1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 07 20 N-STATUS Replaced by WSS-M15P50-B C. McComb, NA 2006 07 28 Activated A. ReaumePrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 9 PERFORMANCE, ENGINE COMPARTMENT AND UNDERBODY WSS-M15P50-A PLAST
2、IC COMPONENTS NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification addresses material durability for engine compartment and underbody plastic components that are not covered by other Ford performance specifications. 2. APPLICATION This specification addresses plastic components where no applica
3、ble Ford performance specification currently exists. This specification covers basic material durability and is comprised of two sections. Section A (para. 3.2) involves mainly preconditioning of parts that will go through full DV/PV testing, such as a new part. The preconditioned parts will then un
4、dergo the durability testing called out in the DVP. Section B (para. 3.3) involves basic material durability test requirements and should be used when full part validation is not required, such as a running change. Section B testing is performed on parts/test samples and should be used when no DVP d
5、urability testing is planned. This specification does not include fuel system components. 3. REQUIREMENTS Material 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 t
6、o the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). Data must be submitted to Materials Engineering upon completion of testing and before PPAP or SREA approval, see appendix A. 3.2 SECTION A, PRE-CONDITIONING OF PARTS Except for paragraph 3.2.5, the pass/fail criteria for
7、 this section are successfully passing the DV/PV testing. The sample size will be dependent on the DV/PV test plan. Subject the minimum number of parts (see table 1) to one cycle as described below: 3.2.1 Short Term Heat, Humidity and Cold Cycle High temperature will be dependent on location of the
8、component. The values below are estimates, if a component is exposed to a higher temperature based on historical data, use the higher temperature. Ramp speed 1 to 5 C per minute. Record actual ramp speed on data sheet. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-A Printed copies are uncontrolled Co
9、pyright 2010, Ford Global Technologies, LLC Page 2 of 9 High Temperature Components exposed to engine oil: 150 C Components exposed to engine coolant: 120 C Components bolted to engine (away from exhaust manifold): 150 C Under hood components not directly bolted to engine: 110 C Parts exposed to pow
10、er steering fluid or transmission fluid: 135 C Short Term Heat, Humidity and Cold Cycle . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at High Temperature +/- 2 C . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -
11、40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at High Temperature +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. 3.2.2 Short Term Heat, Condensing Humidity and Cold Cycle Substitute this test for parts that may be damaged by moisture ingression/freeze damage such as bonded or over molded parts w
12、ith different coefficients of expansion. Ramp speed 1 to 5 C per minute. This test requires 50 cycles of the following program: Short Term Heat, Condensing Humidity and Cold Cycle . 30 min at 23 +/- 2 C and 50% R.H. . 3 h at High Temperature +/- 2 C . 3 h at 65 +/- 2 C and 90 +/- 5% R.H. . 3 h at -
13、30 +/- 2 C 3.2.3 Long Term Heat Exposure . 1000 Hours at High Temperature +/- 2 C (as defined in 3.2.1) 3.2.4 Long Term Resistance to Fluids (continuous use) Test only materials that will be continuously exposed to the fluids listed below. Note the time and temperature for each fluid exposure. Sampl
14、es are to be immersed in, or filled with (depending on the part environment), the fluid for the time and temperature listed. Proper safety precautions must be followed when handling hot and/or flammable fluids. 3.2.4.1 Cooling Agent Resistance (1000 h at 125 +/- 2 C, 50/50 % vol coolant/water, engin
15、e coolant: WSS-M97B51-A1*) 3.2.4.2 Engine Oil Resistance (1000 h at 150 +/- 2 C, ASTM SF 105) ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 9 3.2.4.3 Brake Fluid Resistance (1000 h at 100 +/- 2 C, FMVSS DOT 3 or
16、 4*) 3.2.4.4 Fuel Resistance (1000 h at 40 +/- 2 C, 90% vol Fuel C, 10% vol Ethanol) 3.2.4.5 Windshield Washer Fluid Resistance (1000 h at 50 +/- 2 C, Motorcraft ZC-32 fluid, 1:1 dilution*) 3.2.4.6 Power Steering Fluid Resistance (1000 h at 135 +/- 2 C, WSA-M2C195-A*) 3.2.4.7 Automatic Transmission
17、Fluid Resistance (1000 h at 135 +/- 2 C, WSS-M2C938-A*) *Or currently released equivalent fluid 3.2.5 Short Term Resistance to Fluids (Splash Contact) (FLTM BO 101-05, except substitute each fluid below for the test fuel described in FLTM BO 101-05. Expose 1 part, or a section of a part, per fluid.
