1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2018 05 14 Released L. Rabideau, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 5 EXPANDED POLYPROPYLENE (PP) FOAM, HIGH STRENGTH, WSS-M4D1041-A1 MEDIUM DENSITY CLOSED CELL, INTERIOR 1. SCOP
2、E The material defined by this specification is closed cell polypropylene foam produced by compression molding of expanded polypropylene beads. 2. APPLICATION This specification was originally released for use as a sun visor substrate. 2.1 LIMITATIONS This does not contain UV stabilizers, long term
3、exposure to direct sunlight will cause chalking and loss of gloss. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file,
4、or other documents. The list of approved sources 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 +/-
5、2 C and 50 +/- 5% relative humidity. Testing 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
6、on file at the designated material laboratory. 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
7、MATERIALS 3.4.1 Many 4D resin specifications 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 Tab
8、le 1 for number of samples required for each test. 3.4.2 This specification is based on virgin material and does not allow the addition of recycled content (PIR/PCR). ENGINEERING MATERIAL SPECIFICATION WSS-M4D1041-A1 Copyright 2018, Ford Global Technologies, LLC Page 2 of 5 3.4.3 Ford Materials Engi
9、neering may request a Control Plan and Certificate of Analysis (C of A) containing lot testing requirements, which must include, but are not limited to: Density Compressive Strength 3.5 SAMPLE PREPARATION All test specimens shall be free from molded skin. Test specimen shall be cut to a thickness of
10、 25 +/-2 mm. 3.6 MATERIAL PROPERTIES 3.6.1 Density 51-60 kg/m3 (ISO 845/ASTM D3574, Test A, Core density only, 50 x 50 x 25 mm specimen size minimum) 3.6.2 Tensile Strength 1500 kPa min (ISO 1926/ASTM D3574, Test E 50 mm bench marks, Use ASTM D412A Die) 3.6.2.1 Elongation at Break 2 % min (Test acc.
11、 to 3.6.2) 3.6.2.2 Tensile Strength after Heat Aging +/- 25 % max (ISO 188/ASTM D573, Tensile test acc. to 3.6.2 1000 h at 80 +/- 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
12、properties 3.6.3 Compressive Strength (ISO 844/ASTM D 1621, 50 x 50 x 25 mm specimen) 3.6.3.1 At 10% strain 200 kPa min 3.6.3.2 At 25% strain 300 kPa min 3.6.3.3 At 50% strain 350 kPa min 3.6.3.4 At 75% strain 700 kPa min 3.6.4 Dimensional Stability 4 % max Test Method: A specimen approximately 300
13、x 300 mm in size shall be placed in a mechanical convection oven maintained at 100 +/- 2 C for 3 h. Overall dimensional changes shall be measured after cooling down to room temperature. 3.6.5 Short Term Environmental Cycling (FLTM BO 040-01 Procedure A, 80 C) ENGINEERING MATERIAL SPECIFICATION WSS-M
14、4D1041-A1 Copyright 2018, Ford Global Technologies, LLC Page 3 of 5 Evaluate the visual portion of the evaluation procedure for distortion, blistering, delamination and waviness only. Evaluate the functional and dimensional evaluation procedures as stated in the method.) All parts in assembly and ma
15、ting components must be in place. No warping or distortion that will interfere with normal functional operations. 3.7 FOGGING PHOTOMETRIC (SAE J1756, 3 h at 100 C heating, 21 C Cooling plate, post testing conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for
16、 rejection All materials should be stored in an open environment for 14-28 days after manufacture and then bagged in heat sealed polyethylene (PE) or PE coated aluminum bags for shipping. All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/-2 C and 5
17、0 +/-5% relative humidity for not less than 24 hours prior to testing and tested under the same conditions unless otherwise specified. Parts for testing must be labelled with the correct information: including supplier and date of manufacture. 3.8 ODOR (FLTM BO 131-03, Variant B) Condition 1 Rating
18、3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.9 FLAMMABILITY (ISO 3795) Burn Rate 100 mm/minute max 3.10 MATERIAL PROPERTIES REPORT ONLY 3.10.1 Coefficient of Linear Thermal Expansion (ASTM D696) 3.10.1.1 From -40 to 23 +/- 2 C Report Value, E-5 mm/mm/ C 3.10.1.2 From 23 to 80 +/- 2 C Re
19、port Value, E-5 mm/mm/ 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. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1041-A1 Copyrig
20、ht 2018, Ford Global Technologies, LLC Page 4 of 5 4.1 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PP-E (ISO 1043/11469) Table 1: Minimum Sample Size Initial Approval and/or Initial Approval in a New Region and New Manufacturing Location Approval for Recycled Materials Additional Manufact
21、uring Location for Previously Approved Material Para. Test Minimum Lots Specimens Total Test Specimens Lots Specimens per lot Total Test Specimens per Lot 3.6.1 Density* 3 3 9 1 3 3 3.6.2 Tensile Strength 3 5 15 1 5 5 3.6.2.1 Elongation at Break 3 5 15 3.6.2.2 Tensile Strength after Heat Aging 1 5 5
22、 3.6.3 Compressive Strength* (at 10%, 25%, 50% and 75%) 3 5 15 3.6.4 Dimensional Stability 3 1 3 3.6.5 Short Term Environmental Cycling 1 1 1 3.7 Fogging (interior applications only) 1 3 3 3.8 Odor (interior applications only) 1 9 9 3.9 Flammability 1 5 5 * For these requirements the 3 sigma value f
23、rom the raw data is used to meet the requirements. 4.2 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their labo
24、ratory test reports, signed by a qualified and authorized representativeof the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the
25、 supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1041-A1 Copyright 2018, Ford Global Technologies, LLC Page 5 of 5 4.3 SUPPLIERS ONGOING RESPONSIBILITY
26、 All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall no
27、tify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all s
28、amples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.4 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the
29、 materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 4.5 ADDITIONAL REQ
30、UIREMENTS Requirements beyond those explicitly stated in this document and the material specification may be specified on the Engineering drawing, Engineering specification (ES), performance specification, System Design Specification (SDS) and/or Attribute Requirement List (ARL). 5. SUMMARY OF REVISIONS
