1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 05 2015 03 18 Editorial See Summary of Revisions A. Wagenhaus, NA 2014 01 21 Editorial See Summary of Revisions L. Schmalz, NA 2009 10 14 Activated L. Schmalz, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, L
2、LC Page 1 of 10 ASSEMBLY PERFORMANCE, HARD MOLD-IN-COLOR WSS-M15P4-F INTERIOR COMPONENTS 1. SCOPE This specification defines the minimum durability and performance requirements of hard, mold-in-color interior trim panels, moldings, overhead and floor consoles, and hard instrument panels where variou
3、s materials are combined to provide a trim assembly having decorative and/or functional features. 2. APPLICATION This specification was originally released for plastic mold-in-color and non-visible interior trim items such as door panels, center and overhead consoles, quarter panels, A-, B-, C-, and
4、 D-pillar moldings, hard instrument panels, instrument panel components and garnish molding. Testing for mold-in-color components is detailed in Table 1 unless specified otherwise by Ford Engineering. Testing for non-visible components is detailed in Table 2 unless otherwise specified by Ford Engine
5、ering Testing must be done on parts unless part geometry does not allow. If that is the case, appropriate plaques with production grain and color can be used. 2.1 LIMITATIONS Excluded from this specification are the non resin components within the following assembly performance specifications; soft
6、instrument panels, interior soft trim and wrapped parts (WSS-M15P45-B/latest), package trays (WSS-M15P6-E/latest), steering wheels (WSS-98P12-B/latest), headliners (WSS-M15P27-F/latest), carpeted substrate (WSS-M8P16-B/latest), molded armrests and headrests (WSS-M15P39-B/latest), appliqus (WSS-M15P3
7、4-D/latest), visors (WSS-M98P3-B/latest), painted interior components (WSS-M2P188-A1/latest), chrome plated components (WSS-M1P83-D1/latest) and interior elastomer (WSS-M9P8-B/latest) or whose performance is specified separately. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Mat
8、erial suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). Materials with recycled content as defined by WRS-M99P42-A1 (post-consumer and/or post industrial recyclates and repolymerised recycled materials) should be used whenever
9、technically feasible and following all materials and PV testing required by Ford Materials Engineering. The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in Ford Engineering CAD and Drafting Standard E-4. Part manufacturers using this specification m
10、ust complete DV and PV testing with the allowable amount of regrind and the maximum allowable regrind content must be specified on the engineering drawing. Any changes to what is specified on the drawing (no specification implies zero regrind) must be approved by Materials and PD Engineering through
11、 the formal Ford Motor Company process (SREA). 3.1.1 Vehicle Interior Environment Quality Materials/Component Performance Requirements ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-F Copyright 2015, Ford Global Technologies, LLC Page 2 of 11 Components used in interior applications must meet the requ
12、irements outlined in WSS-M99P2222-D1/latest. 3.2 APPEARANCE Color, gloss, grain, tactile effect shall match master Trim Sample and/or Master Appearance Sample as approved by Corporate Design. 3.2.1 Color (FLTM BI 109-02 Visual Assessment and/or SAE J1545, MA58 Three-Angle CMC) Shall match the Master
13、 Approved Sample . 3.2.2 Gloss (FLTM BI 110-01, ASTM D 523) As released by Engineering: Gloss A: 20o Glossmeter min 92 B: 60o Glossmeter 76-84 C: 60o Glossmeter 66-74 D: 60o Glossmeter 58-66 E: 60o Glossmeter 47-53 F: 60o Glossmeter 33-38 G: 60o Glossmeter 17-23 H: 60o Glossmeter 7-13 J: 60o Glossme
14、ter 4-6 K: 60o Glossmeter 2-4 L: 60o Glossmeter 0.5-2.0 N: 60o Glossmeter 1.8-2.4 R: 60 Glossmeter 1.2-1.6 3.3 ENVIRONMENTAL TESTING Sample Preparation All parts shall be fully trimmed including all components packaged in the environment (eg. speakers, hardware, wiring, etc.) and assembled onto actu
15、al or representative production support foundations. This includes 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 supporting garnish molding
16、s (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 or defined by PD Engineering. . The “significant characteristics l
17、ocations“ specified on the engineering drawing. Measurement 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 ENGINEERING MATERIAL SPECIFICATION WSS-M15
