1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2018 02 26 Released Sandra Werner, EU Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 7 POLYPROPYLENE (PP) WSS-M4D865-B10 30% LONG GLASS FIBER REINFORCED, MOLDED IN COLOR, UV STABLE, INTERIOR 1.
2、SCOPE The material defined by this specification is a thermoplastic injection-molding compound based on a polypropylene matrix, with 30% by weight long glass fiber reinforcement with typical fiber length between 9-16 mm. 2. APPLICATION This specification was released originally for material used for
3、 interior Body Control Module (BCM) Covers. 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 other documents. The
4、 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 and 50 +/- 5% relat
5、ive 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 file at the designat
6、ed 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 MATERIALS 3.4.1 Many 4D
7、 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 and beyond, refer to Table 1 for number of samp
8、les 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). 3.4.3 The use of regrind is permitted, for economic / environmental reasons. Part manufacturers using this specification must complete DV and PV testing wit
9、h the allowable amount of regrind and the maximum allowable regrind content must be specified on the engineering drawing. Any changes to what is specified on the drawing (no specific amount implies zero ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B10 Copyright 2018, Ford Global Technologies, LLC P
10、age 2 of 9 regrind) must be approved by Materials and PD Engineering through the formal Ford Motor Company process (SREA) or Engineering Notice. 3.4.4 Materials requiring High Strain Rate, Creep or fiber oriented Tensile Modulus may be required to test to the requirements of WSS-M99D68-A1/Latest, Th
11、ermoplastic Property Determination For CAE, High Strain Rate Tensile, Creep and Tensile Modulus. Material Suppliers should be prepared to submit data upon request. 3.4.5 Performance Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS-M15P4-H/Latest 3.4
12、.6 Processing Criteria: Proper processing parameters and equipment should be used to preserve maximum fiber length in molded parts as specified and measured by the raw material supplier. Raw material supplier must be involved upfront for mold flow, CAE, and tooling design and should be present at al
13、l molding trial. WSS-M99D514-A1 is to be used for thermoplastic compounds using long glass fiber masterbatch pellets. WSS-M99D514-A2 is to be used for thermplastic compounds using Direct Long glass Fiber Technology (DLFT) or Injection Molding Compounding (IMC). 3.4.7 Ford Materials Engineering may r
14、equest 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 23C Flexural Modulus 3.5 SAMPLE PREPARATION All tests shall be carried out on production materials manufactured
15、 from the production process unless correlation to a non-production process has been reviewed and approved by Ford Materials 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 mold
16、ing conditions defined in ISO 1873-2. No annealing is allowed. See Tables 1 and 2 for the number of samples required. 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 S
17、pecimen D 80 x 10 x 4.0 +/- 0.2 mm (may be cut from 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 3.6 APPEARANCE 3.6.1 Gloss Rating 2-4 or as
18、(FLTM BI 110-01, ASTM D523, specified on Specimen I) Engineering Drawing ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B10 Copyright 2018, Ford Global Technologies, LLC Page 3 of 9 Gloss Description Gloss Code* Gloss Level Very High A 92 min B 76 - 84 High C 66 - 74 D 58 - 66 E 47 - 53 F 33 - 38 Med
19、ium G 17 - 23 H 7 - 13 J 4 - 6 Low K 2 - 4 L 0.5 - 2.0 N 1.8-2.4 P 1.6-2.0 Q 3.8-4.2 S 0.0-0.8 *A use 20 degree, B-N use 60 degree 3.6.2 Weathering Resistance Rating 4 min (FLTM BO 116-01, 2406.4 kJ/m2 exposure Specimen C, ungrained, non-polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) 3.6
20、.2.1 Tackiness Evaluation Every week* remove the samples from the weatherometer and allow them to cool for one hour. Conduct a tactile evaluation and report any tackiness. Visually evaluate and report any spewing or other exudation. After exposure the material shall show no fading or color change in
21、 excess of the specified AATCC rating. In addition, there shall be no cracking, crazing or other deterioration. Use regional choice for initial approval and report the color house used. See Table 2 for additional color durability submission requirements. *When setting machine for automatic shutoff,
22、every 526.4 kJ/m2 is recommended. 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 10 N, max Marring Rating 2 at 2 N, max These values are derived from colored and grained samples in agreement with Materials Engineering.
