1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2010 03 25 N-STATUS Replaced by WSS-M99P29-B L. Schmalz, NA 1997 04 02 Activated L. M. KothWP 3948-a Page 1 of 12 PERFORMANCE, ENERGY ABSORBING FOAM, WSS-M99P29-A INTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOP
2、E This specification defines the material performance requirements for energy absorbing foam used in interior applications. 2. APPLICATION This specification was released originally for material used in energy absorbing foam bolsters and upper trim components. For information regarding the entire ge
3、neral development process for Energy Absorbing Foam, contact Interior Systems. For specific side impact requirements based on the application (such as Energy Absorption, Load-Deflection, Density, and Compressive Strength,) see the VC Safety PAT (Program Activity Team.) If a PAT has not been establis
4、hed, contact the appropriate Vehicle Safety and CAE (VSCAE) supervisor. For specific head impact requirements (similar to those listed above), contact AVT Interior Systems. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requiremen
5、ts, QS-9000. Material specification requirements are to be used for initial qualification of materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prio
6、r to production parts submission. Appropriate statistical tools must be used to analyze process/product data and assure consistent processing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has
7、been approved by STA and/or the relevant Materials Activity. ENGINEERING MATERIAL SPECIFICATION WSS-M99P29-A WP 3948-b Page 2 of 12 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to thi
8、s specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under t
9、he same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specifie
10、d. 3.4 MOLDED TEST BLOCKS The following tests are to be conducted on molded test blocks 254 x 254 x 63.5 mm with an optional 5 deg draft angle to 240 x 240 mm to facilitate removal from the mold. Unless otherwise specified in the test method, evaluate 6 samples for each requirement. 3.4.1 Dynamic En
11、ergy Absorption (FLTM BO 111-04, ETS Bendix machine or equivalent, 18 samples total, 6 samples from 3 material lots) A Load-Deflection Curve shall be plotted for 0 % to 70 % deflection. The curve is to remain smooth and uniform and must be within the range specified for the appropriate classificatio
12、n of foam. See attached load deflection curves (Figures 1 - 4) at the end of the document. 3.4.2 Dimensional Stability, % Volume Change, max (ASTM D 2126, 100 x 100 x 65 mm sample from test block) 3.4.2.1 48 h at 120 +/- 2 C 5 % 3.4.2.2 7 days at 102 +/- 2 C 5 % 3.4.3 Water Absorption (SAE J315, mol
13、ded test block with skin, except weight to be measured to the nearest g.) 3.4.3.1 Weight Change, max 30 % ENGINEERING MATERIAL SPECIFICATION WSS-M99P29-A WP 3948-b Page 3 of 12 3.4.3.2 Cold Cracking No cracking or splitting Place water absorption test piece in cold chamber at - 34 +/- 2 C for 4 h. 3
14、.4.4 Heat Aging (ISO 2440/ASTM E 145 Type IIA, min space 2 L/100 cm2 of specimen, 30 days at 85 +/- 2 C) 3.4.4.1 Weight Change, max 5 % 3.4.4.2 Compressive Strength, max change from un-conditioned (ASTM D 1621, Procedure A molded test block with skin) At 15 % Compression 15 % At 50 % Compression 15
15、% 3.4.5 Heat Aging (ISO 2440/ASTM E 145 Type IIA, min space 2 L/100 cm2 of specimen, 48 h at 120 +/- 2 C) 3.4.5.1 Weight Change, max 5 % 3.4.5.2 Compressive Strength, max change from un-conditioned specimen (ASTM D 1621, Procedure A molded test block with skin) At 15 % Compression 10 % At 50 % Compr
