1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 2 2016 04 06 Editorial See Summary of Revisions A. Wagenhals, NA 2015 10 16 Editorial See Summary of Revisions A. Wagenhals, NA 2015 08 12 Released A.Wagenhals, D. Murtonen, FNA Controlled document at www.MATS Copyright 2016, Ford Global
2、 Technologies, LLC Page 1 of 11 PERFORMANCE, HEADLINING, FORMED WSS-M15P27-G 1. SCOPE The material defined by this specification is a fully finished, unitized formed headlining assembly consisting of a face material (un-laminated or laminated with foam) and substrate layers. Specific tests may requi
3、re all PIA (Part in Assembly) components to be included. 2. APPLICATION This unitized composite assembly is used as a headlining for all vehicles or as specified on the Engineering Drawing. PEC/FEC/PV testing must be conducted in compliance with program milestones unless otherwise specified by Ford
4、Engineering. Each substrate configuration must be tested including all fabric types as the requirement is form/shape dependent. (For example Steel Roof, M/R, Panoramic Roof, Fixed Glass Roof, etc.). If manufacturing localization occurs each regional/global program must be tested (See table 1 for add
5、itional reference). The following components used in the headlining system must meet the following requirements if present in the system: Interior Plastic Parts WSS-M15P4-F/latest Integral Air Duct WSB-M15P38-A/latest Label Performance WSS-M99P41-A10/A72/latest Roof Systems Fabric Performance WSS-M8
6、P27-A1/latest Head Impact Countermeasures (HIC) Material: Energy Absorbing Foam - WSS-M99P29-B/latest Thermoformed Polypropylene WSS-M4D1028-A2/latest Interior NVH Material - WSS-M99P32-D1/latest Foam Stuffers WSS-M99P48-A1/latest Additionally, the following components/materials should conform to th
7、eir respective active Ford Material/Performance Specifications as documented by the Engineering Drawing. Wire harness, washer hose, etc. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 CONDITIONING AND TEST CONDITIONS All test valu
8、es are based on material conditioned for not 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. ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-G Copyrigh
9、t 2016, Ford Global Technologies, LLC Page 2 of 11 3.3 DV/PV TEST PLAN PEC/FEC/PV testing must be conducted in compliance with program milestones unless otherwise specified by Ford Engineering. See Table 1 for DV/PV testing. 3.4 VEHICLE INTERIOR ENVIRONMENTAL PERFORMANCE Materials used in interior a
10、pplications must meet the requirements outlined in WSS-M99P2222-D1/latest, Performance, Vehicle Interior Environmental Quality Material/Component Requirements. Data must be included in material submission package. 3.5 FOGGING (SAE J1756, 3 h at 100 C, 21 C cooling plate, post-test conditioning 16 h)
11、 Test substrate with fabric or fabric/foam composite. PIA (Part in Assembly) components shall meet fogging requirements according to the appropriate specification as listed in section 2.0 or the appropriate specification as called out on the Engineering Drawing. Fog Number 70 min Formation of clear
12、film, droplets or crystals is cause for rejection. 3.6 ODOR Rating 3 max (FLTM BO 131-03-Variant C) 3.7 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate 100 mm/minute max Headliner substrate with fabric composite/non-woven shall be tested as one unit 100% fully bonded. PIA (Part in Assembly) bolt on compo
13、nents must meet flammability requirements for their respective performance or material specification unless 100% bonded to the substrate, such as over head consoles (OHC), finishers, etc. 3.8 CONSTRUCTION PROPERTIES 3.8.1 Transverse Strength 20 N min (SAE J949, average of maximum loads on 5 samples
14、in each direction, headliner thickness must be reported). Cut ten samples, five samples each machine direction (typical, fore-aft) and against machine direction (typical, cross car) as directed from Ford D therefore, each transition period will vary in length of time. Total test time should exceed H
15、eadliner Substrate Roof Metal Z dimension Z dimension Headliner edge near Moon roof/ sun roof opening. Headliner edge near door X/Y dimension: Measure total span of opening at mandatory check center points to adjacent check points. Left side of section not shown. ENGINEERING MATERIAL SPECIFICATION W
16、SS-M15P27-G Copyright 2016, Ford Global Technologies, LLC Page 8 of 11 38 h due to time required to transition from level to level. Test Criteria Visually evaluate the part before and after the test. Measure the part and record data at all specified locations at room temperature before and after cyc
17、ling on test buck or fixture. Depth and or gap measurements for each checkpoint 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 Environmental test. The following requirements must be met both pre and po
