1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 03 09 Activated Balloted for Globalization, added stress cracking resistance. Replacing WSS-M15P50-A C. McComb, NA Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 9 PERFORMANCE, ENGINE COMPARTMENT A
2、ND UNDERBODY WSS-M15P50-B PLASTIC COMPONENTS 1. SCOPE This specification addresses material durability for engine compartment and underbody plastic components that are not covered by other Ford performance specifications. This specification does not include fuel system components. 2. APPLICATION Thi
3、s specification addresses plastic components where no applicable 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 testi
4、ng, such as a new part. The preconditioned parts will then undergo 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 per
5、formed on parts/test samples and should be used when no DVP durability testing is planned. 2.1 LIMITATIONS Excluded from this specification are underbonnet labels (WSS-M99P34-latest and WSS-M99P41-latest) thermal and acoustic assembly (WSS-M99P32-latest) exterior lighting (WSK-M98P10-latest) and pai
6、nted parts (WSS-), exterior plastics (WSS-M99P13-latest) whose performance is specified separately. 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
7、 conform to 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 Unless otherwise noted, the cycled part, if
8、appearance item, shall show no color change in excess of Grey Scale rating 4 (AATCC Evaluation Procedure 1/ISO 105-A02) when compared with the original part. (A color tone shift to the yellow direction is allowed up to Grey Scale rating 4. No other tone change (e.g. pink) is allowed.) For visible an
9、d non visible parts no visible cracks, blisters, softening, dulling, or evidence of material degradation when observed with the unaided eye from a distance of 300 +/- 30 mm. Except for paragraph 3.2.5, the pass/fail criteria for this section are successfully passing the DV/PV testing. The sample siz
10、e will be dependent on the DV/PV test plan. Subject the minimum number of parts (see table 1) to one cycle as described below: ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 9 3.2.1 Short Term Heat, Humidity and
11、Cold Cycle (FLTM BQ 104-07 for conditioning guidelines) High temperature will be dependent on location of the 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 actu
12、al ramp speed on data sheet. 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 power steering fluid or transm
13、ission 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 -40 +/- 2 C . 30 min at 23 +
14、/- 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 with different coefficients
15、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 - 30 +/- 2 C 3.2.3 Long Term
16、Heat Exposure 3.2.3.1 Short 7 days at 25C above High Temperature +/- 2 C (as defined in 3.2.1) 3.2.3.2 Extended 1000 Hours at High Temperature +/- 2 C (as defined in 3.2.1) ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Pa
17、ge 3 of 9 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. Samples are to be immersed in, or filled with (depending on the part environment), the fluid for th
18、e 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, engine coolant: WSS-M97B51-A1*) 3.2.4.2 Engine Oil Resistance (1000 h at 150 +/- 2 C, ASTM SF 105)
19、3.2.4.3 Brake Fluid Resistance (1000 h at 100 +/- 2 C, FMVSS DOT 3 or 4*) 3.2.4.4 Windshield Washer Fluid Resistance (1000 h at 50 +/- 2 C, Motorcraft ZC-32 fluid, 1:1 dilution*) 3.2.4.5 Power Steering Fluid Resistance (1000 h at 135 +/- 2 C, WSA-M2C195-A*) 3.2.4.6 Automatic Transmission Fluid Resis
20、tance (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. Exposed par
21、ts 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 interval. Prop
22、er 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 in distill
23、ed water)* 6. Window washer solvent Motorcraft ZC-32 fluid, 1:1 dilution * 7. Motorcraft Engine Shampoo and Degreaser 8. Sulfuric acid (6% by volume in distilled water) *Or currently released equivalent fluid. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-B Printed copies are uncontrolled Copyright 2
24、010, Ford Global Technologies, LLC Page 4 of 9 Parts where liquid exposure to battery acid is likely, parts near or under the 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
25、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 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 pa
26、ragraphs 3.3.4 and 3.3.5 all of the testing is performed on parts. See table 1 for sample size requirements. 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 production
27、 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
28、assembly is mounted onto a fixture, 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
29、z-dimension direction 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 locat
30、ions at room temperature 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 ext
31、reme hot temperature 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
32、foundation or 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 Eng
33、ineering Activity. Ramp speed 1 to 5 C per minute. Record actual ramp speed on data sheet. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 9 Requirements: The component assemblies shall remain relatively unaffecte
34、d by the exposure cycles during and after the tests as demonstrated: 1) Tactually/visually-no cracking or crazing, no excessive tackiness, surface-color change; no wrinkling, distortion, blistering, warping, delamination, blushing, hazing, milking, staining, waviness, or other objectionable visual a
35、ppearance. 2) Functionally-no excessive expansion, shrinking, or warping that will interfere with normal functional operations or contact adjacent components. 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 e
36、stimates, if a 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
37、bolted to engine (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
38、and record) . 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. (
39、observe and record) 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 cycl
40、es and at end of test. This test requires 50 cycles of the following program: ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-B Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 9 Short Term Heat, Condensing Humidity and Cold Cycle . 30 min at 23 +/- 2 C and 50% R.
41、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. 3.3.1.3 Long Term Heat Exposure (See table 1 for minimum sample size) 3.3.1.3.1 Short 7 days at 25C above High Temperature +/- 2 C (as defined in 3.2.1) 3.3.1.3.2 Exte
42、nded 1000 Hours at High Temperature +/- 2 C (as defined in 3.2.1) 3.3.2 Impact Resistance (Stainless steel ball: 525 +/- 5 g, 50 +/- 2 mm diameter, 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 as
43、sembly to return to 23 +/- 2 C. Test Method: Conduct this test 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 Engineeri
44、ng Drawing. Drop Height . Unprotected areas below the exhaust 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) (F
45、LTM 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. Exposed parts are evaluated per requirements below and do not need to undergo PV/DV tests.) The part shall not dissolve, exhibit tackiness, delaminate, c
46、rack, 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 interval. Proper safety precautions must be followed when handling hot and/or flammable fluids. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P50-B Printed copie
47、s are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 7 of 9 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 in distilled wat
48、er)* 6. Window washer solvent Motorcraft ZC-32 fluid, 1:1 dilution * 7. Motorcraft Engine Shampoo and Degreaser 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 battery, substitute f
49、luid 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 shall be omitted. Evaluate per 3.3.3. 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 specimen use center section of specimen A, 10 specimens for each test, specimens to be notched before immersion) Test materials that will be continuousl
