1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 01 06 Released K. Mueller, FNA Controlled document at www.MATS.com Copyright 2017, Ford Global Technologies, LLC Page 1 of 10 PERFORMANCE, PLASTIC COMPONENTS, ENGINE PRECONDITIONING WSS-M15P50-C1 PERFORMANCE, PLASTIC COMPONENTS,
2、UNDERBODY, UNDERHOOD, ENGINE WSS-M15P50-C2 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 WSS-M
3、15P50-C1: This specification is intended for Engine Released plastic parts. These preconditioned parts will go through full DV/PV testing. (Examples: intake manifolds, air induction components, etc.). Testing must be done on parts as detailed in Table 1.0, unless specified by Ford Design and Release
4、 and Ford Materials Engineering Activities. In addition, this specification may be used when color matching is required for engine plastic components. WSS-M15P50-C2: This specification is intended for parts that do not require preconditioning. It addresses material durability of parts, such as washe
5、r bottles, battery trays, underbody/aeroshields, belly pans, wheel arch liners, AGS/GOR/FEM/Bolster, air deflectors, etc. Testing requirements are referenced in paragraph 3.4. In addition, this specification may be used when color matching is required for underhood/underbody/engine plastic component
6、s. Excluded from this specification are underbonnet labels (WSS-M99P41-latest), thermal and acoustic assembly (WSS-M99P32-latest), exterior lighting (WSK-M98P10-latest), painted parts (WSS-M2P180-latest, or WSS-M2P181-latest), exterior plastics (WSS-M9P13-latest), Windshield Washer Solvent Performan
7、ce (WSS-M14P19-latest), and Fuel System Parts Performance (WSS-M98P14-latest) whose performance is specified separately. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.1 APPROVED SOURCES This specification is performance based and does no
8、t have approved sources Data must be submitted to Ford Engineering upon completion of testing and before PPAP or SREA approval, see appendix A. 3.2 MATERIAL REQUIREMENTS Data must be submitted via the Ford Materials Database (FMD) template. 3.2.1 Density (ISO 1183, Method A) Report Value, g/cm3 ENGI
9、NEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2017, Ford Global Technologies, LLC Page 2 of 10 3.2.2 Melt Flow Rate Report Value, (ISO 1133 190 C, 21.6 kg) g/10 minutes 3.3 WSS-M15P50-C1: ENGINE PRE-CONDITIONING Unless otherwise noted, the cycled part, if appearance item, shal
10、l 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 and non visible parts n
11、o 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 3.3.5, the pass/fail criteria for this section are successfully passing the DV/PV testing. The sample size will be dependent o
12、n the DV/PV test plan. Subject the minimum number of parts (see Table 1.0) to one cycle as described below: 3.3.1 Short Term Heat, Humidity and 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
13、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. High Temperature (use maximum TASE temperature). If maximum TASE temperature is not known, use the following: Components expose
14、d 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 transmission fluid: 135 C Short Term Heat, Humidity and Cold Cycle .
15、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 +/- 2 C and 50% R.H. . 5 h at High Temperature +/- 2 C . 30 min
16、at 23 +/- 2 C and 50% R.H. 3.3.2 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. This test require
17、s 50 cycles of the following program: ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2017, Ford Global Technologies, LLC Page 3 of 10 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
18、C and 90 +/- 5% R.H. . 3 h at - 30 +/- 2 C 3.3.3 Long Term Heat Exposure 3.3.3.1 Short 7 days at 5C above High Temperature +/- 2 C (as defined in 3.3.1) (as defined in 3.3.1, except use 100 +/- 2 C for HDPE applications) 3.3.3.2 Extended 1000 Hours at High Temperature +/- 2 C (as defined in 3.3.1) (
19、as defined in 3.3.1, except use 100 +/- 2 C for HDPE applications) 3.3.4 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 w
20、ith (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. 3.3.4.1 Cooling Agent Resistance (1000 h at 125 +/- 2 C, 50/50 % vol coolant/water, engine coolant: WSS-M97B51-A1*) 3.3.4.2 En
21、gine Oil Resistance (1000 h at 150 +/- 2 C, ASTM SF 105) 3.3.4.3 Brake Fluid Resistance (1000 h at 100 +/- 2 C, FMVSS DOT 3 or 4*) 3.3.4.4 Windshield Washer Fluid Resistance (1000 h at 50 +/- 2 C, Motorcraft ZC-32 fluid, 1:1 dilution*) 3.3.4.5 Power Steering Fluid Resistance (1000 h at 135 +/- 2 C,
22、WSA-M2C195-A*) 3.3.4.6 Automatic Transmission Fluid Resistance (1000 h at 135 +/- 2 C, WSS-M2C938-A*) *Or currently released equivalent fluid 3.3.5 Short Term Resistance to Fluids (Splash Contact) (FLTM BI 168-01, Expose 1 part, or section of a part, per fluid. Exposed parts are evaluated per FLTM B
23、I 168-01 and do not need to undergo PV/DV tests.) Parts where liquid exposure to battery acid is likely, parts near or under battery, substitute battery acid (6% by weight H2SO4) with battery acid ( 37% by weight H2SO4 with a density of 1.28 g/cm3). Paragraph 1. of procedure warming of test specimen
24、 shall be omitted. ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2017, Ford Global Technologies, LLC Page 4 of 10 3.4 WSS-M15P50-C2: UNDERBODY, UNDERHOOD, ENGINE PERFORMANCE This includes plastic underbody/aeroshields, wheel arch liners, washer bottles, underhood deflector
25、s, AGS/GOR/FEM/Bolster, and other plastic engine compartment parts. See Table 2.0 for test sample description: Type (plaques or part/component) and Quantity. Test Plaques Testing: Test plaques must be prepared with the production material (density and melt flow rate) using the production process (in
