1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2017 11 14 Released G. Eaton, NA Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 1 of 10 POLYPROPYLENE (PP) COPOLYMER, 22% MINERAL WSS-M4D556-B8 FILLED MOLDING COMPOUND, EXTERIOR 1. SCOPE The material
2、 defined by this specification is a 22% mineral filled thermoplastic injection molding compound based on polypropylene copolymer, with added UV stabilization and scratch additives for exterior use. 2. APPLICATION This specification was released originally for material used in mold-in-color exterior
3、applications, specifically for cowl top ventilator grills. Any color additives need to be reviewed and approved by the raw material supplier and Ford Materials Engineering. The UV/process/heat stabilizers must be in the base resin from the material supplier, not in the color concentrate, specificall
4、y for mold-in-color applications at the press. 2.1 LIMITATIONS This material should not be used for painted applications since it contains performance additives that negatively affect paint adhesion. Production level materials must be used in preparing test parts / panels. The use of improper sample
5、 prep materials can influence test results. 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, or other documents. The
6、 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 +/- 2 C and 50 +/- 5% relat
7、ive 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 on file at the designat
8、ed 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 MATERIALS 3.4.1 Many 4D
9、 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 Table 1 for number of samp
10、les required for each test. ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-B8 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 2 of 10 3.4.2 This specification is based on virgin material and does not allow the addition of recycled content (PIR/PCR). 3.4.3 Materials
11、requiring High Strain Rate, Creep or fiber oriented Tensile Modulus 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 reques
12、t. 3.4.4 Performance Criteria Parts using this specification shall meet the appropriate performance specifications WSS-M98P13-E / Latest. 3.4.5 Ford Materials Engineering may request a Control Plan and Certificate of Analysis (C of A) containing lot testing requirements which must include, but are n
13、ot limited to: Melt Flow Rate (not for filled materials) Filler Content Impact Strength, 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 be
14、en reviewed and approved by Ford Materials Engineering. Unless otherwise specified 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 annealing is allowed. See Tables 1 and 2
15、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) 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
16、 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 prepare specimens for C through N gloss surfaces. Use a smooth, polished
17、 tool to prepare specimens for A and B gloss surfaces. 3.6 APPEARANCE 3.6.1 Accelerated Weathering Resistance Preferred Method 3.6.1.1 Standard Practice for Xenon Arc Exposure Test Requirements per Table with Enhanced Light and Water Exposure for Transportation Coatings (ASTM D7869, Use an ungrained
18、, non-polished, tool to prepare specimen for C through N gloss, use a smooth, polished tool to prepare specimens ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-B8 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 3 of 10 for A and B gloss, ISO 105-A02/AATCC Evaluation
19、 Procedure 1) Or 3.6.1.2 Performance Based Standard for Accelerated Requirements per Table Exposure of Automotive Exterior Materials Using Controlled Irradiance Xenon-Arc Apparatus (Boro/Boro, SAE J2527, Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilicate inner a
20、nd outer filters, 0.55 W/m2 radiant exposure monitored at 340 nm, Specimen C, ungrained, non-polished mold, use a smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) Type ASTM D7869 (preferred) SAE J2527 Boro/Boro Requirements New Color 2250 h 3000
21、 h Fade Resistance: Rating 4 min There shall be no cracking, chalking, wrinkling, crazing, iridescence, bloom, milkiness, separation, loss of adhesion (coating), or loss of embossment allowed (as defined in ASTM D1566). *New Material Supplier or New Material Grade 2250 h 3000 h Fade Resistance: Rati
22、ng 4 min There shall be no cracking, chalking, wrinkling, crazing, iridescence, bloom, milkiness, separation, loss of adhesion (coating), or loss of embossment allowed (as defined in ASTM D1566). 3000 h and 3750 h 4000 h, 5000 h, and 6000 h Fade Resistance: Report Only Report any cracking, chalking,
23、 wrinkling, crazing, iridescence, bloom, milkiness, separation, loss of adhesion (coating), or loss of embossment (as defined in ASTM D1566) 3.6.2 Outdoor Weathering of Exterior Materials - Florida Initial Qualification for new resin technology (SAE J1976, 5 South, direct weathering inland, ENGINEER
24、ING MATERIAL SPECIFICATION WSS-M4D556-B8 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 4 of 10 Specimen I, use an ungrained, non-polished, tool to prepare specimen for C through N gloss, use a smooth polished tool to prepare specimens for A and B gloss, ISO 105-A
25、02/AATCC Evaluation Procedure 1) 3.6.2.1 1 and 3 year Florida Rating 4 min Florida Submission Required for Approval to ASL 3.6.2.2 5 year Florida Report Only After exposure the material shall show no color change in excess of the specified AATCC Rating. In addition, there shall be no cracking, crazi
26、ng or other deterioration. A slight loss of gloss or chalking will be allowed provided an acceptable appearance can be achieved as specified below by washing with mild detergents and water (ratio 5:95 by volume) or equivalent after the outdoor exposure only. 3.6.3 Resistance to Scratch and Mar (FLTM
27、 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 ratio, colors, grain, etc can be fo
28、und in the approval package. 3.7 MATERIALS PROPERTIES 3.7.1 Determination of Ash 19.5 24.5 % (ISO 3451-1, Method A, 1h at 850 +/-50C, test portion 2 to 2.5g) 3.7.2 Density 1.02-1.10 g/cm3 (ISO 1183, Method A) 3.7.3 Tensile Strength at Yield 17.9 MPa, min (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.
