1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 04 2016 10 26 Revised See Summary of Revisions S. Werner, EU 2014 04 29 Revised See Summary of Revisions L. Soreide, NA 2013 02 18 Released M. Gramlich NA Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page
2、1 of 8 ACRYLONITRILE STYRENE ACRYLATE (ASA), WSS-M4D833-B1 MOLDED IN COLOR, MOLDING COMPOUND, LOW GLOSS, EXTERIOR 1. SCOPE The material defined by this specification is a molding compound based on acrylonitrile-styrene-acrylate (ASA). This material is a UV stabilized resin for parts that require goo
3、d surface appearance and weather resistance for low gloss exterior applications. 2. APPLICATION This specification was released originally for material used for exterior molded in color applications. 2.1 LIMITATIONS This material is not suitable for exterior mold in color applications with any gloss
4、 level above 20 due to not meeting weatherability requirements. 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
5、other documents. The 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
6、 and 50 +/- 5% relative 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
7、file at the designated 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 MAT
8、ERIALS 3.4.1 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 established using 3 sigma values. For 2011 and beyond, refer to Tabl
9、e 1 for number of samples required for each test. 3.4.2 This specification is based on virgin material and does not allow the addition of recycled content (PIR/PCR). ENGINEERING MATERIAL SPECIFICATION WSS-M4D833-B1 Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 2
10、of 8 3.4.3 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 regrind content must be specified on the engineering drawing. Any changes to wh
11、at is specified on the drawing (no specific amount implies zero regrind) must be approved by Materials and PD Engineering through the formal Ford Motor Company process (SREA) or Engineering Notice. 3.4.4 Performance Criteria: Exterior mold-in-color substrates approved to WSS-M4D833-B1 must comply wi
12、th all the requirements of WSS-M98P13-E/Latest. Parts must fulfill applicable SDS/CDS requirements. 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 not limited to: Melt Flow Rate (not for
13、 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 been reviewed and approved by Ford Mater
14、ials 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 6402-02. No annealing is allowed. See Table 1 and 2 for the number of specimens required.
15、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 mm diameter x 3.2 mm Specimen F 80
16、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 tool to prepare specimens for A and
17、 B gloss surfaces. 3.6 APPEARANCE 3.6.1 Accelerated Weathering Resistance 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, non-polished, tool to prepare specimen for C throug
18、h N gloss, use a smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) ENGINEERING MATERIAL SPECIFICATION WSS-M4D833-B1 Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 3 of 8 or 3.6.1.2 Performance Based Standard fo
19、r 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 and outer filters, 0.55 W/m2 radiant exposure monitored
20、 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 h Fade Resistance: Rating 4 min There shall be no cra
21、cking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss Change 25% max (FLTM BI 110-01) *New Material Supplier or New Material Grade 2250 h 3000 h Fade Resistance: Rating 4 min There shall be no cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss Change 2
22、5% max (FLTM BI 110-01) 3000 h and 3750 h 4000 h, 5000 h, and 6000 h Fade Resistance: Report Only Report any cracking, crazing, dulling, or other deterioration A & B Gloss Materials: Report Gloss Change (FLTM BI 110-01) *New Material Supplier or New Material Grade: New resin from unknown or known Ma
23、terial Supplier. New Manufacturing Locations (new GSDB) for previously approved materials and existing colors are not required to test exterior weathering. All initial approvals may be based on the above accelerated weathering exposure. Results from Florida Outdoor Weathering (3.6.2) takes precedenc
24、e over Accelerated Weathering. 3.6.2 Outdoor Weathering of Exterior Materials - Florida Initial Qualification for new resin technology ENGINEERING MATERIAL SPECIFICATION WSS-M4D833-B1 Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 4 of 8 (SAE J1976, 5 South, direc
25、t weathering inland, 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-A02/AATCC Evaluation Procedure 1) 3.6.2.1 1 and 3 year Florida Rating 4 min Florida Submission Required for Appr
