1、 ENGINEERING MATERIAL SPECIFICATIONMaterial Name Specification NumberDate Release No. Release/Revision1993 08 02 EP00E10258823000 Completely Revised L. Rodigas1992 09 01 EP00E10176304000 Revised P. Kuntze1990 06 01 EP00E01031536000 Released P. KuntzeWP 3948-a Page 1 of 11 PLASTIC BUMPER, RIGID WSK-M
2、98P7-A1. SCOPEThis specification defines the requirements for self-coloured as well aspainted plastic bumpers with in situ foamed reinforcements.2. APPLICATIONThis s pecification was released originally to define the performancerequirements for plastic bumpers.3. REQUIREMENTS3.1 STATISTICAL PROCESSS
3、upplie rs must conform to the requirements of Ford Quality SystemStanda rd Q-101. A mutually acceptable Control Plan as describedth erein is required for material/source approval. Appropriatestatist ical tools must be used to analyze process/product data sothat variation in the final product is cont
4、inuously reduced.3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSISFord Motor Company, at its option, may conduct infrared and/ortherma l analysis of material/parts supplied to this specification.The IR spectra and thermograms established for i nitial approval shallconst itute the reference stan
5、dard and shall be kept on file at thedesignated material lab oratory. All samples shall produce IR spectraand thermograms that correspond to the reference standard when testedunder the same conditions.3.3 CONDITIONING AND TEST CONDITIONSThe part shall be conditioned for a minimum of 2 4 h at 23 +/-
6、2 C and50 +/- 5 % relative hum idity prior to test and tested under the sameconditions unless otherwise specified.Painted parts shall be conditioned 16 h at 45 +/- 2 C or 72 h at 23+/- 2 C prior to above conditioning, unless otherwise specified.3.4 APPEARANCE(FLTM BI 109-01)Color, gloss and surfac e
7、 shall match the Master Appearance Sample asapproved by the Design Department.ENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 2 of 11 3.5 ADHESIONAdh esion shall be tested on the original part and 15 to 30 minutesafter the relevant aging tests according to para 3.6, 3.7, 3.8. and3.19.Tes
8、t Methods: Choice of the test method shall be made according tothe de sign of the bumper and shall be shown on the EngineeringDrawing.3.5.1 Coating Adhesion (EAO only)(FLTM BI 106-01, Method B)Applic able to painted surfaces only; must be tested inaccordiance with paint performance specification WSK
9、-M2P145-Aor as defined on the Engineering Drawing.3.5.2 Coating Adhesion (NAAO only)(FLTM BI 106-01, Method D)Applic able to painted surfaces only; must be tested inaccordiance with paint performance specification WSK-M2P145-Aor as defined on Engineering Drawing.3.5.3 Peel Strength As specified on(A
10、STM D 1000) Engrg. DrawingApplicable to laminated and/or attachments (EAO only). For applied moldings with single and/or double coatedpressure sensitive tapes, test and evaluate according tothe Engineering Drawing. For in situ foamed bumper reinforcements or fixing partscovered by foam and/or overmo
11、ulded or welded applications,the adhesion of the foam to all components of bumper beamshall be greater then the cohesive strength of thestructure. Overmoulded or welded applications (profiles, spoilersetc.) must not be separable by mechanical means at jointareas. The bond strength (adhesion) shall b
12、e greater thanthe structures cohesive strength.3.5.4 Visual EvaluationTh e finished part shall show no evidence of blisters ordelamination.3.6 PAINT REPAIR OVEN RESISTANCE (EAO only)The fin ished part shall show no deformation or other changes whichwi ll interfere with assembly to mating parts or af
13、fect itsappearance, as specified on the Engineering Drawing.ENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 3 of 11 Test Method: Mount the finished part according vehicle installationon a suitable fixture and place it in car position in a mechanicalconvection oven maintained at 120 +/- 2
14、 C for 30 minutes. Evaluateafter conditioning at 23 +/- 2 C and a storage o f 24 h at 23 +/- 2 C.Painted surfaces must be tested in accordiance w ith paint performancespecification WSK-M2P145-A or as defined on Engineering Drawing.3.7 ENVIRONMENTAL CYCLING(FLTM BQ 104-07, Procedure 1/FLTM BQ 104-07,
15、Procedure 5, 3 cycles, applicable to paintedsurfaces only; must be tested in accordiancewith paint performance specification WSK-M2P145-Aor as defined on Engineering Drawing)The fin ished part shall show no evidence of warpage, deformation,cracks, delamination or other failures to an ext ent that wo
16、uld affectits use in the ultimate assembly.The finished part shall show no changes in appearance when comparedwith the original finished part.The adhe sion of the individual surface coating shall meet therequirements of paragraph 3.5.3.8 SHOCK TESTThe finished part shall show no breaks, cracks or ot
