1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 00 2014 12 08 Released R. Harris, NA Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 1 of 7 UNSATURATED POLYESTER (UP) INJECTION MOLDING WSS-M3D178-A3 COMPOUND, 14% GLASS FIBER REINFORCED, EXTERIOR APPLI
2、CATIONS, HIGH FILL CONTENT 1. SCOPE The material defined by these specifications is a glass fiber reinforced thermosetting injection molding compound based on unsaturated polyester resin (UP), for exterior applications only. 2. APPLICATION These specifications were released originally for material u
3、sed for complex reflector bodies for exterior lighting. 2.1 LIMITATIONS Due to the high levels of Calcium Carbonate, CaCO3, these materials are hydroscopic and need to be coated. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to
4、the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1.1 Note: Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicated that the mean and +/- 3 sigma values were to be reported. The specification minimum, maximum or r
5、ange was established using 3 sigma values. For 2011 and beyond, refer to Table 1 for number of samples required for each test. 3.1.2 This specification is based on virgin material and does not allow the addition of, recycled content (PIR/PCR). 3.1.3 Materials containing recycled content (PIR/PCR) mu
6、st be specified with a Ford WRS material specification as defined by WRS-M99P42-A1. These materials cannot be substituted without prior Ford approval and addition of the WRS specification to the engineering drawing. 3.1.4 Performance Criteria: Parts using this specification shall meet the appropriat
7、e performance specification, WSS-M98P10-A/Latest. 3.1.5 As specified in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CoA) containing lot testing requirements which must include, but are not limited to: Density Determination of Ash
8、ENGINEERING MATERIAL SPECIFICATION WSS-M3D178-A3 Copyright 2014, Ford Global Technologies, LLC Page 2 of 7 3.1.7 Dry as molded: All test values indicated herein are based on material and specimens with moisture content not exceeding 2.0% except where noted. All test materials have to be sealed in mo
9、isture-proof containers and stored at 23 +/- 2 C for at least 24 h immediately after processing. If the moisture content exceeds 0.2%, conditioning the material for a minimum of 16 h at 40 50 C at a reduced pressure below 133 kPa. Conduct tests in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5%
10、relative humidity. Individual specimens shall not be removed from closed containers until immediately before testing. 3.2 SAMPLE PREPARATION Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens. The test specimens A and D shall be molded using m
11、olding conditions defined in ISO 1872-2 or injection molded ISO multipurpose specimen per ISO 3167. No annealing is allowed. See Tables 1 and 2 for the number of samples required. Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, Specimen Type 1A) Specimen B 355
12、 x 100 x 1.0 +/- 0.1 mm (ISO 3795) Specimen C 145 x 60 x 3.2 +/- 0.2 mm Specimen D Center of Specimen A, 80 x 10 x 4.0 +/- 0.2 mm Specimen E 100 mm diameter x 3.2 mm Specimen F 80 mm diameter x 3.2 mm Specimen G 90 mm x 200 mm Specimen H 50 +/- 1 mm diameter x 3.2 +/- 0.2 mm Specimen I 100 mm x 150
13、mm, min 3.3 MOLDING COMPOUND 3.3.1 Filler Content 3.3.1.1 Determination of Ash (Filler + Glass Fiber) 70 80 % (ISO 3451-1, Method A, or ISO 3451-2, 1 h at 650 +/- 25 C) 3.3.1.2 Glass Fiber Content 12 16 by weight % Test Method: ISO 3451/1, Method B, 1 h at 650 +/- 25 C, except use 5% by volume hydro
14、chloric acid solution for 15 minutes. Rinse the glass fibers several times with distilled water before drying in an oven for 2 h at 120 +/- 2 C. After cooling, weigh the crucibles and calculate the percent glass fibers. NOTE: The glass fiber/mineral content is reported as a range which accommodates
15、the variation due to the pigment loading. 3.3.2 Density, 1.95 2.1 g/cm3 (ISO 1183, Method A) ENGINEERING MATERIAL SPECIFICATION WSS-M3D178-A3 Copyright 2014, Ford Global Technologies, LLC Page 3 of 7 3.3.3 Tensile Strength at Max Load, 14.0 MPa, min (ISO R 527, Specimen A, 5 mm/min test speed) 3.3.4
16、 Tensile Modulus 14 GPa min (ISO 527-1 and ISO 527-2, Specimen A, (range) 1 mm/minute test speed) 3.3.5 Flexural Modulus, 10.0 GPa, min (ISO 178, Specimen D, 2 mm/min test speed, 64 mm support span) 3.3.6 Flexural Strength 35 MPa, min (ISO 178, Specimen D, 2 mm/min test speed, 64 mm support span) 3.
