1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2018 05 14 Revised See Summary of Revisions H. Santos, SA 2018 03 08 Editorial See Summary of Revisions C. Saige, NA 2017 09 15 Relesed C. Saige, FNA Controlled document at www.MATS Copyright 2018 Ford Global Technologies, LLC Page 1
2、of 7 POLYETHYLENE (PE) HIGH DENSITY MOLDING COMPOUND, WSS-M4D695-B1 WASHER FLUID RESERVOIR 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 a blow molded high dens
3、ity polyethylene material used for windshield washer fluid reservoirs. 2.1 LIMITATIONS This material does not contain UV stabilizers, long term exposure to direct sunlight will cause chalking and loss of gloss. This material is susceptible to fluid stress cracking and high mold shrinkage. 3. REQUIRE
4、MENTS 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 list of approved sources is located within Ford at o
5、r 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% relative humidity. Testing of the material should occur in
6、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 designated material laboratory. The material supplier shall en
7、sure 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 resin specifications prior to 2011, identified certai
8、n 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 samples required for each test. ENGINEERING MATERIAL SPECI
9、FICATION WSS-M4D695-B1 Copyright 2018, Ford Global Technologies, LLC Page 2 of 7 3.4.2 The use of regrind is permitted, for economic / environmental reasons. Part manufacturers using this specification must complete DV and PV testing with the allowable amount of regrind and the maximum allowable reg
10、rind 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 Comany process (SREA). 3.4.3 Performance Criteria: Parts using this spec
11、ification shall meet the appropriate performance specifications, WSS-M15P50-C2/Latest. 3.4.4 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: Density Melt Flow Rate Impact Streng
12、th, Notched Charpy at 23 C Flexural Modulus 3.5 SAMPLE PREPARATION 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 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
13、 the center of Specimen A) Specimen E 100 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 All tests specimens shall be prepared from compression molded sheets to approximately 200 x 200
14、 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 on unannealed specimens. See Table 1 for the number of sampl
15、es required. 3.6 MATERIAL PROPERTIES 3.6.1 Melt Flow Rate 2.0 g/10 minutes max (ISO 1133 190 C, 5.0 kg) 3.6.2 Density 0.945 - 0.960 g/cm3 (ISO 1183, Method A) 3.6.3 Tensile Strength at Yield 20 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.6.4 Elongation at Yield 8.0% min
16、(ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WSS-M4D695-B1 Copyright 2018, Ford Global Technologies, LLC Page 3 of 7 3.6.5 Tensile Modulus 800 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.6.6 Flexural Modulus 1.0 GPa min
17、 (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.6.7 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.6.7.1 At 23 +/- 2 C 10 kJ/m2 min, Report Break Type 3.6.7.2 At -40 +/- 2 C 5 kJ/m2 min, Report Break Type The test specimen must be conditioned for minimum of 6 hour
18、s 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 Materials Engineering. 3.6.8 Heat Deflection Temperature 40 C min (ISO 75
19、-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.6.9 Heat Aging Performance (ISO 188, 1000 h at 90+/- 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 a
20、t the time of the aged properties determination) 3.6.9.1 Tensile Strength at Yield, Change +/- 15% max (Test Method per para 3.6.3) 3.6.9.2 Impact Strength, Notched Charpy, Change - 15% max (Test Method per para 3.6.7, specimens to be notched before Heat Aging) 3.6.10 Long Term Resistance to Fluids
21、(continuous use) (Impact Strength, Notched Charpy, ISO 179-1/1eA, Specimen D specimens to be notched before immersion) Test materials that will be continuously exposed to the fluids below. Record the time and temperature for each fluid exposure. Samples are to be immersed in the fluid for the time a
