1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2017 01 04 Released P Addis, EU Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 1 of 7 POLYPROPYLENE (PP), 35% SHORT GLASS FIBER REINFORCED, WSS-M4D1055-A1 CHEMICALLY COUPLED, HEAT RESISTANT, MOLDING
2、COMPOUND 1. SCOPE The material defined by this specification is a thermoplastic injection molding compound based on polypropylene with 35% chemically coupled short glass fiber reinforcement. 2. APPLICATION This specification was released originally for material used for air intake manifolds on natur
3、ally aspirated engines. 2.1 LIMITATIONS This specification does not contain UV stabilizers and is not suitable for visible interior applications. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford materials Approved S
4、ource 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 through a Ford Materials Engineer. 3.2 CONDITIONING AND TEST CONDITIONS All test values are based on materials c
5、onditioned 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 environment or soon after removal. 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms from ini
6、tial 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 material supplied to the specification shall produce IR spectra and thermograms that correspond to the reference standard
7、 when tested under the same conditions. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1055-A1 Copyright 2017, Ford Global Technologies, LLC Page 2 of 7 3.4 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.4.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s)
8、, 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. 3.4.2 This specification is based on virgin material and does no
9、t allow the addition of recycled content (PIR/PCR). 3.4.3 The use of regrind is permitted, for economic / environmental 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 specifie
10、d on the engineering drawing. Any changes to what is specified on the drawing (no specific amount implies zero regrind) must be approved by Materials and PD Engineering through the formal Ford Motor Company process (SREA). 3.4.4 Materials requiring High Strain Rate, Creep or fiber oriented Tensile M
11、odulus may be required to test to the requirements of WSS-M99D68-A1/Latest, Thermoplastic Property Determination For CAE, High Strain Rate Tensile, Creep and Tensile Modulus. Material Suppliers should be prepared to submit data upon request. 3.4.5 Performance Criteria: Parts using this specification
12、 shall meet the appropriate underhood performance specification, WSS-M15P50-B/Latest. Contact Ford Materials Engineering regarding any color, appearance or alternative testing requirements, for the intended application. For applications that have a direct impact on the interior air quality, such as
13、heater and A/C Unit, please note that the Odor test (FLTM BO 131-03, Variant C) is required as prescribed in the relevant performance specification. 3.4.6 Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CofA) containing lot testing requirements which must include,
14、but are not limited to: Melt Temperature Filler Content Impact Strength, Notched Charpy at 23 2 C Flexural Modulus 3.5 SAMPLE PREPARATION All tests shall be carried out on production materials manufactured from the production process unless correlation to a non-production process has been reviewed a
15、nd approved by Ford Materials Engineering. Production level material must be used in preparing test parts / panels. The use of improper sample preparation material can influence test results. Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens.
16、 The test specimens A and D shall be molded using molding conditions defined in ISO 1873-2. No annealing is allowed. See Table 1 for the number of samples required. Mechanical testing shall be carried out on specimens that have been conditioned, at 23 2 C and 50 5% relative humidity, for a minimum o
17、f 96 hours. 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 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) ENGINEERING MATERIAL SPECIFICATION WSS-M4D10
18、55-A1 Copyright 2017, Ford Global Technologies, LLC Page 3 of 7 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 Testing: Use an ungrained, non-polished, tool to pr
19、epare specimens 3.6 APPEARANCE Refer to Ford Materials Engineering for appearance testing, for environmental and fluids resistance, per the performance specification. Peak thermal cycling test temperature for engine applications to be 150 C, unless otherwise advised. 3.7 MATERIAL PROPERTIES 3.7.1 De
20、termination of Ash 32-39 % (ISO 3451-1, Method A, 1 h 750 25 C) 3.7.2 Density 1.16-1.20 g/cm3 (ISO 1183, Method A) 3.7.3 Tensile Strength at Break 100 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.7.4 Elongation at Break 2.4 % min (ISO 527-1 and ISO 527-2, Specimen A, 50 m
21、m/minute test speed) 3.7.5 Tensile Modulus 7.2 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.6 Flexural Modulus 7.5 GPa min (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
22、C 10 kJ/m2 min Report Break Type 3.7.7.2 At 40 2 C 6 kJ/m2 min Report Break Type The test specimen must be conditioned for minimum of 6 hours at the above specified temperature prior to test. Low temperature testing shall be done within the cold chamber, if not possible, test may be conducted outsid
