1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Action Changes1996 01 19 Activated L. RodigasPage 1 of 8ABS, HIGH IMPACT STRENGTH EXTRUSION WSK-M4D905-A1MOLDING COMPOUNDABS, HIGH IMPACT STRENGTH EXTRUSION WSK-M4D905-A2MOLDING COMPOUND, INTERIORABS, HIGH HEAT RESISTANT EXTRU
2、SION WSK-M4D906-A1MOLDING COMPOUNDABS, HIGH HEAT RESISTANT EXTRUSION WSK-M4D906-A2MOLDING COMPOUND, INTERIOR1. SCOPEThe materials defined by these specifications are vacuum formable highimpact (WSK-M4D905-A1 & -A2) and high heat (WSK-M4D906-A1 & -A2) extrusionmolding compounds based on acrylonitrile
3、/butadiene/styrene (ABS). WSK-M4D905-A2 and WSK-M4D906-A2 materials are molded-in-color with low glosssurfaces, and are able to fulfill weathering requirements necessary forvisible interior applications.2. APPLICATIONThese specifications were released originally for material used for variousextruded
4、 and/or coextruded interior body parts such as rear airconditioning duct assemblies, claddigs, door trim and/or quarter trimpanels.3. REQUIREMENTS3.1 QUALITY SYSTEM REQUIREMENTSMaterial suppliers and part producers must conform to Quality SystemRequirements, QS-9000. Material specification requireme
5、nts are to beused for initial qualification of materials. A Control Plan forongoing production verification is required. This plan must bereviewed and approved by the relevant Ford Materials activity and/orFord Supplier Technical Assistance (STA) prior to production partssubmission. Appropriate stat
6、istical tools must be used to analyzeprocess/product data and assure consistent processing of thematerials.Part producers using this material in their products, must use Fordapproved materials and must conform to a process control plan whichhas been approved by STA and/or the relevant Materials Acti
7、vity.3.1.1 All requirements of this specification, identified by symbol(s), shall be met with data representing 3 sigma values.ENGINEERING MATERIAL SPECIFICATIONWSK-M4D905-A1/A2WSK-M4D906-A1/A2Page 2 of 83.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may con
8、duct infrared and/orthermal analysis of material/parts supplied to this specification.The IR spectra and thermograms established for initial approval shallconstitute the reference standard and shall be kept on file at thedesignated material laboratory. All samples shall produce IR spectraand thermog
9、rams that correspond to the reference standard when testedunder the same conditions.3.3 CONDITIONING AND TEST CONDITIONSAll test values indicated herein are based on material conditioned ina controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relativehumidity for not less than 24 h prior to testing a
10、nd tested under thesame conditions unless otherwise specified.3.4 MOLDING COMPOUND(s) 3.4.1 Melt Flow Rate(ISO 1133, 220 C, 10 kg)WSK-M4D905-A1 4 - 9 g/10 minutesWSK-M4D905-A2 2 - 5 g/10 minutesWSK-M4D906-A1 & A2 2 - 5 g/10 minutesThe material shall be dried for 2 h minimum at 80 - 85 C ina mechanic
11、al convection oven immediately preceding the test.3.5 MOLDED TEST SPECIMEN3.5.1 Preparation of Test SpecimensUnless otherwise specified all tests shall be carried out oninjection molded one-end gated test specimens.The following dimensions are required:A. 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 3167,
12、 Type 1A)B. 60 x 60 x 2.0 +/- 0.1 mm (ISO/DIS 294-3)C. 355 x 100 x 1.9 +/- 0.1 mm (ISO 3795)Test specimen A shall be molded using molding conditionsdefined in ISO 3167. Specimens with shorter dimensions shallbe cut from the center of the specimen A. No annealingallowed.3.5.2 Density 1.04 - 1.14 g/cm
13、3(ISO 1183, Method A)ENGINEERING MATERIAL SPECIFICATIONWSK-M4D905-A1/A2WSK-M4D906-A1/A2Page 3 of 8(s) 3.5.3 Tensile Strength at Yield, min(ISO 527-1 & ISO 527-2, 150 minimum x10 x 4.0 +/- 0.2 mm specimen,test speed: 50 mm/minute)WSK-M4D905-A1 & -A2 32 MPaWSK-M4D906-A1 & -A2 44 MPa3.5.3.1 Elongation
14、at Break, min(Test Method accordingto para 3.5.3)WSK-M4D905-A1 & -A2 50 %WSK-M4D906-A1 & -A2 40 %(s) 3.5.4 Flexural Modulus, min(ISO 178, 80 x 10 x 4.0 +/- 0.2 mmspecimen, (use center section ofspecimen A), 2 mm/min test speed,64 mm support span)WSK-M4D905-A1 & -A2 1.7 GPaWSK-M4D906-A1 & -A2 2.2 GPa
15、3.5.5 Shear Modulus at 23 C(ASTM D 5279, forced constantamplitude, 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)WS
