1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Ver. 4 2009 10 20 N-STATUS Replaced by WSS-M15P4-F C. Boese, FNA 2005 07 14 Revised Revised 2, 3.9.1, Table 1; Added 3.8.1.2, 3.9.2, 3.9.3 L. Soreide 1996 02 19 Activated N. Komatsu, M. Masserant Printed copies are uncontrolled Copyright 2008,
2、 Ford Global Technologies, LLC Page 1 of 11 INTERIOR TRIM, ASSEMBLY PERFORMANCE SPECIFICATION WSS-M15P4-E NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines the minimum durability and performance requirements of interior trim panels and moldings where various materials are combined to
3、 provide a trim assembly having decorative and/or functional features. 2. APPLICATION This specification was originally released for interior trim items such as door panel, center and overhead console, quarter panel, seat-back panel, A-, B-, C-, and D-pillar molding, hard instrument panels, all inst
4、rument panel components and garnish molding assemblies used in vehicles. All painted interior components shall meet requirements of WSS-M2P188-A1. Testing must be conducted at each prototype and production build phase unless specified otherwise by Ford Engineering. See Table 1 for sample sizes. Excl
5、uded from this specification are instrument panel pad and retainer, air bag covers, package trays, steering wheels, headlining and carpeting assemblies whose performance is specified separately. This specification is based on virgin material only. The use of in-house regrind is not allowed unless ap
6、proved by Materials Engineering. If approved, the part must then be validated during PV testing with the documented level of regrind noted on the part drawing. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standa
7、rd Requirements For Production Materials (WSS-M99P1111-A). Note: Painted parts to be conditioned for 72 hours prior to test. 3.4 APPEARANCE (FLTM BI 109-01) The color, pattern, and finish shall match the approved Design Center master sample or shall be as specified on the engineering drawing. ENGINE
8、ERING MATERIAL SPECIFICATIONWSS-M15P4-E Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 11 3.5 ENVIRONMENTAL TESTING SAMPLE PREPARATION All parts shall be fully trimmed including all components packaged in the environment (eg. speakers, hardware, wiring, etc.)
9、 and assembled onto actual or representative production support foundations that include not only all attaching points but also any boundary conditions that may restrict movement, unless otherwise specified by the affected Materials Engineering Activity. The retention methods, attachments and suppor
10、ting garnish moldings (if any), shall be the same as proposed for production. MEASUREMENT LOCATIONS . Every twenty centimeters AND AT THE POINTS OF GREATEST MOVEMENT BETWEEN THE TWENTY CENTIMETER MARKS along the parts outside edges and internal openings. . All “Interior Margin/Flushness Specificatio
11、n“ locations for the specified carline as shown in the Body Engineering Office, Product Engineering General Specifications Manual unless otherwise specified by the affected Materials Engineering Activity. . The “significant characteristics locations“ specified on the engineering drawing. MEASUREMENT
12、 TECHNIQUE The movement at each measurement point shall be recorded in two directions: (1) in the x/y plane from the observers view, and (2) in the z-dimension direction into or out of the x/y plane from the observers view. The observers view shall remain consistent always viewing from the front sid
13、e of the part. TEST PROCEDURE Visually evaluate the part before, during, and after the test. Measure the part and record data at all specified locations at room temperature before and after cycling on the production support foundation or test fixture. Also, during para. 3.5.1 “Short Term Heat and Co
14、ld Cycle“ testing, visually evaluate the part and measure any significant characteristic locations only, during the last half-hour of each cold and hot extreme temperature period. Subject the number of assemblies specified to each of the cycles that follow in paragraphs 3.5.1, 3.5.2, and 3.5.3. Auto
15、mated programmable test cycles based on the listed test conditions may be accepted by prior agreement with the affected Materials Engineering Activity. Ramp speed 1 to 5 C per minute. Record actual ramp speed on data sheet. 3.5.1 Short Term Heat, Humidity and Cold Cycle Test three previously unexpos
16、ed assemblies: ENGINEERING MATERIAL SPECIFICATIONWSS-M15P4-E Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 11 3.5.1.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. sail; A-, B-, C-, and D-pillars; upper quarter panels; hard instrument panels a
17、nd roof-rail moldings): . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 100 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 100 +/- 2 C 3.5.1.2 H
18、orizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels, lower quarter trim panels, consoles and glove box doors and overhead consoles. . 5 h at -40 +/- 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. . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. .
19、 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 90 +/- 2 C 3.5.1.3 Scuff plates, kick panels and other non-sun loaded floor level parts. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 80 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.
