1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 07 16 N-STATUS No Replacement Named K. Mueller, NA 2006 08 08 Activated K. Mueller, M. Masserant Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 7 THERMOPLASTIC POLYOLEFIN ELASTOMER (TEO), 12% MINER
2、AL, WSS-M4D961-A4 COLOR PIGMENTED, UV STABILIZED, HIGH MELT FLOW, LOW CLTE, MOLD-IN-COLOR AND PARTIALLY PAINTED, EXTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a filled, weatherable and paintable thermoplastic molding compound. 2. APPLICATION This speci
3、fication was released originally for material used for exterior bumper applications that are mold-in-color and partially painted. Any color additives need to be reviewed and approved by the raw material supplier and Ford Materials Engineering. The UV/heat stabilizers must be in the base resin from t
4、he material supplier, not in the color concentrate, for mold-in-color applications at the press. 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.
5、1 All requirements of this specification, identified by symbol (s), shall be met with data representing 3 sigma values. 3.1.2 This specification was developed using virgin material properties. The use of regrind is permitted, for economic/environmental reasons, with compliance as indicated in WSS-M9
6、9P1111-A. 3.2 MOLDING COMPOUND (s) 3.2.1 Melt Flow Rate 19 - 24 g/ (ISO 1133, 230 C, 2.16 kg) 10 minutes (s) 3.2.2 Mineral Filler Content 10 14% (ISO 3451-1, Method A, talc filler, 3 h at 650 +/- 25 C, test portion 1 - 2 g) 3.3 MOLDED TEST SPECIMEN 3.3.1 Preparation of Test Specimens Unless otherwis
7、e specified all tests shall be carried out on injection molded one-end gated test specimens. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D961-A4 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 7 The following dimensions are required: A. 150 minimum x 10 x 4.0 +/-
8、0.2 mm (ISO 3167, Type 1A) B. 60 x 60 x 2.0 +/- 0.1 mm (ISO/DIS 294-3) C. 355 x 100 x 1.0 +/- 0.1 mm (ISO 3795) Test specimen A shall be molded using molding conditions defined in ISO 1873-2. Specimens with shorter dimensions shall be cut from the center of the specimen A. No annealing allowed. 3.3.
9、2 Density 0.96 1.00 g/cm3(ISO 1183, Method A) 3.3.3 Hardness, Durometer D 54 - 64 (ISO 868, 15 s dwell) (s) 3.3.4 Tensile Strength at Yield, min 17 MPa (ISO 527-1 150 x 1 x 4 mm specimen specimen A) Test speed shall be 50 mm/minute for all materials. Provide a curve of tensile stress versus strain u
10、sing one specimen per lot at each of the following temperatures: -40 C, 23 C and 85 C (Page 7). For ductile materials, the curve shall cover strain through yield point. 3.3.7 Impact Strength, Izod, min (ISO 180/1A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) (s) 3.3.7.1 At 23 +/-
11、2 C 44 kJ/m2(s) 3.3.7.2 At -40 +/- 1 C 5 kJ/m23.3.7.3 At 0 +/- 2 C 10 kJ/m2 (Note: Minimum not -3sigma test data at 0 +/- 2 C is required) The test specimens must be conditioned for a minimum of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within
12、 the cold chamber, if not possible, test may be conducted outside, but within 5 seconds. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D961-A4 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 7 3.3.8 Impact Strength, Multiaxial, Painted and Unpainted Specimens (ASTM
13、D 3763, 100 x 100 x 3.2 +/- 0.2 mm thick smooth surface injection molded specimen, test a minimum of 10 specimens from 3 individual lots at each condition; 2.2 m/s impact velocity; to be tested using production paint systems. For North America: painted primer ESB-M6J142-A PPG MPP6000; Basecoat/Clear
14、coat ESB-M2J218-A1/2 1K/1K PPG Oxford White CBCF6466, PPG Clearcoat CUCC1000XA) Test specimens must be conditioned for minimum of 6 h at test temperature prior to impact testing. Low temperature conditioning and testing shall be conducted within the same environmental chamber as the clamp mechanism
15、of the impact device. Painted test specimens must be oriented with paint in tension (paint side down). Summarize testing at each condition by providing the following information as well as the information in Figure 1. a. Detailed description of specimen preparation b. Molding conditions: melt and mo
16、ld surface temperatures, and average injection velocity c. Number of samples tested per lot per temperature d. Numbers of lots tested e. Number of samples with ductile failure per each test condition f. Representative force vs. deflection curve for each impact event Test results shall be submitted w
17、ith an initial qualification of the material with curves (data on CD as well as paper copies) and test samples. A ductile failure is defined as a crack that does not radiate more than 10 mm from the center of the impact point. 3.3.8.1 Painted Specimens (Test Method per para 3.3.8) 3.3.8.1.1 Energy a