18、Exposed parts are evaluated per requirements below and do not need to undergo PV/DV tests.) The part shall not dissolve, exhibit tackiness, delaminate, crack, or craze when exposed to each of the fluids listed below. Use a new part for each test reagent. Record condition of parts after each test int
19、erval. Proper safety precautions must be followed when handling hot and/or flammable fluids. Test Reagents 1. 3% by wt. Sodium Chloride solution in Water 2. Engine oil, ASTM SF 105 3. Fuel C with 10 % Ethanol (by volume) 4. Brake fluid FMVSS DOT 3 or 4* 5. Engine coolant WSS-M97B51-A1 (50% by volume
20、 in distilled water)* 6. Window washer solvent Motorcraft ZC-32 fluid, 1:1 dilution * 7. Ford Motorcraft Engine Cleaner 8. Sulfuric acid (6% by volume in distilled water) *Or currently released equivalent fluid. Parts where liquid exposure to battery acid is likely, parts near or under the battery,
21、substitute fluid 8 with the following test method: Test method: FLTM BO 101-05, except use as a test fluid sulfuric acid/water solution (37%) with a density of 1.28 g/cm3. Paragraph 1 of procedure warming of specimen shall be omitted. Evaluate per 3.2.5. 3.3 SECTION B, MATERIAL DURABILITY Section B
22、involves basic material durability test requirements and should be used when full part validation is not required, such as a running change. With the exception of paragraphs 3.3.4 and 3.3.5 all of the testing is performed on parts. See table 1 for sample size requirements. ENGINEERING MATERIAL SPECI
23、FICATIONWSS-M15P50-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 9 3.3.1 Environmental Testing Sample Preparation: All parts shall be fully assembled including all components packaged in the environment and assembled onto actual or representative productio
24、n 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 shall be the same as proposed for production. Measurement Locations: Once the
25、 assembly is fixtured measure all critical dimensions including attachment points, package space and critical GDT tolerances. Measurement Technique: The movement at each measurement point shall be recorded in two directions: (1) in the x/y plane from the observers view, and (2) in the z-dimension di
26、rection into or out of the x/y plane from the observers view. The observers view shall remain consistent always viewing from the front side of the part. Test Procedure Visually evaluate the part before, during, and after the test. Measure the part and record data at all specified locations at room t
27、emperature before and after cycling on the production support foundation or test fixture. Also, during para. 3.3.1.1 “Short Term Heat and Cold Cycle“ testing, visually evaluate the part and measure any significant characteristic locations only, after each cold, extreme humidity and extreme hot tempe
28、rature period. For 3.3.1.2 “Short Term Heat, Condensing Humidity and Cold Cycle“ visually evaluate the part before the test and after the last test cycle. Measure the part and record data at all specified locations at room temperature before and after cycling on the production support foundation or
29、test fixture. Subject the number of assemblies specified (see table 1) to each of the cycles that follow in paragraphs 3.3.1.1, 3.3.1.2 and 3.3.1.3. Automated programmable test cycles based on the listed test conditions may be accepted by prior agreement with the affected Materials Engineering Activ
30、ity. Ramp speed 1 to 5 C per minute. Record actual ramp speed on data sheet. Requirements: The component assemblies shall remain relatively unaffected by the exposure cycles during and after the tests as demonstrated: 1) Tactually/visually-no cracking or crazing, no excessive tackiness, surface-colo
31、r change; no wrinkling, distortion, blistering, warping, delamination, blushing, hazing, milking, staining, waviness, or other objectionable visual appearance. 2) Functionally-no excessive expansion, shrinking, or warping that will interfere with normal functional operations or contact adjacent comp
32、onents. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 9 3.3.1.1 Short Term Heat, Humidity and Cold Cycle High temperature will be dependent on location in engine compartment. The values below are estimates, if a
33、 component sees a higher temperature based on historical data, use the higher temperature. Subject the minimum number of parts (see table 1) to one cycle as described below: High Temperature Components exposed to engine oil: 150 C Components exposed to engine coolant: 120 C Components bolted to engi
34、ne (away from exhaust manifold): 150 C Under hood components not directly bolted to engine: 110 C Parts exposed to power steering fluid or transmission fluid: 135 C Short Term Heat, Humidity and Cold Cycle . 5 h at -40 +/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record) .