20、H. . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 80 +/- 2 C 3.5.2 Long Term Heat Exposure Test one previously unexposed assembly as follows: 3.5.2.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (
21、e.g. sail; A-, B-, C-, and D-pillars; upper quarter panels; hard instrument panels and roof-rail moldings): . 7 days at 100 +/- 2 C ENGINEERING MATERIAL SPECIFICATIONWSS-M15P4-E Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 11 3.5.2.2 Horizontal or vertical
22、parts BELOW THE BELT-LINE (e.g., door panels, lower quarter trim panels, consoles and glove box doors) and overhead consoles: . 7 days at 90 +/- 2 C 3.5.2.3 Scuff plates, kick panels and other non-sun loaded floor level parts. . 7 days at 80 +/- 2 C 3.5.3 Heat, Humidity, and Cold Cycle (Vehicle Test
23、) Test two previously unexposed assemblies: . 5 h at -40 +/- 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 -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 9
24、0 +/- 2 C This test must be performed by Ford (or other Ford designated test lab) in a complete fully-trimmed body with surrounding parts (trim, hardware, insulators, wires, etc.) prior to final ISR approval unless otherwise specified by the affected Materials Engineering Activity. 3.5.4 Humidity Te
25、st (Fiberboard parts only) Test five previously unexposed assemblies: Thoroughly soak the top flange of the door or quarter panel by running at least 200 cc of water along the board adjacent to the weatherstrip region and allowing to soak in. Then place the complete assembly in vehicle position in a
26、n environmental chamber per the following cycle: . 16 h at 5 +/- 2 C . 24 h at 38 C and 95 +/- 5% R.H. Then condition for: . 24 h at 23 +/- 2 C and 50 +/- 5% R.H. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P4-E Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 5 of 11
27、Requirements: The trimmed assemblies shall remain relatively unaffected by the exposure cycles during and after the tests as demonstrated: (1) Tactually/visually - no excessive tackiness, loss in surface-grain, or surface-color change (AATCC Procedure 1, Rating 4, min); no wrinkling, distortion, bli
28、stering, warping, delamination, blushing, hazing, milking, staining, waviness, or other objectionable visual appearance. (2) Functionally - no excessive expansion, shrinking, or warping that will interfere with normal functional operations. (3) Dimensionally - no movement exceeding 3.0 mm from the o
29、riginal installed position during or after the test; for the “significant characteristic locations“, no movement exceeding 0.5 mm from the original installed position during or after the test. Dimensional exceptions to these requirements may be allowed on the Engineering drawing. 3.6 INDENTATION AND
30、 RECOVERY All parts of the assembly shall (FLTM BO 111-02, Method “B“) return to their original contours Not Applicable to Hard Plastics within 5 minutes or within the time specified on the engineering drawing. 3.7 LOAD DEFLECTION The test location, depth of (FLTM BO 113-03) deflection, and load val
31、ue will Not Applicable to Hard appear on the engineering Plastics drawing when specified. 3.8 IMPACT RESISTANCE 3.8.1 Rubber Ball 4.5 kg weight, 127 mm dia 60 +/- 5, Durometer “A“, (ISO 686/ASTM D 2240) The assembly shall show no evidence of cracking or breaking and shall fully recover from indentat
32、ion in the time required for the assembly to return to 23 +/- 2 C. Test Method: Conduct this test with the trim assembly mounted on an actual or simulated production support foundation using the approved retention methods. Drop the rubber ball from the height specified below at the impact locations
33、indicated on the Engineering Drawing. Drop Height . Scuff Plates and Load Floor 610 mm . Below belt line 460 mm . Above belt line 305 mm Exception to the above requirements shall be specified on the Engineering Drawing. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P4-E Printed copies are uncontrolled Co
34、pyright 2008, Ford Global Technologies, LLC Page 6 of 11 3.8.1.1 Room Temperature Impact (23 +/- 2 C) 3.8.1.2 Cold Impact for Land Rover, Jaguar and Ford of Europe Only (-30 +/- 2 C) Expose the mounted assembly for 24 h at 80 C +/- 2 C and then for 5 h at -30 +/- 2 C. Drop the rubber ball while the
35、part is in the cold box or within 10 seconds of its removal from the cold box. 3.8.2 Steel Ball for Speaker Grilles 525 +/- 5 g, 50 +/- 2 mm diameter, 440-C Stainless Steel Grade: 100, Hardness Rockwell C 57 to 61. Steel Ball Drop Height . Below armrest on door trim 406 mm* . Beltline on door trim,
