1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 1 of 11 NAVISTAR, INC. Material, Parts, and Process Specifications
2、 (MPAPS) NUMBER: MPAPS K-6045 Former Designation: TMS-6045 TITLE: Door and Body Seals (Rubber) CURRENT REV No.: 1406 DATE: June 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. 1404 April 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRE
3、NT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of
4、 regulatory limits prior to use. Change Notice: Correction to Section 4.3.6.2; editorial changes. Reference: File 30-16 Key Words: Door seal, body seal 1.0 APPLICATION This specification covers elastomeric door, glass and body seals and trim applications. . Type 1: Dual Durometer - solid extrusion w
5、ith sponge bulb; with a woven wire carrier. Type 1A: Dual Durometer solid extrusion with sponge bulb, no carrier. Type 2: Solid extrusion with a woven wire carrier. Type 3: Extruded sponge, adhesive mounted. Type 4: Trim edge covering. Type 5: Glass run channel or belt line seal - solid extrusion wi
6、th flocking. Type 6: Glass run channel or belt line seal - solid extrusion without flocking. Type 7: Solid extrusion without a woven wire carrier (fan seals). Type 8: Solid, dual durometer thermoplastic elastomer extrusion. 2.0 SCOPE This specification covers the general requirements, property and p
7、erformance requirements, quality, identification, qualification, source approval and quality control. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 RE
8、FERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 ASTM D 2240 ASTM D 412 NAVISTAR Manufacturing Standard MS
9、-D-13 ASTM D 573 ASTM D 395 NAVISTAR Engineering Design Standard A-16 ASTM D 1171 ASTM D 2135 CFR Title 29, Part 1910 ASTM D 1056 SAE J200 RMA Handbook (Rubber Manufacturers Association) SAE J18 ASTM D 618 NAVISTAR TMS-9544 MPAPS GT-31 ISO 6945 NAVISTAR CEMS G-5, Part II MPAPS B-50 ASTM D 638 ASTM D
10、 790 ASTM D 3029 MPAPS P-9543 NUMBER: MPAPS K-6045 TITLE: Door and Body Seals (Rubber) REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 201
11、4 by Navistar, Inc. JUNE 2014 Page 2 of 11 4.0 GENERAL REQUIREMENTS Unless otherwise stated, all tests shall be performed at room temperature. Preconditioning: in case of dispute, ASTM D 618, Procedure A, shall govern conditioning of test samples. 4.1 General Properties 4.1.1 Finish Unless otherwise
12、 specified on the engineering drawing, the finish for molded parts shall be uniform as produced from polished steel tools. The mold will be polished to a surface finish of 800 nm or better. Extruded products shall have a smooth, clean surface, free from any foreign matter. Extruded finish will be eq
13、uivalent to Rubber Manufacturers Association (RMA) F2 for mold finish. 4.1.2 Color Unless otherwise stated on the engineering print, the color shall meet NAV0004 black N-gloss (2-5%) 4.1.3 Flash Unless otherwise specified on the engineering drawing, the parts shall have a maximum flash allowance of
14、0.80 mm (RMA T.80mm). 4.1.4 Low-friction Coating (flock, slip coating, wear strips) This requirement is under development. Silicone coatings are not allowed. Contact Materials Engineering for further information. Coating type and thickness shall be specified on engineering print. 4.1.5 Dimensional T
15、olerances Reference part tolerances are shown in Table 1. Engineering print tolerances utilizing Geometric Design and Tolerancing (GD&T) shall be reasonably consistent with the intent of this table. 4.1.6 Appearance Parts should have features that orient them correctly during installation process. T
16、here shall be no cosmetic defects visible after installation of seals. TABLE 1 STANDARD DIMENSIONAL TOLERANCE TABLE Dimension - inch Tolerance - inch Dimension mm Tolerance - mm 0 -1.00 .015 0 -25 .40 1.00-4.00 .025 25 -100 .50 4.00-6.30 .032 100 -160 .80 6.30 & over 0.50% 160 & over 0.50% 4.2 Mater
17、ial Requirements See Table 2 at the end of this specification for solid and sponge elastomer material properties. Closed cell expanded rubber properties (sponge, Types 1 and 3) shall meet ASTM D 1056 for grade 2A2 in EPDM elastomer. The compression deflection requirement may be specified on the engi
18、neering print to fall into one of the other ranges in ASTM D 1056. Unless otherwise specified for a higher requirement the material shall meet the following suffixes in ASTM D 1056 A1, B2, F1. 4.2.1.1 Adhesion: ASTM D 429, Method A. This test applies to any bonded assembly. All fracture modes are to
