1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2010 01 08 N-STATUS Replaced by WSS-M4D556-A8 J. Crist, NA 1996 10 18 Revised Revised para 3.5.8.2, 5.8.5, 5.8.6 L. Rodigas 1996 10 02 Activated L. Rodigas WP 3948-a Page 1 of 7 POLYPROPYLENE COPOLYMER, 22 % M
2、INERAL FILLED, WSS-M4D556-A6 EXTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a 20 to 24 % mineral filled injection molding compound based on polypropylene copolymer and with added UV stabilization for exterior use. 2. APPLICATION This specification was r
3、eleased originally for material used for cowl top ventilator grills. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for initial qualification of materials.
4、A Control Plan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to analyze process/product
5、data and assure consistent processing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. 3.1.1 All requirements of this specificatio
6、n, identified by symbol (s), shall be met with data representing 3 sigma values. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms est
7、ablished for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. ENGINEERING MATERIAL SPECIFICAT
8、ION WSS-M4D556-A6 WP 3948-b Page 2 of 7 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unles
9、s otherwise specified. 3.4 MOLDING COMPOUND (s) 3.4.1 Melt Flow Rate 14 - 22 g/10 minutes (ISO 1133, 230 C, 2.16 kg) (s) 3.4.2 Content 19 - 25 % (ISO 3451/1, Method A, TBD h at 650 +/- 25 C, test portion 1 to 2 g) 3.5 MOLDED TEST SPECIMEN 3.5.1 Preparation of Test Specimens Unless otherwise specifie
10、d all tests shall be carried out on injection molded one-end gated test specimens. The following dimensions are required: A. 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 3167, Type 1A) B. 60 x 60 x 2.0 +/- 0.1 mm (ISO/DIS 294-3) C. 355 x 100 x 1.0 +/- 0.1 mm (ISO 3795) Test specimen A shall be molded usin
11、g molding conditions defined in ISO 3167. Specimens with shorter dimensions shall be cut from the center of the specimen A. No annealing allowed. 3.5.2 Density 1.02 - 1.11 g/cm3 (ISO 1183, Method A) (s) 3.5.3 Tensile Strength at Yield, min 20 MPa (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.
12、2 mm specimen, test speed: 50 mm/minute) (s) 3.5.4 Flexural Modulus, min 1.9 GPa (ISO 178, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, 2 mm/min test speed, 64 mm support span) ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A6 WP 3948-b Page 3 of 7 3.5.5 Shear Modulus at 23 C 0
13、.75 - 1.30 GPa (ASTM D 5279, forced constant amplitude, fixed frequency of 1 Hz +/- 15 %, strain level below 1 %. Specimen approx. 60 x 10 x 4.0 +/- 0.2 mm cut from the center of specimen A. Specimen length between clamps 35 - 40 mm. Soak time at each temperature interval - 3 minutes minimum) Additi
14、onally, a shear modulus versus temperature curve shall be plotted for - 50 to + 150 C temperature range, at 5 C minimum intervals. The plotted curve must be within tolerance range granted on the original material approval and it shall constitute the reference standard for materials supplied to this
15、specification and shall be kept on file at the designated material laboratory and be available on request. (s) 3.5.6 Impact Strength, Izod, min (ISO 180/1A, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C 4.0 kJ/m2 3.5.6.2 At 0 +/
16、- 1 C 2.5 kJ/m2 3.5.6.3 At - 40 +/- 1 C 1.8 kJ/m2 The test specimen must be conditioned for minimum of 6 h 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. (s)
17、 3.5.7 Heat Deflection Temperature, min 52 C (ISO 75-1 & ISO 75-2, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, edgewise, 0.32 +/- 0.1 mm deflection. At 1.80 MPa) 3.5.8 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. Unaged property val
18、ues shall be determined at the time of the aged properties determination) 3.5.8.1 Tensile Strength at Yield +/- 25 % Change (Test Method per para 3.5.4) ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A6 WP 3948-b Page 4 of 7 3.5.8.2 Impact Strength, Izod +/- 15 % Change, max (Test Method per para 5.6
19、.1, specimens to be notched before heat aging) 3.6 WEATHERING RESISTANCE After exposure in accordance with para 3.6.1, 3.6.2, and 3.6.3, the material shall show no color change in excess of specified Gray Scale rating (AATCC Evaluation Procedure 1/ISO 105-A02). In addition, there shall be no crackin