36、quarter trim, liftgate 254 mm* hard instrument panel and package tray *Changes in the above drop height must be mutually agreed upon with the Design and Release Engineer and the applicable Materials Engineering Department. 3.8.2.1 Room Temperature Impact (23 +/- 2 C) 3.9 COLOR AND APPEARANCE PROPERT
37、IES 3.9.1 Resistance to Fade (SAE J1885), ISO 105 A-02/AATCC Evaluation Procedure 1) Sample shall be tested as part of a production assembly composite. In Vehicle Sunlight Exposure Level Test Exposure AATCC Rating After Exposure, min - Low exposure: lower trim panels below armrest level 112.8 kJ/m2R
38、ating 4 - Moderate exposure: upper trim panels and armrest 225.6 kJ/m2Rating 4 - High exposure: trim panel rollover, pillars, and garnish moldings 488.8 kJ/m2Rating 3 ENGINEERING MATERIAL SPECIFICATIONWSS-M15P4-E Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 7 of
39、 11 Or for North American Programs only (SAE J1885 modified (FLTM BO 116-01) ISO 105 A-02/AATCC Evaluation Procedure 1) In Vehicle Sunlight Exposure Level Test Exposure AATCC Rating After Exposure, min - Low exposure: lower trim panels below armrest level 225.6 kJ/m2Rating 4 - Moderate exposure: upp
40、er trim panels and armrest 601.6 kJ/m2Rating 4 - High exposure: trim panel rollover, pillars, and garnish moldings 1052.8 kJ/m2Rating 4 - Severe exposure: IP top and defroster grille 3609.6 kJ/m2Rating 4 The materials shall be rejected if adhesive staining or other non-uniform staining results from
41、material incompatibility. 3.9.2 Coating Adhesion - For top coated or painted parts only see Grade 0 WSS-M2P188-A1 (FLTM BI 106-01, Method B) 3.9.3 Resistance to Cleaning Agents - For top coated or painted parts Rating 4 only see WSS-M2P188-A1 (FLTM BN 107-01, 10 cycles, max discoloration AATCC Evalu
42、ation Procedure 2) Test Procedure: Evaluate topcoated or painted parts only. Saturate white cotton cloth with the cleaners listed. Cleaners: 1) Window cleaner with ammonia 2) All Purpose Cleaner ZC-11-A/B/C* 3) Isopropyl Alcohol/Water 50% v/v (5 cycles, Rating 3) *or Ford Motor Company recommended e
43、quivalent 3.9.4 Resistance to Crocking, min (FLTM BN 107-01, AATCC Evaluation Procedure 2) Dry and Wet Rating 4 3.9.5 Stain Resistance to Identification Markings (FLTM BO 112-06) Required of soft trim. No evidence of staining on the cover material surface. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P4
44、-E Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 8 of 11 3.9.6 Resistance to Migration Staining Rating 4 (FLTM BN 103-01, AATCC Evaluation Procedure 2) Required of soft trim After test, the specimens and the accessory test materials must not show any surface dete
45、rioration, change in color tone (hue), or any other defects and they must be equal to or better than the sample originally approved by Materials Engineering. 3.10 ADHESION AND BONDING PROPERTIES 3.10.1 Dielectric Bond Strength, minimum average (FLTM BN 113-01 except age per para 3.5.1 and 3.5.2) Ori
46、ginal 5.0 N Aged 75% of original The above method is to be employed only for dielectric bonded materials. All bond lines 25 mm wide or less and 25 mm x 200 mm cut specimens from samples with wider bonded areas must meet the above minimum requirements unless otherwise specified by the affected Materi
47、als Engineering Activity. Specially bonded sections (such as corrugated designs, etc., as well as extra wide bonded areas exhibiting low prorated bond strength values) may be accepted provided they have been approved by the appropriate Materials Engineering Activity, and the Trim and Seating Enginee
48、ring Activity. 3.10.2 Bonded Strength, minimum average (FLTM BN 151-05, except age per para 3.5.1 and 3.5.2) Original 12 N* Aged 75% of original result, no visual change in appearance *Cohesive failure below 12 N requires Materials Engineering approval. The above method is to be employed for all adh
49、esive or heat bonded materials, use 3.10.1 for evaluating dielectric bonds. All bond lines 25 mm wide or less and 25 mm x 200 mm cut specimens from samples with wider bonded areas must meet the above minimum requirements unless otherwise specified by the affected Materials Engineering Activity. Specially bonded sections (such as corrugated designs, etc., as well as extra wide bonded areas exhibiting low prorated bond strength values) may be accepted provided they have been approved by the appropriate Materials Engin