23、e, but within 5 seconds. Tested specimens must be reviewed by Materials Engineering. Break types are listed in section 4.5. 3.7.8 Heat Deflection Temperature 150 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). ENGINEERING MATERIAL SPECIF
24、ICATION WSS-M4D1055-A1 Copyright 2017, Ford Global Technologies, LLC Page 4 of 7 3.7.9 Heat Aging Performance (ISO 188, 150 50 air changes/h, 1000 h at 150 2 C. After heat aging test specimens are to be conditioned in a desiccator for 35 h at 23 2 C. Unaged property values shall be determined at the
25、 time of the aged properties determination) 3.7.9.1 Tensile Strength at Break, Change +/- 25% max (Test Method per para 3.7.3) 3.7.9.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per para 3.7.7.1, specimens to be notched before Heat Aging) 3.7.10 Flammability (ISO 3795/SAE J369,
26、 Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.8 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.8.1 Melt Temperature Report Value, C (ISO 11357, 10 C/min heating rate) 3.8.2 Heat Deflection Temperature Report Value, C min (ISO 75-1 and ISO 75-2, Specim
27、en D, flatwise, Bath silicone oil, 0.34 0.1 mm deflection, at 0.45 MPa) 3.8.3 Molding Shrinkage (After 48 h at 23 2 C. Report method used, sample size and value) In Flow Report Value, % Cross Flow Report Value, % 3.8.4 Coefficient of Linear Thermal Expansion (ISO 11359-2, 30 2 C to Tg; Tg to 100 2 C
28、) In Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.8.5 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.8.6 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC first and second hea
29、t CLTE Engineering Stress/Strain at 23 2 C ENGINEERING MATERIAL SPECIFICATION WSS-M4D1055-A1 Copyright 2017, Ford Global Technologies, LLC Page 5 of 7 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Co
30、ntact for questions concerning Engineering Material Specifications. 4.1 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PP-GF35 (ISO 1043/11469) 4.2 TYPICAL PROPERTIES USING METHODS IN SECTION 3.8 Para. Test Typical Value Units 3.8.1 Melt Temperature 260 g/10 minutes 3.8.2 Heat Deflection Te
31、mperature (At 0.45 MPa) 155 C min 3.8.3 Molding Shrinkage (Report method used, sample size and value) - After 48 h at 23 2 C In Flow Cross Flow 0.3 1.0 % % 3.8.4 Coefficient of Linear Thermal Expansion In Flow Cross Flow 4 12 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.5 Poissons Ratio 0.4 N/A ENGINEERING MATERIA
32、L SPECIFICATION WSS-M4D1055-A1 Copyright 2017, Ford Global Technologies, LLC Page 6 of 7 4.3 TEST SAMPLE REQUIREMENTS GUIDE 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 Sp
33、ecimens per Lot Total Test Specimens 3.4.6 WSS-M15P50-B Reference the Performance Specification 3.7.1 Determination of Ash 3 1 3 1 1 1 3.7.2 Density 1 3 3 1 3 3 3.7.3 Tensile Strength at Break* 3 5 15 1 5 5 3.7.4 Elongation at Break 3 5 15 1 5 5 3.7.5 Tensile Modulus 1 10 10 3.7.6 Flexural Modulus*
34、3 10 30 1 10 10 3.7.7 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.7.8 Heat Deflection Temperature (1.8 MPa) 3 2 6 1 2 2 3.7.9 Heat Aging Performance 3.7.9.1 Tensile Strength at Break, Change 1 5 5 3.7.9.2 Impact Strength, Notched Charpy, Change 1 10 10 3.7.10 Flammability 1 5 5
35、 3.8.1 Melt Temperature 3 2 6 1 2 2 3.8.2 Heat Deflection Temperature (0.45 MPa) 3 2 6 1 2 2 3.8.3 Mold Shrinkage 1 5 5 1 5 5 3.8.4 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.8.5 Poissons Ratio 1 2 2 1 2 2 3.8.6 Curves - IR - TGA - DSC (first and second heat) - CLTE (3 In Flow a
36、nd 3 Cross Flow) - Stress/Strain Curves 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements (see below). 4.4 IMPACT STRENGTH BREAK TYPES GUIDE Four types of Impact Test breaks may occur, designated by the following codes: C: Complete Break A b
37、reak in which the specimen separates into two or more pieces. H: Hinge Break An incomplete break such that both parts of the specimen are held only ENGINEERING MATERIAL SPECIFICATION WSS-M4D1055-A1 Copyright 2017, Ford Global Technologies, LLC Page 7 of 7 by a thin peripheral layer in the form of a
38、hinge having low residual stiffness. P: Partial Break An incomplete break that does not meet the definition for hinge break. N: Non Break There is no break and the specimen is only bent and pushed through the supporting blocks, possibly combined with stress whitening. 4.5 APPROVAL OF MATERIALS Suppl
39、iers 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 qualified and authorized representative of the te
40、st facility, demonstrating full compliance with all the requirements of the Ford 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 associated quality control documents (including: P
41、rocess Failure Mode and Effects Analysis; Control Plans; Certification testing) with Ford. 4.6 SUPPLIERS ONGOING RESPONSIBILITY 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 a
42、pproved, 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 justification), by submission of a comp
43、leted 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 off must be kept until
44、 Job 1. 4.7 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 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
