1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 03 20 Activated Marcos Rogrio de Souza Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 1 of 5 70% POLYPROPYLENE COPOLYMER (PP), 30% SISAL FIBER WSS-M4D1004-A CONTENT MOLDING COMPOUND, INTERIOR PARTS 1. S
2、COPE The materials defined by this specification is a 30% sisal fiber filled injection thermoplastic molding compound based on 70% polypropylene copolymer prime. 2. APPLICATION These specifications were released originally for materials used for non visible parts, interior painted parts and interior
3、 appearance parts. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements Ford Production Materials (WSS-M99P1111-A). 3.1.1 All requirements of this specification, identified by symbol (s), shall be
4、met with data representing 3 sigma values. 3.2 SISAL FIBER The sisal fiber length must be at least 3.0 mm. The material must be dried for 5 h at 90 - 95 C minimum in a mechanical convection oven. The fiber humidity before the extrusion of the polypropylene compound must be less than 3%. 3.2.1 Drying
5、 Process To achieve good results at the drying process (3%), we recommend: 1) Forced Air Circulation oven with dry air line (The distances between the trays at the oven must be 5cm or more. The maximum height allowed per tray is 5cm. To improve the efficiency of drying process is recommendable some
6、small holes under the tray) Or 2) Continuous drier turbulent hot air flow/fluidized bed drier ENGINEERING MATERIAL SPECIFICATIONWSS-M4D1004-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 5 3.3 MOLDING COMPOUND (s) 3.3.1 Melt Flow Rate 3 - 15g/10 minutes (IS
7、O 1133/ASTM D 1238, 230 C, 2.16 kg) 3.3.2 Melt Temperature, min 160 C (ISO 3146, Method C, 10 C/min heating rate) (s) 3.3.3 Sisal Fiber Content 28 - 32% (Thermogravimetric Analysis TGA) 3.4 MOLDED TEST SPECIMEN 3.4.1 Preparation of Test Specimens Unless otherwise specified all tests shall be carried
8、 out on injection molded one-end gated test specimens. The following dimensions are required: A. 150 min x 10 x 4.0 +/- 0.2 mm (Tensile Bar, ISO 3167) B. 120 x 10 x 4.0 +/- 0.2 mm Specimens with shorter dimensions shall be cut from the center portion of the test specimen A and/or B. The specimens sh
9、all be prepared according to ISO 294. No annealing allowed. 3.4.2 Density 1.05 - 1.11 g/cm3(ISO 1183, Method A/ASTM D 792, Method A1) 3.4.3 Hardness Durometer D 45 - 60 (ISO 868/ASTM D 2240, 15 s dwell) (s) 3.4.4 Tensile Strength at Yield, min 21.5 MPa (ISO R 527/ASTM D 638M, 150 min x 10 x 4.0 +/-
10、0.2 mm specimen, 50 mm/minute test speed) (s) 3.4.4.1 Tensile Modulus, min 2.4 GPa (Test Method according to para 3.6.4) (s) 3.4.4.2 Elongation at Break, min 5% (Test Method according to para 3.6.4) (s) 3.4.5 Flexural Modulus, min 2.0 GPa (ISO 178/ASTM D 790M, Method I, Procedure A, 80 x 10 x 4.0 +/
11、- 0.2 mm specimen, 2 mm/ minute test speed, 64 mm support span, the radius of the loading nose 5.0 +/- 0.1 mm and of the supports 2.0 +/- 0.2 mm) ENGINEERING MATERIAL SPECIFICATIONWSS-M4D1004-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 5 3.4.6 Shear Modu
12、lus at 23 C 600 1200 MPa (ASTM D 4065, forced constant amplitude, fixed frequency of 1 Hz +/- 15%, strain level below 1 %. Specimen approximately 60 x 10 x 4.0 +/- 0.2 mm cut from the center of specimen A. Specimen length between clamps 35 - 40 mm. Soak time at each temperature interval - 3 minutes
13、minimum) Additionally, a Shear Modulus versus Temperature curve shall be plotted for - 50 to + 150 C temperature range, at 5 C minimum intervals. The plotted curve must be within tolerance range granted on the original material approval and it shall constitute the reference standard for materials su
14、pplied to this specification and shall be kept on file at designated material laboratory and be available on request. (s) 3.4.7 Impact Strength, Izod, min (ISO 180/1A/ASTM D 256, Method A,80 x 10 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) 3.4.7.1 At 23 +/- 2 C 13.0 kJ/m2 (131.3 J/m) 3.4.