22、nd temperature specified. Report the loss of impact strength versus unaged values. Unaged samples shall be tested at the same time as the aged samples. If a Ford material specification is being used and already contains this data, this testing does not have to be performed. Proper safety precautions
23、 must be followed when handling hot and/or flammable fluids. ENGINEERING MATERIAL SPECIFICATION WSS-M4D695-B1 Copyright 2018, Ford Global Technologies, LLC Page 4 of 7 3.6.10.1 Windshield Washer Fluid Resistance - 25%, max (1000 h at 50 +/- 2 C, Motorcraft ZC-32 fluid, 1:1 dilution*) 3.6.11 Flammabi
24、lity (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.6.12 Standard Test Method for Environmental 400 h min, f50 Stress-Cracking of Ethylene Plastics (ASTM D1693, bath temperature 50 +/- 0.5 C, define reagent/surfactant) 3.7 MATERIAL PROPERTIES REPORT ONLY Values are ret
25、ained in Ford Materials Database (MSC) . 3.7.1 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.7.2 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2 C) Flow Report Value, E-5 mm/mm/
26、 C Cross Flow Report Value, E-5 mm/mm/ C 3.7.3 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.4 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
27、C, -40 C, and 90 C. ENGINEERING MATERIAL SPECIFICATION WSS-M4D695-B1 Copyright 2018, Ford Global Technologies, LLC Page 5 of 7 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions con
28、cerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.7 Para. Test Typical Value Units 3.7.1 Molding Shrinkage (Report method used, sample size and value) - After 48 h at 23 +/- 2 C Flow Cross Flow 2.0 - 3.0 1.6 - 2.0 % % 3.7.2 Coefficient of Linear Thermal E
29、xpansion Flow Cross Flow 14.8 16.6 Report E-5 mm/mm/ C E-5 mm/mm/ C 3.7.3 Poissons Ratio 0.43 N/A 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PE-HD (ISO1043/11469)ENGINEERING MATERIAL SPECIFICATION WSS-M4D695-B1 Copyright 2018, Ford Global Technologies, LLC Page 6 of 7 Table 1: Minimu
30、m Sample Size Initial Approval and/or Initial Approval in a New Region and New Manufacturing Location Approval for Recycled Materials Additional Manufacturing Location for Previously Approved Material Para. Test Min. Lots Specimens per Lot Total Test Specimens Min. Lots Specimens per lot Total Test
31、Specimens 3.4.3 WSS-M15P50-C2 Reference the Performance Specification 3.6.1 Melt Flow Rate 3 1 3 3 1 3 3.6.2 Density 1 3 3 1 3 3 3.6.3 Tensile Strength at Yield 3 5 15 1 5 5 3.6.4 Elongation at Yield 3 5 15 1 5 5 3.6.5 Tensile Modulus 1 10 10 3.6.6 Flexural Modulus* 3 10 30 1 10 10 3.6.7 Impact Stre
32、ngth Notched Charpy (per condition)* 3 10 30 1 10 10 3.6.8 Heat Deflection Temperature (per condition)* 3 2 6 1 2 2 3.6.9 Heat Aging Performance 3.6.9.1 Tensile Strength at Yield, Change 1 5 5 3.6.9.2 Impact Strength, Notched Charpy, Change 1 10 10 3.6.10 Long Term Resistance to Fluids 3.6.10.1 Wind
33、shield Washer Fluid Resistance 1 10 10 3.6.11 Flammability 1 5 5 3.6.12 Standard Method for Environmental Stress Cracking (PE-HD) 1 10 10 3.7.1 Mold Shrinkage 1 5 5 1 5 5 3.7.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.7.3 Poissons Ratio 1 2 2 1 2 2 3.7.4 Curves - IR - TGA - DS
34、C (first and second heat) - CLTE (3 flow and 3 cross flow) - Stress/Strain Curves at 23C, -40C, and 90C. 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-M4D695-B1 Copyright 2018, Ford Global Technolo
35、gies, LLC Page 7 of 7 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 Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed b
36、y 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 upon request and kept for a minimum of one year. Upon request, the supplier will review the ass
37、ociated 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 approval was originally granted. Prior to making any
38、changes to the material originally approved, whether or not such changes affect the materials 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 rea
39、sons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For 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
40、) sign off must be kept until Job 1. 4.5 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance 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 wh
41、ich is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2018 05 14 Revised Removed “Condition A” from ASTM test method in 3.6.12 2018 03 08 Editorial removed 150 +/- 50 air changes/h from 3.6.9