17、3.7 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.3.7.1 At 23 +/- 2 C 10 kJ/m2 min 3.3.7.2 At -40 +/- 2 C 11 kJ/m2 min The test specimen must be conditioned for minimum of 6 hours at the above specified temperature prior to impact test. Low temperature testing shall be done within th
18、e cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 3.3.8 Heat Deflection Temperature 255 C, min (ISO 75, Specimen D, edgewise, 0.32 +/- 0.01 mm deflection. At 1.80 MPa) 3.3.9 Water Absorption 2.0 %, max (ISO 62, 24 h, boiling water, Specimen A) 3.3.10 Heat Aging Pe
19、rformance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 150 +/- 2 C) Unaged property values shall be determined at the time of the aged properties determination. 3.3.10.1 Tensile Strength at Max +/- 25% Load Change (Test Method per para 3.3.3) 3.3.10.2 Flexural Strength Change +/- 25% (Test M
20、ethod per para 3.3.6) 3.5.10.3 Impact Strength, Charpy Change +/- 25% (Test Method per para 3.3.7, specimens to be notched before heat aging) ENGINEERING MATERIAL SPECIFICATION WSS-M3D178-A3 Copyright 2014, Ford Global Technologies, LLC Page 4 of 7 3.3.11 Flammability (ISO 3795/SAE J369) Burn Rate,
21、max 100 mm/minute The specimen size required for material approval is 355 x 100 x 4.0 +/- 0.1 mm with a smooth surface. 3.3.12 Fogging Photometric 90 min (SAE J1756, Specimen F, 3 hr at 100 C Heating, 21 C cooling) Formation of clear film, droplets or crystals is cause for rejection. 3.4 MATERIAL PR
22、OPERTIES - REPORT ONLY Values are retained in Ford Materials Database . 3.4.1 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.4.2 Post Shrinkage (Report method used, sample size and value. Separate specimens req
23、uired for each test, report total shrinkage) After 48 h at 80 C Flow Report Value, % Cross Flow Report Value, % After 30 minutes at 120 C Flow Report Value, % Cross Flow Report Value, % 3.4.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2 C, 5 C/min) Plaque size is 10
24、0 x 150 minimum at 3.2 +/- 0.2 mm thickness. Plaque to be fan or edge gated. Specimens to be water jet or die cut from the center of plaque, minimum of three samples each direction. Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.4.4 Impact Strength, Izod (ISO 180/1A, 80 x 10
25、 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) 3.4.4.1 At 23 +/- 2 C Report Value,kJ/m2 Report Break Type ENGINEERING MATERIAL SPECIFICATION WSS-M3D178-A3 Copyright 2014, Ford Global Technologies, LLC Page 5 of 7 3.4.4.2 At -40 +/- 2 C Report Value,kJ/m2 Report Break Type The test specimens
26、 must be conditioned for minimum of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box. 3.4.5 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.4.6 Hardness, Barcol Report Hardness (ASTM D25
27、83) 3.4.7 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC CLTE Stress Strain at 23 C and -40 C 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Con
28、tact for questions concerning Engineering Material Specifications. ENGINEERING MATERIAL SPECIFICATION WSS-M3D178-A3 Copyright 2014, Ford Global Technologies, LLC Page 6 of 7 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.4 Para. Test Typical Value Units 3.4.1 Molding Shrinkage After 48 h at 23 +
29、/- 2 C (ISO 2577) Flow Cross Flow 0 0 % % 3.4.2 Post Shrinkage (ISO 2577) - After 48 h at 80 +/- 2 C Flow Cross Flow - After 30 minutes at 120 +/- 2 C Flow Cross Flow 0.02 0 0 0 % % % % 3.4.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 1.2 2.1 E-5 mm/mm/ C E-5 mm/mm/ C 3.4.4 Impact Stren
30、gth, Notched Izod At 23 +/- 2 C At -40 +/-2 C 6 7 kJ/m2 kJ/m2 3.4.5 Poissons Ratio 0.3 N/A 3.4.6 Barcol Hardness 53 N/A 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES UP- (GF+M) 75 (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M3D178-A3 Copyright 2014, Ford Global Technologies, LLC Pag
31、e 7 of 7 Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Previously Approved Material Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 3.3.1 Determination of Ash 3 1 3 1 1 1 3.3.2 Density 1 3 3
32、3.3.3 Tensile Strength at Break* 3 5 15 1 5 5 3.3.4 Tensile Modulus 1 10 10 3.3.5 Flexural Modulus* 3 10 30 1 10 10 3.3.6 Flexural Strength 3 5 15 1 5 5 3.3.7 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.3.8 Heat Deflection Temperature, 1.80 MPa 3 2 6 1 2 2 3.3.9 Water Absorptio
33、n 1 3 3 3.3.10 Heat Aging Performance 3.3.10.1 Tensile Strength at Break, Change 1 5 5 3.3.10.2 Flexural Strength, Change 1 5 15 3.3.10.3 Impact Strength, Notched Charpy, Change 1 10 10 3.3.11 Flammability 1 5 5 3.3.12 Fogging Photometric 1 3 3 3.4.1 Mold Shrinkage 1 5 5 1 5 5 3.4.2 Post Shrinkage 1
34、 5 5 1 5 5 3.4.3 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.4.4 Impact Strength, Notched Izod (per condition) 1 10 10 3.4.5 Poissons Ratio 1 5 5 3.4.6 Hardness, Barcol 1 3 3 3.4.7 Curves - FTIR - TGA - DSC - CLTE - Stress/Strain Curves 23C and -40 C 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements.
