1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 03 26 Activated Y. Bankowski, C. BoesePrinted copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 1 of 6 FLEXIBLE COVERSTOCK, AROMATIC SPRAY POLYURETHANE SKIN, WSS-M4D983-A3 WITH ONE COMPONENT ALIPHATIC WATERBORNE I
2、N-MOLD COATING SYSTEM 1. SCOPE The material defined by this specification is one component aliphatic waterborne in-mold coating over an aromatic polyurethane sprayable elastomer used for instrument or door panels. 2. APPLICATION This specification was released originally on the 2010 Taurus to be use
3、d as a flexible molded skin for a seamless instrument panel with a foamed plastic substrate. This material must also meet the requirements in WSS-M15P45-A, performance spec for flexible cover skin materials used in an instrument panel assembly. 2.1 LIMITATIONS If the plastic substrate is an olefin b
4、ased material, it must be pretreated with either adhesion promoter, flame or plasma treatment and no slip agent should be present unless validated with the slip agent. Validated mold release, in-mold coat, PU skin and foam must be treated as a system as documented on the ASL. Humidity and temperatur
5、e must be tightly controlled in an enclosed chamber as specified by the material supplier. Features in the part design such as deep undercuts and deep draws that limit wand access should be avoided. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part produc
6、ers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1.1 All requirements of this specification, identified by symbol (s), shall be met with data representing 3 sigma values using latest ISO test methods. 3.1.2 This specification was developed using vir
7、gin material properties. The use of regrind is permitted, for economic/environmental reasons, with compliance as indicated in WSS-M99P1111-A. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D983-A3 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 6 Critical Process Par
8、ameters At the request of Ford Materials Engineering the supplier shall be responsible to collect critical process control data on each lot of material produced. Testing required will be jointly developed between Ford Materials Engineering and the supplier based on CP and PFMEA review at the time of
9、 initial approval. Annually the supplier will review the in process data with Ford Materials Engineering to show that the process has remained under control. The data needs to be submitted in January for the previous calendar year. Data showing poor quality control measures or lack of submitted data
10、 may result in deletion from the Ford Approved Source List. 3.3 TEST SPECIMENS 3.3.1 Preparation of test specimens Unless otherwise specified, all tests shall be carried out on specimens die cut from flat ungrained skins. 3.3.2 Density 0.95 1.10 g/cm3(ISO 1183, Method A) 3.3.3 Hardness, Durometer A
11、70 +/- 5 (ISO 868, 15 s dwell (s) 3.3.4 Tensile Strength at Break, min 6.0 MPa (ISO 37, Type 1, test speed: 500 mm/minute) (s) 3.3.4.1 Elongation at Break, min 125% (Test Method according to para 3.3.4) (s) 3.3.5 Tear Strength, min 20 N/mm (ISO 34, Method B, Procedure A, 500 mm/minute) 3.3.6 Heat Ag
12、ing Performance (ISO 188, except 150 +/- 50 air changes/h, 500 h at 120 C+/- 2 C, Unaged property values shall be determined at the time of the aged properties determination) 3.3.6.1 Color Stability, min Rating 4 (AATCC Procedure 1/ISO 105-A02) 3.3.6.2 Cold Flexibility No Cracks (SAE J323 Method A,
13、-20 C, 20 mm mandrel, Specimen size, 50 x 150 mm) ENGINEERING MATERIAL SPECIFICATIONWSS-M4D983-A3 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 6 3.3.6.3 Tensile Strength at Break, Change from original value, max -20% (Per para. 3.3.4) 3.3.6.4 Elongation at
14、Break, Change from original value, max -20% (Per para. 3.3.4.1) 3.3.7 Humidity Aging Performance (FLTM BQ 104-02, 80 C, 90% RH, 168 hrs) 3.3.7.1 Color Stability, min Rating 4 (AATCC Procedure 1/ISO 105-A02) 3.3.7.2 Cold Flexibility No Cracks (180 bend at -20 C over a 20 mm mandrel, Specimen size, 50
