1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev.1 2015 08 27 Revised See Summary of Revisions A. Houston, NA 2012 10 22 Released K. Waugh, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 11 THERMOPLASTIC POLYOLEFIN ELASTOMER (TPO), WSS-M4D1024
2、-A1 MOLD-IN-COLOR, MOLDING COMPOUND, EXTERIOR, HIGH IMPACT, 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
3、 appearance and weather resistance for exterior applications. 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
4、 painted applications. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Sources List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved so
5、urces is located within Ford at or available externally through a Ford Materials Engineer. 3.2 CONDITIONING AND TEST CONDITIONS All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testin
6、g of the material should occur in the conditioning environment or soon after removal. 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms from initial material approval shall constitute the reference standard and shall be kept on file at the designated material laborato
7、ry. The material supplier shall ensure that all future material supplied to the specification shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.4.1 Many 4D resin specification
8、s 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 range was established using 3 sigma data. For 2011 and beyond, refer to Table 1 for number of samples required for eac
9、h test. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 11 3.4.2 This specification is based on virgin material and does not allow the addition of recycled content (PIR/PCR). 3.4.3 The use of regrind is permitted, for economic / environmental
10、 reasons. Part manufacturers using this specification must complete DV and PV testing with the allowable amount of regrind and the maximum allowable regrind content must be specified on the engineering drawing. Any changes to what is specified on the drawing (no specific amount implies zero regrind)
11、 must be approved by Materials and PD Engineering through the formal Ford Motor Company process (SREA). 3.4.4 Performance Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS-M98P13-C/Latest. Parts must fulfill applicable SDS/CDS requirements. 3.4.5 For
12、d Materials Engineering may request a Control Plan and Certificate of Analysis (C of A) containing lot testing requirements which must include, but are not limited to: Melt Flow Rate Impact Strength, Notched Charpy at 23 C Flexural Modulus 3.5 SAMPLE PREPARATION All tests shall be carried out on pro
13、duction materials manufactured from the production process unless correlation to a non-production process has been reviewed and approved by Ford Materials Engineering. Unless otherwise specified all test shall be carried out on injection molded, one-end gated test specimens. The test specimens A and
14、 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 +/- 0.1 mm Specimen
15、C 145 x 60 x 3.2 +/- 0.2 mm Specimen D 80 x 10 x 4.0 +/- 0.2 mm (may be cut from the center of Specimen A) 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 For Appearance
16、Testing: Use an ungrained, non-polished, tool to prepare specimens for C through N gloss surfaces. Use a smooth, polished tool to prepare specimens for A and B gloss surfaces. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 11 3.6 APPEARANCE
17、3.6.1 Accelerated Weathering Resistance Preferred Method 3.6.1.1 Standard Practice for Xenon Arc Exposure Test Requirements per Table with Enhanced Light and Water Exposure for Transportation Coatings (ASTM D7869, Use an ungrained, non-polished, tool to prepare specimen for C through N gloss, use a
18、smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) or 3.6.1.2 Performance Based Standard for Accelerated Requirements per Table Exposure of Automotive Exterior Materials Using Controlled Irradiance Xenon-Arc Apparatus (Boro/Boro, SAE J2527, Atlas
19、Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilicate inner and outer filters, 0.55 W/m radiant exposure monitored at 340 nm, Specimen C, ungrained, non-polished mold, use a smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Proced
20、ure 1) Type ASTM D7869 (preferred) SAE J2527 Boro/Boro Requirements New Color 2250 h 3000 h Fade Resistance: Rating 4 min There shall be no cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss Change 25% max (FLTM BI 110-01) *New Material Supplier or New Material Grade 2250
21、h 3000 h Fade Resistance: Rating 4 min There shall be no cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss Change 25% max (FLTM BI 110-01) 3000 h and 3750 h 4000 h, 5000 h, and 6000 h Fade Resistance: Report Only Report any cracking, crazing, dulling, or other deteriorati
22、on A&B Gloss Materials: Report Gloss Change (FLTM BI 110-01) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 11 *New Material Supplier or New Material Grade: New resin from unknown or known Material Supplier. New Manufacturing Locations (new
23、GSDB) for previously approved materials and existing colors are not required to test exterior weathering. All initial approvals may be based on the above accelerated weathering exposure. Results from Florida Outdoor Weathering (3.3.2) takes precedence over Accelerated Weathering 3.6.2 Outdoor Weathe
24、ring of Exterior Materials - Florida Initial Qualification for new resin technology (SAE J1976, 5 South, direct weathering inland, Specimen I, use an ungrained, non- polished, tool to prepare specimen for C through N gloss, use a smooth polished tool to prepare specimens for A and B gloss, ISO 105-A
