1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev. 0 2009 02 04 Activated New specification replacing WSS-M2P184-A L. Sinclair, FNA Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 6 PERFORMANCE, INSTRUMENT CLUSTER ASSEMBLY WSS-M15P52-A 1. SCOPE This
2、 specification defines the performance requirements for the instrument cluster assembly and visible components up to the lens. 2. APPLICATION This specification was released originally for instrument clusters. Testing must be conducted on parts per Table 1, which defines sample size and testing requ
3、ired. Chrome components outside of the lens must meet WSS-M1P83-C1. Painted components outside of the lens must meet WSS-M2P188-A1. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Producti
4、on Materials (WSS-M99P1111-A). The use of regrind is permitted, for economic/environmental reasons, with compliance as indicated in WSS-M99P1111-A. 3.1 SYSTEM COMPONENTS 3.1.1 Resistance to Scratch Initial Hardness of all painted parts within this assembly must be cured/dry at time of packing to wit
5、hstand normal handling and shipping without marring. 3.1.2 Substrate ABS, Polycarbonate, Polypropylene or as specified on Engineering Drawing. Substrate must not contain any additives, or mold release agents which will adversely affect the in mold decorating process. 3.1.3 Aging Test panels or test
6、specimens prepared for investigations according to this specification must be aged for at least 72 h at 23 +/- 2 C or 16 h at 45 +/- 1 C prior to testing. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P52-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, Inc. Page 2 of 6 3.2 APP
7、EARANCE Color, gloss, grain, tactile effect and surface finish shall match master Trim Sample and/or Master Appearance sample as approved by Design Studio. The coating shall exhibit no craters, pinholes, solvent popping, seediness, abnormal roughness, excessive flow or any other detrimental defect.
8、3.2.1 Color (FLTM BI 109-01 Visual Assessment) (SAE J1545, Three-Angle CMC) Shall match the Master Approved Sample. 3.2.2 Gloss, min Report (FLTM BI 110-01, ASTM D 523) As released by Engineering: A: 20 Glossmeter, min 92 B: 60 Glossmeter 76 - 84 C: 60 Glossmeter 66 - 74 D: 60 Glossmeter 58 - 66 E:
9、60 Glossmeter 47 - 53 F: 60 Glossmeter 33 - 38 G: 60 Glossmeter 17 - 23 H: 60 Glossmeter 7 - 13 J: 60 Glossmeter 4 - 6 K: 60 Glossmeter 2 - 4 L: 60 Glossmeter 0.5 - 2.0 N: 60 Glossmeter 1.8 - 2.4 The color, pattern and finish shall match the approved Design Center master sample, or shall be as speci
10、fied on the Engineering Document. 3.2.3 Ink Film Thickness Report (ASTM B 487, PELT or equivalent) Coating thickness must be sufficient to meet all requirements of this material specification. 3.3 ENVIRONMENTAL TESTING 3.3.1 Sample Preparation All parts shall be fully trimmed including all component
11、s packaged in the environment (e.g. speakers, hardware, wiring, etc.) 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 Material
12、s Engineering Activity. The retention methods, attachments and supporting garnish molding (if any), shall be the same as proposed for production. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P52-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, Inc. Page 3 of 6 3.3.2 Measuremen
13、t Locations Every twenty centimeters AND AT THE POINTS OF GREATEST MOVEMENT BETWEEN THE TWENTY CENTIMETER MARKS along the parts outside edges and internal openings. The “significant characteristics locations“ specified on the engineering drawing. 3.3.3 Measurement Technique The movement at each meas
14、urement 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 side of the part. 3.3.4 Test Procedure
15、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 cycling on the production support foundation or test fixture. Also, during para. 3.3.5 “Short Term Heat and Cold Cycle“ testing, visually evaluate th
16、e part and measure any significant characteristic locations only, during the last half-hour of each cold and hot extreme temperature period. Automated programmable test cycles based on the listed test conditions may be accepted by prior agreement with the affected Materials Engineering Activity. Ram
17、p speed 1 to 5 C per minute. Record actual ramp speed on data sheet. 3.3.5 SHORT TERM HEAT, HUMIDITY, AND COLD CYCLE 3.3.5.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. sail, A-, B-,C-, and D-pillars, upper quarter panels, seats, hard instrument panels and roof-rail moldings): . 5 h