26、oval 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, crazing or other deterioration. A slight loss of gloss or chalking will be allowed provided an acceptable appearance
27、 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 BO 162-01, Specimen I) Scratch Rating 2 at 2 N, max Whitening/Color Change Rating 1 at 7 N, max Marring Rating
28、 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 found in the approval package. 3.7 MATERIAL PROPERTIES 3.7.1 Density 1.05 1.10 g/cm3 (ISO 1183, Method A) 3.7.2 T
29、ensile Strength at Yield 42 MPa min (ISO 527-1 & ISO 527-2, specimen A, 50 mm/minute test speed) 3.7.3 Elongation at Yield 2% min (ISO 527-1 & ISO 527-2, specimen A, 50 mm/minute test speed) 3.7.4 Tensile Modulus 2.0 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.5 Flexura
30、l Modulus 2.0 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.7.6 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) ENGINEERING MATERIAL SPECIFICATION WSS-M4D833-B1 Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 5 of 8 3.7.6.1
31、 At 23 +/- 2 C 7.0 kJ/m2 min Report Break Type 3.7.6.2 At -40 +/- 2 C 1.5 kJ/m2 min Report Break Type 3.7.6.3 At 20 +/- 2 C 4.0 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 sh
32、all be done within the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. 3.7.7 Heat Deflection Temperature 77 C min (ISO 75-1 and ISO 75-2 Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) All specimens dry as molded. If not tested immediately after mol
33、ding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.7.8 Vicat Softening Temperature 94 C min (ISO 306, Specimen D, Bath - silicone oil, temperature raise 50 +/- 5 C/h. Dial gage reset to O after addition of 5 kg weight, at 50 N load) All specimens dry as mo
34、lded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.7.9 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 80 +/- 2 C. After heat aging test specimens are to be conditioned in a desiccator fo
35、r 3 - 5 h at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.7.9.1 Tensile Strength at Yield, Change +/- 25% (Test method per para 3.7.2) 3.7.9.2 Impact Strength, Notched Charpy, Change +/- 25% (Test Method per para 3.7.6.1, specimens to be
36、notched before heat aging) 3.7.10 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.8 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.8.1 Melt Flow Rate Report Value, g/10 minutes ENGINEERING MATERIAL SPECIFICATION WSS-M4D83
37、3-B1 Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 6 of 8 (ISO 1133 220 C,10.0 kg) The material shall be dried for 4 h minimum at 80 C in a mechanical convection oven immediately preceding the test. 3.8.2 Molding Shrinkage After 48 h at 23 +/- 2 C Flow Report Val
38、ue, % Cross Flow Report Value, % 3.8.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 100 +/- 2 C) Flow Report Value, E-5 mm/mm/ C Across Flow Report Value, E-5 mm/mm/ C 3.8.4 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.
39、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 assistance in meeting the requirements of this specification. Contact
40、 for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.5 Para. Test Typical Value Units 3.8.1 Melt Flow Rate 3 15 g/10 minutes 3.8.2 Molding Shrinkage (For specific method and sample size, contact Materials Engineering) After 48 h at 23 +/-
41、2 C Flow Cross Flow 0.4 0.7 0.4 0.7 % % 3.8.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 8.0 10.0 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.4 Poissons Ratio 0.39 N/A 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS ASA (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D833-B1 Cont
42、rolled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 7 of 8 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 su
43、bmit 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 the Material Specification. Tested material samples must be available for review upon request and kept for a mi
44、nimum 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
45、 upon which approval was originally granted. Prior to making any 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 M
46、aterials Engineering activities of the proposed changes (with reasons) 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), Produc
47、tion Verification (PV) and Production Part Approval Process (PPAP) 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 i
48、n the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 4.6 ADDITIONAL REQUIREMENTS Requirements beyond those explicitly stated in this document and the material specification may be specified on the Engineering drawing, Engineering specification (ES), performance specification, System Design Specification (SDS) and/or Attribute Requirement List (ARL). 5. SUMMARY OF REVISIONS 2016 10 26 Added limitations Adjustment to meet new M
