1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 04 2016 04 11 Re-Activated T.Nover, EU 2010 01 20 N-Status No replacement named J. Crist, NA 1995 04 03 Activated L. Rodigas Controlled document at www.MATS Copyright 2016 Ford Global Technologies, LLC Page 1 of 8 POLYBUTYLENE TEREPHTHALA
2、TE + ACRYLONITRILE WSK-M4D894-A2 STYRENE ACRYLATE BLEND (PBT+ASA), 10% GLASS FIBER REINFORCED MOLDING COMPOUND, INTERIOR 1. SCOPE The materials defined by these specifications are 10% glass fiber reinforced blends of polybutylene terephthalate and acrylonitrile-styrene-acrylate (PBT+ASA), UV stabili
3、zed and scratch resistant for interior use. 2. APPLICATION This specification was released originally for material used for tweeter mesh. 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) c
4、an be used when this specification is listed on 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
5、 less than 24 h prior to testing in a controlled 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 mater
6、ial approval shall constitute the reference standard 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 test
7、ed under the same conditions. 3.4 STANDARD REQUIREMENTS 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 rang
8、e was established using 3 sigma data. For 2011 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 Materials used in interior applications must meet the re
9、quirements outlined in WSS-M99P2222- D1/Latest, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submission package. ENGINEERING MATERIAL SPECIFICATION WSS-M4D894-A2 Copyright 2016, Ford Global Technologies, LLC Page 2 of 8 3.4.4 Pe
10、rformance Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS- M15P4-FLatest. 3.4.5 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 t
11、o: Melt Flow Rate Filler Content Impact Strength, Notched Charpy at 23C Flexural Modulus 3.5 SAMPLE PREPARATION All tests shall 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 Materi
12、als Engineering. Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defined in ISO 7792-2. No additional annealing is allowed. See Tables 1 and 2 for the number of samples re
13、quired. 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 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
14、 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 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 s
15、pecimens for A and B gloss surfaces. 3.6 APPEARANCE 3.6.1 Weathering Resistance Rating 4 min (FLTM BO 116-01, 2481.6 kJ/m2 exposure Specimen C, ungrained, non-polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) After exposure the material shall show no fading or color change in excess of the
16、specified AATCC rating. In addition, there shall be no cracking, crazing or other deterioration. Use regional choice for initial approval and report the color house used. See Table 2 for additional color durability submission requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M4D894-A2 Copyright 2
17、016, Ford Global Technologies, LLC Page 3 of 8 3.7 MATERIAL PROPERTIES 3.7.1 Glass Fiber Content 8 - 12% (ISO 3451-2, 2 h at 750 +/- 25 C test portion 2.5 - 3.0 g) 3.7.2 Density 1.29 - 1.34 g/cm3 (ISO 1183, Method A) 3.7.3 Tensile Strength at Break 60 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50
18、 mm/minute test speed) 3.7.4 Tensile Modulus 4.1 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.5 Flexural Modulus 3.4 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.7.6 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.7.6.1 At 23
19、+/- 2 C 2.0 kJ/m2 min Report Break Type 3.7.6.2 At -40 +/- 2 C 1.5 kJ/m2 min 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 testing shall be done within the cold chamber, if not possible, test ma
20、y be conducted outside, but within 5 seconds. Test specimens must be reviewed by Materials Engineering. 3.7.7 Heat Deflection Temperature 118 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) All specimens dry as molded. If not tested imm
21、ediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.7.8 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 140+/- 2 C. After heat aging test specimens are to be conditioned in a desiccator for 3 - 5 h at 23 +/- 2 C. Unage
22、d property values shall be determined at the time of the aged properties determination) 3.7.8.1 Tensile Strength at Break, Change +/- 25% max (Test Method per para 3.7.3) ENGINEERING MATERIAL SPECIFICATION WSS-M4D894-A2 Copyright 2016, Ford Global Technologies, LLC Page 4 of 8 3.7.8.2 Impact Strengt
23、h, Notched Charpy, Change +/- 25% max (Test Method per para 3.7.6.1, specimens to be notched before Heat Aging) 3.7.9 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 3.7.10 Determination of the Fogging Characterist
24、ics of Interior Automotive Materials Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. 3.7.11 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface)
25、Burn Rate 100 mm/minute max 3.8 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.8.1 Melt Flow Rate Report Value (ISO 1133 260 C, 2.16 kg) g/10 minutes The material shall be dried for 2 h minimum at 125 C in a mechanical convection oven immediately preceding the tes