15、7.2 At -40 +/- 2 C 3.5 kJ/m2 (35.3 J/m) 3.4.7.3 At 10 +/- 2 C 4.8 kJ/m2 (48.5 J/m) The test specimens must be conditioned for min of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box, if not possible, test can be conducted outside,
16、 but within 5s. (s) 3.4.8 Heat Deflection Temperature, min (ISO 75/ASTM D 648, 120 x 10 x 4.0 +/- 0.2mm specimen, tested edgewise, deflection of 0.32 +/- 0.01 mm) 3.4.8.1 At 1.80 MPa 50 C 3.4.8.2 At 0.45 MPa 95 C 3.4.9 Heat Aging Performance (ISO 188/ASTM D 573, 140 +/- 50 air changes/h, 1000 h at 1
17、20 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.4.9.1 Tensile Strength at Yield Change +/- 25% (Test Method per para 3.5.4) ENGINEERING MATERIAL SPECIFICATIONWSS-M4D1004-A Printed copies are uncontrolled Copyright 2008, Ford Global Technolog
18、ies, LLC Page 4 of 5 3.4.9.2 Elongation at Yield Change +/- 25% (Test Method per para 3.5.4) 3.4.9.3 Impact Strength, Izod Change, -25% max (Test Method per para 3.5.7.1, specimens to be notched before heat aging) 3.5 FOGGING SAE J1756, 3 h at 100 C heating, (21 C cooling plate, post test conditioni
19、ng 1 h) Fog Number, min 70 Formation of clear film, droplets or crystals is cause for rejection. 3.6 FLAMMABILITY (ISO 3795) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355 x 100 x 1.0 +/- 0.1 mm with a smooth surface. 3.7 WEATHERING RESISTANCE After exposure in
20、accordance with 3.7.1 the material shall show no fading or color change in excess of specified Gray Scale Rating (AATCC Evaluation Procedure 1/ISO 105-A02). In addition, there shall be no cracking, crazing or other deterioration. All initial approvals will be based on the preliminary Weatherometer e
21、xposure. 3.7.1 Xenon Arc Weatherometer Rating 4 - 5 (SAE J1885, 1240 kJ/m2exposure minimum, specimen size: 150 x 100 mm minimum, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) 3.8 ODOR, max Rating 2 (FLTM BO 131-01) 3.9 RESISTANCE TO SCRATCHING Rating 1 at 2 N (FLTM BN 108-13, visual evaluati
22、on, 1 mm force scratch balls, grain: Cordwain and/or equivalents) 3.10 GLOSS (FLTM BI 110-01, Glossmeter 60, 5 measurements min on grained surfaces, grain: Cordwain and/or equivalents) Gloss Level, max As specified by Design activity ENGINEERING MATERIAL SPECIFICATIONWSS-M4D1004-A Printed copies are
23、 uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 5 of 5 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 5 - 12-5/ C (ASTM D 696 or ASTM E 831 (TMA), Temperature range 30 to + 30 C) 4.2 MOLD SHRINKAGE (ISO 2577, approximately 150 x 100 x 3.2 +/- 0.2 mm injection molded specimen) 4.2.1 Molding Shrinkage After 48 h at 23 +/- 2 C 1.2 1.8% 4.3 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PP-N30
