1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 1 2015 02 16 Revised See summary of revisions G.Kowalski, NA 2013 09 09 Released G. Kowalski, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 5 POLYETHYLENE (PE) HIGH DENSITY MOLDING COMPOUND, W
2、SS-M4D645-B1 MONOWALL FUEL TANK 1. SCOPE The material defined by this specification is a thermoplastic high density molding compound based on polyethylene. 2. APPLICATION This specification was released originally for material used for monowall fuel tanks. 2.1 LIMITATIONS This material does not cont
3、ain UV stabilizers, long term exposure to direct sun light will cause chalking and loss of gloss. This material is susceptible to fluid stress cracking and high mold shrinkage. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to th
4、e Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.1.1 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. The specification minimum, maximum or range was
5、 established using 3 sigma data. For 2011 and beyond, refer to Table 1 for number of samples required for each test. 3.1.2 This specification is based on virgin materials, however materials with recycled content as defined by WRS-M99P42-A1 (post-consumer and/or postindustrial recyclates and repolyme
6、rised recycled materials) should be used whenever technically feasible and following all materials and PV testing required by Ford Materials Engineering. 3.1.3 The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in Ford Engineering CAD and Drafting Sta
7、ndard E-4 3.1.4 Performance Criteria: Parts using this specification shall meet the appropriate performance specification, WSS-M15P50-B/Latest. 3.1.5 As specified in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CoA) containing lot
8、testing requirements which must include, but are not limited to: ENGINEERING MATERIAL SPECIFICATION WSS-M4D645-B1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 5 Melt Flow Rate Impact Strength, Notched Charpy at 23C Flexural Modulus 3.2 SAMPLE PREPARATION All tests specimens shall be prepa
9、red from compression molded sheets to approximately 400 x 200 x 4.0 +/- 0.2 mm unless otherwise specified. Preparation of compression molded sheets according to ISO 293, except; aluminum foil, 180 - 200 C molding temperature, 15 +/- 2 C/minute cooling rate. The values of this specification are based
10、 on unannealed specimens. See Table 1 for the number of samples required. Specimens shall be defined 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 D center of specimen A, 80 x 10 x 4.0 +/- 0.2 mm) 3.3
11、MATERIAL PROPERTIES 3.3.1 Melt Flow Rate 4.1 6.8 g/10 minutes (ISO 1133 190 C, 21.6 kg) 3.3.2 Density 0.943 0.949 g/cm3 (ISO 1183, Method A) 3.3.3 Tensile Strength at Yield 20 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.3.4 Elongation at Yield 8 % min (ISO 527-1 and ISO
12、527-2, Specimen A, 50 mm/minute test speed) 3.3.5 Tensile Modulus 0.86 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.3.6 Flexural Modulus 0.58 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.3.7 Impact Strength, Notched Charpy (ISO 179-1/1eA, Spe
13、cimen D) 3.3.7.1 At 23 +/- 2 C 20 kJ/m2 min Report Break Type 3.3.7.2 At -40 +/- 2 C 6.5 kJ/m2 min 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
14、 not possible, test may be conducted outside, but within 5 seconds. ENGINEERING MATERIAL SPECIFICATION WSS-M4D645-B1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 5 3.3.8 Heat Deflection Temperature 37 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80
15、MPa) 3.3.9 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 shall be determined at the time of the aged properties determination) 3.3.9.1 Tensile S
16、trength at Yield, Change +/- 15% max (Test Method per para 3.3.3) 3.3.9.2 Impact Strength, Notched Charpy, Change - 15% max (Test Method per para 3.3.7.1, specimens to be notched before Heat Aging) 3.3.10 Flammability 100 mm/minute max ISO 3795/SAE J369, Specimen B, smooth surface) 3.4 MATERIAL PROP
17、ERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.4.1 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.4.2 Coefficient of Linear Thermal Expansion Report Value, E-5 mm/mm/ C (ISO 11359-2, -30
18、+/- 2 C to 100 +/- 2 C) 3.4.3 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.4.4 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC CLTE Engineering Stress/Strain at 23 C ENGINEERING MATERIAL SPECIFICATI
19、ON WSS-M4D645-B1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 5 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 TYP
20、ICAL PROPERTIES USING METHODS IN SECTION 3.4 Para. Test Typical Value Units 3.4.1 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering) Flow Cross Flow 3.5 1.5 % % 3.4.2 Coefficient of Linear Thermal Expansion 93 E-5 mm/mm/ C 3.4.3 Poissons R
21、atio 0.42 N/A 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PE-HD (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D645-B1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 5 Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Previously Approved
22、Material Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 3.1.4 WSS-M15P50-B Reference the Performance Specification 3.3.1 Melt Flow Rate* 3 1 3 1 1 1 3.3.2 Density 1 3 3 1 3 3 3.3.3 Tensile Strength at Yield* 3 5 15 1 5 5
23、3.3.4 Elongation at Yield* 3 5 15 1 5 5 3.3.5 Tensile Modulus 1 10 10 3.3.6 Flexural Modulus* 3 10 30 1 10 10 3.3.7 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.3.8 Heat Deflection Temperature* 3 2 6 1 2 2 3.3.9 Heat Aging Performance 3.3.9.1 Tensile Strength at Yield, Change 1
24、5 5 3.3.9.2 Impact Strength, Notched Charpy, Change 1 10 10 3.3.10 Flammability 1 5 5 3.4.1 Mold Shrinkage 1 5 5 1 5 5 3.4.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.4.3 Poissons Ratio 1 2 2 1 2 2 3.4.4 Curves - IR - TGA - DSC - CLTE - Stress/Strain Curves 23C) 1 1 1 per test
25、* For these requirements the 3 sigma value from the raw data is used to meet the requirements. 5. SUMMARY OF REVISIONS 2015 02 16 - para. 3.3.7.2 Charpy at -40 C, revised minimum from 7 to 6.5 - para. 3.4.2 Coefficient of Linear Expansion, revised max temp from 120 C to 100 C to agree with other HDPE specs.
