1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Ver. 0 2010 06 11 Actiavted A. Pan and Global Materials TeamPrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 4 POLYBUTYLENE TEREPHTHALATE (PBT) MOLDING COMPOUND, WSS-M4D1014-A DIRECT METALLIZABLE GRADE 1.
2、 SCOPE The material defined by this specification is a direct metallizable, melt flow rate higher than 28g/10 minutes, low moisture uptake thermoplastic polyester molding compound based on polybutylene terephthalate (PBT). 2. APPLICATION This specification was released originally for material used f
3、or headlamp / rear lamp direct-metallized inner bezel. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1.1 All requirements of this specification,
4、identified by symbol(s), shall be met with data representing 3 sigma values using latest ISO test methods. 3.1.2 This specification is based on virgin materials, however materials with recycled content as defined by WSS-M99P42-A (post-consumer and/or post industrial recyclates and repolymerised recy
5、cled 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. Critical Process Parameters At the re
6、quest of Ford Materials Engineering the supplier shall be responsible to collect critical process control data on each lot of material produced. Testing required will be jointly developed between Ford Materials Engineering and the supplier based on Control Plan and PFMEA review at the time of initia
7、l approval. Annually the supplier will review the in process data with Ford Materials Engineering to show that the process has remained under control. The data needs to be submitted in January for the previous calendar year. Data showing poor quality control measures or lack of submitted data may re
8、sult in deletion from the Ford Approved Source List. 3.2 MOLDING COMPOUND (s) 3.2.1 Melt Flow Rate, min 28 g/10 minutes (ISO 1133, 250 C, 2.16 kg) The material shall be dried for 4 h minimum at 120 C in a mechanical convection oven immediately preceding the test. The high flow reduces cycle times an
9、d enables molding of more complex geometries. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D1014-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 4 3.3 MOLDED TEST SPECIMEN 3.3.1 Preparation of Test Specimens Unless otherwise specified all tests shall be carried o
10、ut on injection molded one-end gated test specimens. The following dimensions are required: A. 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, specimen type 1A) B. 355 x 100 x 1.0 +/- 0.1 mm (ISO 3795) Test specimen A shall be molded using molding conditions defined in ISO 7792-2. Specimens with short
11、er dimensions shall be cut from the center of the specimen A. No annealing allowed. 3.3.2 Density 1.28 - 1.34 g/cm3(ISO 1183, Method A) (s) 3.3.3 Tensile Strength at Yield, min 52 MPa (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A, test speed: 50 mm/minute) (s) 3.3.3.1 Elongati
12、on at Yield, min 3% (Test Method according to para 3.3.3) (s) 3.3.4 Tensile Modulus, min 2.0 GPa (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A test speed: 1 mm/min, 10 specimens) (s) 3.3.5 Flexural Modulus (Initial Qualification), min 2.0 GPa (ISO 178, 80 x 10 x 4.0 +/- 0.2 mm
13、 specimen use center section of specimen A, 2 mm/min test speed, 64 mm support span) 3.3.6 Impact Strength, Izod, notched (Initial Qualification), min (ISO 180/1A, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, 10 specimens for each test) (s) 3.3.6.1 At 23 +/- 2 C 2.5 kJ/m2(s) 3
14、.3.6.2 At -40 +/- 2 C 1.8 kJ/m2The 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. 3.3.7 Impact Stren
15、gth Charpy, notched, min (ISO 179/1eA, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, 10 specimens for each test) (s) 3.3.7.1 At 23 +/- 2 C 2.0 kJ/m2 (s) 3.3.7.2 At -40 +/- 2 C 2.0 kJ/m2The test specimen must be conditioned for minimum of 6 hours at the above specified temperatu
16、re 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. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D1014-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 4 (s)
17、3.3.8 Heat Deflection Temperature, min 44 C (ISO 75-1 & ISO 75-2, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.3.9 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. Unaged property valu
18、es shall be determined at the time of the aged properties determination) 3.3.9.1 Tensile Strength at Yield Change, max +/- 25% 3.3.9.2 Impact Strength, Izod Change, max - 25% (Test method per para 3.3.6.1, specimens to be notched before heat aging) 3.3.10 Fogging (SAE J1756, 3 h at 100 C heating, 21
19、 C cooling plate, post test conditioning 16 h) Fog Number, min 95 Formation of clear film, droplets or crystals is cause for rejection. Plastics in bezels tend to suffer from fogging in chronic use due to high temperatures and the gas emitted can precipitate on the lighting cover. Moreover, the surf
20、ace of the bezels becomes uneven due to new defects. Material exhibiting significantly decreased fogging will help light reflection and the appearance of the lighting system. 3.3.11 Flammability (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355
21、x 100 x 1.0 +/- 0.1 mm (use specimen B) with a smooth surface. 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 8 - 15 E-5mm/mm/ C (ISO 11359-2 TMA, -30 C to
22、100 C) 4.2 MOLD SHRINKAGE Report method used, sample size and value. 4.2.1 Molding Shrinkage After 48 h at 23 +/- 2 C Report Value, % 4.2.2 Post Shrinkage (Separate specimens required for each test) report total shrinkage After 48 h at 80 C Report Value, % After 30 minutes at 120 C Report Value, % E
23、NGINEERING MATERIAL SPECIFICATIONWSS-M4D1014-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 4 4.3 MELT TEMPERATURE 220 - 228 C (ISO 11357or ISO 3146 Method C, 10 C/min heating rate) 4.4 HEAT DEFLECTION TEMPERATURE, min (ISO 75-1 & ISO 75-2, 80 x 10 x 4.0 +/
24、- 0.2 mm specimen use center section of specimen A, flatwise, 0.34 +/- 0.1 mm deflection) At 0.45 MPa 80 C 4.5 POISSONS RATIO 0.41 Test Method-ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 mm specimen (specimen A), test speed 1 mm/minute. 4.6 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES (ISO 1043/ ISO 11469 latest) PBT