18、 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 3.3.6 LONG TERM HEAT EXPOSURE Test thr
19、ee previously unexposed assemblies as follows: 3.3.6.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g., door panels, lower quarter trim panels, carpet, headliner, consoles and glove box doors and overhead consoles): . 7 days at 100 +/- 2 C ENGINEERING MATERIAL SPECIFICATIONWSS-M15P52-A
20、Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, Inc. Page 4 of 6 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,
21、or surface-color change (AATCC Procedure 1, Rating 4, min.); no wrinkling, distortion, blistering, warping, delamination, blushing, hazing, milking, staining, waviness, or other objectionable visual appearance. (2) Dimensionally/Functionally no excessive expansion, shrinking, or warping that will in
22、terfere with normal functional operations. (See test procedure paragraph 3.3.4 for details on during test data acquisition intervals) or after the test; for the “significant characteristic locations“. NOTE: Allowable expansion, shrinking or warping from the original installed position will be noted
23、on the engineering drawing. Dimensional exceptions to these requirements may be allowed on the Engineering drawing. 3.4 COLOR AND APPEARANCE PROPERTIES 3.4.1 Resistance to Fade (FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1) In Vehicle Sunlight Exposure Level FLTM BO 116-01 Test Exposure
24、 AATCC Rating After Exposure, min. Appliqu, Coated parts (i.e. pointer) 601.6 kJ/m2Rating 4 Lens Cover, Film and Housing 977.6 kJ/m2Rating 4 3.5 PHYSICAL/RESISTANCE PROPERTIES 3.5.1 Adhesion of Paint/Ink Grade 0 Max (FLTM BI 106-01, Method B) 3.5.2 Water Immersion Test 96 h (FLTM BI 104-01) No blist
25、ering, softening, dulling, color change or loss of adhesion per para 3.5.1 within 30 minutes of removal from water on all paint systems. 3.5.3 Resistance to Water and Soap Spotting, Rating 4 max discoloration (FLTM BI 113-01/ ISO 105-A02/ AATCC Evaluation Procedure 1) No film softening allowed for a
26、ny solution. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P52-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, Inc. Page 5 of 6 3.5.4 Resistance to Cleaning Agents, max Rating 4 Discoloration Apply 0.25 ml of cleaner (see below) on the test sample using a non-reactive O-ring.
27、Expose the sample at the room temperature for 1 h. Evaluate per ISO 105- A02/AATCC Evaluation Procedure 1. No film softening allowed for any solution. Cleaners 1) Window cleaner 2) All purpose cleaner 3.6 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog
28、Number, min 70 Formation of clear film, droplets or crystals is cause for rejection. 3.7 ODOR, max Rating 3 (FLTM BO 131-03) 3.8 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute 3.9 PROCESS WINDOW DEFINITION The supplier shall perform a Design of Experiments (Response Surface Analysis i
29、s recommended) to determine the process window of the substrate/paint combination. The three variables/parameters to be included in the design are bake temperature, bake time, and film thickness. An initial screening experiment should be run to determine what levels should be tested for the variable
30、s/parameters. This screening experiment should be reviewed with the materials engineer to set up the final DOE. Responses for the DOE shall include, but are not limited to, the following: Film Thickness, para 3.2.3 Gloss, para 3.2.2 Initial Adhesion, para 3.5.1 Water Resistance, para 3.5.3 4.0 SUMMA
31、RY OF REVISIONS 2009 02 04 New Document ENGINEERING MATERIAL SPECIFICATIONWSS-M15P52-A Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, Inc. Page 6 of 6 TESTING REQUIREMENTS TABLE 1 Instrument Cluster AssemblyClear Lens Cover / FilmApplique / Coated PartsAppliquePer Color Ch
32、angeShort Term Heat, Humidity and Cold Cycle1X XXLong Term Heat Exposure 1 X X XResistance to Fade 1 X X XResistance to Water and Soap Spotting3XResistance to Cleaning Agents 3 XInk Film Thickness 1 X* X XAdhesion of Paint/Ink/ Film 3 X* X XWater Immersion Test 3 X* X XFogging 1 X XOdor 1XFlammability 3 X X X* = coated lens onlyX = applicable requirementREQUIREMENTSSample SizePer New/Modified product designs, or New/Modified production process for production or service parts
