1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 2 2015 11 11 Editorial See Summary of Revisions M. Corley, EU 2014 11 07 Editorial Editorial See Summary of Revisions L. Soreide, NA 2013 01 03 Released G. Eaton, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies
2、, LLC Page 1 of 8 POLYPROPYLENE (PP) WSS-M4D865-B5 20% LONG GLASS FIBER (9-13 mm) REINFORCED, STRUCTURAL, MOLDED IN COLOR, UV STABLE, INTERIOR 1. SCOPE The material defined by this specification is an injection molding compound composed of a polypropylene matrix, with 20% by weight long glass fiber
3、reinforcement with typical fiber length between 9-13 mm. 2. APPLICATION This specification was released originally for material used for U222/U228 Navigator/Expedition overhead consoles. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must con
4、form to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). Note: 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
5、 range was established using 3 sigma data. For 2011 and beyond, refer to Table 1 for number of samples required for each test to establish specification limits. 3.1.1 This specification is based on virgin materials, however materials with recycled content as defined by WRS-M99P42-A1 (post-consumer a
6、nd/or post industrial recyclates and repolymerised recycled materials) should be used whenever technically feasible. The use of regrind is permitted, for economic / environmental reasons, with compliance as indicated in WSS-M99P1111-A. 3.1.2 Materials used in interior applications must meet the requ
7、irements outlined in WSS-M99P2222-D1/Latest, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submission package. 3.1.3 Performance Criteria: Parts using this specification shall meet the appropriate performance specification, WSS-M
8、15P4-F/Latest. 3.1.4 As specified in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CoA) containing lot testing requirements which must include, but are not limited to: Melt Flow Rate Filler Content Impact Strength, Notched Charpy at
9、 23C Flexural Modulus ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B5 Copyright 2015, Ford Global Technologies, LLC Page 2 of 8 3.1.5 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
10、material supplier. Raw material supplier must be involved upfront for mold flow, CAE, and tooling design and should be present at all molding trials. Proper processing parameters should be used to obtain a resin rich surface and prevent glass fibers visible on the surface. WSS-M99D514-A1 is to be us
11、ed 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). 3.2 SAMPLE PREPERATION Unless otherwise specified all tests shall be carried out
12、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 Table 1 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-
13、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 mm diameter x 3.2 mm Specimen G 90 mm x 200 mm Specimen H 50 +/- 1 mm diameter x 3.2
14、+/- 0.2 mm Specimen I 100 mm x 150 mm, min 3.3 APPEARANCE 3.3.1 Gloss Rating 2-4, or as (FLTM BI 110-01, ASTM D 523 specified on molded from smooth polished mold, Specimen I) Engineering Drawing 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
15、 33 - 38 Medium G 17 - 23 H 7 - 13 J 4 - 6 Low K 2 - 4 L 0.5 - 2.0 N 1.8-2.4 *A use 20 degree, B-N use 60 degree ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B5 Copyright 2015, Ford Global Technologies, LLC Page 3 of 8 3.3.2 Weathering Resistance Rating 4 min (FLTM BO 116-01, 3609.6 kJ/m2 exposure
16、Specimen C from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) Every 526.4 kJ/m2 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
17、 exposure the material shall show no fading or color change in excess of the specified AATCC rating. In addition, there shall be no cracking, crazing or other deterioration. Use regional choice colors for initial approval and report the color house used. For color durability submissions, test all pr
18、ogram colors. 3.3.3 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 2 at 2 N, max These values are derived from colored and grained samples in agreement with Materials Engineering. Details regarding co
19、lor house, let down ratio, colors, grain, etc can be found in the approval package. 3.4 MATERIAL PROPERTIES 3.4.1 Glass Fiber Content, 18% - 22% (ISO 3451-1, Method A, 1h at 650 +/- 25C, test portion, 2 2.5g) 3.4.2 Density 1.01 1.05 g/cm3 (ISO 1183, Method A) 3.4.3 Tensile Strength at Break, 64 MPa
20、min (ISO 527-1 and ISO 527-2, Specimen A, test speed: 5 mm/minute) 3.4.4 Tensile Modulus 4.1 GPa min (ISO 527-1 and ISO 527-2, Specimen A, test speed: 1 mm/min) 3.4.5 Flexural Modulus 4.3 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WSS
