1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 3 2017 07 26 Revised Added B5,See Summary of revisions A. Weatherhead, EU 2013 09 09 Revised See Summary of revisions H. Santos, SA 2012 08 27 Released V. Cerato, FoE Controlled document at www.MATS Copyright 2017, Ford Global Technologi
2、es, LLC Page 1 of 8 POLYPROPYLENE (PP) HOMOPOLYMER, 30% GLASS FIBER REINFORCED, WSS-M4D854-B1 MOLDING COMPOUND POLYPROPYLENE (PP), 30% GLASS FIBER REINFORCED, WRS-M4D854-B2 MOLDING COMPOUND, 25% RECYCLED MATERIAL BY WEIGHT POLYPROPYLENE (PP), 30% GLASS FIBER REINFORCED, WRS-M4D854-B3 MOLDING COMPOUN
3、D, 50% RECYCLED MATERIAL BY WEIGHT POLYPROPYLENE (PP), 30% GLASS FIBER REINFORCED, LOW FOGGING, WRS-M4D854-B5 MOLDING COMPOUND, 50% RECYCLED MATERIAL BY WEIGHT 1. SCOPE The material defined by this specification is a thermoplastic injection molding compound based on polypropylene 30% coupled glass f
4、iber reinforced. B2 - POLYPROPYLENE (PP), 30% GLASS FIBER REINFORCED, MOLDING COMPOUND, 25% RECYCLED MATERIAL BY WEIGHT Type of Material % Material Type by Weight Recycled Resin PCR/PIR 25 Virgin Resin 45 Glass Fiber 30 Minimum % Recycled Material 25 B3/4 - POLYPROPYLENE (PP), 30% GLASS FIBER REINFO
5、RCED, MOLDING COMPOUND, 50% RECYCLED MATERIAL BY WEIGHT (STANDARD AND LOW FOGGING) Type of Material % Material Type by Weight Recycled Resin PCR/PIR 50 Virgin Resin 20 Glass Fiber 30 Minimum % Recycled Material 50 2. APPLICATION WSS-M4D854-B1 This specification is released for material used for batt
6、ery trays and fan shrouds. WRS-M4D854-B2/B3 These specifications are released for materials containing post consumer and/or post-industrial recycled content. WRS-M4D854-B5 This specification is released for recycled content material used for headlamp housings. ENGINEERING MATERIAL SPECIFICATION WSS-
7、M4D854-B1 / WRS-M4D854-B2/B3/B5 Copyright 2017, Ford Global Technologies, LLC Page 2 of 8 2.1 LIMITATIONS These specifications are not for visible interior applications. Use only the B5 specification for Exterior Lighting Applications. For applications that have a direct impact on the interior air q
8、uality, such as heater and A/C unit use the B5 specification and include the odor test (FLTM BO 131-03, Variant C). 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is part of the Ford Co-Managed Buy (CMB) agreement. Tier 1 molders who are participating under the CMB agreement must use one th
9、e following approved sources (deviations require approval from Raw Materials Purchasing and Materials Engineering): Specification North American Programs European Programs WSS-M4D854B1 Washington Penn, PPH4GF3 Lyondell Basell / Equistar, Hostacom G3 Washington Penn, PPH4GF3 WRS-M4D854-B2 Washington
10、Penn, PRC25GF3 Washington Penn, PRC25GF3 WRS-M4D854-B3 Washington Penn, PRC50GF3 Wellman Ecolon, PP8002 Washington Penn, PRC50GF3 Molders not on the CMB program or regions without CMB are required to use materials listed on the Ford Approved Source List (ASL), and are encouraged to use the CMB sourc
11、es listed above. Only the sources identified on the Approved Source List 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 or available externally through a Ford Materials Engineer. Approval of new sour
12、ces requires the completion of the latest version of the FMD template. Data should be submitted at the time as the specification data package. Only one FMD package is required per trade name approved, FMD is not required for each manufacturing site. FMD is required for new site approvals that do not
13、 have an existing FMD record 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 the conditioning environment
14、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 ensure that all future material
15、 supplied to the specification shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. ENGINEERING MATERIAL SPECIFICATION WSS-M4D854-B1 / WRS-M4D854-B2/B3/B5 Copyright 2017, Ford Global Technologies, LLC Page 3 of 8 3.4 STANDARD REQUI
16、REMENTS FOR PRODUCTION MATERIALS 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 data. For 2011 a
