1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 2 2015 02 16 Editorial See Summary of Revisions K. Mueller, NA 2011 07 14 Revised See Summary of revisions K. Mueller NA 2008 11 20 Activated K.Mueller, FNA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Pa
2、ge 1 of 9 THERMOPLASTIC POLYOLEFIN ELASTOMER (TPO), WSS-M4D1005-A1 HIGH MELT FLOW, 22% MINERAL FILLED, MOLD-IN-COLOR ONLY, MOLDING COMPOUND, FASCIA / THIN-WALLED EXTERIOR THERMOPLASTIC POLYOLEFIN ELASTOMER (TPO), WSS-M4D1005-A2 HIGH MELT FLOW, 22% MINERAL FILLED, FULLY PAINTED ONLY, MOLDING COMPOUND
3、, FASCIA / THIN-WALLED EXTERIOR 1. SCOPE The material defined by these specifications are 22% mineral filled thermoplastic molding compounds for mold-in-color (A1) and painted (A2) applications, based on thermoplastic polyolefin elastomer. 2. APPLICATION WSS-M4D1005-A1 This specification was release
4、d originally for material used for mold-in-color exterior bumper applications (where the fascia thickness is less than 3mm), requiring high melt flow rate. Any color additives need to be reviewed and approved by the raw material supplier and Ford Materials Engineering. The UV/process/heat stabilizer
5、s must be in the base resin from the material supplier, not in the color concentrate, specifically for mold-in-color applications at the press. WSS-M4D1005-A2 This specification was released originally for material used for painted exterior bumper applications (where the fascia thickness is less tha
6、n 3mm), requiring high melt flow rate. Any color additives need to be reviewed and approved by the raw material supplier and Ford Materials Engineering. The process/heat stabilizers must be in the base resin from the material supplier. 2.1 LIMITATIONS Material approved to WSS-M4D1005-A1 is likely to
7、 contain additives that may negatively affect paint adhesion, therefore should not be used for painted applications. Material approved to WSS-M4D1005-A2 is unlikely to contain UV stabilizers, therefore long term exposure to direct sunlight could cause chalking and loss of gloss. 3. REQUIREMENTS 3.1
8、STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). Note: Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicated th
9、at the mean and +/- 3 sigma values were to be reported. The specification minimum, maximum or range was established using 3 sigma data. For 2011 and beyond, refer to Table 1 for number of samples required for each test to establish specification limits. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1005
10、-A1 WSS-M4D1005-A2 Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 2 of 9 This specification is based on virgin materials, however materials with recycled content as defined by WRS-M99P42-A1 (post-consumer and/or post industrial recyclates and repolymerised recycle
11、d materials) should be used whenever 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 WSS-M99P1111-A. 3.1.1 Performance Criteria: Exterior mol
12、d-in-color substrates approved to WSS-M4D1005-A1 must comply with all the requirements of WSS-M98P13-C/Latest. Painted substrates approved to WSS-M4D1005-A2 must comply with all the requirements of paint performance WSS-M2P181-C/Latest. Parts must fulfill applicable SDS/CDS requirements. 3.1.3 The m
13、aterial supplier must retain 30-50 lbs. (14-23 kg) of pelletized material / lot produced for 6 months (WSS-M4D1005-A2 only). 3.1.4 Unless otherwise agreed to by Ford Materials Engineering, Control Plan and Certificate of Analysis (CoA) lot testing requirements must include, but are not limited to: M
14、elt Flow Rate Mineral Filler Content Impact Strength, Notched Izod at 23C Flexural Modulus Molding Shrinkage (WSS-M4D1005-A1 / A2) Post Shrinkage (WSS-M4D1005-A2) 3.2 SAMPLE PREPARATION Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens. The t
15、est specimens A and D shall be molded using molding conditions defined in ISO 1873-2. 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 x 100 x 1.0 +
16、/- 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 mm, min 3.3 AP
17、PEARANCE (WSS-M41005-A1 only) 3.3.1 Weathering Resistance Rating 4 min (SAE J2527 Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant exposure monitored at 340 nm, 3000 h total exposure or as otherwise defined, Specimen
18、C, from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) For color durability submissions, test all program colors ENGINEERING MATERIAL SPECIFICATION WSS-M4D1005-A1 WSS-M4D1005-A2 Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 3 of 9 3.3.2 1 and 2
