1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2010 01 14 N-STATUS No replacement named J. Crist, NA 1990 08 17 ECA54241 Released R.J. Balodis WP 3948-a Page 1 of 5 POLYPROPYLENE (PP) COPOLYMER, 20 % MINERAL WSZ-M4D783-A FILLED, MELT FLOW RATE 0.8 - 2.0 NO
2、T TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a 20 % mineral (talc) filled molding and extrusion compound based on polypropylene copolymer with melt flow rate of 0.8 - 2.0 g/10 minutes. 2. APPLICATION This specification was released originally for material used f
3、or engine air cleaner intake tube. 3. REQUIREMENTS 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to
4、 analyze process/product data so that variation in the final product is continuously reduced. 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 this specification. The IR spectra and th
5、ermograms 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 the same conditions. 3.3 CONDITIONING A
6、ND 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 96 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 MOULDING COMPOUND 3.4.1 Melt Fl
7、ow Rate 0.8 - 2.0 g/10 minutes (ISO 1133/ASTM D 1238, 230 C, 2.16 kg) 3.4.2 Filler Content 18 - 23 % (ISO 3451/1, Method A, 1 h at 750 +/- 25 C) ENGINEERING MATERIAL SPECIFICATION WSZ-M4D783-A WP 3948-a Page 2 of 5 3.5 MOULDED TEST SPECIMEN 3.5.1 Preparation of Test Specimens Unless otherwise specif
8、ied all tests shall be carried out on injection moulded one-end gated test specimens. The following dimensions are required: A. 150 min x 10 x 4.0 +/- 0.2 mm (Tensile Bar, ISO 3167) B. 120 x 10 x 4.0 +/- 0.2 mm Specimens with shorter dimensions shall be cut from the centre portion of the test specim
9、en A and/or B. The specimens shall be prepared according to ISO 294. No annealing allowed. 3.5.2 Density 1.00 - 1.12 g/cm3 (ISO 1183, Method A/ASTM D 792, Method A1) 3.5.3 Tensile Strength at Max Load, min 24 MPa (ISO R 527/ASTM D 638M, 150 min x 10 x 4.0 +/- 0.2 mm specimen, 5 mm/min test speed) 3.
10、5.4 Flexural Modulus, min 1.7 GPa (ISO 178/ASTM D 790M, Method I, Procedure A, 80 x 10 x 4.0 +/- 0.2 mm specimen, 64 mm support span) 3.5.5 Shear Modulus at 23 C tbd 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
11、+/- 0.2 mm cut from the centre of specimen A. Specimen length between clamps 35-40 mm. Soak time at each temperature interval - 3 minutes minimum) Additionally, a Shear Modulus vs. Temperature curve shall be plotted for - 50 to + 160 C temperature range, at 5 C minimum intervals. The plotted curve m
12、ust be within tolerance range shown on page 6. 3.5.6 Impact Strength, Izod, min (ISO 180, Method A/ASTM D 256, Method A, 80 x 10 x 4.0 +/-0.2 mm specimen, 10 specimens for each test) 3.5.6.1 At 23 +/- 2 C 6.0 kJ/m2 3.5.6.2 At - 40 +/- 2 C 3.0 kJ/m2 3.5.6.3 At 0 +/- 2 C 4.0 kJ/m2 The test specimens m
13、ust be conditioned for minimum of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box, if not possible, test can be conducted outside, but within 5 s. ENGINEERING MATERIAL SPECIFICATION WSZ-M4D783-A WP 3948-a Page 3 of 5 3.5.7 Heat D
14、eflection Temperature, min (ISO 75/ASTM D 648, 120 x 10.0 x 4.0 +/- 0.2 mm specimen) 3.5.7.1 At 1.82 MPa 55 C 3.5.7.2 At 0.45 MPa 110 C 3.5.8 Heat Aging Performance (ISO 188/ASTM D 573, 150 +/- 50 air changes/h, 1000 h at 140 +/- 2 C. Unaged property values shall be determined at the time of the age
15、d properties determination) 3.5.8.1 Tensile Strength Change +/- 25 % (Test Method per para 3.5.3) 3.5.8.2 Impact Strength, Izod Change +/- 25 % (Test Method per para 3.5.6, specimens to be notched before heat aging) 3.6 FLAMMABILITY (ISO 3795) Burn Rate, max 100 mm/minute The specimen size required
16、for material approval is 355 x 100 x tbd +/- 0.1 mm with a smooth surface. 3.7 FOGGING (FLTM BO 116-03) Fog Number, min 60 Formation of excessive amounts of clear film or droplets is cause for rejection. 3.8 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall b
17、e specified on the Engineering drawing, Engineering parts specification and/or performance specifications. All critical areas with respect to these properties shall be clearly designated on the Engineering drawing. 3.9 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equ
18、ivalent in all characteristics to the material upon which approval was originally granted. ENGINEERING MATERIAL SPECIFICATION WSZ-M4D783-A WP 3948-a Page 4 of 5 Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved
19、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 obtain the written approval of the Materials Enginee
20、ring 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 restrictions are defined in Engineering Material Specification WSS-M99P9999-A1
21、, unless a different suffix (e.g., A2 or A3) is specified on the engineering document for the application. 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
22、 first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity its own laboratory report to the specification (test results, not nominal values), the material desi
23、gnation and code number, and test specimens for Ford evaluation. Upon approval, the material will be added to the Engineering Material Approved Source List. 5. GENERAL INFORMATION The information below is provided for assistance and clarification and does not represent requirements to this specifica
24、tion. 5.1 COEFFICIENT OF LINEAR THERMAL EXPANSION 8.0E-5/ C (ASTM D 696) 5.2 MOLD SHRINKAGE (ISO 2577, approx. 150 x 100 x 3.2 +/- 0.2 mm injection molded specimen) 5.2.1 Moulding Shrinkage . After 48 h at 23 +/- 2 C tbd 5.2.2 Post Shrinkage (Separate specimens required for each test) . After 48 h at 80 C tbd . After 30 min at 120 C tbd ENGINEERING MATERIAL SPECIFICATION WSZ-M4D783-A WP 3948-a Page 5 of 5 Shear Modulus vs. Temperature Plot - tbd
