1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 2 2013 04 25 Revised Editorial, corrected Recycling code Y. Bankowski, NA 2009 12 10 Revised Changed MFR from 14-21 to 14-23 so that 3rd source (Wash Penn) can be added Y. Bankowski, NA 2009 04 14 Activated Y. Bankowski, FNA Controlled d
2、ocument at www.MATS Copyright 2013, Ford Global Technologies, LLC Page 1 of 6 POLYPROPYLENE (PP) COPOLYMER MOLDING COMPOUND, MOLD-IN-COLOR, WSS-M4D638-D2 LOW GLOSS, UV STABILIZED, HIGH IMPACT AT COLD TEMPERATURE, INTERIOR 1. SCOPE The material defined by this specification is a molded-in-color low g
3、loss, polypropylene copolymer that is UV stabilized for unpainted interior door trim applications with excellent cold impact and thermal performance. 2. APPLICATION This specification was released originally for material used for interior door trim applications with airbags requiring excellent cold
4、impact performance. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1.1 All requirements of this specification, identified by symbol (s), shall be
5、met with data representing 3 sigma values using latest ISO test methods. 3.1.2 This specification is based on virgin materials, however materials with recycled content as defined by WSS-M99P42-A (post-consumer and/or post industrial recyclates and repolymerised recycled materials) should be used whe
6、never technically feasible and following all materials and PV testing required by Ford Materials Engineering. The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in WSS-M99P1111-A. Critical Process Parameters At the request of Ford Materials Engineerin
7、g the supplier shall be responsible to collect critical process control data on each lot of material produced. Testing required will be jointly developed between Ford Materials Engineering and the supplier based on Control Plan and PFMEA review at the time of initial approval. Annually the supplier
8、will review the in process data with Ford Materials Engineering to show that the process has remained under control. The data needs to be submitted in January for the previous calendar year. Data showing poor quality control measures or lack of submitted data may result in deletion from the Ford App
9、roved Source List. 3.2 MOLDING COMPOUND (s) 3.2.1 Melt Flow Rate 14 - 23 g/10 minutes (ISO 1133, 230 C, 2.16 kg) ENGINEERING MATERIAL SPECIFICATION WSS-M4D638-D2 Copyright 2013, Ford Global Technologies, LLC Page 2 of 6 3.3 MOLDED TEST SPECIMEN 3.3.1 Preparation of Test Specimens Unless otherwise sp
10、ecified 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 527-2, specimen 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
11、 be molded using molding conditions defined in ISO 1873-2. Specimens with shorter dimensions shall be cut from the center of the specimen A. No annealing allowed. 3.3.2 Density 0.89 - 0.91 g/cm3 (ISO 1183, Method A) (s) 3.3.3 Tensile Strength at Max Load, min 18 MPa (ISO 527-1 150 x 10 x 4 mm specim
12、en A). Test speed shall be 50 mm/minute for all materials. Provide a curve of tensile stress versus strain using one specimen per lot at each of the following temperatures: -40 C, 23 C and 80 C. For ductile materials, the curve shall cover strain through yield point. (s) 3.3.5 Tensile Modulus 0.8 GP
13、a (ISO 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A test speed 5 mm/min) 3.3.6 Impact Strength, Izod, notched, 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) (s) 3.3.6.1 At 23 +/- 2 C 9.0 kJ/m2 (s) 3.3.6.2 At -40 +/
14、- 2 C 3.0 kJ/m2 The test specimens must be conditioned for min of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box, if not possible, test can be conducted outside, but within 5 s. ENGINEERING MATERIAL SPECIFICATION WSS-M4D638-D2 C
15、opyright 2013, Ford Global Technologies, LLC Page 3 of 6 (s) 3.3.7 Flexural Modulus, min 850 MPa (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) (s) 3.3.8 Heat Deflection Temperature, min 46 C (ISO 75-1 & ISO 75-2, 80 x 10 x 4.0
16、+/- 0.2 mm specimen use center section of specimen A, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.3.9 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 130 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.3.9.1
17、 Tensile Strength at Max Load Change +/- 25% (Test Method per para 3.3.3) 3.3.9.2 Impact Strength, Izod Change, max +/- 25% (Test Method per para 3.3.6.1, specimens to be notched before heat aging) 3.4 ODOR, max Rating 3 (FLTM BO 131-03) 3.5 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling pla
18、te, post test conditioning 16 h) Fog Number, min 90 Formation of clear film, droplets or crystals is cause for rejection. 3.6 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355 x 100 x 1.0 +/- 0.1 mm (use specimen C) with a smooth su
19、rface. 3.7 WEATHERING RESISTANCE After exposure in accordance with 3.7.1 the material shall show no fading or color change in excess of specified Gray Scale rating (AATCC Evaluation Procedure 1/ISO 105-A02). In addition, there shall be no cracking, crazing or other deterioration. ENGINEERING MATERIA
20、L SPECIFICATION WSS-M4D638-D2 Copyright 2013, Ford Global Technologies, LLC Page 4 of 6 3.7.1 Filtered Xenon Arc Weatherometer, min Rating 4 (FLTM BO 116-01, 2481.6 kJ/m2 exposure monitored at 420 nm, specimen size: 150 x 100 mm min, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) Use current
21、program black, grey and tan colors for initial approval, 3.8 IMPACT STRENGTH, MULTIAXIAL, MIN (ASTM D 3763, 100 mm diameter x 3.2 mm thick smooth surface injection molded specimen) 3.8.1 At 23 +/- 2 C 18.0 J 3.8.2 At -30 +/- 2 C 24.0 J Note: For WSS-M4D638-D2, material must be ductile at -30C. Impac
22、t velocity: 6.6 m/s for materials used in interior applications only Report test data for 23 +/- 2 C, and the lowest of the following temperatures in which a minimum of 24 out of 30 ductile failures were observed: -40 +/- 2 C, or -30 +/- 2 C, or -15 +/- 2 C, or 0 +/-2 C, and 23 +/- 2 C. Test specime
23、ns must be conditioned for minimum of 6 h at test temperature prior to impact testing. Low temperature testing shall be conducted within the same environmental chamber as the clamp mechanism of the impact device. Specimens can be transported from the conditioning environment to the testing environme
24、nt, provided the transfer is within 5 seconds. Test a minimum of 10 specimens from 3 individual lots at a single condition. A ductile failure is defined as a crack that does not radiate more than 10 mm from the center of the impact point. 4. GENERAL INFORMATION The information given below is provide
25、d for clarification and assistance in meeting the requirements of this specification. 4.1 COEFFICIENT OF LINEAR THERMAL EXPANSION (ISO 11359-2 TMA, temperature range -30 to +30 C) Axial 9.8 E-05 /C Transverse 10.3 E-05 /C 4.2 MOLD SHRINKAGE (ISO 294-3 and 294-4, 60 x 60 x 2.0 +/- 0.1 mm injection mo
26、lded specimen B) 4.2.1 Molding Shrinkage After 48 h at 23 +/- 2 C, Flow Direction 1.2% - 1.6% After 48 h at 23 +/- 2 C, Cross Flow Direction 1.2% - 1.6% ENGINEERING MATERIAL SPECIFICATION WSS-M4D638-D2 Copyright 2013, Ford Global Technologies, LLC Page 5 of 6 4.3 RECYCLING CODE (ISO 1043) PP ENGINEERING MATERIAL SPECIFICATION WSS-M4D638-D2 Copyright 2013, Ford Global Technologies, LLC Page 6 of 6