16、K-M4D905-A1 & -A2 0.57 - 0.73 GPaWSK-M4D906-A1 & -A2 0.8 - 1.20 GPaAdditionally, shear modulus versus temperature curves shallbe plotted for - 50 to + 120 C temperature range, at 5 Cminimum intervals. The plotted curves must be withintolerance range granted on the original material approval andit sh
17、all constitute the reference standards for materialssupplied to these specifications and shall be kept on file atthe designated material laboratory and be available onrequest.(s) 3.5.6 Impact Strength, Izod, min(ISO 180/1A, 80 x 10 x 4.0+/- 0.2 mm specimen (use centersection of specimen A), 10 speci
18、mensfor each test)3.5.6.1 At 23 +/- 2 CWSK-M4D905-A1 & -A2 30 kJ/m2WSK-M4D906-A1 & -A2 20 kJ/m2ENGINEERING MATERIAL SPECIFICATIONWSK-M4D905-A1/A2WSK-M4D906-A1/A2Page 4 of 83.5.6.2 At - 40 +/- 2 CWSK-M4D905-A1 & -A2 10 kJ/m2WSK-M4D906-A1 & -A2 7 kJ/m23.5.6.3 At 0 +/- 2 CWSK-M4D905-A1 & -A2 22 kJ/m2WS
19、K-M4D906-A1 & -A2 10 kJ/m2The test specimens must be conditioned for minimumof 6 h at the above specified temperature prior toimpact test. Low temperature testing shall be donewithin the cold chamber, if not possible, test maybe conducted outside, but within 5 seconds.(s) 3.5.7 Heat Deflection Tempe
20、rature, min(ISO 75-1 & ISO 75-2, 120 x 10 x 4.0+/- 0.2 mm specimen (use centersection of specimen A), edgewise,0.32 +/- 0.01 mm deflection. At 1.80 MPa)WSK-M4D905-A1 & -A2 70 CWSK-M4D906-A1 & -A2 85 CAll specimens dry as molded. If not tested immediately aftermolding, specimens must be stored in a s
21、ealed, moisture-proofcontainer filled with silica gel.(s) 3.5.8 Vicat Softening Temperature, min(ISO 306, 10 x 10 x 4.0 +/- 0.2 mmspecimens (use center section ofspecimen A). Bath - silicone oil,temperature raise 50 +/- 5 C/h.Dial gage reset to 0 after addition5 kg weight. At 50 N load)WSK-M4D905-A1
22、 & -A2 89 CWSK-M4D906-A1 & -A2 105 CAll specimens dry as molded. If not tested immediately aftermolding, specimens must be stored in a sealed, moisture-proofcontainer filled with silica gel.3.5.9 Heat Aging Performance(ISO 188, except 150 +/- 50 airchanges/h, 1000 h at 80 +/- 2 C.Unaged property val
23、ues shall bedetermined at the time of the agedproperties determination)3.5.9.1 Tensile Strength at Yield,Change +/- 20 %(Test Method per para 3.5.3)ENGINEERING MATERIAL SPECIFICATIONWSK-M4D905-A1/A2WSK-M4D906-A1/A2Page 5 of 83.5.9.2 Impact Strength, Izod Change,max - 35 %(Test Method per para 3.5.6.
24、1,specimens to be notched beforeheat aging)3.6 FOGGING(SAE J1756, 3 h at 100 C heating, 21 C coolingplate, post test conditioning 1 h)Fog Number, min 90Formation of a clear film, droplets or crystals is cause forrejection.3.7 FLAMMABILITY(ISO 3795/SAE J369)Burn Rate, max 100 mm/minuteThe specimen si
25、ze required for material approval is 355 x 100 x 1.9+/- 0.1 mm (use specimen C) with a smooth surface.3.8 WEATHERING RESISTANCE (WSK-M4D905-A2 & WSK-M4D906-A2 only)After exposure in accordance with 3.8.1 and 3.8.2 the material shallshow no fading or color change in excess of specified Gray Scalerati
26、ng (AATCC Evaluation Procedure 1/ISO 105-A02).In addition, there shall be no cracking, crazing or otherdeterioration.A slight loss of gloss or chalking will be allowed provided anacceptable appearance can be achieved by washing with mild detergentsand water (ratio 5:95 by volume), or equivalent, aft
27、er the Floridaexposure.All initial approvals will be based on the preliminary Weatherometerexposure, pending Florida exposure results for final approval.3.8.1 Xenon Arc Weatherometer Rating 4(SAE J1885, except Black PanelTemperature at 80 C, 300 kJ/m2exposure minimum, specimen size:60 x 60 mm minimu
28、m, 2.0 +/- 0.1 mmthick, smooth surface, low glossinjection molded specimen).3.8.2 12 months Florida Rating 4(FLTM BI 160-01, 5 deg south,under PPG Herculite K, temperedsafety glass, 3 mm thick. Specimensize: 60 x 60 minimum, 2.0 +/- 0.1mm thick, smooth surface, low glossinjection molded specimen)ENG
29、INEERING MATERIAL SPECIFICATIONWSK-M4D905-A1/A2WSK-M4D906-A1/A2Page 6 of 83.9 ADDITIONAL REQUIREMENTSSpecific requirements for material and/or manufactured parts shall bespecified on the Engineering drawing, Engineering parts specificationand/or performance specification. All critical areas with res
30、pect tothese properties shall be clearly designated on the engineeringdrawing.3.10 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inall characteristics to the material upon which approval wasoriginally granted.Prior to making any change in the properties, com