20、g, crazing or other deterioration. A slight loss of gloss or chalking will be allowed provided an acceptable appearance can be achieved by washing and/or polishing with Ford car polish (auto wax) after the outdoor exposure, at permission of the affected Product Development Materials Activity. All in
21、itial approvals will be based on the preliminary Weatherometer exposure, pending Florida and Arizona exposure results for final approval. 3.6.1 Xenon Arc Weatherometer Rating 4 - 5 (SAE J1960, 1980 kJ/m2 exposure minimum, specimen size: 60 x 60 minimum, 2.0 +/- 0.1 mm thick, smooth surface, low glos
22、s injection molded specimen) 3.6.2 12 months Florida Rating 4 - 5 12 months Arizona (SAE J1976, 5 degrees south, direct weathering inland, specimen size: 60 x 60 minimum, 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen) 3.6.3 24 months Florida Rating 4 24 months Arizona (SA
23、E J1976, 5 degrees south, direct weathering inland, specimen size: 60 x 60 minimum, 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen) 3.7 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engin
24、eering parts specification and/or performance specification. All critical areas with respect to these properties shall be clearly designated on the engineering drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A6 WP 3948-b Page 5 of 7 3.8 SUPPLIERS RESPONSIBILITY All materials supplied to this
25、specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such
26、 changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a
27、new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Materials Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined
28、 by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall sub
29、mit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification (test results, not nominal values), the materi
30、al designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Eng
31、ineering Material Approved Source List. 5. GENERAL INFORMATION The information below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 8 - 12E-5/ C (ASTM E 831 TMA, temperature range - 30 to + 100 C) 5.2 MOLD S
32、HRINKAGE (ISO/DIS 294-3, 60 x 60 x 2.0 +/- 0.1 mm injection molded specimen) ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A6 WP 3948-b Page 6 of 7 5.2.1 Molding Shrinkage After 48 h at 23 +/- 2 C, max . Injection Direction (ID) 1.1 % . Across Injection Direction (AID) 1.1 % 5.2.2 Post Shrinkage (Se
33、parate specimens required for each test) . After 48 h at 80 C, max 0.25 % . After 30 minutes at 120 C, max 0.25 % 5.3 HEAT DEFLECTION TEMPERATURE TBD C (ISO 75-1 & ISO 75-2, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) All spe
34、cimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 5.4 MODULUS OF ELASTICITY TBD GPa (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4 +/- 0.2 mm specimen, test speed: 1 mm/minute) 5.5 IMPACT STRENGTH, CHAR
35、PY (ISO 179/1eA, 80 x 10 x 4.0 +/- 0.2 mm specimen (use center section of specimen A), 10 specimens for each test) 5.5.1 At 23 +/- 2 C TBD 5.5.2 At - 40 +/- 1 C TBD The test specimens must be conditioned for minimum of 6 hours at the above specified temperature prior to impact test. Low temperature
36、testing shall be done within the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 5.6 IMPACT STRENGTH, MULTIAXIAL (ASTM D 3763, 100 mm diameter x 3.2 mm thick smooth surface injection molded specimen. Impact velocity: 2.2 m/s for exterior, 6.6 m/s for interior appl
37、ications.) 5.6.1 At 23 +/- 2 C TBD J 5.6.2 At - 15 +/- 2 C TBD J ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-A6 WP 3948-b Page 7 of 7 5.7 RESISTANCE TO SCRATCHING (FLTM BN 108-13, grain: easiclean and/or equivalent, 1 mm scratch balls, instrumental evaluation of 3.0 N scratch mark) Percentage of M
38、arking, max 40 % 5.8 USE OF REGRIND MATERIAL (Property values of regrind material shall be compared with original virgin material. Regrind: compound of 20 weight % regrind based on single reprocessed material, free of contaminations, and 80 weight % virgin material.) 5.8.1 Melt Flow Rate Change, max
39、 + 30 % (Test method per para 3.4.1) 5.8.2 Tensile Strength at Yield Change +/- 10 % (Test method per para 3.5.3) 5.8.3 Flexural Modulus, Change +/- 10 % (Test method per para 3.5.4) 5.8.4 Impact Strength, Izod Change, max - 10 % (Test method per para 3.5.6.1) 5.8.5 Heat Deflection Temperature Change +/- 10 % (Test method per para 3.5.7) 5.8.6 Weathering Resistance 5.8.6.1 Xenon Arc Weatherometer Rating 4 - 5 (Test method per para 3.6.1) 5.8.6.2 12 Months Florida TBD (Test method per para 3.6.2) 5.9 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PP-TD22