26、t. 3.8.2 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.8.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 110 +/- 2 C) Flow Report Value, Cross Flow E-5 mm/mm/ C 3.8.4 Melt Volu
27、me Rate Report Range, (ISO 1133, 260 C, 2.16 kg, cm3/10 min extrudate volume in cm3/10 minutes) ENGINEERING MATERIAL SPECIFICATION WSS-M4D894-A2 Copyright 2016, Ford Global Technologies, LLC Page 5 of 8 The material shall be dried for 2 h minimum at 125 C in a mechanical convection oven immediately
28、preceding the test. 3.8.5 Heat Deflection Temperature Report Value,C(ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 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 con
29、tainer filled with silica gel. 3.8.6 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 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeti
30、ng the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.8 Para. Test Typical Value Units 3.8.1 Melt Flow Rate 8 - 20 g/10 minutes 3.8.2 Molding Shrinkage (Report method used, sample size and v
31、alue) - After 48 h at 23 +/- 2 C Flow Cross Flow 0.3 0.6 0.6 0.9 % % 3.8.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 5 12 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.4 Melt Volume Rate 6 - 18 cm3/10 min 3.8.5 Heat Deflection Temperature 200 C 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCT
32、S PBT+ASA-GF10 (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D894-A2 Copyright 2016, Ford Global Technologies, LLC Page 6 of 8 Table 1: Minimum Sample Size Initial Approval and/or Initial Approval in a New Region Additional Manufacturing Location for Previously Approved Material Para. Te
33、st Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4.3 WSS-M99P2222-D1/Latest Total Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See below for Odor and Fogging) 1 1 1 per test 3.4.4 WSS-M15P4-F/Latest Reference the Performan
34、ce Specification 3.6.1 Weathering Resistance 1 1 1 3.7.1 Glass Fiber Content 3 1 3 1 1 1 3.7.2 Density 1 3 3 1 3 3 3.7.3 Tensile Strength at Break * 3 5 15 1 5 5 3.7.4 Tensile Modulus 1 10 10 3.7.5 Flexural Modulus* 3 10 30 1 10 10 3.7.6 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 1
35、0 3.7.7 3.8.5 Heat Deflection Temperature (per condition)* 3 2 6 1 2 2 3.7.8 Heat Aging Performance 3.7.8.1 Tensile Strength at Break, Change 1 5 5 3.7.8.2 Impact Strength, Notched Charpy, Change 1 10 10 3.7.9 Odor 1 9 9 3.7.10 Fogging Photometric 1 3 3 3.7.11 Flammability 1 5 5 3.8.1 Melt Flow Rate
36、 3 1 3 3 1 3 3.8.2 Mold Shrinkage 1 5 5 1 5 5 3.8.3 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.8.4 Melt Volume Rate 3 1 3 3.8.6 Curves - IR - TGA - DSC (first and second heat) - CLTE (3 flow and 3 cross flow) - Stress/Strain Curves 1 1 1 per test * For these requirements the 3 s
37、igma value from the raw data is used to meet the requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M4D894-A2 Copyright 2016, Ford Global Technologies, LLC Page 7 of 8 Table 2: Minimum Color Property Testing - Contact Materials Engineering for Color Test Work Plan 4.3 APPROVAL OF MATERIALS Supplie
38、rs 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 of their laboratory test reports, signed by a qualified and authorized representativeof the test
39、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. Upon request, the supplier will review the associated quality control documents (Process Failure Mode
40、 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 was originally granted. Prior to making any changes to the material originally approved, whether or
41、 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 completed Suppliers Request fo
42、r 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 Job 1. 4.4 RESTRICTED SUB
43、STANCE 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 the suppliers responsibili
44、ty to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 4.5 ADDITIONAL REQUIREMENTS Para. Test Lots Specimens per Lot Total Test Specimens Color Test Direction 3.6.1 Weathering Resistance 1 1 1 Every color 3.7.3 Tensile Strength at Break 1 5 5 As directed by Materia
45、ls Engineering 3.7.5 Flexural Modulus 1 10 10 As directed by Materials Engineering 3.7.6 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering 3.7.9 Odor 1 9 9 As directed by Materials Engineering 3.7.11 Flammability 1 5 5 As directed by Materials Engineering ENG
46、INEERING MATERIAL SPECIFICATION WSS-M4D894-A2 Copyright 2016, Ford Global Technologies, LLC Page 8 of 8 Requirements beyond those explicitly stated in this document and the material specification may be specified on the Engineering drawing, Engineering specification (ES), performance specification,
47、System Design Specification (SDS) and/or Attribute Requirement List (ARL). 5. SUMMARY OF REVISIONS 2016 04 11 Re-actived, Separated A2 from A1 and A3. Deleted WSS-M99P1111-A and moved those requirements directly into this specification. 2010 01 20 N-status, No replacement named. 2006 06 26 Revised Inserted 3.0; Deleted 3.1, 3.2, 3.3, 3.11, 3.9-Suppliers Resp. & 4
