 C. Unaged pr
17、operty values shall be determined at the time of the aged properties determination) 3.5.9.1 Tensile Strength at max +/- 25 % Load Change (Test Method per para 3.5.3) 3.5.9.2 Impact Strength, Izod Change - 40 % (Test Method per para 3.5.6.1, specimens to be notched before heat aging) 3.6 FLAMMABILITY
18、 (ISO 3795) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355 x 100 x 1.0 +/- 0.1 mm with a smooth surface. ENGINEERING MATERIAL SPECIFICATION WSK-M4D796-A1 Page 5 of 6 3.7 FOGGING (FLTM BO 116-03) Fog Number, min 95 The formation of droplets or coalescence into a
19、clear film is cause for rejection. 3.8 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 shall be c
20、learly designated on the Engineering drawing. 3.9 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color
21、, 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 Purchasing, Toxicology and the affected Materials Engineering activity of the proposed cha
22、nges 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, regulations or Ford, apply to the materials addressed by this document. The restrictions are
23、defined in Engineering Material Specification WSS-M99P9999-A1, unless a different suffix (e.g., A2 or A3) is specified on the engineering document for the application. 4. APPROVAL OF MATERIALS: Materials defined by this specification must have prior approval by the responsible Materials Engineering
24、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 laboratory t
25、est 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. In addition to me
26、eting the requirements of this specification, the materials will be assessed for suitability for intended applications as part of the approval process. Upon approval, the material will be added to the Engineering Material Approved Source List. ENGINEERING MATERIAL SPECIFICATION WSK-M4D796-A1 Page 6
27、of 6 5. GENERAL INFORMATION: The information below is provided for clarification and assistance in meeting the requirements to the specification. 5.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 7 - 8E-5/C (ASTM D 696) 5.2 MOLD SHRINKAGE (ISO 2577, approx. 150 x 100 x 3.2 +/- 0.2 mm injection molded spec
28、imen) 5.2.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.8 - 0.9 % 5.2.2 Post Shrinkage (Separate specimens required for each test) . After 48 h at 80 C 0.05 % . After 30 min at 120 C 0.05 % 5.3 MELT VOLUME RATE 4 -8 cm3/10 minutes (ISO 1133/ASTM D 1238, 320 C, 2.16 kg) The material shall be dried for min of 4 h at 130 - 140 C in a mechanical convection oven immediately prior to testing. ENGINEERING MATERIAL SPECIFICATION WSK-M4D796-A1 Page 7 of 6
