1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Ver. 3 2010 01 06 N-STATUS Replaced by WSS-M98P13-C K. Mueller, FNA 2008 10 08 Revised Changed the red text boxes to translucent K. Mueller, FNA 2008 08 08 Activated K. Mueller, FNA Printed copies are uncontrolled Copyright 2010, Ford Global T
2、echnologies, LLC Page 1 of 10 EXTERIOR PLASTIC PERFORMANCE, MOLD-IN-COLOR WSS-M98P13-B NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines the minimum durability and performance requirements of exterior mold-in-color plastic components. 2. APPLICATION This specification was released or
3、iginally for exterior unpainted molded in color plastic components used in exterior subsystems including outside rearview mirror (OSRVM), cowl grilles and leaf screens (COWLVENT), bumpers (BUMPER), radiator grilles (RADGRL), door handles (DRLT), wipers (WIPER), pick-up box liners/moldings (PUBOX), a
4、nd exterior ornamentation (EXTORN). Typical methods of manufacture include injection molding, blow molding, and extrusion. All painted exterior components shall meet the requirements of WSS-M2P180-latest for rigid substrates, WSS-M2P181-latest for flexible substrates and WSS-M1P83-latest for chrome
5、plated rigid substrates. When specific properties of a coated substrate are not covered by these referenced performance specifications, test methods within this specification may be applied. 2.1 LIMITATIONS 2.1.1 Materials used in all systems shall withstand a paint repair surface temperature of 115
6、 C for 20 minutes without deformation, functional damage or loss of appearance or other specified physical characteristics. If material cannot meet this requirement it must be capable of being protected, e.g., with shielding, during repair processing of the vehicle. 2.1.2 The color/pigment loading,
7、grain, and material of the part influences scratch performance. Materials Engineering recommends grains that have large rounded characteristics (both valleys/peaks), varying heights (with a minimum depth of 100 micrometers), and an irregular pattern. Reference paragraph 3.5.5. 3. REQUIREMENTS Materi
8、al specification requirements are to be used for initial qualification of materials. 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). This specification is based on v
9、irgin material only. The use of in-house regrind, Post Industrial Recyclate (PIR), or Post Consumer Recyclate (PCR) is not allowed unless the part is validated during PV testing with the documented level of regrind, PIR, or PCR noted on the part drawing. ENGINEERING MATERIAL SPECIFICATIONWSS-M98P13-
10、B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 10 3.2 FINISHED PARTS Unless otherwise indicated, testing must be done on actual production parts or a section of the part whenever possible. Where part dimensions limit equipment access, representative panels
11、or plaques may be substituted for production parts. Testing must be conducted at Design Verification (DV) and Product Validation (PV) per Table 1.0, unless otherwise agreed to by Ford Materials Engineering. 3.3 APPEARANCE The color, gloss, and finish shall match the Master Appearance Sample as appro
12、ved by the Design Department or shall be as specified on the engineering drawing. 3.3.1 Color As determined by (FLTM BI 109-01 Visual Assessment) Color Harmony team (SAE J1545, Three-Angle CMC) 3.3.2 Gloss (FLTM BI 110-01) As released by Corporate Design: (Use as a guide) A: 20 Glossmeter, min 92 B:
13、 60 Glossmeter 76 - 84 C: 60 Glossmeter 66 - 74 D: 60 Glossmeter 58 - 66 E: 60 Glossmeter 47 - 53 F: 60 Glossmeter 33 - 38 G: 60 Glossmeter 17 - 23 H: 60 Glossmeter 7 - 13 J: 60 Glossmeter 4 - 6 K: 60 Glossmeter 2 - 4 L: 60 Glossmeter 0.5 - 2 3.4 HEAT AGING and ENVIRONMENTAL TESTING 3.4.1 Acceptance
14、 Criteria Unless otherwise noted, the cycled part shall show no color change in excess of Grey Scale rating 4 (AATCC Evaluation Procedure 1/ISO 105-A02) when compared with the original part. (A color tone shift to the yellow direction is allowed up to Grey Scale rating 4. No other tone change (e.g.