21、-M4D865-B5 Copyright 2015, Ford Global Technologies, LLC Page 4 of 8 3.4.6 Impact Strength Notched Charpy (ISO 179-1/2, Specimen D) 3.4.6.1 At 23 +/- 2 C 14 kJ/m2 min Report Break Type 3.4.6.2 At -40 +/- 2 C 15 kJ/m2 min Report Break Type The test specimen must be conditioned for minimum of 6 hours
22、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. 3.4.7 Heat Deflection Temperature 152 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm defl
23、ection. At 1.80 MPa) 3.4.8 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 140 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.4.8.1 Tensile Strength at Break, Change +/- 25% max (Test Method per para 3.4.3) 3.4.8.2 Impact
24、Strength, Notched Charpy Change +/- 25% max (Test Method per para 3.4.6.1 specimens to be notched before Heat Aging) 3.4.9 Odor Rating 3 max (FLTM BO 131-03, Specimen G) 3.4.10 Fogging Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Numb
25、er 70 min Formation of clear film, droplets or crystals is cause for rejection. 3.4.11 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.5 MATERIAL PROPERTIES REPORT ONLY The information given below is provided for clarification and assistance in meeting the
26、requirements of this specification. ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B5 Copyright 2015, Ford Global Technologies, LLC Page 5 of 8 3.5.1 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C, Flow Report Value, % Cross Flow Report Value, % 3.5.2 Coefficie
27、nt of Linear Thermal Expansion (ISO 11359-2 TMA, temperature range -30 to +30 C) Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.5.3 Impact Strength, Notched Izod (ISO 180/1A, Specimen D) 3.5.3.1 At 23 +/- 2 C Report Value, kJ/m2 Report Break Type 3.5.3.2 At -40 +/- 2 C Repor
28、t Value, kJ/m2 Report Break Type The test specimens must be conditioned for min of 6 hours at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box, if not possible, test can be conducted outside, but within 5 seconds. 3.5.4 Poissons Ratio Re
29、port Ratio (ISO 527-1/2, Specimen A, 1 mm/minute test speed) 3.5.5 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 SPECIFICATION WSS-M4D865-B5 Copyright 2015, Ford Global Technologies,
30、LLC Page 6 of 8 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 TYPICAL PROPERTIES USING METHODS IN SECTION 3.5 Test Typical Va
31、lue Units 3.5.1 Molding Shrinkage (For specific method and sample size, contact Materials Engineering) 48 h at 23 +/- 2 C Flow Cross Flow 0.35-0.45 0.61-0.79 % % 3.5.2 Coefficient of Linear Thermal Expansion Flow Cross Flow 5.3 7.7 E-5 mm/mm/ C E-5 mm/mm/ C 3.5.3 Impact Strength, Notched Izod At 23
32、+/- 2 C At -40 +/- 2 C 19 19 kJ/m2 kJ/m2 3.5.4 Poissons Ratio 0.34 N/A ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B5 Copyright 2015, Ford Global Technologies, LLC Page 7 of 8 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PP-GLF20 (ISO 1043/11469) Table 1: Minimum Sample Size Initial Approval
33、 New Manufacturing Location for Previously Approved Material Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.1 WSS-M99P1111-A 3.1.2 WSS-M99P2222-D1/Latest Total Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See bel
34、ow for Odor and Fogging) 1 1 1 per test 3.3.1 Gloss 1 1 1 3.3.2 Weathering Resistance 1 1 1 3.3.3 Resistance to Scratch and Mar 1 3 3 3.4.1 Glass Fiber Content* 3 1 3 1 1 1 3.4.2 Density 1 3 3 3.4.3 Tensile Strength at Break* 3 5 15 1 5 5 3.4.4 Tensile Modulus 1 10 10 3.4.5 Flexural Modulus* 3 10 30
35、 1 10 10 3.4.6 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.4.7 Heat Deflection Temperature* 3 2 6 1 2 2 3.4.8 Heat Aging Performance 3.4.8.1 Tensile Strength at Break, Change 1 5 5 3.4.8.2 Impact Strength, Notched Charpy, Change 1 10 10 3.4.9 Odor 1 9 9 3.4.10 Fogging Photometr
36、ic 1 3 3 3.4.11 Flammability 1 5 5 3.5.1 Molding Shrinkage 1 5 5 1 5 5 3.5.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.5.3 Impact Strength, Notched Izod (per condition) 1 10 10 3.5.4 Poissons Ratio 1 2 2 3.5.5 Curves - FTIR - TGA - DSC - CLTE - Stress/Strain Curves 1 1 1 per te
37、st * For these requirements the 3 sigma value from the raw data is used to meet the requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M4D865-B5 Copyright 2015, Ford Global Technologies, LLC Page 8 of 8 Table 2: Color Property Testing 5. SUMMARY OF REVISIONS 11/11/2015 Corrected paragraph number i
38、n table 1. 11/7/2014 Corrected recycling code Para. Test Lots Specimens per Lot Total Test Specimens Color Test Direction 3.3.2 Weathering Resistance 1 1 1 Every color 3.3.3 Resistance to Scratch and Mar 1 3 3 As directed by Materials Engineering 3.4.3 Tensile Strength at Break 1 5 5 As directed by Materials Engineering 3.4.5 Flexural Modulus 1 10 10 As directed by Materials Engineering 3.4.6.1 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering 3.4.9 Odor 1 9 9 As directed by Materials Engineering 3.4.12 Flammability 1 5 5 Every color
