1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev.0 2012 10 22 Released K. Waugh, NA Controlled document at www.MATS Copyright 2012, Ford Global Technologies, LLC Page 1 of 9 THERMOPLASTIC POLYOLEFIN ELASTOMER (TPO), WSS-M4D1024-A1 MOLD-IN-COLOR, MOLDING COMPOUND, EXTERIOR, HIGH IMPACT,
2、LOW STIFFNESS 1. SCOPE The material defined by this specification is a thermoplastic injection molding compound based on thermoplastic polyolefin elastomer. This material is a UV stabilized resin for parts that requires good impact, surface appearance and weather resistance for exterior applications
3、. 2. APPLICATION This specification was released originally for materials used for low stiffness applications, primarily roof rack components. 2.1 LIMITATIONS This material is limited to mold-in-color applications and should not be used for painted applications. 3. REQUIREMENTS 3.1 STANDARD REQUIREM
4、ENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.1.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicated that the mean and +
5、/- 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. 3.1.2 This specification is based on virgin materials, however materials with recycled content as
6、 defined by WRS-M99P42-A1 (post-consumer and/or postindustrial recyclates and repolymerised recycled materials) should be used whenever feasible. 3.1.3 The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in Ford Engineering CAD and Drafting Standard E-
7、4. 3.1.4 Performance Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS-M98P13-C/Latest. Parts must fulfill applicable SDS/CDS requirements. 3.1.5 As specified in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and
8、 Certificate of Analysis (CoA) containing lot testing requirements which must include, but are not limited to: ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 2 of 9 Melt Flow Rate Filler Content Density Tensile Strength at Yield Flexural Modulus
9、Impact Strength, Notched Charpy at 23 C 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 molding conditions defined in ISO 1873-2. See Tables 1 and 2 for the number of
10、specimens 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 +/- 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
11、.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 APPEARANCE 3.3.1 Weathering Resistance Rating 4 min (SAE J2527 Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilic
12、ate inner and outer filters, 0.55 W/m2 radiant exposure monitored at 340 nm, 3000 h total exposure. Specimen C, from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) For color durability submissions, test all program colors 3.3.2 1 and 2 year Florida Rating 4 min Initial Qualificati
13、on 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. In addition, there shall be no cracking, crazin
14、g 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 only. ENGINEERING MATERIAL SPECIFICATION WSS-M4D
15、1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 3 of 9 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 W
16、hitening/Color Change Rating 1 at 7 N, max Marring Rating 2 at 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
17、.4.1 Density 0.88 0.92 g/cm3 (ISO 1183, Method A) 3.4.2 Hardness, Durometer D 38 - 50 (ISO 868, 15 s dwell) 3.4.3 Tensile Strength at Yield 8 MPa min (ISO 527-1 & ISO 527-2, Specimen A, 50 mm/minute test speed) 3.4.4 Elongation at Yield 11% min (ISO 527-1 & ISO 527-2, Specimen A 50 mm/minute test sp
18、eed) 3.4.5 Tensile Modulus 290 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.4.6 Flexural Modulus 250 MPa min (ISO 178, Specimen D,64 mm support span, 2 mm/minute test speed) 3.4.7 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.4.7.1 At 23 +/- 2 C 60 kJ/m2 mi
19、n Report Break Type3.4.7.2 At -40 +/- 2 C 1 kJ/m2 min Report Break TypeThe 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,
20、but within 5 seconds. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 4 of 9 3.4.8 Impact Strength Multiaxial (ASTM D 3763, Impact velocity: 2.2m/s, Specimen E, smooth surface injection molded specimen) Max Load Energy and % Ductility Report J Ene
21、rgy Absorbed of samples at 23 +/- 2 C 100% Ductile Failure, minMax Load Energy and % Ductility Report J Energy Absorbed of samples at -40 +/- 2 C 100% Ductile Failure, minReport test data for 23 +/- 2 C, and continue until a minimum of 100% ductile are observed. A ductile failure is defined as a cra
22、ck that does not radiate more than 10 mm from the center of the impact point. 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 devic
23、e. Specimens can be transported from the conditioning environment to the testing environment, provided the transfer is within 5 seconds. Summarize testing at each condition by providing the following information as well as the information in Figure 1. a. Detailed description of specimen preparation
24、b. Molding conditions: melt and mold surface temperatures, and average injection velocity c. Number 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