17、her failures.The adhe sion of the individual surface coating shall meet therequirements of paragraph 3.5.Test Method: Maintain the finished part or sect ion of it at - 40 +/-2 C for 16 h. Then immediately immerse part in water at 70 +/- 2 Cfor 5 minutes.Evaluate after conditioning at 23 +/- 2 C.Pain
18、ted surfaces must be tested in accordiance w ith paint performancespecification WSK-M2P145-A or as defined on Engineering Drawing.3.9 RESISTANCE TO COLD IMPACT (Bumper Shell Only)The finished part shall show no breaks, cracks or other failures.Test Method as specified on Engineering Drawing.Painted
19、surfaces must be tested in accordiance w ith paint performancespecification WSK-M2P145-A or as defined on Engineering Drawing.ENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 4 of 11 3.10 CHANGE OF MELT FLOW RATE (MFR) orMELT VOLUME RATE (MVR) - (EAO only)Applicable for bumper bars and re
20、inforcements ma de of PC+PBT mouldingcompound without painted surface only.Test Method: ISO 1133, except 250 +/- 0.5 C with a weight force of5 kg, or according to released material specification.The material shall be dried for 2 h at 123 +/- 2 C in a mechanicalcon vection oven. The MFR/MVR shall be
21、tested immediately afterdrying.3.10.1 Proced ure for a Fundamental Determination of the MFR/MVRCon trol-Regions on Bumper Bars and the MFR/MVR Testing inLine with Acceptance Testing(NOTE: Same procedure for reinforcements)1) After having the moulding machine and the tool inoptimized and constant con
22、dition take 10 g of thedried granule from the bottom of the hopperimmediately before the screw feed.2) Wait for a further th ree shots, then take the next5 bump er bars in sequence for numbering andtesting.3) The bumper bar No. 1 serves as fundamental testingwi th appropriate many MFR/MVR-control re
23、gions.Subdivide the regions into areas with knitline s andbetween knitlines and other critical areas andnumber accordingly. The individual MFR/MVR sampleareas should normally not exceed 40 g.4) Mark th e 5th bumper with the same regions andnumbers. This bumper serves as Master Bumper Bar.5) Cut bump
24、er No. 1 into the individual marked MF R/MVRregio ns and granulate. Mix the granule of eachregion properly to get a representative value.6) Determine:a) the MFR or MVR of the original granuleaccording to para. 1,b) the MFR or MVR of each region of bumper barNo. 1 and mark the result on bumper bar No
25、.5accordingly.7) Calc ulate the % change in MFR or MVR for eachregion compared to the original granule and markthese figures too on bumper bar No. 5.8) Identify for each “hot runner“ fill region theENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 5 of 11 lowest c hange in MFR or MVR and m
26、ark only thosefuture control region s on bumper bars No. 2, 3 and4.9) Cut out the control r egions from bumper 2, 3 and 4(as defined in para. 8) and granule. The granulesof t he individual regions again should be mixedproperly. Determine the MFR/MVR and the change ofMFR/MVR compared to t he original
27、 granule (para 1).10) The co ntrol regions should show less than 25 %change in MFR/MVR or as shown on drawing.Note: To control the influence of further changesin processing conditions only the control regions(according to para. 8 ) have to be tested. In caseof ch ange of wall thickness or cold runne
28、rs theprocedure according t o para. 1 has to be repeated.The frequence of testing the change in MFI or MVIhas to be carried out according to Q-101.3.10.2 Change of MFI or MVI on Bumper Bars before establishing the“Acceptance Testing“ according to para. 3.10.1. The process conditio ns have to be opti
29、mized in such a waythat the change in MFI/MVI - compared with theoriginalgranule - does not exceed 35 %. Test regions have to betaken from character istic sensitive areas, e.g. impact orwelding areas.3.11 WEATHERING RESISTANCE(Preferable for visible unpainted parts)NAAO only: Applicable to parts usi
30、ng materials without previousweathering approval.After exposure in accordance with 3.11.1, 3.11.2 and 3.11.3, themateria l shall show no color change in excess of specified AATCCrating (AATCC Gray Scale for Evaluating Change in Color, 10 step).In addition, there shall be no cracking, crazing or othe
31、rdeterioration.A slig ht loss of gloss or chalking will be allowed provided anaccep table appearance can be achieved by polishing with Ford carpolish (auto wax) at permission of the affected Product DevelopmentMaterials Activity.All initial approvals w ill be based on the preliminary Weatherometerex
32、p osure (para 3.11.1), pending Florida exposure results for finalapproval.ENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 6 of 11 3.11.1 Xenon Arc Weatherometer Rating 4(SAE J1960, 660 kJ/m2 exposure except Rating 4-5minimum or higher if defined in for PP must be tested in accordiancewit
33、 h paint performance specification WSK-M2P145-A or as defined onEngineering Drawing.ENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 8 of 11 3.15 RESISTANCE TO WATER IMMERSION(FLTM BI 104-01)The part shall not show any surface changes, loss of gloss oradhesio n. The adhesion of the indivi
