1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2013 12 09 N Status A1 Replaced by WSS-M4D1051-A1/2, WSS-M4D1052-A1/2, WSS-M4D1052-A1/2 L. Soreide, NA 2010 12 14 A1 Re-Activated Move A1 back to active status L. Soreide, NA 2010 09 10 N-STATUS Replaced by WSS-M4D1051-A1, WSS-M4D1052-A2, WSS
2、-M4D1053-A1, WSS-M4D1053-A2 L. Soreide, NA 1975 12 12 Released AF1-6000-53 Copyright 2013, Ford Global Technologies, LLC Page 1 of 4 POLYCARBONATE (PC), GENERAL PURPOSE GRADE NOT FOR NEW DESIGN ESF-M4D100-A1 POLYCARBONATE (PC), OPTICAL GRADE COATED NOT FOR NEW DESIGN ESB-M4D100-A2 POLYCARBONATE (PC)
3、, OPTICAL GRADE UNCOATED NOT FOR NEW DESIGN ESB-M4D100-A3 1. SCOPE The materials defined by these specifications are polycarbonate resins characterized by high strength and high heat resistance. These materials are naturally transparent. Three types are defined. 2. APPLICATION ESF-M4D100-A1: This sp
4、ecification was released originally for material used in applications requiring optical clarity, such as instrument cluster light filters and lenses. This material may be color pigmented when optical transparency is not required, and may be specified for applications requiring high strength and high
5、 impact resistance. This general purpose resin is not used for exterior signal lenses. ESB-M4D100-A2: This specification was released originally for material used in exterior signal lamp lenses incorporating reflex reflectance where any surface change due to weathering is unacceptable (SAE J 576c).
6、These applications, when using material defined by this specification, must have an approved coating (para 3.4.5) applied to the first surface. ESB-M4D100-A3: This specification was released originally for material used in uncoated exterior signal lamp lenses not incorporating reflex reflectance. No
7、te: Materials defined by ESF-M4D100-A1 or ESB-M4D100-A2 designation correspond to former ESF-M4D100-A, Type I or Type II designation as follows: ESF-M4D100-A1 replaces ESF-M4D100-A, Type I ESB-M4D100-A2 replaces ESF-M4D100-A, Type II Existing drawings specifying ESF-M4D100-A, Type I or Type II, do n
8、ot require revision to reflect this new classification. ESF-M4D100-A specification shown without type designation is understood to be ESF-M4D100-A1. ESF-M4D100-A1 also replaces ESB-M4D100-A1. Drawings showing the ESB-M4D100-A1 do not require revision to reflect the ESF designation. 3. REQUIREMENTS 3
9、.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 MOLDED TEST SPECIMEN The following requirements are intended for initial source qualifications, and Initial Sample
10、 Inspection Report. These will be rechecked at intervals specified by Quality Assurance. ENGINEERING MATERIAL SPECIFICATION ESF-M4D100-A1 ESB-M4D100-A2/A3 Copyright 2013, Ford Global Technologies, LLC Page 2 of 4 3.2.1 Preparation of Test Specimens All test specimens shall be injection molded in acc
11、ordance with ASTM D 1897. The values of this specification are based on natural color, injection molded specimens unless otherwise specified. ESF-M4D100-A1 ESB-M4D100-A2 ESB-M4D100-A3 3.2.3 Specific Gravity 1.19 - 1.26 1.22 max (ASTM D 792) 3.2.4 Tensile Strength, MPa, min (ASTM D 638, Type 1 specim
12、en, 50 mm/minute test speed) Natural 59 56 Pigmented 57 55 Elongation, % min 60 100 3.2.5 Flexural Modulus, GPa, min 2 2.1 (ASTM D 790, Method I, Procedure A) 3.2.6 Flexural Strength, MPa, min 76 83 (ASTM D 790 Method I, Procedure A) 3.2.7 Impact Strength, Izod, J/m, min (ASTM D 256, 63.5 x 12.7 x 3
