1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 4 2017 05 12 Revision See Summary of Revisions T. Nover, EU 2014 12 16 Editorial See Summary of Revisions L. Soreide, NA 2012 06 22 Activated G. Eaton, NA Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page
2、 1 of 8 POLYCARBONATE (PC), GENERAL PURPOSE, EXTERIOR WSS-M4D1051-A1 POLYCARBONATE (PC), GENERAL PURPOSE, INTERIOR WSS-M4D1051-A2 1. SCOPE The material defined by this specification is a thermoplastic injection molded compound based on polycarbonate. This is a non UV-stable material. 2. APPLICATION
3、WSS-M4D1051-A1: This specification was released originally for materials used for headlamp lenses and rear lamp housings and protected by UV resistant coatings. WSS-M4D1051-A2: This specification was released originally for materials used for general purpose applications not requiring optical clarit
4、y, such as instrument cluster light filters. This material may be color pigmented when optical transparency is not required. 2.1 LIMITATIONS This material does not contain UV stabilizers, long term exposure to direct sunlight will cause chalking and loss of gloss. 3. REQUIREMENTS 3.1 APPROVED SOURCE
5、S 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, or other documents. The list of approved sources is located within Ford at or available externally th
6、rough 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. Testing of the material should occur in the conditioning environm
7、ent 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 laboratory. The material supplier shall ensure that all future mate
8、rial 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 specifications prior to 2011, identified certain requirements with the s
9、ymbol (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 each test. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1051-A1 W
10、SS-M4D1051-A2 Copyright 2017, Ford Global Technologies, LLC Page 2 of 8 3.4.2 The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in Ford Engineering CAD and Drafting Standard E-4. 3.4.3 WSS-M4D1051-A2: Materials used in interior applications must meet
11、 the requirements outlined in WSS-M99P2222-C1/Latest, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submission. 3.4.4 Performance Criteria: WSS-M4D1051-A1: Parts using this specification shall meet the appropriate performance spe
12、cifications, WSS-M98P13-C/Latest (MIC Exterior) or WSK-M98P10-A/Latest (Exterior Lamp Assembly). WSS-M4D1051-A2: Parts using this specification shall meet the appropriate performance specification, WSS-M15P4-F/Latest. 3.5 SAMPLE PREPARATION Unless otherwise specified all tests shall be carried out o
13、n injection molded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defined in ISO 7391-2. 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
14、) 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 3.2 mm thick 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 Sp
15、ecimen I 100 mm x 150 mm, min 3.6 APPEARANCE 3.6.1 Weathering Resistance (WSS-M4D1051-A2 only) Rating 4 min (FLTM BO 116-01, 601.6 kJ/m2 exposure Specimen C from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) After exposure the material shall show no fading or color change in exce
16、ss of the specified AATCC rating. In addition, there shall be no cracking, crazing or other deterioration. Use regional choice for initial approval and report the color house used. See Table 2 for additional color durability submission requirements. 3.7 MATERIAL PROPERTIES 3.7.1 Density 1.17 1.23 g/
17、cm3 (ISO 1183, Method A) 3.7.2 Tensile Strength at Yield 59 MPa min (ISO 527-1 Flow Cross Flow 7.1 7.7 E-5 mm/mm/C E-5 mm/mm/C 3.8.3 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering) Flow Cross Flow 0.78 0.78 % % 3.8.4.1 Impact Strength,
18、Notched Izod; At 23 +/- 2 C 10 kJ/m2 3.8.4.2 Impact Strength, Notched Izod; At -40 +/- 2 C 6 kJ/m2 3.8.5 Poissons Ratio 0.38 N/A 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES (ISO 1043/ 11469) PC ENGINEERING MATERIAL SPECIFICATION WSS-M4D1051-A1 WSS-M4D1051-A2 Copyright 2017, Ford Global Techno
19、logies, LLC Page 6 of 8 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 Specimens 3.4.3 WSS-M99P2222-C1/Latest Total Carbon, Hazardous Substances
20、, Formaldehyde, Acraldehyde, Acetaldehyde (See below for Odor and Fogging) 1 1 1 per test 3.6.1 Weathering 1 1 1 3.7.1 Density 1 3 3 3.7.2 Tensile Strength at Yield* 3 5 15 1 5 5 3.7.3 Elongation at Yield* 3 5 15 1 5 5 3.7.4 Tensile Modulus 1 10 10 3.7.5 Flexural Modulus 3 10 30 1 10 10 3.7.6 Impact
21、 Strength Izod, Notched (per condition)* 3 10 30 1 10 10 3.7.7 Heat Deflection Temperature* 3 2 6 1 2 2 3.7.8 Vicat Softening Temperature 3 2 6 1 2 2 3.7.9 Heat Aging Performance 3.7.9.1 Tensile Strength at Yield, Change 1 5 5 3.7.9.2 Impact Strength, Notched Charpy Change 1 10 10 3.7.10 Fogging Pho
22、tometric 1 3 3 3.7.11 Odor 1 9 9 3.7.12 Flammability 1 5 5 3.8.1 Melt Flow Rate 1 1 1 3.8.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.8.3 Mold Shrinkage 1 5 5 3.8.4 Impact Strength, Izod, Notched (per condition) 1 10 10 3.8.5 Poissons Ratio 1 2 2 3.8.6 Curves - IR - TGA - DSC -
23、 CLTE - Engineering Stress/Strain at 23 C 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1051-A1 WSS-M4D1051-A2 Copyright 2017, Ford Global Technologies, LLC Page 7 of 8 Table 2: Minimum Color Pr
24、operty Testing 4.3 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 laboratory test reports, signed by a qua
25、lified and authorized representative of 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 supplier will review the associate
26、d quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.4 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change
27、s to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons)
28、by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign
29、 off must be kept until Job 1. 4.5 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Para. Test Lots Specimens per Lot Total Test
30、 Specimens Color Test Direction 3.6.1 Weathering Resistance 1 1 1 Every color 3.7.2 Tensile Strength at Yield 1 5 5 As directed by Materials Engineering 3.7.5 Flexural Modulus 1 10 10 As directed by Materials Engineering 3.7.6.1 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Ma
31、terials Engineering 3.7.10 Fogging Photometric 1 3 3 As directed by Materials Engineering 3.7.11 Odor 1 9 9 As directed by Materials Engineering 3.7.12 Flammability 1 5 5 Every color ENGINEERING MATERIAL SPECIFICATION WSS-M4D1051-A1 WSS-M4D1051-A2 Copyright 2017, Ford Global Technologies, LLC Page 8
32、 of 8 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. 5. SUMMARY OF REVISIONS 2017 05 12 Section 3.4.9.2: Change from +/-25% to Report only Updated generic paragraphs and removed reference to WSS-M99P1111-A. 2014 12 15 Editorial Corrected prefix in section 3.1.4 2014 07 21 Changed melt flow from 14.5-21.9 low flow 11 and high flow of 18. Removed gravimetric fogging. 2014 01 21 Editorial added PC to titles.