35、5 h at High Temperature +/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record) . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record) . 5 h at - 40 +/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and re
36、cord) 3.3.1.2 Short Term Heat, Condensing Humidity and Cold Cycle Substitute this test for parts that may be damaged by moisture ingression/freeze damage such as bonded or over molded parts with different coefficients of expansion. Ramp speed 1 to 5 C per minute. Evaluate after 25 cycles and at end
37、of test. This test requires 50 cycles of the following program: Short Term Heat, Condensing Humidity and Cold Cycle . 30 min at 23 +/- 2 C and 50% R.H. . 3 h at High Temperature +/- 2 C . 3 h at 65 +/- 2 C and 90 +/- 5% R.H. . 3 h at -30 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. ENGINEERING MATERI
38、AL SPECIFICATIONWSS-M15P50-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 9 3.3.1.3 Long Term Heat Exposure (See table 1 for minimum sample size) . 1000 Hours at High Temperature +/- 2 C (as defined in 3.3.1.1) 3.3.2 Impact Resistance (Steel ball: 525 +/- 5
39、 g, 50 +/- 2 mm diameter, 440C Stainless Steel Grade: 100, Hardness Rockwell C 57 to 61. Test at 23 +/- 2 C) The assembly shall show no evidence of cracking or breaking and shall fully recover from indentation in the time required for the assembly to return to 23 +/- 2 C. Test Method: Conduct this t
40、est with the assembly mounted on an actual or simulated production support foundation using the approved retention methods. Drop the ball from the height specified below at areas where impact damage is likely or as indicated on the Engineering Drawing. Drop Height . Unprotected areas below the exhau
41、st manifold: 610 mm . Areas above the exhaust manifold where customer/service contact likely: 460 mm Exception to the above requirements shall be specified on the Engineering Drawing. 3.3.3 Short Term Resistance to Fluids (Splash Contact) (FLTM BO 101-05, except substitute each fluid below for the t
42、est fuel described in FLTM BO 101-05. Expose 1 part, or a section of a part, per fluid. Exposed parts are evaluated per requirements below and do not need to undergo PV/DV tests.) The part shall not dissolve, exhibit tackiness, delaminate, crack, or craze when exposed to each of the fluids listed be
43、low. Use a new part for each test reagent. Record condition of parts after each test interval. Proper safety precautions must be followed when handling hot and/or flammable fluids. Test Reagents 1. 3% by wt. Sodium Chloride solution in Water 2. Engine oil, ASTM SF 105 3. Fuel C with 10% Ethanol (by
44、volume) 4. Brake fluid FMVSS DOT 3 or 4* 5. Engine coolant WSS-M97B51-A1 (50% by volume in distilled water)* 6. Window washer solvent Motorcraft ZC-32 fluid, 1:1 dilution * 7. Ford Motorcraft Engine Cleaner 8. Sulfuric acid (6% by volume in distilled water) *Or currently released equivalent fluid. P
45、arts where liquid exposure to battery acid is likely, parts near or under battery, substitute fluid 8 with the following test method: Test method: FLTM BO 101-05, except use as a test fluid sulfuric acid/water solution (37%) with a density of 1.28 g/cm3, para. 1 of procedure warming of specimen shal
46、l be omitted. Evaluate per 3.3.3. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 7 of 9 3.3.4 Long Term Resistance to Fluids (Continuous Use) (Impact Strength, Notched Izod, ISO 180/1A, 80 x 10 x 4.0 +/- 0.2 mm specim
47、en use center section of specimen A, 10 specimens for each test, specimens to be notched before immersion) Test materials that will be continuously exposed to the fluids below. Record the time and temperature for each fluid exposure. Samples are to be immersed in the fluid for the time and temperatu
48、re specified. Report the loss of impact strength versus unaged samples. Unaged samples shall be tested at the same time as the aged samples. If a Ford material specification is being used and already contains this data, this testing does not have to be performed. Proper safety precautions must be fo
49、llowed when handling hot and/or flammable fluids. 3.3.4.1 Cooling Agent Resistance -25% max (FLTM BO 130-01, 1000 h at 125 +/- 2 C, 50/50% vol coolant/water, engine coolant: WSS-M97B51-A1*) 3.3.4.2 Engine Oil Resistance -25% max (1000 h at 150 +/- 2 C, ASTM SF 105) 3.3.4.3 Brake Fluid Resistance -25% max (1000 h at 100 +/- 2 C, FMVSS DOT 3 or 4*) 3.3.4.4 Fuel Resistance -25% max (1000 h at 40 +/- 2 C, 90% vol Fuel C, 10% vol Ethanol) 3.3.4.5 Windshield Washer Fluid Resistance -25% max (1000 h at 50 +/- 2 C
