1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2004 11 19 Activated K. Bruley Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 1 of 5 POLYPROPYLENE (PP) COPOLYMER, 15% GLASS FIBER WSS-M4D994-A REINFORCED, COLOR PIGMENTED, UV STABILIZED, BLOW MOLDING COMPOU
2、ND, EXTERIOR 1. SCOPE The material defined by this specification is a glass-filled blow-molding compound based on a polypropylene copolymer. 2. APPLICATION This specification was released originally for material used for blow-molded side step bars. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODU
3、CTION MATERIALS Material suppliers and part producers 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.
4、 3.1.2 This specification was developed for virgin material only. The use of regrind in parts used on Ford vehicles is not allowed without the prior written approval from Ford Materials Engineering. Written approval from Ford Materials Engineering must be requested on a part-by-part basis. All reque
5、sts for approval must be accompanied with the following: Engineering drawing defining the maximum allowable regrind content as a significant characteristic. Complete PV test data for parts manufactured with the maximum allowable regrind content as specified on the engineering drawing. 3.2 MOLDING CO
6、MPOUND (s) 3.2.1 Melt Flow Rate 0.2 2.6 g/10 minutes (ISO 1133, 230 C, 2.16 kg) (s) 3.2.2 Glass Fiber Content 12 - 17% (ISO 3451-1, Method A, 30 minutes at 600 +/- 25 C, test portion 4 - 5g) ENGINEERING MATERIAL SPECIFICATIONWSS-M4D994-A Printed copies are uncontrolled Copyright 2004, Ford Global Te
7、chnologies, LLC Page 2 of 5 3.3 MOLDED TEST SPECIMEN 3.3.1 Preparation of Test Specimens Unless otherwise specified all tests shall be carried out on injection molded one-end gated test specimens. The following dimensions are required: A. 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 3167, Type 1A) B. 60 x
8、 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 294. Specimens with shorter dimensions shall be cut from the center of the specimen A. No annealing allowed. 3.3.2 Density 0.95 1.01 g/cm (ISO 1183, M
9、ethod A) (s) 3.3.3 Tensile Strength at Yield, min 35 MPa (ISO 527-1 150 x 1 x 4 mm specimen specimen A) Test speed shall be 5 mm/minute for all materials. Provide a curve of tensile stress versus strain using one specimen per lot at each of the following temperatures: -40 C, 23 C and 85 C (high temp
10、 is dependent on material type). For ductile materials, the curve shall cover strain through yield point. (s) 3.3.5 Flexural Modulus, min 2.0 GPa (ISO 178, 80 x 10 x 4.0 +/- 0.2 mm specimen, use center section of specimen A, 2 mm/min test speed, 64 mm support span) (s) 3.3.6 Impact Strength, Izod, m
11、in (ISO 180/1A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 10 specimens for each test) 3.3.6.1 At 23 +/- 2 C 10 kJ/m23.3.6.2 At -40 +/- 1 C 2 kJ/m2ENGINEERING MATERIAL SPECIFICATIONWSS-M4D994-A Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 3 of 5 3.3.6.3 At -20 +/- 2 C 3
12、 kJ/m2 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 the cold chamber. If not possible, test may be conducted outside, but within 5 seconds. (s) 3.3.7 Heat Deflection Temperature, min
13、78 C (ISO 75-1 & ISO 75-2, 80 x 10 x 4.0 +/- 0.2 mm specimen use center section of specimen A, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.3.8 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 140 +/- 2 C. Unaged property values shall be determined at the time of t
14、he aged properties determination) 3.3.8.1 Tensile Strength at Yield Change +/- 20% (Test Method per para 3.5.3) 3.3.8.2 Impact Strength, Izod Change +/- 10% (Test Method per para 3.5.6.1, specimens to be notched before heat aging) 3.4 FLAMMABILITY (ISO 3795) Burn Rate, max 100 mm/minute The specimen