18、sttest: No excessive deformation, irregularities in shape or contour should be observed causing perceived craftsmanship issues. The attachment system and any other PIA component that is attached to the back side of the substrate shall not show any evidence of delamination or separation from the head
19、liner or mating components that will cause a failure for serviceability per IT-0036 (RTQ# 010500-013080/15 or latest) No discoloration or defect should be observed to the class A surface. The headliner shall not show any delamination or loss of embossed definition. No movement exceeding the general
20、tolerance on the drawing for the assembly unless otherwise stated on the Engineering Drawing Maximum Allowable Sag Delta from Design Nominal or Pretest Dimension: Front Edge 3.5 mm Rear Edge 3.5 mm Door Openings 3.5 mm Moon roof/Pano Roof 3.5 mm Qtr. Windows or Opera Windows 3.5 mm Headliner Surface
21、 13 mm 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 ENGINEERING 2D/3D DRAWING CALL-OUT Engineering drawings shall call out
22、the following: Location of transverse strength samples. Layered bill of material for headliner with weight (gsm). Layered bill of material for fabric composite/non-woven with weight (gsm). Type and location of hot melt adhesives. Shipping and sequencing labels. 4.2 STORAGE AND ASSEMBLY To avoid crus
23、h marks on the face fabric, finished headliners are supplied in packaging that will protect part integrity. They should not be removed from the pallets until required for fitting to the vehicle. To prevent soiling during handling and fitting operations, the face side of the assembly may be covered b
24、y a self-adhesive polyethylene film. ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-G Copyright 2016, Ford Global Technologies, LLC Page 9 of 11 4.3 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 o
25、f identification mark bleed through onto the cover materials surface, nor any staining of adjacent assemblies during storage. If a class A surface protective film is used no adhesive residue can remain after removal. 4.4 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall firs
26、t 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 representative of the test facility, demonstrating full compliance with all
27、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 and Effects Analysis, Control Plans, Certificati
28、on testing) with Ford. 4.5 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 not such changes affect the materials ability to
29、 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 for Engineering Approval, SREA. For parts and compo
30、nents 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. 4.6 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions
31、 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 responsibility to comply with this standard on a continuing b
32、asis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2016 04 06 Editorial Corrected paragraph number reference in 3.8.2 2015 10 16 Editorial - Corrected time typo in section 3.9.2 ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-G Copyright 2016, Ford Global Technologies, LLC Page 10 of 11
33、Table 1 DV/PV Testing Plan WSS-M15P27-G Amount of Samples Required For Paragraphs DV PV Regional PV/ Change in Mfg. Location * 3.5 Fogging 3 3 3.6 Odor 1 per condition 1 per condition 1 per condition 3.7 Flammability 3 3 3 3.8 Construction Properties 3.8.1 Transverse Strength 5 per direction 5 per d
34、irection 5 per direction 3.8.2 Adhesion Strength 3.8.2.1. Cover Fabric (non-woven) to Substrate 3 3 3 3.8.2.2. Cover Fabric/Foam Composite to Substrate 3 3 3 3.8.2.3. Cover Fabric/Foam Composite with Scrim to Substrate 3 3 3 3.8.2.4 Autoclave 3 3 3 3.8.3 Resistance to Mildew 1 1 3.9 Functional Prope
35、rties 3.9.1 Indentation and Recovery 3 3 3 3.9.2 Environmental Cycling and Sag Requirements 3 3 3 *Implies that the headliner is the same construction, shape, and supplied by the same tier one supplier. ENGINEERING MATERIAL SPECIFICATION WSS-M15P27-G Copyright 2016, Ford Global Technologies, LLC Pag
36、e 11 of 11 Table 2 Design Change Test Plan WSS-M15P27-G Amount of Samples Required For Paragraphs Carry over substrate, New Face Fabric Carry over Face Fabric, New Substrate Carry over Face Fabric, Carry over Substrate (new shape) 3.5 Fogging 3 3 3.6 Odor 1 per condition 1 per condition 3.7 Flammabi
37、lity 3 3 3 3.8 Construction Properties 3.8.1 Transverse Strength 5 per direction 5 per direction 3.8.2 Adhesion Strength 3.8.2.1. Cover Fabric to Substrate 3 3 3 3.8.2.2. Cover Fabric/Foam Composite to Substrate 3 3 3 3.8.2.3. Cover Fabric/Foam Composite with Scrim to Substrate 3 3 3 3.8.2.4 Autoclave 3 3 3 3.8.3 Resistance to Mildew 1 3.9 Functional Properties 3.9.1 Indentation and Recovery 3 3 3 3.9.2 Environmental Cycling and Sag Requirements 3 3