19、 be cohesive fractures or fracture through the substrate. The Qualification Test Report will NUMBER: MPAPS K-6045 TITLE: Door and Body Seals (Rubber) REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standa
20、rds. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 3 of 11 include the fracture loads reported as MPa values, tested at standard lab conditions. Any adhesive failure modes shall be noted and explained in the report. 4.2.1.1.2 Pressure Sensitive Adhesive
21、: When a pressure sensitive adhesive is specified, it shall meet the requirements of TMS-6929 unless it is directed to be a temporary adhesive on the engineering print. 4.2.1.2 Seal Abrasion Resistance ISO 6945 4.2.1.2.1 Method: Prepare samples at 250 mm (10 in) in length and measure mass to 0.01 gr
22、ams. Use a wear resistance tester per ISO 6945 except modified as described herein. Support the test sample as appropriate for its intended use. Set the rate to 1 Hz (60 cycles per minute) and the stroke is 150 mm (6 in) with one back and forth movement as one cycle. Apply 5 N for sponge, 50 N for s
23、olid force to the specimen. Test samples to 10,000 cycles. Record cycles, report weight loss and record final surface condition. 4.2.1.2.2 Required: The requirements for this test are still under development. Sponge materials shall not break the surface skin. Solid shall show minimal surface distres
24、s. Contact Materials Engineering for further judgment on results. 4.2.1.3 Staining Resistance: This requirement is temporarily ASTM D 925 Method B to be consistent with ASTM D 2000 classifications. 4.2.1.4 Salt Spray/Adhesion: ASTM B117 salt spray test for 100 hours. Test per 4.2.1.1 Adhesion. 4.2.1
25、.5 Heat Aged/Adhesion: Age test samples for the time, temperature and method specified in Table 2. Perform test as per 4.2.1.1 Adhesion. 4.2.1.6 UV Exposure 4.2.1.6.1 Method: Test per Navistar MPAPS GT-31 Xenon Arc Exposure (SAE J2527) 4.2.1.6.2 Required: Report results 4.2.2 Material Requirements S
26、ponge only - Types 1 & 3 Material testing shall be done as closely as possible to finished product material conditions. 4.2.2.1 Compression Deflection 4.2.2.1.1 Method: Test per ASTM D 1056 on samples prepared in paragraph 19. 4.2.2.1.2 Required: Range shall be between 35 to 65 KPa or as specified b
27、y the class and specified by ASTM D 1056. 4.2.2.2 Water Absorption 4.2.2.2.1 Method: Test per ASTM D 1056 on samples prepared in paragraph 43. 4.2.2.2.2 Required: Weight shall not change more than 5% of the original weight. 4.2.2.3 Weather Resistance 4.2.2.3.1 Method: Test per ASTM D 1171 method D,
28、outdoor exposure. 4.2.2.3.2 Requires: Shall obtain 100% to pass. 4.3 Property and Performance Requirements Mechanical Properties The need for these tests, and details of the specific tests to be performed, will be indicated on the engineering drawing for the part or assembly. Additional details of t
29、he testing may be included in the Engineering Validation Plan for these parts. Unless otherwise specified all tests shall be performed on finished parts. Test fixtures, replicating, as closely possible, the production usage and intent shall be built. Details of the test fixtures, including engineeri
30、ng drawings and pictures shall be included in the suppliers qualification report (see Section 5.1). NUMBER: MPAPS K-6045 TITLE: Door and Body Seals (Rubber) REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical
31、 Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 4 of 11 4.3.1 Compression Load Deflection: ASTM D 575, Test Method A, except that a finished part shall be used. The direction and amount of deflection shall be indicated on the engineering drawi
32、ng. 4.3.2 Glass Edge Rub The glass system for this test consists of the door assembly, door module with below belt run seals, window crank (manual systems), drop glass, glass run seal, inner belt seal, and outer belt seal. All areas coated with flock or LFC must complete the following testing withou
33、t rub through, or any other defects that would affect the function of the system. Test Plan One Life = 50,000 cycles (full up to full down to full up) for front doors consisting of Ambient (235C) = 20,000 cycles Cold (-403C) = 7,500 cycles Hot (823C) = 7,500 cycles Humidity (403C 955% RH) = 15,000 c