15、 size required for material approval is 355 x 100 x 2.0 +/- 0.1 mm with a smooth surface. 3.5 FOGGING (SAE J1756, 3 h at 100C heating, 21 C cooling plate, post test conditioning 1 h) Fog Number, min 80 Formation of clear film, droplets or crystals is cause for rejection. ENGINEERING MATERIAL SPECIFI
16、CATIONWSS-M4D994-A Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 4 of 5 3.6 WEATHERING RESISTANCE 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 Procedu
17、re 1/ISO 105-A02). In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss 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 th
18、e affected Product Development Materials Activity. All initial approvals will be based on the preliminary Weatherometer exposure, pending Florida and Arizona exposure results for final approval. 3.6.1 Xenon Arc Weatherometer Rating 4 (SAE J1960 modified Type “S“ with at least borosilicate inner and
19、outer filters, 75% gloss 0.55 W/m2radiant exposure retention 3000 h exposure, specimen size: 60 x 60 x 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen) 3.6.2 12 months Florida Rating 4 12 months Arizona (SAE J1976, 5 south, direct weathering inland, specimen size: 60 x 60 m
20、inimum, 2.0 +/- 0.1 mm thick, smooth surface, low gloss injection molded specimen) 3.6.3 24 months Florida Rating 3 - 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) 4. GENER
21、AL 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 (ASTM E 696) Flow Direction 5 -5C Cross-Flow Direction 16 -5C 4.2 MOLD SHRINKAGE (ISO 294-3 and 294-4, 60 x 60 x 2.0
22、+/- 0.1 mm injection molded specimen) 4.2.1 Molding Shrinkage . After 48 h at 23 +/- 2 C 0.5 0.9% ENGINEERING MATERIAL SPECIFICATIONWSS-M4D994-A Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 5 of 5 4.2.2 Post Shrinkage (Separate specimens required for each test)
23、. After 48 h at 80 C 0.8 1.1% . After 30 minutes at 120 C 0.8 1.0% 4.3 HEAT DEFLECTION TEMPERATURE 143 C (ISO 75 -1 120 x 10 x 4.0 +/-0.2 mm specimen use center section of specimen A, flatwise, 0.34 +/- 0.1 mm deflection. At 0.45 MPa) 4.4 IMPACT STRENGTH, CHARPY, nominal (ISO 179/1eA, 80 x 10 x 4.0
24、+/- 0.2 mm specimen use center section of specimen A, 10 specimens for each test) 4.4.1 At 23 +/- 2 C 14 kJ/m24.4.2 At -40 +/- 1 C 5 kJ/m24.4.3 At -20 +/- 2 C 6 kJ/m2The test specimen must be conditioned for minimum of 6 hours at the above specified temperature prior to impact test. Low temperature
25、testing shall be done within the cold chamber. If not possible, test may be conducted outside, but within 5 seconds. 4.5 IMPACT STRENGTH, MULTIAXIAL (ASTM D 3763, 100 mm diameter x 3.2 mm thick smooth surface injection molded specimen (specimen C). Impact velocity: 2.2 m/s at 23 +/- 2 C Energy at ma
26、ximum load 5.8 J Failure Mode brittle 4.6 SHEAR MODULUS at 23 C 540 - 900 MPa (ASTM D 4065, forced constant amplitude, fixed frequency of 1 Hz +/- 15%, strain level below 1%. Specimen approx. 60 x 10 x 4.0 +/- 0.2 mm cut from the center of specimen A. Specimen length between clamps 35-40 mm. Soak ti
27、me at each temperature interval - 3 minutes minimum) Additionally, a Shear Modulus versus Temperature curve shall be plotted for -50 to +150 C temperature range, at 5 C minimum intervals. The plotted curve must be within tolerance range granted on the original material approval and it shall constitute the reference standard for materials supplied to this specification and shall be kept on file at the designated material laboratory and be available on request. 4.7 RECYCLING CODE PP-GF15