19、 year Florida Rating 4 min Initial Qualification for new resin technology (SAE J1976, 5 south, direct weathering inland, Specimen C from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) After exposure the material shall show no color change in excess of the specified AATCC Rating. I
20、n addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss or chalking will be allowed provided an acceptable appearance can be achieved as specified below by washing with mild detergents and water (ratio 5:95 by volume) or equivalent after the outdoor exposure on
21、ly. All initial approvals may be based on the accelerated weathering exposure, pending real world outdoor exposure results for final approval. 3.3.3 Resistance to Scratch and Mar (FLTM BO 162-01, Specimen I) Scratch Rating 2 at 2 N, max Whitening/Color Change Rating 1 at 7 N, max Marring Rating 2 at
22、 2 N, max These values are derived from colored and grained samples in agreement with Materials Engineering. Details regarding color house, let down ratio, colors, grain, etc can be found in the approval package. 3.4 MATERIAL PROPERTIES 3.4.1 Melt Flow Rate 28 - 46 g/10 minutes (ISO 1133, 230 C, 2.1
23、6 kg) 3.4.2 Filler Content 21 23.5% (ISO 3451-1, Method A, talc filler, (online process control) 3 h at 650 +/- 25 C, test portion 1 -2 g) 3.4.3 Density 1.04 1.08 g/cm3 (ISO 1183, Method A) 3.4.4 Hardness, Durometer D 56 - 67 (ISO 868, 15 s dwell) 3.4.5 Tensile Strength at Yield 17 MPa, min (ISO 527
24、-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A, test speed: 50 mm/minute) 3.4.6 Tensile Modulus 1994 MPa, min (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A test speed: 5 mm/min) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1005-A1 WSS-M4D1005-A2 Controlled document
25、at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 4 of 9 3.4.7 Impact Strength, Notched Izod (ISO 180/1A, Specimen D) 3.4.7.1 At 23 +/- 2 C 28 kJ/m2, min Partial Break 3.4.7.2 At - 40 +/- 2 C 2.6 kJ/m2, min Complete Break 3.4.7.3 At 0 +/- 2 C 8.0 kJ/m2, min Partial and Complete Break Th
26、e 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 the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 3.4.8 Flexural Modulus 1900 2400 MPa (ISO 178, Spec
27、imen D, 64 mm support span, 2 mm/minute test speed) 3.4.9 Heat Deflection Temperature 47 C, min (ISO 75-1 & ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.4.10 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. Unaged property values shall b
28、e determined at the time of the aged properties determination) 3.4.10.1 Tensile Strength at Yield Change +/- 10% max (Test Method per para 3.4.5) 3.4.10.2 Impact Strength, Notched Izod Change +/- 20% max (Test Method per para 3.4.7.1, specimens to be notched before heat aging) 3.4.11 Coefficient of
29、Linear Thermal Expansion (ISO 11359-2, -30C to 100C) Flow Direction 4.4 - 6.5 E-5 mm/mm/ C X-Flow Direction 5.0 - 7.4 E-5 mm/mm/ C (For Reference only: ASTM E228, -30 C - 100 C) Flow Direction 2.7 - 4.5 E-5 mm/mm/ C X-Flow Direction 3.5 - 4.4 E-5 mm/mm/ C 3.4.12 Flammability (ISO 3795/SAE J369 Speci
30、men B smooth surface) Burn Rate 100 mm/minute 3.4.13 Mold Shrinkage (ISO 294-3 and 294-4/ISO 2577, (specimen size is approx. 100 x 150 x 3.2 mm) 3.4.13.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.55 0.75% ENGINEERING MATERIAL SPECIFICATION WSS-M4D1005-A1 WSS-M4D1005-A2 Controlled document at ww
31、w.MATS Copyright 2015, Ford Global Technologies, LLC Page 5 of 9 3.4.13.2 Post Shrinkage (Separate specimens required for each test). Report total shrinkage. . After 30 minutes at 80 C 0.75 0.85% . After 30 minutes at 120 C 0.7 - 1.0% NOTE: For Part Shrinkage, please follow Design Rule EF011900-1201
32、. 3.5 PAINTABILITY 3.5.1 Painted substrate must comply with the requirements of WSS-M2P181-C/Latest, Table 1, Change In Approved Paint System, Primer or Substrate (plaques are acceptable). Submission data is not to be used as surrogate for final part performance testing. Paint system documented. 3.6
33、 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.6.1 SLIDO (Friction Induced Wear) (FLTM BI 167-01, color = white only. Paint system consistent with 3.5.1.) 3.6.2 Impact Strength Multiaxial (ASTM D 3763, Impact velocity: 2.2 m/s Specimen E, smooth surface injection