18、t Maximum Load, min (At 0 +/- 2 C) 14.0 J % Ductile, min (At 0 +/- 2 C) 30% 3.3.8.1.2 Energy at Maximum Load, min (At -10 +/- 2C) 7.8 J % Ductile, min (At -10 +/- 2C) 0% 3.3.8.2 Unpainted Specimens (Test Method per para 3.3.8) 3.3.8.2.1 % Ductile, min (At -40 +/- 2 C) 0% ENGINEERING MATERIAL SPECIFI
19、CATIONWSS-M4D961-A4 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 7 Operator NameSample IDTest no Date/time Lot ID Temperature ( C )Impact velocity (m/s)Impact energy (J)Time to max load (ms)Total time (ms)Maximum load (kN)Energy to max load (J)Total energy
20、(J)Deflection at max load (mm)# of CracksCrack length, max. (mm)Failure type (Ductile / Brittle) 12345678910AverageMedianMinimumMaximumCoef. of Var.Std. Dev.Figure 1 - Data Summary(s) 3.3.9 Heat Deflection Temperature, min 48 C (ISO 75-1 & ISO 75-2, 80 x 10 x 4.0 +/- 0.2 mm specimen use center secti
21、on of specimen A, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.3.10 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.3.10.1 Tensile Strength at Yield Change
22、+/- 10% (Test Method per para 3.3.3) 3.3.10.2 Impact Strength, Izod Change +/- 15% (Test Method per para 3.5.5.1, specimens to be notched before heat aging) 3.4 FLAMMABILITY (ISO 3795) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355 x 100 x 2.0 +/- 0.1 mm with a
23、smooth surface. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D961-A4 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 7 3.5 PAINTABILITY Painted substrate using this material must comply with all the requirements of paint performance WSS-M2P181-B. Production level m
24、aterials must be used in preparing test parts/panels. The use of improper sample prep materials can influence test results. 3.6 SCRATCH RESISTANCE, MOLD-IN-COLOR ONLY Rating 2 required at 2.0 N (FLTM BN 108-13, 1.0 +/- 0.1 mm steel ball at 7.0 N, 6.0 N, 4.5 N, 3.0 N and 2.0 N) 3.7 WEATHERING RESISTA
25、NCE, MOLD-IN-COLOR ONLY After exposure in accordance with 3.6.1, 3.6.2, and 3.6.3, the material shall show no color change in excess of specified Gray Scale rating (AATCC Evaluation Procedure 1/ISO 105-A02). In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gl
26、oss or chalking will be allowed provided an acceptable appearance can be achieved by washing and/or polishing with Ford car polish (auto wax) after the outdoor exposure, at permission of the affected Product Development Materials Activity. All initial approvals will be based on the preliminary Weath
27、erometer exposure, pending Florida and Arizona exposure results for final approval. 3.7.1 Xenon Arc Weatherometer Rating 4 - 5 (SAE J1960 modified Type “S“ with at least borosilicate inner and outer filters, 75% gloss 0.55 W/m2 radiant exposure retention 3000 h exposure, specimen size: 60 x 60 x 2.0
28、 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen B) 3.7.2 12 months Florida Rating 4 - 5 12 months Arizona (SAE J1976, 5 south, direct weathering inland, specimen size: 60 x 60 minimum, 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen) 3.7.3 24 months F
29、lorida Rating 4 24 months Arizona (SAE J1976, 5 south, direct weathering inland, specimen size: 60 x 60 minimum, 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen) ENGINEERING MATERIAL SPECIFICATIONWSS-M4D961-A4 Printed copies are uncontrolled Copyright 2009, Ford Global Tech
30、nologies, LLC Page 6 of 7 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 COEFFICIENT OF LINEAR THERMAL EXPANSION (ISO 11359-2 TMA, temperature range 30 to 100C) Flow Direction, E-5 mm/mm/C 6.6 Cro
31、ss Flow Direction, E-5 mm/mm/C 6.4 4.2 MOLD SHRINKAGE (ISO/DIS 294-3, 60 x 60 x 2.0 +/- 0.1 mm injection molded specimen) 4.2.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.8% 4.2.2 Post Shrinkage (Separate specimens required for each test) . After 30 minutes at 120 C 1.0% 4.3 TENSILE MODULUS (ISO
32、 527-1 & ISO 527-2, 150 minimum x 10 x 4.0 +/- 0.2 mm specimen A test speed: 1 mm/min) 1550 MPa 4.4 CHARPY, NOTCHED (ISO 179/1eA, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, 10 specimens) 4.4.1 At 23 +/- 2 C 61 kJ/m24.4.2 At -40 +/- 2 C 5 kJ/m24.4.3 At 0 +/- 2 C 15 kJ/m2The t
33、est 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. 4.5 RECYCLING CODE PP+EPDM-TD12 ENGINEERING MATERIAL S
34、PECIFICATIONWSS-M4D961-A4 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7 of 7 TYPICAL TENSILE STRESS VS TENSILE STRAIN ISO Tensile (50 mm/min Test Speed) 05001000150020002500300035004000450050005500600065000.00 2.00 4.00 6.00 8.00 10.00 12.00Engineering Strain (%)Engineering Stress(psi)0.004.008.0012.0016.0020.0024.0028.0032.0036.0040.0044.00Engineering Stress(MPa)185 F(85C)-40 F (C) -2 F(-19 C)73 F (23 C)
