1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2016 05 19 Released T.Nover, EU Controlled document at www.MATS Copyright 2016 Ford Global Technologies, LLC Page 1 of 7 THERMOPLASTIC POLYOLEFIN ELASTOMER (TPO), 5% MINERAL WSS-M4D1061-A1 FILLED, MOLDED IN COLOR, INTERIOR 1. SCOPE Th
2、e material defined by this specification is a molding compound based on thermoplastic polyolefin elastomer, mineral filled, molded-in-color, for unpainted interior applications. 2. APPLICATION This specification was released originally for material used for interior trim applications which can be fo
3、amed. 2.1 LIMITATIONS This material should not be used in safety relevant locations such as locations in which vehicle crash forces or airbag deployment could cause part breakage. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identifie
4、d 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 through a Ford Materials Engineer. 3.2 CONDITIONING AND TEST CONDITIONS All test values
5、 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 environment or soon after removal. 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR
6、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 material supplied to the specification shall produce IR spectra and thermograms that corr
7、espond 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 symbol (s), which indicated that the mean and +/- 3 sigma values were to be reported.
8、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 not allow the addition of recycled content (PIR/PCR). 3.4.3 The use of reg
9、rind is permitted, for economic / environmental reasons. Part manufacturers using this specification must complete DV and PV testing with the allowable amount of regrind ENGINEERING MATERIAL SPECIFICATION WSS-M4D1061-A1 Copyright 2016, Ford Global Technologies, LLC Page 2 of 7 and the maximum allowa
10、ble regrind content must be specified 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 used in interior applicat
11、ions must meet the requirements outlined in WSS-M99P2222-D1/Latest, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submission package. 3.4.5 Materials requiring High Strain Rate, Creep or fiber oriented Tensile Modulus may be requ
12、ired 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. 3.4.6 Performance Criteria: Parts using this specification shall meet the ap
13、propriate performance specifications, WSS-M15P4-G/Latest. 3.4.7 Ford 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 (not for filled materials) Filler Content Impact S
14、trength, Notched Charpy at 23C 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 and approved by Ford Materials Engineering. Unless otherwise specifi
15、ed 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. No additional annealing is allowed. See Tables 1 and 2 for the number of samples required. Specimens shall be as follows: S
16、pecimen 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) Specimen E 100 mm diameter x 3.2 mm Specimen F 80 mm diameter x 3.2 mm S
17、pecimen 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 prepare specimens for C through N gloss surfaces. Use a smooth, polished tool to prepare specimens for A and B gloss surfaces. ENG
18、INEERING MATERIAL SPECIFICATION WSS-M4D1061-A1 Copyright 2016, Ford Global Technologies, LLC Page 3 of 7 3.6 APPEARANCE 3.6.1 Weathering Resistance Rating 4 min (FLTM BO 116-01, 2406.4 kJ/m2 exposure Specimen C, ungrained, non-polished mold ISO 105-A02 / AATCC Evaluation Procedure 1) Every week* rem
19、ove the samples from the weatherometer and allow them to cool for one hour. Conduct a tactile evaluation and report any tackiness. Visually evaluate and report any spewing or other exudation. After exposure the material shall show no fading or color change in excess of the specified AATCC rating. In
20、 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. *When setting machine for automatic shutoff, every 526.4 kJ/m2 is recommended. 3.6.2 R
21、esistance to Scratch and Mar (FLTM 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 r
22、atio, colors, grain, etc can be found in the approval package. 3.7 MATERIAL PROPERTIES 3.7.1 Determination of Ash, talc filler 4.0 - 9.0 % (ISO 3451-1, Method A, at 650 C +25 C) 3.7.2 Density 0.92 0.95 g/cm3 (ISO 1183, Method A) 3.7.3 Tensile Strength at Yield 24.0 MPa min (ISO 527-1 and ISO 527-2,
23、Specimen A, 50 mm/minute test speed) 3.7.4 Elongation at Yield 4 % min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.7.5 Tensile Modulus 1.8 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.6 Flexural Modulus 1.5 GPa min (ISO 178, Specimen D, 64 mm support
24、 span, 2 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1061-A1 Copyright 2016, Ford Global Technologies, LLC Page 4 of 7 3.7.7 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.7.7.1 At 23 +/- 2 C 5.0 kJ/m2 min Report Break Type 3.7.7.1 At -40 +/- 2 C 1.3 kJ/m2 min Repo
25、rt Break Type The 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, but within 5 seconds. Test specimens must be reviewed by