31、position,construction, color, processing or labeling of the materialoriginally approved under this specification, whether or not suchchanges affect the materials ability to meet the specificationrequirements, the Supplier shall notify Purchasing, Toxicology andthe affected Materials Engineering acti
32、vity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Test data, test samples and a new code identification areto be submitted with the request.Substance restrictions imposed by law, regulations or Ford, apply tothe materials addressed by this document. Th
33、e restrictions aredefined in Engineering Materials Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSMaterials defined by this specification must have prior approval by theresponsible Materials Engineering activity. Suppliers desiring approvalof their materials shall first obtain an expression o
34、f interest from theaffected Purchasing, Design and Materials Engineering activity. Uponrequest, the Supplier shall submit to the affected Materials Engineeringactivity a completed copy of their laboratory test reports, signed by aqualified and authorized representative of the test facility, demonstr
35、atingfull compliance with all the requirements of this specification (testresults, not nominal values), the material designation and code number, andtest specimens for Ford evaluation. Fords engineering approval of amaterial will be based on its performance to this specification and on anassessment
36、of suitability for intended processes and/or applications. Uponapproval, the material will be added to the Engineering Material ApprovedSource List.5. GENERAL INFORMATIONThe information given below is provided for clarification and assistancein meeting the requirements of this specification.5.1 COEF
37、FICIENT OF LINEAR THERMAL EXPANSION 7 - 10E-5/ C(ASTM E 831 TMA, temperature range- 20 to + 40 C)ENGINEERING MATERIAL SPECIFICATIONWSK-M4D905-A1/A2WSK-M4D906-A1/A2Page 7 of 85.2 MOLD SHRINKAGE(ISO/DIS 294-3, 60 x 60 x 2.0 +/- 0.1 mminjection molded specimen)5.2.1 Molding Shrinkage. After 48 h at 23
38、+/- 2 C 0.5 - 0.8 %5.2.2 Post Shrinkage(Separate specimens required foreach test). After 48 h at 80 C 0.1 - 0.2 %5.3 MELT VOLUME RATE(ISO 1133, 220 C, 10 kg,extrudate volume in cm3/10 minutes)The material shall be dried for 2 h minimum at 80 - 85 C in amechanical convection oven immediately precedin
39、g the test.WSK-M4D905-A1 4 - 9 cm3/10 minutesWSK-M4D905-A2 2 - 5 cm3/10 minutesWSK-M4D906-A1 & -A2 2 - 4 cm3/10 minutesNote: The material shall be dried for 2 h minimum at 80 - 85 C in amechanical convection oven immediately preceding the test.5.4 MODULUS OF ELASTICITY(ISO 527-1 & 527-2, 150 minimum
40、 x10 x 4 +/- 0.2 mm specimen,test speed: 1 mm/minute)WSK-M4D905-A1 & -A2 1.7 GPaWSK-M4D906-A1 & -A2 tbd GPa5.5 IMPACT STRENGTH, CHARPY(ISO 179/leA, 80 x 10 x 4.0+/- 0.2 mm specimen (use centersection of specimen A), 10 specimensfor each test)5.5.1 At 23 +/- 2 CWSK-M4D905-A1 & -A2 19 kJ/m2WSK-M4D906-
41、A1 & -A2 tbd kJ/m2ENGINEERING MATERIAL SPECIFICATIONWSK-M4D905-A1/A2WSK-M4D906-A1/A2Page 8 of 85.5.2 At - 40 +/- 1 CWSK-M4D905-A1 & -A2 tbd kJ/m2WSK-M4D906-A1 & -A2 tbd kJ/m2The test specimens must be conditioned for minimum of 6 hoursat the above specified temperature prior to impact test. Lowtempe
42、rature testing shall be done within the cold chamber, ifnot possible, test may be conducted outside, but within 5seconds.5.6 HEAT DEFLECTION TEMPERATURE, min(ISO 75-1 & ISO 75-2, 120 x 10 x 4.0+/- 0.2 mm specimen (use centersection of specimen A), edgewise,0.32 +/- 0.01 mm deflection. At 0.45 MPa)WS
43、K-M4D905-A1 & -A2 100 CWSK-M4D905-A1 & -A2 103 CAll specimens dry as molded. If not tested immediately aftermolding, specimens must be stored in a sealed, moisture-proofcontainer filled with silica gel.5.7 HEAT DEFLECTION TEMPERATURE, min(ISO 75-1 & ISO 75-2, 120 x 10 x 4.0+/- 0.2 mm specimen (use c
44、entersection of specimen A), flatwise,0.34 +/- 0.01 mm deflection. At 1.80 MPa)WSK-M4D905-A1 & -A2 tbd CWSK-M4D906-A1 & -A2 tbd CAll specimens dry as molded. If not tested immediately aftermolding, specimens must be stored in a sealed, moisture-proofcontainer filled with silica gel.5.8 GLOSS LEVEL tbdTest method under development.5.9 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSESABS
