1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 3 2014 12 10 Editorial See Summary of Revisions A. Wagenhals, NA 2014 02 25 Editorial See Summary of Revisions D. Murtonen, NA 2008 05 28 Activated M. Dumitrescu, FNA; J.Williams, FOE Controlled document at www.MATS Copyright 2014, Ford
2、Global Technologies, LLC Page 1 of 7 PERFORMANCE, HEADLINING, FORMED WSS-M15P27-F 1. SCOPE The material defined by this specification is fully finished, unitized formed headlining assembly consisting of a face material and substrate layers. 2. APPLICATION This unitized composite assembly is used as
3、a headlining for passenger cars and trucks or as specified on the Engineering Drawing. Headliners bonded to body sheet metal must meet the requirements of WSB-M11P59-A. Testing must be conducted at each prototype and production build phase unless specified otherwise by Ford Engineering. See Table 1
4、for DV/PV testing. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.1.1 Vehicle Interior Environment Quality Materials/Component Performance Require
5、ments Materials used in interior applications must meet the requirements outlined in WSS-M99P2222-C1/latest. Components in vehicles that will be TUV certified must also meet the requirements outlined in WSS-M99P2222-C2/latest. 3.2 APPEARANCE (FLTM BI 109-01) The color, pattern, and finish shall matc
6、h the approved Design Center master sample, or shall be as specified on the Engineering Drawing. 3.3 WEIGHT, g/m2 As specified on the (FLTM BN 106-01) Engineering Drawing 3.4 TRANSVERSE STRENGTH*, min 20 N (SAE J949, average of maximum loads on 5 samples) *In addition, the part shall not be damaged
7、during installation in the vehicle. ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-F Copyright 2014, Ford Global Technologies, LLC Page 2 of 7 3.5 DIMENSIONAL STABILITY (SAE J315 test both flat and deep draw areas of part, with measurements on A and B surfaces) After testing, there shall be no bliste
8、ring or loss of adhesion of the surface material, and visible distortion or shrinkage of the component. Method “A“ +/- 0.5% Method “C“ (following Method A) +/- 0.5% Or as otherwise specified on the engineering drawing. 3.6 ADHESION STRENGTH (FLTM BN 151-05, all environmental conditioning of the proc
9、edure with exceptions as indicated below*) Face to substrate 6 N min All layers shall be bonded at all points without blisters. All areas of the part shall meet adhesion values specified above. After conditioning, the coverstock shall not blister, bubble or show areas of no adhesion. In addition, ad
10、hesion of the face fabric shall be greater than 6 N unless otherwise specified in the material specification. * Exceptions from FLTM BN 151-05 are: Environmental Aging which shall be following the cycling steps of para 3.21 Autoclave Aging which will be performed according with para 3.22 And Cleanin
11、g for which an approved Brand Cleaner shall be used. 3.7 RESISTANCE TO HEAT AGING Rating 4 min (7 days at 90 +/- 2 C) The test specimen shall not show any change of color as above when examined using ISO 105-A02/AATCC Evaluation Procedure 1. Any spotty or non-uniform staining, discoloration or color
12、 tone change shall be cause for rejection. The sample must not produce any unpleasant odors when hot. 3.8 ODOR (FLTM BO 131-03, all 3 conditions) Condition 1 = 23 +/- 2C Rating 3 max Condition 2 = 40 +/- 2C Rating 3 max Condition 3 = 65 +/- 2C Rating 3 max 3.9 FOGGING (SAE J1756, 3 h at 100 C heatin
13、g, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-F Copyright 2014, Ford Global Technologies, LLC Page 3 of 7 3.10 RESISTANCE TO MILDEW The material shall exhibit n
14、o visual evidence of mildew growth and/or objectionable odor after 7 days exposure in a humidity cabinet at 38 +/- 2 C and 98 +/- 2% relative humidity. 3.11 INDENTATION AND RECOVERY (FLTM BO 111-02, Method B, except load is 1.5 kg) The indented headliner must return to its original contour within 5
15、minutes. In addition, the part shall not be damaged during installation in the vehicle. 3.12 RESISTANCE TO ABRASION 150 cycles (SAE J948, 500 g, CS-10 wheels) No evidence of excessive surface deterioration. The resistance to abrasion of production materials shall be equal to or better than that exhi
16、bited by the sample originally approved by the Materials Engineering Activity. 3.13 RESISTANCE TO SCUFFING 25 cycles (SAE J365, 0.9 kg load, A head) No evidence of lifting, peeling, excessive scuffing or excessive surface deterioration. The resistance to scuffing of production materials shall be equ
17、al to or better than that exhibited by the sample originally approved by the Materials Engineering Activity. 3.14 RESISTANCE TO SNAGGING 25 cycles min (SAE J1530-A, 500 g load, H-18 wheels) Applicable to non-woven face fabrics No evidence of fiber pullout in excess of the material originally approve
18、d by Materials Engineering. The print on printed fabrics shall not be removed. 3.15 RESISTANCE TO FADE (FLTM BO 116-01, ISO 105-A02/) AATCC Evaluation Procedure 1) 225.6 kJ/m2 Rating 4 min The material shall not exhibit any change in appearance, such as color tone change, fading in excess of the req
19、uired AATCC rating. In addition, the material shall not exhibit staining, blistering, or delamination. 3.16 RESISTANCE TO CROCKING (FLTM BN 107-01, AATCC Procedure 2) Dry Rating 4 min Wet Rating 4 min 3.17 RESISTANCE TO BLEEDING Rating 4 min (FLTM AN 101-01, AATCC Evaluation Procedure 2) 3.18 RESIST
20、ANCE TO WATER SPOTTING (FLTM AN 101-01) No spots shall remain after the distilled water has completely dried off. ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-F Copyright 2014, Ford Global Technologies, LLC Page 4 of 7 3.19 SOILING AND CLEANABILITY OF CLOTH, (AATCC Evaluation Procedure 2) After cle
21、aning Rating 4 Marks with an artists charcoal crayon must be easily removed, using an approved Brand Interior Trim Cleaner, without serious damage to the face fabric. The print on printed fabrics shall not be removed. With moderate pressure mark the face fabric with the crayon, length of mark approx
22、imately 70mm by approximately 2-3mm wide. There shall be no pilling of the face fabric after the above testing. Printed fabrics shall retain all print detail after cleaning. The performance of production material shall be equal to or better than that exhibited by the sample originally approved for p
23、roduction by the Materials Engineering Activity. 3.20 IDENTIFICATION MARKING The reverse side of each assembly must be marked in a suitable way to identify its production batch. There shall be no evidence of identification mark bleed through onto the cover materials surface, nor any staining of adja
24、cent assemblies during storage. 3.21 SIMULATED IN-CAR ENVIRONMENTAL AGING Headliner Sag, max 13 mm Edge Gap Deformation, max 3.5 mm Horizontal Movement, max 3.5 mm The headliner shall not show any delamination, loss of embossed definition, excessive deformation, or any objectionable surface imperfec
25、tions. The attachment system shall not show any evidence of delamination or separation from the headliner or mating components. Test Method: Install a complete headliner using production assembly techniques, in an approved test buck or vehicle, representative of intended production dimensions. Expos
26、e the vehicle (with windows open) or test buck to the following environmental cycle: Confirm with the affected Materials Engineering Activity for agreement prior to using test chambers with automated programmable test cycles for the listed test conditions below. Ramp speed 1 to 5 C per minute (recor
27、d actual ramp speed on data sheet). . 5 h at -30 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 90 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 16 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -30 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 90 +/- 2
28、C *Please note that this list does not include ramp times to transition from level to level. Each specimen can have different size, geometry, density, etc. which impacts ramp times; therefore, each transition period will vary in length of time. Total test time should exceed 38 hrs due to time requir
29、ed to transition from level to level. The sag test is to be conducted at the prototype stage using a fixture representing the vehicle fixing points. For full vehicle testing, during the CP phase, the test procedure given below will be ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-F Copyright 2014, F
30、ord Global Technologies, LLC Page 5 of 7 maintained, but the method of achieving the check points is as follows: The check points will be achieved by drilling 6mm diameter holes in the headliner above the H points for depth micrometer measurements. The five points across the front and rear obscurati
31、on bands are noted by tape markers attached to the front and a rear screen, an example is shown in the diagram. During the full vehicle test, the air vents are to be set to open and the windows are to be open. Check point locations are marked at the following locations on the test headliner: Front E
32、dge along the windscreen obscuration line, five points on one line beginning at the center point and spaced at approximately 220mm to the left and right of the center. Rear Edge along the rear screen line, with check points as above. Five checkpoint locations are also to be marked directly above the
33、 headform center points. The head form center points are to be determined from the H points on the vehicle layout drawing, shown on the diagram below. Moonroof/Sunroof eight checkpoint locations are to be determined according to the attached sketch. Test Criteria Depth measurements for each checkpoi
34、nt location are to be noted prior to and at the end of the environmental cycle. The test criterion is to be applied 24 hours after completion of the sag test. From the compiled test data a maximum desired sag of 3.5mm should be allowed across the ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-F Copyr
35、ight 2014, Ford Global Technologies, LLC Page 6 of 7 front and rear edges and around the moonroof/sunroof aperture and 13.0mm above the head form points. No irregularities in shape or contour should be observed No damage to the face fabric and material bonding is allowed. There should be no loosenin
36、g of inserts or attachments. 3.22 STEAM AUTOCLAVE AGING, Retained Strength min 50% of original This requirement applies to urethane foams used in headliner constructions (fabric backing and substrate). 3.22.1 ASTM D3574, TEST J 1, one autoclave cycle for 3 h at 105 C Applicable for all Temperate Mar
37、kets 3.22.2 ASTM D3574, TEST J 2, two autoclave cycles of 5h at 120 C each Applicable for all Tropical, Sub Tropical and NA Markets. Flexible Foam: Adhesion strength method: Cut two adjacent 250 x 250 mm samples from the headliner. Expose one to steam autoclave aging. Dry the autoclaved samples for
38、a period of 3 h at 100 C +/- 5 C. Then condition for 24 h at 23 +/- 2 and 50% relative humidity. Die cut 50 mm wide strips from both sets of original and autoclave-aged samples and test foam peel adhesion per Method A of FLTM BN 151-05. Report the percentage retained foam adhesion strength of the au
39、toclave-aged sample from the original. Rigid Foam: Transverse strength method - Cut a duplicate set of transverse strength samples per para 3.4. Expose one to steam autoclave aging. Then condition both for 24 h at 23 +/- 2 C and 50% relative humidity, evaluate transverse strength and report the perc
40、ent retained transverse strength of the autoclave aged sample from the original. 3.23 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate 100 mm/minute max 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contac
41、t for questions concerning Engineering Material Specifications. 4.1 STORAGE AND ASSEMBLY To avoid crush marks on the face fabric, finished headliners are supplied in special pallets. They should not be removed from the pallets until required for fitting to the vehicle. To prevent soiling during han
42、dling and fitting operations, the face side of the assembly may be covered by a self-adhesive polyethylene film. 5. SUMMARY OF REVISIONS 12/10/2014 Editorial Change Clarification on environmental cycling. Section 3.21. 02/25/2014 Editorial update: Added condition 1,2,3 to clarify odor requirement. 0
43、9/26/2012 ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-F Copyright 2014, Ford Global Technologies, LLC Page 7 of 7 Section 3 added para 3.1.1- Vehicle Interior Environment Quality Materials/Component Performance Requirements Para 3.4 was 10N min Para 3.5 added A and B surfaces Para 3.6 updated with
44、 more test directions Para 3.8 clarified, removed SAE J1351 Para 3.9 updated; 1 hr post conditioning evaluation removed Para 3.13 clarified Para 3.15 updated, removed SAE J2412 Para 3.21 updated Table 1 WSS-M15P27-F For Paragraphs DV PV Surrogate data from Material Spec Allowed 3.4 Transverse Streng
45、th X X 3.5 Dimensional Stability X 3.6 Adhesion Strength X X 3.7 Resistance to Heat Aging X 3.8 Odor X 3.9 Fogging X 3.10 Resistance to Mildew X 3.11 Indentation and Recovery X X 3.12 Resistance to Abrasion X X 3.13 Resistance to Scuffing X X 3.14 Resistance to Snagging X X 3.15 Resistance to Fade X
46、 3.16 Resistance to Crocking X * * 3.17 Resistance to Bleeding X * * 3.18 Resistance to Water spotting X * * 3.19 Soiling and Cleanability of cloth X * * 3.20 Identification Marking X X 3.21 Simulated in-car environmental aging X X 3.22 Steam Autoclave Aging, Retained Strength X X 3.23 Flammability X X