17、nd beyond, refer to Table 1 for number of samples required for each test to meet specification limits. 3.4.2 WSS-M4D854-B1 is based on virgin materials. 3.4.3 WRS-M4D854-B2 and B3/B4 must contain 25% and 50% Post Consumer (PCR) and/or Post Industrial (PIR) recycled content respectively, as defined b
18、y WRS-M99P42-A1. The remaining portion of the material can come from virgin sources. 3.4.4 The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in Ford Engineering CAD and Drafting Standard E-4. 3.4.5 Performance Criteria: Parts using this specification
19、 shall meet the appropriate performance specifications. 3.4.6 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: Filler Content Impact Strength, Notched Charpy at 23 C Flexural Mod
20、ulus 3.5 SAMPLE PREPARATION 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 for the number of samples re
21、quired. 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 Specim
22、en 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 3.6 MATERIAL PROPERTIES 3.6.1 Glass Fiber Content 27-33 % (ISO 3451-1, Method A, 1h at 750 +/-25C, test portion 1 to 2g) 3.6.2 Density 1.08-1.21 g/cm3 (ISO 1183, Me
23、thod A) ENGINEERING MATERIAL SPECIFICATION WSS-M4D854-B1 / WRS-M4D854-B2/B3/B5 Copyright 2017, Ford Global Technologies, LLC Page 4 of 8 3.6.3 Tensile Strength at break 55 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.6.4 Elongation at break 1.5 % min (ISO 527-1 and ISO 52
24、7-2, Specimen A, 50 mm/minute test speed) 3.6.5 Tensile Modulus 4.0 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.6.6 Flexural Modulus 4.0 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.6.7 Impact Strength, Notched Charpy (ISO 179-1/2, Specimen
25、D) 3.3.7.1 At 23 +/- 2 C 6.0 kJ/m2 min Report Break Type 3.3.7.2 At -40 +/- 2 C 3.1 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 not
26、possible, test may be conducted outside, but within 5 seconds. 3.6.8 Heat Deflection Temperature 130 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.6.9 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 140/- 2 C. After heat aging tes
27、t 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 Strength at break, Change +/- 25% max (Test Method per para 3.3.3) 3.3.9.2 Impact Strength, Notched Charpy, Change
28、 +/- 25% max (Test Method per para 3.3.7.1, specimens to be notched before Heat Aging) 3.6.10 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max ENGINEERING MATERIAL SPECIFICATION WSS-M4D854-B1 / WRS-M4D854-B2/B3/B5 Copyright 2017, Ford Global Technologies, LLC
29、Page 5 of 8 3.6.11 Fogging Photometric, (B5 grade only for exterior lighting), (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 90 min Formation of clear film, droplets or crystals is cause for rejection. 3.7 MATERIAL PROPERTIES REPORT ONLY Va
30、lues are retained in Ford Materials Database . 3.7.1 Melt Flow Rate Report Value, g/10 (ISO 1133, 230 C, 2.16 kg) minutes 3.7.2 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.7.3 Coefficient of Linear Thermal E
31、xpansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2 C) Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.7.4 Impact Strength, Notched Izod (ISO 180/1A, Specimen D) 3.7.4.1 At 23 +/- 2 C Report Value kJ/m2 Report Break Type 3.7.4.2 At -40 +/- 2 C Report Value kJ/m2 Report Break Type
32、 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 not possible, test may be conducted outside, but within 5 seconds. 3.7.5 Poissons Ratio Report Ratio (ISO 527-1 and
33、 ISO 527-2, Specimen A 1 mm/minute test speed) 3.7.6 Heat Deflection Temperature Report Value C (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 0.45 MPa) ENGINEERING MATERIAL SPECIFICATION WSS-M4D854-B1 / WRS-M4D854-B2/B3/B5 Copyright 2017, Ford Global Technologies, LLC
34、Page 6 of 8 3.7.7 The following curves are to be submitted with the data packages: FTIR TGA DSC CLTE Engineering Stress/Strain at -40 C, 23 C and 120 C. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification.