16、ession 10 % 3.4.6 Humidity Aging (ASTM D 2126, 85 +/- 2 C, 95 - 100 % R.H., 30 day duration) Compressive Strength, max change from un-conditioned specimen (ASTM D 1621, Procedure A molded test block with skin) At 15 % Compression 15 % At 50 % Compression 15 % ENGINEERING MATERIAL SPECIFICATION WSS-M
17、99P29-A WP 3948-b Page 4 of 12 3.4.7 Environmental Aging Expose test block to three of the following cycles prior to testing: . 20 h at 38 +/- 2 C and 95 +/- 5 % R.H. . 4 h at - 34 +/- 2 C Compressive Strength, max change from un-conditioned specimen (ASTM D 1621, Procedure A molded test block with
18、skin) At 15 % Compression 15 % At 50 % Compression 15 % 3.4.8 Resilience Note: This section not applicable for 138 kPa and 207 kPa foam. 3.4.8.1 Resilience, min 11 % 310 kPa Foam Class (ASTM D 3574, Test H, average of 8 samples cut from 2 blocks) Test Sample Preparation: Test samples are prepared by
19、 cutting 12.5 mm from the top of the test block. The block is further cut to produce four samples (approximately 127 x 127 mm). Impact each sample at 3 different locations on the non-skinned surface. 3.4.8.2 Resilience, min 93 % recovery 310 kPa and 448 kPa Head Impact Foam Classes (FLTM BO 111-02,
20、Method A - except 25.4 mm diameter spherical indentor, 22.7 kg load and 4 h recovery at 23 +/- 2 C and 50 % R.H. then take recovery measurement. Test Block to be cut to approximately 101.6 x 101.6 x 25.4 mm leaving skin on the top surface.) Recovery is to be measured after 4 h. ENGINEERING MATERIAL
21、SPECIFICATION WSS-M99P29-A WP 3948-b Page 5 of 12 3.4.9 Wet Environment Testing The following requirements apply only to parts designed for use in wet environments. A “wet“ environment will be defined by the Ford Design Engineer. 3.4.9.1 Water Immersion (SAE J315, 240 h, 23 +/- 2 C water, condition
22、1 h at 23 +/- 2 C and 50 % R.H. prior to evaluation) 3.4.9.1.1 Weight Change, 15 % max 3.4.9.1.2 Compressive Strength, max change from un-conditioned specimen (ASTM D 1621, Procedure A molded test block with skin) At 15 % Compression 10 % At 50 % Compression 10 % 3.4.9.2 Cass Test (ASTM B 368, 240 h
23、, condition 3 h at 23 +/- 2 C and 50 % R.H. prior to evaluation) Compressive Strength, max change from un-conditioned specimen (ASTM D 1621, Procedure A molded test block with skin) At 15 % Compression 10 % At 50 % Compression 10 % 3.4.9.3 Water/Cold Cycling (SAE J315) Exposure Cycle: . 24 h water i
24、mmersion at 23 +/- 2 C . 8 h at - 34 +/- 2 C . 24 h water immersion at 23 +/- 2 C . 8 h at - 34 +/- 2 C . condition for 1 h at 23 +/- 2 C and 50 % R.H. prior to evaluation ENGINEERING MATERIAL SPECIFICATION WSS-M99P29-A WP 3948-b Page 6 of 12 Compressive Strength, max change from un-conditioned spec
25、imen (ASTM D 1621, Procedure A molded test block with skin) At 15 % Compression 10 % At 50 % Compression 10 % 3.5 MOLDED PARTS Whenever possible, test samples are to be taken from energy absorbing foam that has been molded into the production part configuration using a production-representative proc
26、ess. The test sample shall include skin and foam. When this is not possible, use the molded test blocks referenced in para 3.4. 3.5.1 FOGGING (SAE J1756, 3 h at 100 C, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 70 Formation of a clear film, droplets or crystals is cause
27、 for rejection. However, an exception may be made for droplets that can be identified as water by Ford Central Laboratory. 3.5.2 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute 3.5.3 ODOR, max Rating 2 (SAE J1351) 3.7 ADDITIONAL REQUIREMENTS Specific requirements for material and/or ma