29、0 +/- 0.2 mm specimen A, test speed: 50 mm/minute as noted below) 3.7.4 Tensile Modulus 1.9 GPa, min (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A test speed: 1 mm/min) 3.7.5 Flexural Modulus 1.7 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) ENGINEE
30、RING MATERIAL SPECIFICATION WSS-M4D556-B8 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 5 of 10 3.7.6 Impact Strength, Charpy, notched, typical (ISO 180/1A, specimen D) 3.7.6.1 At 23 +/- 2 C 4.0 kJ/m2 Report Break Type 3.7.6.2 At - 40 +/- 2 C 1.8 kJ/m2 Report Bre
31、ak Type The test specimen must be conditioned for a 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. 3.7.7 Heat Deflection Temperature 50.5C
32、 min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.7.8 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 120 +/- 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
33、shall be determined at the time of the aged properties determination) 3.7.8.1 Tensile Strength at Yield, Change +/- 25% max (Test Method per para 3.7.3) 3.7.8.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per para 3.7.6, specimens to be notched before Heat Aging) 3.7.9 Flammabil
34、ity (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.8 MATERIALS PROPERTIES - REPORT ONLY Values are retained in Ford Materials Database . 3.8.1 Melt Flow Rate Report Value, g/10 minutes (ISO 1133 230 C, 2.16 kg) 3.8.2 Molding Shrinkage (Report method used, sample size a
35、nd value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.8.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2 C) Plaque size is 100 x 150 minimum at 3.2 +/- 0.2 mm thickness. Plaque to be ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-B8 Contr
36、olled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 6 of 10 fan or edge gated. Specimens to be water jet or die cut from the center of plaque, minimum of three samples each direction. Conditioning procedure consists of steps 1-4. Start at 23 C. 1. Ramp 5 C/minute to -40 C 2
37、. Isothermal hold for 5 minutes 3. Ramp 5 C/minute to 110 C 4. Isothermal hold for 10 minutes Leave the test specimen in the equipment and run steps 5-7 5. Ramp 5 C/minute to -40 C 6. Isothermal hold for 10 minutes 7. Ramp 5 C/minute to 110 C Report CLTE value after Step 4 (un-annealed value) for bo
38、th Flow and Cross Flow directions. Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C Report CLTE value again after Step 7 (annealed value) for both Flow and Cross Flow directions. Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.8.4 Poissons Ratio Report Ra
39、tio (ISO 527-1 and ISO 527-2, Specimen A 1 mm/minute test speed) 3.8.5 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC CLTE Engineering Stress/Strain at 23 C 4. GENERAL INFORMATION The information given below is provided for clarification and as
40、sistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-B8 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 7 of 10 4.1 TYPICAL PROPERTIES USING
41、METHODS IN SECTION 3.8 Para. Test Typical Value Units 3.8.1 Melt Flow rate 17-27 g/10 min 3.8.2 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering) Flow Cross Flow 0.9 1.2 % % 3.8.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 8.
42、5 9.5 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.4 Poissons Ratio 0.43 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PP-TD22 (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-B8 Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 8 of 10 Table 1: Minimum Sample Si
43、ze 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 3.4.4 WSS-M98P13-E/latest Reference the Performance Specification 3.6.1 Weathering Resistance 1 1 1 3.6.2 1 , 3 a
44、nd 5 year Florida 1 3 3 3.6.3 Scratch Resistance 1 3 3 3.7.1 Determination of Ash* 3 1 3 1 1 1 3.7.2 Density 1 3 3 3.7.3 Tensile Strength 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 Strength Notched Charpy (per condition)* 3 10 30 1 10 10
45、 3.7.7 Heat Deflection Temperature* 3 2 6 1 2 2 3.7.8 Heat Aging Performance 3.7.8.1 Tensile Strength at Yield, Change 1 5 5 3.7.8.2 Impact Strength, Notched Charpy, Change 1 10 10 3.7.9 Flammability 1 5 5 3.8.1 Melt Flow Rate* 3 1 3 1 1 1 3.8.2 Mold Shrinkage 1 5 5 1 5 5 3.8.3 Coefficient of Linear
46、 Thermal Expansion (per condition) 1 3 3 3.8.4 Poissons Ratio 1 5 5 3.8.5 Curves - IR - TGA - DSC - CLTE - 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. ENGINEERING MATERIAL SPECIFICATION WSS-M4D556-B8 Controlled do
47、cument at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 9 of 10 Table 2: Minimum Color Property 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 En
48、gineering. The supplier shall submit a completed copy of their laboratory 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
49、 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 Plans, Certification testing) with Ford. 4.4 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which