18、P4-F Copyright 2015, Ford Global Technologies, LLC Page 3 of 11 from the observers view. The observers view shall remain consistent always viewing from the front side of the part. Test Procedure Visually evaluate the part before, during, and after the test. Measure the part and record data at all sp
19、ecified locations at room temperature before and after cycling on the production support foundation or test fixture. Also, during paragraph. 3.3.1 “Short Term Heat and Cold Cycle“ testing, visually evaluate the part and measure any significant characteristic locations only, during the last half-hour
20、 of each cold and hot extreme temperature period. Subject the number of assemblies specified to each of the cycles that follow in paragraphs 3.3.1 and 3.3.2. Automated programmable test cycles based on the listed test conditions may be accepted by prior agreement with the affected Materials Engineer
21、ing Activity. Ramp speed 1 to 5 C per minute. Record actual ramp speed on data sheet. 3.3.1 Short Term Heat, Humidity and Cold Cycle 3.3.1.1 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, and window garnish
22、moldings): . 5 h at -30 +/- 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 -30 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 100 +/- 2 C 3.3.1.2 Horizontal or v
23、ertical parts BELOW THE BELT-LINE (e.g., door panels, lower quarter trim panels, floor and overhead consoles, and glove box doors.) . 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. . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +
24、/- 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 C 3.3.1.3 Scuff plates, kick panels, and other non-sun loaded floor level parts. . 5 h at -30 +/- 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.H. . 2 h at 50
25、 +/- 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. ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-F Copyright 2015, Ford Global Technologies, LLC Page 4 of 11 . 5 h at 80 +/- 2 C 3.3.2 Long Term Heat Exposure/Sun Load 3.3.2.1 All ha
26、rd instrument panels (with or without integrated floor consoles) Sun Load per IP-0105, 107C surface temperature via heat lamps with a chamber temperature of 90C for 240 hours 3.3.2.2 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. sail; A-, B-, C-, and D-pillars; upper quarter panels; a
27、nd window garnish moldings): . 7 days at 100 +/- 2 C 3.3.2.3 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels, lower quarter trim panels, glove box doors, overhead consoles, and floor consoles that are not integrated with the instrument panel and the unit stands alone): . 7 days a
28、t 90 +/- 2 C 3.3.2.4 Non-sun loaded floor level parts (e.g., scuff plates and kick panels) . 7 days at 80 +/- 2 C 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
29、, loss in surface-grain, or surface-color change (ISO 105-A02 AATCC Procedure 1, Rating 4, min); no wrinkling, distortion, blistering, warping, delamination, blushing, hazing, milking, staining, waviness, or other objectionable visual appearance. (2) Functionally - no excessive expansion, shrinking,
30、 or warping that will interfere with normal functional operations. (3) Dimensionally - no movement exceeding what is required on the Engineering drawing from the original installed position during or after the test. 3.4 IMPACT RESISTANCE- ROOM TEMPERATURE (23 +/-2 C) Required for scuff plates, floor
31、 consoles, load floors, seating components, door map pockets or any other parts as required by Ford Engineering. 3.4.1 Rubber Ball 4.5 kg weight, 127 mm dia, 60 +/- 5 Durometer “A“ Test Method: Conduct this test with the trim assembly mounted on an actual or simulated production support foundation u
32、sing the approved retention methods. Drop the rubber ball from the height specified below at the impact locations indicated on the Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-F Copyright 2015, Ford Global Technologies, LLC Page 5 of 11 Drop Height . Scuff Plates 610 mm Load Flo
33、or 500 mm Below belt line 460 mm Above the belt line 305 mm The assembly shall show no evidence of cracking or breaking and shall fully recover from indentation. 3.5 RESISTANCE TO INTERIOR WEATHERING (FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1) In Vehicle Sunlight Exposure Level FLTM
34、BO 116-01 Test Exposure AATCC Rating After Exposure, min. Severe Exposure: Instrument panel top, defroster grille, 3609.6 kJ/m2 Rating 4 Heavy Exposure: Instrument panel lower top cover, 2 tone IP, IP bezel, IP registers, airbag, steering wheel, message center, appliqus, parcel shelf assembly/packag