25、02/AATCC Evaluation Procedure 1) 3.6.2.1 1 and 3 year Florida Rating 4 min Florida Submission Required for Approval to ASL 3.6.2.2 5 year Florida Report Only After exposure the material shall show no color change in excess of the specified AATCC Rating. In addition, there shall be no cracking, crazi
26、ng 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. 3.6.3 Resistance to Scratch and Mar (FLTM
27、 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 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 fo
28、und in the approval package. 3.7 MATERIALS PROPERTIES 3.7.1 Density 0.88 0.92 g/cm3 (ISO 1183, Method A) 3.7.2 Hardness, Durometer D 38 - 50 (ISO 868, 15 s dwell) 3.7.3 Tensile Strength at Yield 8 MPa min (ISO 527-1 & ISO 527-2, Specimen A, 50 mm/minute test speed) 3.7.4 Elongation at Yield 11% min
29、(ISO 527-1 & ISO 527-2, Specimen A 50 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 11 3.7.5 Tensile Modulus 290 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.6 Flexural Modulus 250 MPa min
30、(ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.7.7 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.7.7.1 At 23 +/- 2 C 60 kJ/m2 min Report Break Type3.7.7.2 At -40 +/- 2 C 1 kJ/m2 min Report Break TypeThe test specimen must be conditioned for minimum of 6 hours at
31、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. Test specimens must be reviewed by Materials Engineering. 3.7.8 Standard Test Method for High Speed Puncture Prop
32、erties of Plastic Using Load and Displacement Sensors (ASTM D3763, Impact velocity: 2.2 m/s, Specimen E, smooth surface) Max Load Energy at 23 +/- 2 C Report J Energy Absorbed 100% Ductile Failure Max Load Energy at -40 +/- 2 C Report J Energy Absorbed 100% Ductile Failure Test specimens must be con
33、ditioned 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 the testing environment, provided t
34、he transfer is within 5 seconds. Ductile is defined as a failure in which plastic deformation precedes fracture sample does not fracture into two or more pieces sample does not show cracks radiating more than 10 mm beyond the center of the impact point In borderline cases Ford Materials Engineering
35、can use additional data such as load versus deflection curves or maximum load data to establish ductility. Summarize testing at each condition by providing the following information: a. Detailed description of specimen preparation if different then Specimen E. b. Molding conditions: melt and mold su
36、rface temperatures, and average injection velocity. c. All force versus deflection curves for each impact event. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 6 of 11 d. Original samples are to be submitted for review or, in agreement with Ford
37、Materials Engineering, photos of the tested samples. 3.7.9 Heat Deflection Temperature 36 C min (ISO 75-1 and ISO 75-2 Specimen D, flatwise, Bath silicone oil,0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.7.10 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. Afte
38、r 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) 3.7.10.1 Tensile Strength at Yield, Change +/- 25% max (Test method per para 3.7.3) 3.7.10.2 Impact Strength, Notc
39、hed Charpy, Change +/- 25% max (Test Method per para 3.7.7.1, specimens to be notched before Heat Aging) 3.7.11 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.8 MATERIALS PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.8.1 Melt Fl
40、ow Rate Report Value, g/10 minutes (ISO 1133 230 C, 2.16 kg) 3.8.2 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.8.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 100 +/- 2 C,
41、3 curves per directions, flow and cross flow) Plaque size is 100 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. Conditioning procedure consists of steps 1-4. Start at
42、23 C. 1. Ramp 5 C/minute to -40 C 2. Isothermal hold for 5 minutes ENGINEERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 7 of 11 3. Ramp 5 C/minute to 110 C 4. Isothermal hold for 10 minutes Leave the test specimen in the equipment and run steps 5-7 5.
43、Ramp 5 C/minute to -40 C 6. Isothermal hold for 10 minutes 7. Ramp 5 C/minute to 110 C Report CLTE value after Step 4 (un-annealed value) for both Flow and Cross Flow directions. Flow Report Value E-5 mm/mm/ C Cross Flow Report Value E-5 mm/mm/ C Report CLTE value again after Step 7 (annealed value)
44、 for both Flow and Cross Flow directions. Flow Report Value E-5 mm/mm/ C Cross Flow Report Value E-5 mm/mm/ C 3.8.4 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.8.5 Supplemental Information The following curves are to be submitted with the data packages
45、: FTIR TGA DSC first and second heat 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. ENGINE
46、ERING MATERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 8 of 11 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.8 Para. Test Typical Value Units 3.8.1 Melt Flow Rate 40 50 g/10 minutes 3.8.2 Molding Shrinkage (Report method used, sample size and value) -After
47、 48 h at 23 +/- 2 C Flow Cross Flow 1.3 1.4 1.3 1.4 % % 3.8.3 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 3.8.4 Poissons Ratio 0.49 NA 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS TPO-(PP+EPDM) (ISO1043/11469/18064) ENGINEERING MA
48、TERIAL SPECIFICATION WSS-M4D1024-A1 Copyright 2015, Ford Global Technologies, LLC Page 9 of 11 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 Sp
49、ecimens 3.4.5 WSS-M98P13-E/Latest Reference the performance specification 3.6.1 Weathering Resistance 1 1 1 3.6.2 1, 3 and 5 year Florida 1 3 3 3.6.3 Resistance to Scratch and Mar 1 3 3 3.7.1 Density 1 3 3 1 3 3 3.7.2 Hardness, Durometer D* 1 5 measurements 1 3.7.3 Tensile Strength at Yield* 3 5 15 1 5 5 3.7.4 Elongation at Yield* 3 5 15 1 5 5 3.7.5 Tensile Modulus* 1 10 10 3.7.6 Flexu