35、Contact for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.7 Para. Test Typical Value Units 3.7.1 Melt Flow Rate 2.4-14 g/10 minutes 3.7.2 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials
36、Engineering) Flow Cross Flow 0.2 1.2 % % 3.7.3 Coefficient of Linear Thermal Expansion Flow Cross Flow 2 12 E-5 mm/mm/ C E-5 mm/mm/ C 3.7.4 Impact Strength, Notched Izod (ISO 180/1A, Specimen D) At 23 +/- 2 C At -40 +/-2 C 7 3.1 kJ/m2 kJ/m2 3.7.5 Poissons Ratio 0.4 3.7.6 Heat Deflection Temperature
37、At 0.45 MPa 145 C 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PP-GF30 (ISO 1043 Latest) ENGINEERING MATERIAL SPECIFICATION WSS-M4D854-B1 / WRS-M4D854-B2/B3/B5 Copyright 2017, Ford Global Technologies, LLC Page 7 of 8 Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for
38、 Previously Approved Material Para. Test Min Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.6.1 Filler Content* 3 1 3 1 1 1 3.6.2 Density 1 3 3 1 3 3 3.6.3 Tensile Strength at Break* 3 5 15 1 5 5 3.6.4 Elongation at Break 3 5 15 1 5 5 3.6.5 Tensile Modulus
39、1 10 10 3.6.6 Flexural Modulus* 3 10 30 1 10 10 3.6.7 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.6.8 (3.7.6) Heat Deflection Temperature* 3 2 6 1 2 2 3.6.9 Heat Aging Performance 3.6.9.1 Tensile Strength at break, Change 1 5 5 3.6.9.2 Impact Strength, Notched Charpy, Change 1
40、10 10 3.6.10 Flammability 1 5 5 3.6.11 Fogging 1 3 3 3.6.1 Melt Flow Rate 3 1 3 3.6.2 Mold Shrinkage 1 5 5 1 5 5 3.6.3 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.6.4 Impact Strength, Notched Izod (per condition) 1 10 10 3.6.5 Poissons Ratio 1 2 2 3.6.7 Curves - IR - TGA - DSC -
41、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. 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Developme
42、nt, and Materials Engineering. The supplier shall submit 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
43、 available for review 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
44、be equivalent in all characteristics to the material upon which approval was originally granted. ENGINEERING MATERIAL SPECIFICATION WSS-M4D854-B1 / WRS-M4D854-B2/B3/B5 Copyright 2017, Ford Global Technologies, LLC Page 8 of 8 Prior to making any changes to the material originally approved, whether o
45、r 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 reasons) by submission of a completed Suppliers Request f
46、or 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) sign off must be kept until Job 1. 4.5 RESTRICTED SU
47、BSTANCE 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 which is updated yearly. It is the suppliers responsibil
48、ity 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
49、specification, System Design Specification (SDS) and/or Attribute Requirement List (ARL). 5. SUMMARY OF REVISIONS 2017 07 26 Released B5 suffix, Added para 3.3.11 Fogging requirement, updated recycled definitions and added tables and updates to latest M4D template. 2013 09 09 Change Para 3.3.7.2 from 3.5 kJ/m2 to 3.1 kJ/m2 and 4.1 Impact Strength, Notched Izod At -
