1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 0 2015 04 28 Released M. Corley, EU Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 8 POLYCARBONATE + POLYETHYLENE TEREPHTHALATE WSS-M4D879-B2 BLEND (PC + PET), FULLY PAINTED, MOLDING COMPOUND, EXTE
2、RIOR 1 SCOPE The material defined by this specification is a thermoplastic molding compound based on blend of polycarbonate and polyethylene terephthalate. 2 APPLICATION This specification was released originally for material used for exterior painted applications such as front grill, with high glos
3、s monocoat paint on C346 MCA styling packages. 2.1 LIMITATIONS Material approved to WSS-M4D879-B2 is unlikely to contain UV stabilizers, therefore long term exposure to direct sunlight could cause chalking and loss of gloss. Materials approved to this specification should not be used for exterior bo
4、dy colors unless validated for each color as per paragraph 3.1.2 below. 3 REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.1.1 Many 4D resin specificat
5、ions 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 samples required for
6、each test. 3.1.2 Performance Criteria: Substrates approved to WSS-M4D879-B2 must comply with all the requirements of WSS-M2P180-D/Latest. Parts must fulfill applicable SDS/CDS requirements. 3.1.3 Materials requiring High Strain Rate, Creep or fiber oriented Tensile Modulus must test to the requireme
7、nts of WSS-M99D68-A1/Latest, Thermoplastic Property Determination For CAE, High Strain Rate Tensile, Creep and Tensile Modulus. Data must be included in the material submission package. 3.1.4 As specified in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Cer
8、tificate of Analysis (CoA) containing lot testing requirements which must include, but are not limited to: Melt Flow Rate Impact Strength, notched Charpy 23C Flexural Modulus Molding Shrinkage and Post Shrinkage 3.1.5 This specification is based on virgin material and does not allow the addition of
9、recycled content (PIR/PCR) ENGINEERING MATERIAL SPECIFICATION WSS-M4D879-B2 Copyright 2015, Ford Global Technologies, LLC Page 2 of 8 3.1.6 The use of regrind is permitted, for economic / environmental reasons. Part manufacturers using this specification must complete DV and PV testing with the allo
10、wable 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 regrind) must be approved by Materials and PD Engineering through the formal Ford Motor Company process (SR
11、EA). 3.2 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 294. See Table 1 for the number of samples required. Specimens shall be as follo
12、ws: 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 mm diameter x 3.2 mm Specim
13、en 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 3.3 MATERIAL PROPERTIES 3.3.1 Density 1.21 1.24 g/cm3 (ISO 1183, Method A) 3.3.2 Tensile Strength at Yield, 48 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.3.3 Elongation
14、at Yield, 3 % min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.3.4 Tensile Modulus 1.9 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.3.5 Flexural Modulus 2 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.3.6 Impact Strength, N
15、otched Charpy (ISO 179-1/1eA, Specimen D) 3.3.6.1 At 23 +/- 2 C 25 kJ/m2 min Report Break Type3.3.6.2 At -40 +/- 2 C 14 kJ/m2 min Report Break Type ENGINEERING MATERIAL SPECIFICATION WSS-M4D879-B2 Copyright 2015, Ford Global Technologies, LLC Page 3 of 8 3.3.6.3 At -20 +/- 2 C 18 kJ/m2 min Report Br
16、eak TypeThe 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. Break type should be defined as one of th
17、e following: C: Complete Break a break in which the specimen separates into two or more pieces H: Hinge Break An incomplete break such that both parts of the specimen are held together only by a thin peripheral layer in the form of a hinge having low residual stiffness P: Partial Break An incomplete
18、 break that does not meet the definition for hinge break N: Non-Break There is no break and a specimen is only bent and pushed through the supporting blocks, possibly combined with stress whitening 3.3.7 Heat Deflection Temperature (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflec
19、tion. 3.3.7.1 At 1.80 MPa 88 C min 3.3.7.2 At 0.45 MPa 115 C min All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.3.8 Vicat Softening Temperature 125 C min (ISO 306, Specimen D, Bath - silic
20、one oil, temperature raise 120 +/- 5 C/h. Dial gage reset to O after addition of 5 kg weight, at 50 N load) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.3.9 Heat Aging Performance (ISO 1
21、88, 150 +/- 50 air changes/h, 1000 h at 85+/- 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 at the time of the aged properties determination) 3.3.9.1 Tensile Strength at Yield, Change +/- 25% max (Test
22、 Method per para 3.3.2) 3.3.9.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per para 3.3.6.1 specimens to be notched before Heat Aging) ENGINEERING MATERIAL SPECIFICATION WSS-M4D879-B2 Copyright 2015, Ford Global Technologies, LLC Page 4 of 8 3.3.10 Flammability (ISO 3795/SAE J3
23、69, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.3.11 Standard Test Method for High Speed Puncture (Multiaxial Impact) Properties of Plastic Using Load and Displacement Sensors (ASTM D 3763, Impact velocity: 2.2 m/s Specimen E, smooth surface injection molded specimen) Max Load Energy a
24、t 23 +/- 2 C Report J Energy Absorbed Min 100% Ductile Failure Max Load Energy at 0 +/- 2 C Report J Energy Absorbed Min 100% Ductile Failure Test specimens must be conditioned for minimum of 6 h at test temperature prior to impact testing. Low temperature testing shall be conducted within the same
25、environmental chamber as the clamp mechanism of the impact device. Specimens can be transported from the conditioning environment to the testing environment, provided the transfer is within 5 seconds. Ductile ist defined as a failure in which: Plastic deformation precedes fracture Sample does not fr
26、acture into two or more pieces Sample does not show cracks radiating more than 10mm beyond the center of the impact point In borderline cases Ford Materials Engineering can use additional data such as load versus deflection curves or maximum load data to establish ductility Summarize testing at each
27、 condition by providing the following information a. Detailed description of specimen preparation if different than specimen E b. Molding conditions: melt and mold surface temperatures, and average injection velocity c. All force versus deflection curves for each impact event d. Original samples are
28、 to be submitted for review or, in agreement with Ford Materials Engineering, photos of the tested samples 3.4 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Materials Database . 3.4.1 Melt Flow Rate Report Value, g/10 minutes (ISO 1133 270 C, 5 kg) The material shall be dried for 4 h m
29、inimum at 110 C in a mechanical convection oven immediately preceding the test. ENGINEERING MATERIAL SPECIFICATION WSS-M4D879-B2 Copyright 2015, Ford Global Technologies, LLC Page 5 of 8 3.4.2 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, %
30、 Cross Flow Report Value, % 3.4.3 Post Shrinkage (Report method used, sample size and value Separate specimens required for each test, report total shrinkage) After 1 h at 80 C Flow Report Value, % Cross Flow Report Value, % After 1 hr at 120 C Flow Report Value, % Cross Flow Report Value, % 3.4.4 C
31、oefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2 C) Plaque size is 100x150 minimum at 3.2 +/- mm thickness. Plaque to be fan or edge gated. Specimens to be water jet or die cut from the center of plaque, minimum of three samples each direction. Conditioning procedure con
32、sists of steps 1-4. Start at 23C 1. Ramp 5C/minute to -40C 2. Isothermal hold for 5 minutes 3. Ramp 5C/minute to 110C 4. Isothermal hold for 10 minutes 5. Ramp 5C/minute to -40C 6. Isothermal hold for 10 minutes 7. Ramp 5C/minute to 110C Report CLTE value after Step 4 (un-annealed value) for both Fl
33、ow and Cross Flow directions Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C Report CLTE value again after Step 7 (un-annealed value) for both Flow and Cross Flow directions Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C ENGINEERING MATERIAL SPECIFICATION
34、 WSS-M4D879-B2 Copyright 2015, Ford Global Technologies, LLC Page 6 of 8 3.4.5 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.4.6 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC first and second heat
35、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 for questions concerning Engineering Material Specifications. ENGINEERING MATERIAL SPECIFICATION WSS-M4D87
36、9-B2 Copyright 2015, Ford Global Technologies, LLC Page 7 of 8 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.4 Para. Test Typical Value Units 3.4.1 Melt Flow Rate 22-28 g/10 min 3.4.2 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering)
37、Flow Cross Flow 0.8-0.9 0.9 % % 3.4.3 Post Shrinkage including molding shrinkage (For specific method and sample size, contact Materials Eng); 80C Flow Cross Flow 120 C Flow Cross Flow 0.9 1.0 1.1 1.2 % % % % 3.4.4 Coefficient of Linear Thermal Expansion Flow Cross Flow 8.1 8.8 E-5 mm/mm/ C E-5 mm/m
38、m/ C 3.4.5 Poissons Ratio 0.35 N/A ENGINEERING MATERIAL SPECIFICATION WSS-M4D879-B2 Copyright 2015, Ford Global Technologies, LLC Page 8 of 8 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PC + PET (ISO 1043/11469) Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Prev
39、iously 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-M2P180-D/Latest As per WSS-M2P180-D/Latest 3.1.3 WSS-M99D68-A1/Latest As per WSS-M99D68-A1/Latest 3.3.1 Density 1 3 3 1 3 3 3.3.2 Tensile S
40、trength at Yield 3 5 15 1 5 5 3.3.3 Elongation at Yield 3 5 15 1 5 5 3.3.4 Tensile Modulus 1 10 10 3.3.5 Flexural Modulus* 3 10 30 1 10 10 3.3.6 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.3.7 Heat Deflection Temperature* (per condition) 3 2 6 1 2 2 3.3.8 Vicat Softening Temper
41、ature* 3 2 6 1 2 2 3.3.9 Heat Aging Performance 3.3.9.1 Tensile Strength at Yield, Change 1 5 5 3.3.9.2 Impact Strength, Notched Charpy, Change 1 10 10 3.3.10 Flammability 1 5 5 3.3.11 Standard Procedure for High Speed Puncture (Multiaxial Impact) 3 10 10 1 10 10 3.4.1 Melt Flow Rate 3 1 3 1 1 1 3.4
42、.2 Mold Shrinkage 1 5 5 1 5 5 3.4.3 Post Shrinkage 1 5 5 1 5 5 3.4.4 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.4.5 Poissons Ratio 1 2 2 1 2 2 3.4.6 Curves - IR - TGA - DSC - 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. 5 SUMMARY OF REVISIONS