15、pink) is allowed.) No visible cracks, blisters, softening, dulling, or evidence of material degradation when observed with the unaided eye from a distance of 300 +/- 30 mm. Gaps, margins and surface waviness must be within original vehicle design tolerances after returning to ambient temperature. EN
16、GINEERING MATERIAL SPECIFICATIONWSS-M98P13-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 10 3.4.2 Heat Aging All parts shall be complete including all components packaged in the assembly (eg. mirror glass and back, motor, etc. packaged into mirror shell an
17、d structure) and fastened onto actual or representative production support foundations that include not only all attaching points but also any boundary conditions that may restrict movement, unless otherwise specified by the affected Materials Engineering Activity. The retention methods, attachments
18、 and supporting moldings shall be the same as proposed for production. 3.4.2.1 Short Test Procedure: Expose the test sample to 95 +/- 2 C in a mechanical convection oven for 3 hrs. After heat exposure, allow samples to cool to 23 +/- 2 C for a minimum of 1 hour prior to evaluation. Should the compon
19、ent during usage, under any circumstances, be exposed to higher peak temperatures, then the above mentioned temperature should be changed to the real peak temperature. Temperatures to be advised by the Materials Engineering department. The part shall show no visible evidence of warpage, deformation,
20、 cracking, delamination, color change or other detrimental affect. There shall be no local shrinkage where the part has been gated which would interfere with assembly to relating parts, or affect its appearance 3.4.2.2 Extended Test Procedure: Expose the test sample to 80 +/- 2 C in a mechanical con
21、vection oven for 7 days. After heat exposure, allow samples to cool to 23 +/- 2 C for a minimum of 1 hour prior to evaluation. 3.4.3 Environmental Testing All parts shall be complete including all components packaged in the assembly (eg. mirror glass and back, motor, etc. packaged into mirror shell
22、and structure) and fastened onto actual or representative production support foundations that include not only all attaching points but also any boundary conditions that may restrict movement, unless otherwise specified by the affected Materials Engineering Activity. The retention methods, attachmen
23、ts and supporting moldings shall be the same as proposed for production. Test Procedure: All exterior subsystems should test 5 cycles of: After exposure, allow samples to return to 23 +/- 2 C for a minimum of 1 hour prior to evaluation. 3 h at 80 +/- 2 C 1 h at 23 +/- 2 C and 50 +/- 5% R.H 3 h at -4
24、0 +/- 2 C 1 h at 23 +/- 2 C and 50 +/- 5% R.H 16 h at 38 +/- 2 C and 95 to 98% R.H ENGINEERING MATERIAL SPECIFICATIONWSS-M98P13-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 10 3.5 RESISTANCE PROPERTIES 3.5.1 Resistance to Cold Impact, Bumper Cover / Fasci
25、a Only The bumper cover / fascia material must be selected from the bumpers subsystem material strategies and comply with cold temperature requirements which are both located in EKB: https:/ or contact Ford Materials Engineering. 3.5.2 Resistance to Cold Impact, Cowl Vent / Leaf Screen Only (LS-0002
26、) The cowl vent / leaf screen cold impact requirement shall follow the existing requirement in the SDS, LS-0002. 3.5.3 Resistance to Cold Impact, All Exterior Mold-in-Color Parts not captured in 3.5.1 & 3.5.2 (OR-0020) The cold impact requirement shall follow the existing requirement in the SDS, OR-
27、0020. The operating conditions should follow steps 7 and 8. Where part geometry restricts impact locations, discuss with design and release engineer. 3.5.4 Resistance to Exterior Weathering (Surrogate data may be acceptable, as agreed upon by Ford Materials Engineering). After exposure in accordance
28、 with 3.5.4.1 and/or 3.5.4.2, the material shall show no color change in excess of the specified Grey Scale rating (AATCC Evaluation Procedure 1/ISO 105-A02). In addition, there shall be no cracking, crazing, dulling, or other deterioration. 3.5.4.1 Accelerated, Xenon Arc Weatherometer Rating 4 (SAE
29、 J2527 modified Type “S“ borosilicate inner and outer filters, 0.55 W/m2radiant exposure 3000 h exposure, specimen size: 60 x 60 minimum x 2.0 +/- 0.1 mm thick) A & B Gloss Materials, only Gloss retention 75% (FLTM BI 110-01) All Color Submissions Required. 3.5.4.2 Natural Weathering, New Resin Tech
30、nology Only Rating 4 (SAE J1976, Procedure A) 1 & 2 year required ENGINEERING MATERIAL SPECIFICATIONWSS-M98P13-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 10 3.5.5 Resistance to Scratching (FLTM BN 108-13, 1.0 +/- 0.1 mm steel ball at 7.0 N, 6.0 N, 4.5 N
31、, 3.0 N and 2.0 N) For filled and unfilled TEOs and other semi-rigid materials such as PVC, defer to the relevant material specifications. If the material specification doesnt indicate scratch performance, 3.5.5 is required. Grained sample cut from production part No whitening at 7N load A & B Gloss
32、 Materials, only Rating 1 at 2N Note: If the results are disputed, contact the appropriate Ford Materials Engineer for evaluation. 3.5.6 Chemical Resistance Production representative materials specific to the application should be used for the following tests. 3.5.6.1 Resistance to Incidental Fluid