26、jection molding or vacuum forming) conditions. Part/Component Testing is applicable per judgment of Ford Product Development Engineering Activity: Parts shall be fully trimmed including all components packaged in the environment and assembled onto actual or representative production support foundati
27、ons. This includes not only all attaching points, but also any boundary conditions that may restrict movement, unless otherwise specified by the responsible PD Engineer. The retention methods, attachments, and supporting garnish moldings (if any), shall be the same as proposed for production. All te
28、st values are based on a part conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. 3.4.1 Environmental Testing Measurement: Once the assembly is mounted onto a fixture, measure all critical dimensions including attachment poin
29、ts, package space and critical GDT tolerances. Test Procedure Visually evaluate the part before, during, and after the test. Measure the part and record data at all specified locations at room temperature before and after cycling on the production support foundation or test fixture. For 3.4.1.1 “Sho
30、rt 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 temperature period. For 3.4.1.2 “Short Term Heat, Condensing Humidity and Cold Cycle“ visually evaluate the part before the te
31、st 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 test fixture. Subject the number of assemblies specified (see Table 2.0) to each of the cycles that follow in paragraphs
32、3.4.1.1, 3.4.1.2 and 3.4.1.3. Automated programmable test cycles based on the listed test conditions may be accepted by prior agreement with the affected Materials Engineering Activity. Ramp speed 1 to 5 C per minute. Record actual ramp speed on data sheet. Acceptance Criteria: No cracking, crazing,
33、 tackiness, surface-color change, wrinkling, blistering, warping, delamination, permanent surface distortion, or softening. After testing is complete, part must be able to function (as reviewed by Ford Design and Release Engineering Activity). ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15
34、P50-C2 Copyright 2017, Ford Global Technologies, LLC Page 5 of 10 3.4.1.1 Short Term Heat, Humidity and Cold Cycle High temperature will be dependent on part location. The values below are estimates, if a component sees a higher temperature based on historical data, use the higher temperature. Subje
35、ct the minimum number of parts (see Table 2.0) to one cycle as described below: High Temperature (use maximum TASE temperature). If maximum TASE temperature is not known, use the following: Underbody Shields, Wheel Arch Liners, 100 C Washer Reservoirs/Bottles 90 C (The reservoir to be filled With H2
36、O to its design capacity) AGS/GOR/FEM/Bolster 110 C 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
37、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 results) . 5 h at High Temperature +/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record results) . 2 h at 50 +/- 2 C
38、and 95 +/- 5% R.H. . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record results) . 5 h at - 40 +/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record results) 3.4.1.2 Short Term Heat, Condensing Humidity and Cold Cycle (Use only for parts that may be damaged b
39、y 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 of test. This test requires 50 cycles of the following program: ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-
40、M15P50-C2 Copyright 2017, Ford Global Technologies, LLC Page 6 of 10 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. 3.4.1.3 Long
41、Term Heat Exposure (See Table 2.0 for minimum sample size) 3.4.1.3.1 Short 7 days at 5 C above High Temperature +/- 2 C (as defined in 3.4.1, except use 90 C for washer Reservoirs/Bottles. All other HDPE applications use 100 +/- 2 C). 3.4.1.3.2 Extended - Not required if material is already approved
42、 1000 Hours at High Temperature +/- 2 C (as defined in 3.4.1, except use except use 90 C for washer Reservoirs/Bottles. All other HDPE applications use 100 +/- 2 C). 3.4.2 Gravelometer Report (Mid-rocker Underbody Shields and Front Wheel Arch/Well Liners Only) (SAE J400 / ISO 20567-1, 5 cycles of 70
43、0g (473ml), at 23 +/- 2 C and -30 +/- 2 C, test specimens size 100 x 305 mm (4 x 12 in), impingement angle at 45 degrees with edge-supported backer plate) There shall be no holes, separation, or other changes that impact the function or reduce the perceived quality of the vehicle. 3.4.3 Short Term R
44、esistance to Fluids (Splash Contact) Report (FLTM BI 168-01) 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. Parts where liquid expos
45、ure to battery acid is likely, parts near or under battery, substitute Battery Acid (6% by weight H2SO4) with Battery Acid ( 37% by weight H2SO4 with a density of 1.28 g/cm3). Paragraph 1. of procedure warming of test specimen shall be omitted. ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M1
46、5P50-C2 Copyright 2017, Ford Global Technologies, LLC Page 7 of 10 Underhood/Underbody Parts use: Gasoline: Any commercially available lead free product with 20% laboratory grade ethanol. Windshield wash fluid, methanol based. 1 part Motorcraft fluid to 1.5 parts water Motorcraft ZC-20 Engine Shampo
47、o and Degreaser Diesel: Any commercially available low sulfur diesel, grade 2 with 20% (by volume) biodiesel added. (any commercially available type) Transmission Fluid (Mercon or Ford brand) Coolant: Motorcraft full OAT 50/50 dilution Battery Acid (6% by weight H2SO4) Engine Oil: Any commercially a
48、vailable engine oil meeting the latest API-ILSAC requirements. Brake Fluid (DOT 3 or DOT 4) Deionized Water with 3% sodium chloride (w/w) 3.4.4 Long Term Resistance to Fluids (Continuous Use Only) (Impact Strength, Notched Charpy, ISO 179-1/1eA, specimen D mm specimen use center section of specimen
49、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 temperature 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 testin