23、 Details regarding color house, let down ratio, colors, grain, etc. can be found in the approval package. 3.7 MATERIAL PROPERTIES 3.7.1 Determination of Ash 28% - 33% (ISO 3451-1, Method A, 1h at 650 +/- 25C, test portion, 2 2.5g) 3.7.2 Density 1.10 1.15 g/cm3 (ISO 1183, Method A) ENGINEERING MATERI
24、AL SPECIFICATION WSS-M4D865-B10 Copyright 2018, Ford Global Technologies, LLC Page 4 of 9 3.7.3 Tensile Strength at Break 79 MPa min (ISO 527-1 At 23 +/- 2 C 26 kJ/m2 3.8.5.2 Impact Strength, Notched Izod; At -40 +/- 2 C 27 kJ/m2 3.8.7 Poissons Ratio 0.34 N/A 4.2 MATERIAL IDENTIFICATION FOR RECYCLIN
25、G PURPOSES PP-GLF30 (ISO 1043/ISO 11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B10 Copyright 2018, Ford Global Technologies, LLC Page 7 of 9 Table 1: Minimum Sample Size Initial Approval and/or Initial Approval in a New Region Additional Manufacturing Location for Previously Approved Materia
26、l Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4.4 Thermoplastic Property Determination For CAE WSS-M99D68-A1 Reference the Performance Specification 3.4.5 WSS-M15P4-H Reference the Performance Specification 3.6.1 Gloss 1 1 1 3.6.2 Weat
27、hering Resistance 1 1 1 3.6.2.1 Tackiness on weathered samples 1 1 1 3.6.3 Resistance to Scratch and Mar 1 3 3 3.7.1 Glass Fiber Content 3 1 3 1 1 1 3.7.2 Density 1 3 3 3.7.3 Tensile Strength at Break* 3 5 15 1 5 5 3.7.4 Tensile Modulus 1 10 10 3.7.5 Flexural Modulus* 3 10 30 1 10 10 3.7.6 Impact St
28、rength Notched Charpy (per condition)* 3 10 30 1 10 10 3.7.7 Heat Deflection Temperature at 1.8 MPa* 3 2 6 1 2 2 3.7.8 Heat Aging Performance 3.7.8.1 Tensile Strength at Break, Change 1 5 5 3.7.8.2 Impact Strength, Notched Charpy, Change 1 10 10 3.7.9 Odor 1 9 9 3.7.10 Fogging Photometric 1 3 3 3.7.
29、11 Flammability 1 5 5 3.8.1 Elongation at Break 3 5 15 1 5 5 3.8.2 Heat Deflection Temperature at 0.45 MPa 3 2 6 1 2 2 3.8.3 Mold Shrinkage 1 5 5 1 5 5 3.8.4 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.8.5 Impact Strength, Notched Izod (per condition) 1 10 10 3.8.6 Melt Temperatu
30、re 3 1 3 3.8.7 Poissons Ratio 1 2 2 3.8.8 Curves - IR - TGA - DSC (first and second heat) - CLTE (3 flow and 3 cross flow) - Stress/Strain Curves (23 C, -40 C and 140 C) 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements. ENGINEERING MATERIAL
31、 SPECIFICATION WSS-M4D865-B10 Copyright 2018, Ford Global Technologies, LLC Page 8 of 9 Table 2: Minimum Color Property Testing - Contact Materials Engineering for Color Test Work Plan 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of intere
32、st from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representativeof the test facility, demonstrating full compliance with all the requirements of the Material
33、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 associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.4 SUPPLI
34、ERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material 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 requireme
35、nts, 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 for Engineering Approval, SREA. For parts and components using Ford Engineering Mate
36、rial 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 SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Compan
37、y 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 responsibility to comply with this standard on a continuing basis through IMDS and or GMAP rep
38、orting. Para. Test Lots Specimens per Lot Total Test Specimens Color Test Direction 3.6.2 Weathering Resistance (excluding 3.6.2.1) 1 1 1 Every color 3.7.3 Tensile Strength at Break 1 5 5 As directed by Materials Engineering 3.7.5 Flexural Modulus 1 10 10 As directed by Materials Engineering 3.7.8.2
39、 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering 3.6.3 Resistance to Scratch and Mar 1 3 3 As directed by Materials Engineering 3.7.11 Flammability 1 5 5 As directed by Materials Engineering 3.7.9 Odor 1 9 9 As directed by Materials Engineering ENGINEERING
40、MATERIAL SPECIFICATION WSS-M4D865-B10 Copyright 2018, Ford Global Technologies, LLC Page 9 of 9 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