33、Spotting, Vertical Surfaces Only (FLTM BI 168-01, Method B. Reference Appendix 1.0 for the test fluids to be used per application). No color change in excess of Grey Scale rating of 4-5 (AATCC Evaluation procedure1/ISO 105-A02), surface distortion, dulling, or permanent softening permitted. 3.5.6.2
34、Resistance to Incidental Fluid Spotting, Horizontal Surfaces Only (FLTM BI 113-01. Reference Appendix 1.0 for the test fluids to be used per application). No color change in excess of Grey Scale rating of 4-5 (AATCC Evaluation procedure1/ISO 105-A02), surface distortion, dulling, or permanent soften
35、ing permitted. 3.5.6.3 Resistance to Stress Cracking No cracking or crazing (FLTM BO 127-03) Note: Include resistance to stress cracking when used in contact with other materials, such as, oil, grease, cleaners, gasketing, plasticizers, and elastomers. Not applicable when the part is not in contact
36、with these these other materials. 3.5.6.4 Resistance to Water and Soap Spotting (FLTM BI 113-01) No color change in excess of Gray Scale rating of 4-5 (AATCC Evaluation procedure1/ISO 105-A02), surface distortion or permanent softening permitted. ENGINEERING MATERIAL SPECIFICATIONWSS-M98P13-B Printe
37、d copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 10 3.5.7 Resistance to Road Asphalt Staining, maximum 1.5 E (For uncoated PVC applications below the beltline, only) Prepare a solution of 50% asphalt cement and 50% unleaded gasoline. Dip the test specimen in the solu
38、tion for 10 seconds. Suspend specimen for 15 minutes allowing the solution to drain/evaporate. Clean specimen thoroughly with naphtha. Use an untested portion of the part as the control. Before and after staining, measure the color per SAE J1545, CIELAB color space, 10 observer, illuminant C, specul
39、ar included. Calculate E. NOTE: A part that fails this test must be coated with an appropriate clear coat and retested. 3.6 CO-INJECTION and MULTI-INJECTION MOLDING Report Failure Mode and (Bond Tear Strength: DVM-0007-DY) Maximum Load to Failure Any successful attempt to separate the components of
40、co-injected or multi-injected parts must result in cohesive failure only. Any adhesive failure will be cause for rejection. 3.7 RESIDUAL STRESS TEST Report should include (Test Method: Dip entire part in Glacial Acetic Acid for 30 seconds) Photographs of Tested Part(s) and Control Part Any color cha
41、nge (from the control) indicates concentration of residual or molded-in-stresses. The intent of this test is to illustrate to the engineering team where these stresses are located within the molded part. ENGINEERING MATERIAL SPECIFICATIONWSS-M98P13-B Printed copies are uncontrolled Copyright 2010, F
42、ord Global Technologies, LLC Page 7 of 10 TABLE 1.0: DV/PV Requirements Sample size Required for each Color To be done at DV Testing To be done at PV Testing 3.4.2 Heat Aging 3.4.2.1 3.4.2.2 3 each, when applicable No X * 3.4.3 Environmental Testing 3 No X * 3.5.1 Resistance to Cold Impact, Bumper C
43、over / Fascia Only See Material Specification No (Surrogate data may be acceptable) X 3.5.2 Resistance to Cold Impact, Cowl Vent / Leaf Screen Only 3 No (Select color with the highest % of pigment loading) X * 3.5.3 Resistance to Cold Impact, All Exterior Mold-in-Color Parts not captured in 3.5.1 &
44、3.5.2 3 No (Select color with the highest % of pigment loading) X * 3.5.4 Resistance to Exterior Weathering 3.5.4.1 3.5.4.2 (as required) 3 Yes (Surrogate data may be acceptable) X 3.5.5 Resistance to Scratching 3 Yes X 3.5.6 Chemical Resistance 3.5.6.1 3.5.6.2 3.5.6.3 3.5.6.4 3 each, when applicabl
45、e No (Surrogate data may be acceptable) X 3.5.7 Resistance to Road Asphalt Staining 3 Yes (Surrogate data may be acceptable) X 3.6 Co-injection or Mulit- injection Molding 3 No X X 3.7 Residual Stress Test 3 No X X * = If DV did not test production representative processed parts, PV testing required
46、. X = Required ENGINEERING MATERIAL SPECIFICATIONWSS-M98P13-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 8 of 10 Appendix 1.0 Chemical Requirements List / Zoning Diagram The following list of chemicals should be used to validate each brands product. Ford (As s
47、pecified in FLTM BI 168-01) Volvo Multipurpose Cleaner (Example: Formula 409, Fantastic, Armor All) Windshield wash fluid, methanol based. 1 part Motorcraft fluid to 1.5 parts water Washer fluid concentrated and diluted (33%) methanol-based (US-type), part number: 9437501 ethanol/isopropanol-based (
48、European-type), part number: 9437500 Any commercially available ethylene glycol based coolant mixed 50/50 with water. Volvo engine coolant, concentrated and diluted (50%), part number: 9437601 Any commercially available engine oil meeting the latest API-ILSAC requirements. Oil (IRM 902) Any commerci
49、ally available 87 octane lead free product with 20% laboratory grade ethanol. Unleaded petrol 97833 according to STD 1278,33 Common Fluid Types NB Chemical composition may differ.Any commercially available diesel, grade 2 with 20% (by volume) biodiesel added. (any commercially available type). Diesel fuel 97863 according to STD 1278,63 Motorcraft Bug and Tar Remover Solvent 98310 according to STD 1283,1 Glass cleaner Any commercially available product Vo