34、dual surface shall meet therequirements of para 3. 5 within 15 to 30 minutes of water immersion.Applicable to painted surfaces only, must be tested in accordiancewit h paint performance specification WSK-M2P145-A or as defined onEngineering Drawing.3.16 CONTACT & MIGRATION STAINING(FLTM BN 103-01, e
35、xcept 72 hat 80 +/- 2 C)Released contact materials shall not cause migration staining,embrittlement or stress cracks in the finished part. Slight contactstaining is permitted.Tes t Method: Place on the finished part or critical sections asuitable large piece of released contact material. Apply a loa
36、d sothat t he molding is in close contact with the finished part asrelea sed. Expose this assembly in a mechanical convection oven.Remove contact material and evaluate the part af ter cooling at 23 +/-2 C.Applicab le for painted areas and areas with appliques of foamsubst rates. Painted surfaces mus
37、t be tested in accordiance withpaint performance specification WSK-M2P145-A or as defined onEngineering Drawing.3.17 RESISTANCE TO WAXING AND DEWAXING COMPOUNDS(FLTM BO 155-01, for NAAO applications useESB-M99J371-A1/A2 instead of specified material)The part shall show no breaks, cracks or other fai
38、lures. Theadhe sion of the individual surface coating shall meet therequirements of paragraph 3.5.Painted surfaces must be tested in accordiance w ith paint performancespecification WSK-M2P145-A or as defined on Engineering Drawing.3.18 FUEL RESISTANCE(FLTM BO 101-05, except test at 23 +/- 2 C)The p
39、ar t (bumper or section of bumper) shall show no significantstaining, change in color, loss of gloss or adhesion. The adhesionof the indivisual surface shall meet the requirements of para 3.5.Treatm ent of the part with a soft cloth prior to evaluation ispermitted. Visual eval uation is to be carrie
40、d out with the finishedpart mounted in vehicle position and viewed from a distance of 1.5 m.The part shall show no fading or color change in excess of Rating 4of AATCC rating (AATCC Gray Scale for Evaluating Change in color, 10step).ENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 9 of 11
41、 Painted surfaces must be tested in accordiance w ith paint performancespecification WSK-M2P145-A or as defined on Engineering Drawing.Test Fuels:3.18.1 85 % Fuel C + 15 % Methanol(ISO 1817)3.18.2 Diesel Fuel(ISO 1817, Fuel F)3.18.3 Fuel as specified on Engineering Drawing.3.19 SCRATCH RESISTANCE3.1
42、9.1 Test Method A(FLTM BN 108-13, 1 mm scratchballs, instrumental evaluationof 3.0 N scratch mark)Percentage of Marking, max 30 %or as defined onEngineering Drawing3.19.2 Test Method B(FLTM BN 108-13, 1 mm scratch balls,visual evaluation)Rating 1 at 2 N scratch mark or as defined on EngineeringDrawi
43、ng.3.20 HEAT RESISTANCE(7 days at 80 +/- 2 C, a part or section of it)No color change, blistering, delamination, deformation or any otherfailures. Adhesion shall meet para 3.5.3.21 CLEANABILITY(Applicable to visible unpainted parts/areas only)The applied car polish wax must remove easily without any
44、 residue.Test Method: The finish part or section of the part shall be treatedwith a car polish wax (Simonize) according to the direction of use.After drying period of 4 h remove the polish wax with a smooth cloth.SOURCE: Car polish wax Simonize GT, (soft paste formula),Messr. Simonize Ltd. England3.
45、22 RESISTANCE TO ABRASION(FLTM BN 154-01, 1000 cycles, applicable for hot stamped/metallized/laminated areas or attachments)The a braded area shall be compatible with the adjacent unabradedarea.ENGINEERING MATERIAL SPECIFICATIONWSK-M98P7-AWP 3948-b Page 10 of 11 Tests carried out on or iginal parts
46、and after heat aging (para 3.19)and environmental cycling (para 3.7).3.23 MATERIALS3.22.1 Base Material As specified onEngineering Drawing3.22.2 Us e of Regrind Material is only allowed if specified onEngineering Drawing.3.24 PAINT MATERIAL REQUIREMENTSPainted surfaces must be tested in accordiance
47、w ith paint performancespecification WSK-M2P145-A or as defined on Engineering Drawing andas crossreferenced on the applied requirements o f this specification.3.25 SUPPLIERS RESPONSIBILITYAll materials supplied to this specification must be equivalent inal l characteristics to the material upon whi
48、ch approval wasoriginally granted.Pri or to making any change in the properties, composition,constr uction, color, processing or labeling of the materialorig inally approved under this specification, whether or not suchchange s affect the materials ability to meet the specificationrequir ements, the
49、 Supplier shall notify Purchasing, Toxicology andthe affected Materials Engineering activity of the proposed changesand obtain the written approval of the Materials Engineeringactivity. Test data, t est 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. The restrictions aredefined in Engineering Material Specification WSS-M99P9999-A1.4. APPROVAL OF MATERIALSThis specification is intended to define the performance and/or prope