34、ycles One Life = 20,000 cycles for rear doors consisting of Ambient (235C) = 8,000 cycles Cold (-403C) = 3,000 cycles Hot (823C) = 3,000 cycles Humidity (403C 955% RH) = 6,000 cycles The system must be tested to a B10 life of 50,000 cycles for front doors and 20,000 cycles for rear doors. The target
35、 program goals are R90 C95 using Weibull with = 1.5 for both power and manual systems. Full Inspection Every 5K Notify Navistar Engineering and Reliability departments of any concerns during the test to determine if the concerns are considered failures. Any concerns at less than one life are failure
36、s. 4.3.3 Load Loss Set 4.3.3.1 Method: Use samples from the Compression Load Deflection test to perform this test. Compress the samples using two compression plates that can be secured in the compressed state. Place the samples in an oven for 24 0.1 h 70 2C. Remove from the oven and remove the sampl
37、es from the compression plates. Allow the samples to cool for 1 0.1 h at room temperature 23 2C. Rerun the samples in the Compression Load Deflection test. 4.3.3.2 Required: Report. % allowed TBD. 4.3.4 Separation of the Bulb from the Carrier 4.3.4.1 Method: Prepare 25 mm (1”) sections from producti
38、on parts. Cut the bulb material on a taper so that the knit line, where the bulb meets the carrier, to be tested is 12.5 mm (.5 in). Measure and record the thickness of the bulb material at the knit line. Pull the sample at a rate of 500 mm/min (20.0 in/min). Tensile Strength (MPa) = (Load (N)/ (Are
39、a (12.5mm x Thickness, mm) 4.3.4.2 Required: Report the tensile strength of the samples. NUMBER: MPAPS K-6045 TITLE: Door and Body Seals (Rubber) REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
40、 Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 5 of 11 4.3.5 Splice Strength 4.3.5.1 Method: Prepare samples at 150 mm (6 in) long with the splice being at the center. Remove the bulb from the carrier and test the bulb section. Pull at a rate of 250 mm/
41、minute (10 in/min). 4.3.5.2 Required: Record the peak load and note any cohesive failures. 4.3.6 Thermal Shock 4.3.6.1 Method: Sample parts shall be subjected to four complete cycles consisting of the following sequence: 1) 853C (1855F) for 30 minutes. 2) -343C (-305F) ethylene glycol/H2O bath for 3
42、0 minutes. 4.3.6.2 Required: Samples should be 305 mm (12 in) and at least one sample should contain all of the bonded area. Samples shall be transferred immediately from one environment to the other with no time allowed between cycles. There shall be no evidence of cracking, splitting, and adhesion
43、 loss on bonded area, stress fractures, or any other defects. 4.3.7 Air Leakage 4.3.7.1 Method: Perform per TMS-9545. 0CFM at 1 in H20 4.3.7.2 Required: Under development 4.3.8 Water Leakage 4.3.8.1 Method: Perform per TMS-9545. 8 minutes at 40GFM. 4.3.8.2 Required: No leaking, breaking, dropping of
44、f or any other failures 5.0 QUALITY All parts supplied to this specification shall be uniform in appearance and free from pinholes, blowholes, bubbles, and mold flash. No change in the formulation shall be made by the supplier without prior approval of Materials Engineering. 5.1 Qualification Materi
45、als submitted for approval to this specification shall include the following: 5.1.1 A detailed, signed test report documenting testing to this specification per MPAPS P-9543. 5.1.2 The complete procedure used for preparing and curing materials for test, especially surface preparation (when appropria
46、te) and condition of the test materials. 5.1.3 A complete description, including engineering prints and pictures of any non-standard test fixtures used. 5.1.4 Adhesive, substrate and any chemicals used for bonding where appropriate. 5.2 Submission The material test report shall be submitted to: Mana
47、ger of Non-Metallic Materials Materials Engineering and Technology Navistar, Inc. 2601 Navistar Dr. Lisle, IL 60532 5.3 Approval A report from Navistar will be issued approving new materials to this specification. Formal approval is not granted until this report has been published and the new materi
48、al is listed in this specification. However, the approval report may be used as authorization for usage of that approved material/process prior to a change to this specification. NUMBER: MPAPS K-6045 TITLE: Door and Body Seals (Rubber) REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navis