15、 x 150 mm) 3.3.7.3 Tensile Strength at Break, Change from original value, max -20% (Per para. 3.3.4) 3.3.7.4 Elongation at Break, Change from original value, max -20% (Per para. 3.3.4.1) 3.4 ODOR, max FLTM BO 131-01 Rating 2 or SAE J1351 Rating 3 Test report must state method used. 3.5 FOGGING (SAE
16、J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 90 Formation of clear film, droplets or crystals is cause for rejection. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D983-A3 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC
17、 Page 4 of 6 3.6 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute The specimen size required for material approval is 355 x 100 x 1.0 +/- 0.1 mm (use specimen C) with a smooth surface. 3.7 WEATHERING RESISTANCE After exposure in accordance with 3.7.1, 3.7.2 and 3.7.3 the material shall
18、show no fading or 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. All initial approvals will be based on the preliminary Weatherometer exposure, pending Florida exposure results
19、 for final approval Not required for North America. 3.7.1 Xenon Arc Weatherometer Rating 4, min Required Worldwide except North America (SAE J2412, 1240 kJ/m2exposure min, specimen size: 150 x 100 mm min, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) 3.7.2 Filtered Xenon Arc Weatherometer Ra
20、ting 4, min Required for North America (SAE J2412 modified (FLTM BO 116-01), 3609.6 kJ/m2 exposure min, specimen size: 150 x 100 mm min, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) 3.7.3 12 months Florida Not required for North America Rating 4, min (FLTM BI 160-01, 5 south, under glass, s
21、pecimen size: 150 x 100 mm, min, 3.2 +/- 0.2 mm thick, molded in smooth polished mold) 3.8 RESISTANCE TO ABRASION, min (SAE J948, CS-10 wheels, 500g, 250 cycles) The surface shall show no evidence of wear through and shall be compatible to the adjacent unbraided area. ENGINEERING MATERIAL SPECIFICAT
22、IONWSS-M4D983-A3 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 5 of 6 3.9 RESISTANCE TO SCUFFING, min (SAE J365, 250 cycles) The surface shall show no evidence of wear through and shall be compatible to the adjacent unscuffed area. 3.10 RESISTANCE TO MIGRATION ST
23、AINING AND BLOCKING, min Rating 5 (FLTM BN 103-01, ISO 105-A02/AATCC Evaluation Procedure 1) No evidence of injurious exudation, adhesion (tackiness), separation, color transfer, staining, or flattening of the embossing when material is placed in the following positions: Top surface to top surface T
24、op surface to standard vinyl test material Top surface to back surface 3.11 SOILING AND CLEANABILITY, min (FLTM BN 112-08, ISO 105-A02/AATCC Evaluation Procedure 1) Cleanability Rating 3 3.12 RESISTANCE TO CLEANING AGENTS, min Rating 4 (FLTM BN 107-01, 10 cycles, AATCC Evaluation Procedure 2) Test p
25、rocedure: Saturate white cotton cloth with the cleaners listed. Evaluation according to the AATCC Scale. Cleaners: 1. Deionized water 2. Window cleaner with ammonia, see para 4.1 3. All purpose cleaner, see para 4.1 4. Dry (no cleaners or water) 3.13 RESISTANCE TO WINDOW CLEANER SPOTTING, min Rating
26、 4 Window cleaning solution must contain at least 1% butyl cellusolve. Test procedure: Prepare test samples by placing 2.0 ml of cleaner on the sample. A non-reactive washer may be used to control the location of the cleaner on the sample. Expose the sample at room temperature for 1 h, rinse with ta
27、p water, and dry carefully with a clean paper towel; do not rub spots. Evaluate per ISO 105-A02/AATCC Evaluation Procedure 1 No film softening allowed. ENGINEERING MATERIAL SPECIFICATIONWSS-M4D983-A3 Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 6 of 6 4. GENERAL
28、 INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 CLEANING AGENTS (See para 3.12) 1. Window cleaner with ammonia 2. All purpose cleaner ZC-38-A* * or Ford Motor Company recommended equivalents 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PU