25、 Test results shall be submitted with an Initial Qualification of the material with curves (electronic data as well as paper copies) and test samples. Operator NameSample IDTest noDate/tim Lot IDTemperature( C Impacvelocity(m/s)Impacenergy(JTime tomax load(ms)Total time(ms)Maximumload (kN)Energy to
26、max load(JTotaenergy(JDeflectioat max load(mm)# ofCrackCracklengthmax. (mm)Failuretype (Ductile /Brittle12345678910 AverageMedianMinimuMaximumCoef. of Var.Std. Dev.Figure 1 - Data SummaryENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 5 of 9 3.4.9
27、 Heat Deflection Temperature 36 C min (ISO 75-1 and ISO 75-2 Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.4.10 Heat Aging P
28、erformance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. After heat aging test specimens are to be conditioned in a desiccator for 3 - 5 h at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.4.10.1 Tensile Strength at Yiel
29、d, Change +/- 25% (Test method per para 3.4.3) 3.4.10.2 Impact Strength, Charpy, Change +/- 25% (Test Method per para 3.4.7.1, specimens to be notched before heat aging) 3.4.11 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.5 MATERIAL PROPERTIES REPORT ONL
30、Y Values are retained in Ford Materials Database . 3.5.1 Melt Flow Rate Report Value, g/10 minutes (ISO 1133 230 C, 2.16 kg) 3.5.2 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.5.3 Coefficient of Linear Therma
31、l Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 100 +/- 2 C) Flow Report Value, E-5 mm/mm/C Across Flow Report Value, E-5 mm/mm/C ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 6 of 9 3.5.4 Impact Strength, Notched Izod (ISO 180/1A, Specimen D
32、) 3.5.4.1 At 23 +/- 2 C Report, kJ/m2 Report Break Type 3.5.4.2 At -40 +/- 2 C Report, kJ/m2 Report Break Type 3.5.4.3 At 0 +/- 2 C Report, 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 te
33、sting shall be done within the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 3.5.5 Poissons Ratio Report Ratio (ISO 527-1/2, Specimen A, 1 mm/minute test speed) 3.5.6 Supplemental Information The following curves are to be submitted with the data packages: FTIR
34、TGA DSC CLTE Engineering Stress/Strain at 23 C 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHOD
35、S IN SECTION 3.5 Para. Test Typical Value Units 3.5.1 Melt Flow Rate 40 50 g/10 minutes 3.5.2 Molding Shrinkage After 48 h at 23 +/- 2 C Flow Cross Flow 1.3 1.4 1.3 1.4 % % 3.5.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 13.1 15.1 15.1 16.8 E-5 mm/mm/C E-5 mm/mm/C ENGINEERING MATERIAL
36、SPECIFICATION WSS-M4D1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 7 of 9 3.5.4 3.5.4.1 3.5.4.2 3.5.4.3 Impact Strength, Notched Izod At 23 +/- 2 C At -40 +/- 2 C At 0 +/- 2 C 34 - 53 2.5 - 6.5 25 - 77 kJ/m2 Report Break Type 3.5.5 Poisson Ratio 0.49 NA 4.2 MATERIAL IDENTIFICATION FOR R
37、ECYCLING PURPOSES TPO-(PP+EPDM) (ISO1043/11469/18064) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 8 of 9 Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Previously Approved Material Para. Test Minimum Lots Specimen
38、s per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 3.1.4 WSS-M98P13-C Reference the performance specification 3.3.1 Weathering Resistance 1 1 1 3.3.2 1 and 2 year Florida 1 1 1 3.3.3 Resistance to Scratch and Mar 1 3 3 3.4.1 Density 1 3 3 1 3 3 3.4.2 Hardne
39、ss, Durometer D* 3 5 measurements 3 1 5 measurements 1 3.4.3 Tensile Strength at Yield* 3 5 15 1 5 5 3.4.4 Elongation at Yield* 3 5 15 1 5 5 3.4.5 Tensile Modulus* 3 10 30 1 10 10 3.4.6 Flexural Modulus* 3 10 30 1 10 10 3.4.7 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.4.8 Impa
40、ct Strength, Multiaxial (per condition)* 3 10 30 1 10 10 3.4.9 Heat Deflection Temperature* 3 2 6 1 2 2 3.4.10 Heat Aging Performance 3.4.10.1 Tensile Strength at Yield, Change 1 5 5 3.4.10.2 Impact Strength, Charpy, Change 1 10 10 3.4.11 Flammability 1 5 5 3.5.1 Melt Flow Rate 1 3 3 1 1 1 3.5.2 Mol
41、d Shrinkage 1 5 5 1 5 5 3.5.3 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.5.4 Impact Strength Notched Izod (per condition) 1 10 10 3.5.5 Poissons Ratio 1 2 2 1 2 2 3.5.6 Curves - FTIR - TGA - DSC - CLTE - Engineering Stress/Strain at 23 C 1 1 1 per test *For these requirements th
42、e 3 sigma value from the raw data is used to meet the requirements. Individual data ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2012, Ford Global Technologies, LLC Page 9 of 9 points shall be reported. Table 2: Minimum Color Property Testing Para. Test Lots Specimens per Lot Total Te
43、st Specimens Color Test Direction 3.3.1 Weathering Resistance 1 1 1 Every color 3.3.3 Resistance to Scratch and Mar 1 3 3 As directed by Materials Engineering 3.4.3 Tensile Strength at Yield 1 5 5 As directed by Materials Engineering 3.4.6 Flexural Modulus 1 10 10 As directed by Materials Engineering 3.4.10.1 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering 3.4.11 Flammability 1 5 5 Every color