34、 molded specimen) Test specimens must be conditioned for minimum of 6 h at test temperature prior to impact testing. Low temperature conditioning and testing shall be conducted within the same environmental chamber as the clamp mechanism of the impact device. Painted test specimens must be oriented
35、with paint in tension (paint side down). Summarize testing at each condition by providing the following information as well as the information in Figure 1. a. Detailed description of specimen preparation b. Molding conditions: melt and mold surface temperatures, and average injection velocity c. Num
36、ber of samples tested per lot per temperature d. Numbers of lots tested e. Number of samples with ductile failure per each test condition f. Representative force vs. deflection curve for each impact event Test results shall be submitted with an initial qualification of the material with curves (data
37、 on CD as well as paper copies) and test samples. A ductile failure is defined as a crack that does not radiate more than 10 mm from the center of the impact point. Report test data for 23 +/- 2 C, and the lowest of the following temperatures in which a minimum of 24 out of 30 ductile failures were
38、observed. Test specimens must be conditioned for minimum of 6 h at test temperature prior to impact testing. Low temperature testing shall be conducted within the same environmental chamber as the clamp mechanism of the impact device. Specimens can be transported from the conditioning environment to
39、 the testing environment, provided the transfer is within 5 seconds. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1005-A1 WSS-M4D1005-A2 Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 6 of 9 3.6.2.1 Painted Specimens (WSS-M4D1005-A2) (Painted samples: Paint system co
40、nsistent with 3.5.1. Color = white only). 3.6.2.1.1 Energy at Maximum Load (At 23 2C) Report J Energy Absorbed % Ductile, min 100% 3.6.2.1.2 Energy at Maximum Load (At 15 2C) Report J Energy Absorbed % Ductile, min 80% 3.6.2.2 Unpainted Specimens (WSS-M4D1005-A1 and WSS-M4D1005-A2 should be tested u
41、npainted) 3.6.2.2.1 Energy at Maximum Load (At -5 2 C) Report J Energy Absorbed % Ductile, min 100% 3.6.2.2.2 Energy at Maximum Load (At -10 2 C) Report J Energy Absorbed % Ductile, min 80% Operator NameSample IDTest no Date/time Lot ID Temperature ( C )Impact velocity (m/s)Impact energy (J)Time to
42、max load (ms)Total time (ms)Maximum load (kN)Energy to max load (J)Total energy (J)Deflection at max load (mm)# of CracksCrack length, max. (mm)Failure type (Ductile / Brittle) 12345678910AverageMedianMinimumMaximumCoef. of Var.Std. Dev.Figure 1 - Data Summary 3.6.3 Optical Microscopy Test specimen
43、preparation includes immersion oil mount, with the thickness of the test specimen being 5 um thick. Test specimen shall be evaluated parallel to flow, taken half-way between the gate and edge of plaque. Magnifications shall be at both 200x and 600x. Photographs required at 200x and 600x magnificatio
44、ns. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1005-A1 WSS-M4D1005-A2 Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 7 of 9 3.6.4 Impact Strength, Notched Charpy (ISO 179-1/2, Specimen D) 3.6.4.1 At 23 +/- 2 C Report Value, kJ/m2 Report Break Type 3.6.4.2 At -40 +/
45、- 2 C Report Value, kJ/m2 Report Break Type 3.6.4.3 At 0 +/- 2 C Report Value, kJ/m2 Report Break Type 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 the cold chamber, if not possible,
46、 test may be conducted outside, but within 5 seconds. 3.6.5 Poissons Ratio Report Ratio (ISO 527-1/2, Specimen A, 1 mm/minute test speed) 3.6.6 Additional FMD Required Information FTIR/TGA/DSC/CLTE Curves 4. GENERAL INFORMATION The information given below is provided for clarification and assistance
47、 in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.6 Test Typical Value Units 3.6.1 SLIDO (Friction Induced Wear) 1100 - 1500 / 4893 - 6672 lbf / N 3.6.2.1 Impact Strength Multiax
48、ial, Painted Specimens, Energy at Maximum Load At 23 C At 15 C 15 12 J J 3.6.2.2 Impact Strength Multiaxial, Unpainted Specimens, Energy at Maximum Load At -5 C At -10 C 25 20 J J 3.6.4 Impact Strength, Notched Charpy At 23C At -40C At 0C 44 2.7 11 kJ/m2 kJ/m2 kJ/m2 3.6.5 Poisson Ratio 0.43 n/a ENGI
49、NEERING MATERIAL SPECIFICATION WSS-M4D1005-A1 WSS-M4D1005-A2 Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 8 of 9 4.2 MATERIAL IDENTIFICATION FOR TPO-(PP+EPDM)-MD22 RECYCLING PURPOSES (ISO 1043, ISO 11469, ISO 18064) Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Previo