13、.2 mm specimen) 3.2.7.1 Notched Natural 640 640 Pigmented 534 534 3.2.7.2 Unnotched 3200 2400 3.2.8 Heat Deflection Temperature, C, min (ASTM D 648, 127 x 12.7 x 6.4 mm specimen) At 1.82 MPa 124 121 At 0.45 MPa - 135 ENGINEERING MATERIAL SPECIFICATION ESF-M4D100-A1 ESB-M4D100-A2/A3 Copyright 2013, F
14、ord Global Technologies, LLC Page 3 of 4 3.3 OPTICAL PROPERTIES (ESB-M4D100-A2 and A3) 3.3.1 Haze, max 2.0% (ASTM D 1003) 3.3.2 Luminous Transmission, min 87.0% (ASTM D 791, 3.2 mm molded disc) 3.3.3 Color As specified on the engineering drawing. Color shall match master sample approved for producti
15、on on file in the Quality Control or Product Engineering Laboratory. 3.3.4 Resistance to Fade No change in color (FLTM BN 001-01) after exposure to 500 SFH. 3.4 MOLDED PART 3.4.1 Color Natural or as specified on engineering drawing. 3.4.2 Appearance Shall be uniform in density, texture and finish, f
16、ree of visible porosity, warpage, heat scorch, checks, cracks, chipped edges and uneven surfaces. Shall also be free of other contamination. 3.4.3 Heat Resistance Finished parts must pass the following test. Test Method: Condition the parts for 3 h in a mechanical convection oven maintained at 107 +
17、/- 3 C (or as otherwise specified on engineering drawing). After removal, parts shall exhibit no more than 0.5% shrinkage. There shall be no local shrinkage where the part has been gated which will interfere with assembly to mating parts of affects its appearance. The part shall not warp to an exten
18、t that would affect its use in ultimate assembly. 3.4.4 Optics - Including Outdoor Exposure, for Exterior Lens Applications 3.4.4.1 ESB-M4D100-A2 Parts must be molded from a material which conforms to the requirements of SAE J 576c and any further special requirements indicated on the engineering dr
19、awing. In addition, proof of ETL approval and State of California Highway Patrol approval must be furnished to PEO on samples weathered for 3 years in both Florida and Arizona. ENGINEERING MATERIAL SPECIFICATION ESF-M4D100-A1 ESB-M4D100-A2/A3 Copyright 2013, Ford Global Technologies, LLC Page 4 of 4
20、 3.4.4.2 ESB-M4D100-A3 Material approved to this specification must satisfy all requirements of 3.4.4.1 with the noted exception of surface haze. After outdoor exposure, surface haze shall not exceed 30%. 3.4.5 Clear Coating (ESB-M4D100-A2 only) The polycarbonate, clear coat system shall conform to
21、all requirements of ESB-M2P80. Only those clear coatings approved by the responsible PEO and referenced in the general information section of ESB-M2P80 shall be utilized. 3.5 FLAMMABILITY Burn Rate, max 100 mm/min (FLTM BN 024-02, without the lot Self-extinguishing (SE) sampling plan) In addition, t
22、he test specimen shall not exhibit any flashing or sudden flaming on either surface in excess of the above maximum value. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. 5.1 DIELECTRIC STRENGTH 13.8
23、kV/mm (ASTM D 149, short time) 5.2 WATER ABSORPTION, by weight 0.5% (ASTM D 570) 5.3 MOLD SHRINKAGE 0.005 - 0.007 (ASTM D 955) 5.4 COEFFICIENT OF LINEAR THERMAL EXPANSION 6.75-5/C (ASTM D 696) 5.5 REFRACTIVE INDEX (ASTM D 542) ESB-M4D100-A2 and A3 only 1.58 5.6 HARDNESS, ROCKWELL M 65 - 80 (ASTM D 785) 5.7 CHEMICAL SENSITIVITY These materials are soluble in chlorinated hydrocarbons and aromatic solvents. 5.8 FLEXURAL MODULUS ESF-M4D100-A1 only 2 GPa (ASTM D 790, Method I, Procedure A)