28、nufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or performance specification. All critical areas with respect to these properties shall be clearly designated on the engineering drawing. 3.8 FUNCTIONAL APPROVAL Materials being evaluated for approval
29、 to this specification shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. ENGINEERING MATERIAL SPECIFICATION WS
30、S-M99P29-A WP 3948-b Page 7 of 12 3.9 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing
31、 or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obt
32、ain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The regulations are defined in En
33、gineering Materials Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affecte
34、d Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance w
35、ith all the requirements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for
36、 intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List. ENGINEERING MATERIAL SPECIFICATION WSS-M99P29-A WP 3948-b Page 8 of 12 Dynamic Energy Curves (Figures 1 through 5) per para 3.4.1 Figure 1 310 kPa Head Impact EA Foam
37、Dynamic Energy Absorption Specification Test Procedure: FLTM BO 111-04 Impactor Type: Flat Plate Speed: 24.0 km/h Specimen Size: 127 x 127 x 63 mm Impact Carriage Weight: 22.7 kg Load Lower Limit (kPa) Upper Limit (kPa) at 10 % Deflection 295 696 at 30 % Deflection 369 696 at 50 % Deflection 514 696
38、 at 70 % Deflection 863 1241 310 kPa Dynamic Energy Absorption Specification02004006008001000120014001030507090Strain (% Deflection)Stress (KPa)ENGINEERING MATERIAL SPECIFICATION WSS-M99P29-A WP 3948-b Page 9 of 12 Figure 2 448 kPa Head Impact EA Foam Dynamic Energy Absorption Specification Test Pro
39、cedure: FLTM BO 111-04 Impactor Type: Flat Plate Speed: 24.0 km/h Specimen Size: 127 x 127 x 63 mm Impact Carriage Weight: 50 lbs Load Lower Limit (kPa) Upper Limit (kPa) at 10 % Deflection 360 805 at 30 % Deflection 425 805 at 50 % Deflection 595 805 at 70 % Deflection 960 1440 448 kPa Dynamic Ener
40、gy Absorption Specification020040060080010001200140016001030507090Strain (% Deflection)Stress (KPa)ENGINEERING MATERIAL SPECIFICATION WSS-M99P29-A WP 3948-b Page 10 of 12 Figure 3 138 kPa EA Foam Dynamic Energy Absorption Specification Test Procedure: FLTM BO 111-04 Impactor Type: Half Cylinder Spee
41、d: 19.2 km/h Load Lower Limit (kN) Upper Limit (kN) at 15 % Deflection 1.566 7.538 at 50 % Deflection 4.922 7.538 at 60 % Deflection 4.922 9.110 at 70 % Deflection 4.922 10.68 138 kPa Dynamic Energy AbsorptionSpecification0246810121020304050607080% DeflectionLoad (kN)ENGINEERING MATERIAL SPECIFICATI
42、ON WSS-M99P29-A WP 3948-b Page 11 of 12 Figure 4 207 kPa EA Foam Dynamic Energy Absorption Specification Test Procedure: FLTM BO 111-04 Impactor Type: Half Cylinder Speed: 24.0 km/h Load Lower Limit (kN) Upper Limit (kN) at 15 % Deflection 2.465 10.83 at 50 % Deflection 6.639 10.83 at 60 % Deflectio
43、n 6.639 11.75 at 70 % Deflection 6.639 12.67 207 kPa Dynamic Energy AbsorptionSpecification024681012141020304050607080% DeflectionLoad (kN)ENGINEERING MATERIAL SPECIFICATION WSS-M99P29-A WP 3948-b Page 12 of 12 Figure 5 310 kPa EA Foam Dynamic Energy Absorption Specification Test Procedure: FLTM BO
44、111-04 Impactor Type: Half Cylinder Speed: 32.0 km/h Load Lower Limit (kN) Upper Limit (kN) at 15 % Deflection 2.541 16.80 at 30 % Deflection 8.685 16.80 at 50 % Deflection 11.06 16.80 at 60 % Deflection 11.06 22.21 at 70 % Deflection 11.06 27.62 310 kPa Dynamic Energy AbsorptionSpecification0510152025301020304050607080% DeflectionLoad (kN)