35、e tray and center finish panel. 2406.4 kJ/m2 Rating 4 Medium Exposure: Instrument panel lower, door trim, interior trim, pillars, garnish moldings, seats, head rest, sunshade, sun visor, seat belt webbing vinyl must be tested for compatibility with the substrate material they are covering. No cracki
36、ng or crazing allowed. 4. GENERAL INFORMATION This information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. Rubber Ball Contact Information Dave Clow, Schap Specialt
37、y Machine, Inc. 17309 Taft Street Spring Lake, MI 49456 Ph : 616 846-6530 5. SUMMARY OF REVISIONS 2015 03 18 -Editorial added clarification to 2.1 limitations to identify that the performance specifications not applicable are for non resin components. 2014 01 21 - Changed section 3.2.2 gloss from AS
38、TM F523 to ASTM D523 (editorial change) 2013 11 20 -Deleted 3.4.1.2 Cold Temperature Impact -Updated rubber ball contact information -Editorial changes 2012 11 21 - Moved interior rear view mirror housing from severe exposure to medium exposure in section 3.5 Resistance to fade. 2012 03 06 - Updated
39、 application and limitation sections - Added gloss ranges - Section 3.3, modified dimensional requirements to allow engineering to define acceptable movement after test. - Section 3.4 modified load floor drop height to line up with M15P6 - Removed 3.6.3 cold bond strength - Section 3.8 added require
40、ment for seating components removed definitions. - Modified wording in section 3.12 environmental stress cracking - Added general information section and rubber ball contact information. - Revised Table 1 and created Table 2 ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-F Copyright 2015, Ford Global
41、Technologies, LLC Page 8 of 11 ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-F Copyright 2015, Ford Global Technologies, LLC Page 9 of 11 TABLE 1 TESTING REQUIREMENTS NOTE: This table is only for APPROVED RESIN technologies as shown on Ford Approved Source List otherwise full WSS-M15P4-F specificatio
42、n testing is required. Sample size/color New Color (Data from MCDCC approval can be used as surrogate) DV Required for New part geometry or new material Technology (post FDJ) PV Must use production tools Molder/resin supplier change Comments Components 3.2 Appearance All colors X X 3.3.1 Short Term
43、Heat Exposure 1/part-darkest color 2 parts/new technology X Required in assembly X (testing can be waived at the discretion of Materials and PD Engineering) *Key life testing can be used in lieu. Bonded parts must be production representative. 3.3.2 Long Term Heat Exposure 1/part-darkest color 2 par
44、ts/new technology X Required in assembly X (testing can be waived at the discretion of Materials and PD Engineering) For IP-Sunload testing per IP-105. Bonded parts must be production representative. 3.4.1.1 Impact Resistance-Room Temp 1/part-darkest color X Required in assembly 3.6.1 Original Bond
45、Strength 3/part-any color X X Must be bonded using production process. If not, retest at PV. 3.6.2 Aged Bond Strength 3/part-any color X X Must be bonded using production process. If not, retest at PV Grained Plaque/Part tests 3.7 Soiling and Cleanability* 3 per grain/per color X X Production intent
46、 resin, grain and colorant to complete testing by FEC for all new colors and grains Concentrate letdown ratio must be production representative 3.8 Scratch Resistance* 3 per grain/per color X X Testing on plaques X Testing on production Concentrate letdown ratio must be ENGINEERING MATERIAL SPECIFIC
47、ATION WSS-M15P4-F Copyright 2015, Ford Global Technologies, LLC Page 10 of 11 Sample size/color New Color (Data from MCDCC approval can be used as surrogate) DV Required for New part geometry or new material Technology (post FDJ) PV Must use production tools Molder/resin supplier change Comments wit
48、h Production intent resin, grain and color (with production intent colorant) if available parts if they differ in grain, material, color and/or processing from plaques tested at DV or if unavailable at DV. production representative Material Tests (ungrained/grained parts or plaques) 3.5 Resistance t
49、o Fade 1 per color X X Production intent resin and colorant to complete testing by PEC MCDCC form may be used as evidence Concentrate letdown ratio must be production representative 3.9 Fogging 1 component darkest color X Prototype parts Contact Materials Engineering if surrogate data is acceptable 3.10 Odor 1 component darkest color X Prototype parts Contact Materials Engineering if surrogate