26、Materials Engineering. 3.7.8 Heat Deflection Temperature (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection. At 1.80 MPa 53 C min At 0.45 MPa 91 C min 3.7.9 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 120+/- 2 C. After heat aging test
27、 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) 3.7.9.1 Tensile Strength at Yield, Change +/- 25% max (Test Method per para 3.7.3) 3.7.9.2 Impact Strength, Notched Charpy, Change
28、+/- 25% max (Test Method per para 3.7.7.1, specimens to be notched before Heat Aging) 3.7.10 Interior Odor Test (FLTM BO 131-03, Variant C, Specimen G) Condition 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.7.11 Determination of the Fogging Characteristics of Interior Automotiv
29、e Materials Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. 3.7.12 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute m
30、ax ENGINEERING MATERIAL SPECIFICATION WSS-M4D1061-A1 Copyright 2016, Ford Global Technologies, LLC Page 5 of 7 3.8 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.8.1 Melt Flow Rate Report MFR (ISO 1133 230 C, 2.16 kg) 3.8.2 Molding Shrinkage Report Shrinkage (Repo
31、rt method used, sample size and value) 3.8.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 100 +/- 2 C) Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.8.4 Impact Strength, Notched Izod Report Value kJ/m2 (ISO 180-1/1eA, Specimen D, 23 +/- 2 C
32、) 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 testing shall be done within the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 3.8.5 Poissons Ratio Report R
33、atio (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 heat Engineering Stress/Strain at 23 C 4. GENERAL INFORMATION The information given below is provided for c
34、larification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.8 Test Typical Value Units 3.8.1 Melt Flow Rate Foaming material 50 g/10 minutes 3.8.2 Molding Shrin
35、kage Flow Cross Flow 1.5 1.6 1.3 1.4 % % 3.8.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 9 - 11 10 - 13 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.4 Impact Strength, Notched Izod At 23 +/- 2 C At - 40 +/- 2 C 5.5 1.9 kJ/m2 kJ/m2 3.8.5 Poissons Ratio 0.37 N/A ENGINEERING MATERIAL SPECIFICATION WSS-M
36、4D1061-A1 Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS TPO-(PP+EPM)-TD5 (ISO 1043/11469) Table 1: Minimum Sample Size Initial Approval and/or Initial Approval in a New Region Additional Manufacturing Location for Previously Appr
37、oved Material Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4.4 WSS-M99P2222-D1/Latest Total Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See below for Odor and Fogging) 1 1 1 per test 3.4.5 Thermoplastic Proper
38、ty Determination For CAE WSS-M99D68-A1 Reference the Performance Specification 3.4.6 WSS-M15P4-G/Latest Reference the Performance Specification 3.6.1 Weathering Resistance 1 1 1 3.6.2 Scratch Resistance 1 3 3 3.7.1 Determination of Ash, talc filler* 3 1 3 1 1 1 3.7.2 Density 1 3 measurements 3 1 3 3
39、 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 Flexural Modulus* 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 (per condition)* 3 2 6 1 2 2 3.7.9 Heat
40、 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 Odor 1 9 9 3.7.11 Fogging Photometric 1 3 3 3.7.12 Flammability 1 5 5 3.8.1 Melt Flow Rate 3 1 3 3 1 3 3.8.2 Mold Shrinkage 1 5 5 1 5 5 3.8.3 Coefficient of Linear Therma
41、l Expansion (per condition) 1 3 3 3.8.4 Impact Strength, Notched Izod 1 10 10 3.8.5 Poissons Ratio 1 2 2 1 2 2 3.8.6 Curves - IR - TGA - DSC (first and second heat) - CLTE (3 flow and 3 cross flow) - Stress/Strain Curves 1 1 1 per test * For these requirements the 3 sigma value from the raw data is
42、used to meet the requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1061-A1 Copyright 2016, Ford Global Technologies, LLC Page 7 of 7 Table 2: Minimum Color Property Testing - Contact Materials Engineering for Color Test Work Plan 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their m
43、aterials 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 representativeof the test facility, demonstrating full co
44、mpliance 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 associated quality control documents (Process Failure Mode and Effects Analysis, Control
45、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 changes to the material originally approved, whether or not such changes affect the ma
46、terials 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) by submission of a completed Suppliers Request for Engineering Approval, SREA. F
47、or 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 Job 1. 4.4 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Subs
48、tance 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
49、 on a continuing basis through IMDS and or GMAP reporting. 4.5 ADDITIONAL REQUIREMENTS 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). Para. Test Lots Specimens per Lot Total Test Specimens Color Test Direction 3.6.1 Weathering Resi
