1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 00 2015 10 15 Released M. Katz, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 9 THERMOPLASTIC POLYOLEFIN ELASTOMER (TPO), 24% MINERAL FILLED, WSS-M4D1057-A1 MOLD IN COLOR, HIGH IMPACT, UV STABI
2、LIZED, MOLDING COMPOUND, EXTERIOR 1. SCOPE The material defined by this specification is a 24% mineral filled, impact modified, low thermal expansion, UV stabilized thermoplastic polyolefin elastomer (TPO) injection molding compound for mold-in-color applications. 2. APPLICATION This specification w
3、as released originally for material used for exterior mold-in-color applications, which require low thermal expansion, low molding shrinkage, and good weatherability, such as grilles or exterior trim. 2.1 LIMITATIONS Materials approved to this specification may contain additives which inhibit adhesi
4、on, and therefore should not be used in painted applications. These materials are not intended for high gloss applications. Final part gloss levels are dependant on multiple factors, including part design, molding and tooling. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use
5、of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engineer. 3.2 C
6、ONDITIONING AND TEST CONDITIONS All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 INFRARE
7、D SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms from initial material approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. The material supplier shall ensure that all future material supplied to the specification sha
8、ll produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.4.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicated that the me
9、an and +/- 3 sigma values were to be reported. The specification minimum, maximum or range was established using 3 sigma data. For 2011 and beyond, refer to Tables 1 and 2 for number of samples required for each test 3.4.2 This specification is based on virgin material and does not allow the additio
10、n of recycled content (PIR/PCR). ENGINEERING MATERIAL SPECIFICATION WSS-M4D1057-A1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 9 3.4.3 Materials requiring High Strain Rate, Creep or fiber oriented Tensile Modulus may be required to test to the requirements of WSS-M99D68-A1/Latest, Thermo
11、plastic Property Determination For CAE, High Strain Rate Tensile, Creep and Tensile Modulus. Data must be included in the material submission package. 3.4.4 Performance Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS-M98P13-E/Latest. 3.4.5 As speci
12、fied in WSS-M99P1111-A, paragraph 3.2, Ford Materials Engineering may request a Control Plan and Certificate of Analysis (CofA) containing lot testing requirements which must include, but are not limited to: Melt Flow Rate Determination of Ash Impact Strength, Notched Charpy at 23C Flexural Modulus
13、3.5 SAMPLE PREPERATION All tests shall be carried out on production materials manufactured from the production process unless correlation to a non-production process has been reviewed and approved by Ford Materials Engineering. Unless otherwise specified all tests shall be carried out on injection m
14、olded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defined in ISO 1873-2. No additional annealing is allowed. See Tables 1 for the number of samples required. Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2,
15、 Specimen Type 1A) Specimen B 355 x 100 x 1.0 +/- 0.1 mm (ISO 3795) Specimen C 145 x 60 x 3.2 +/- 0.2 mm Specimen D Center of Specimen A. 80 x 10 x 4.0 +/- 0.2 mm Specimen E 100 mm diameter x 3.2 mm Specimen F 80 mm diameter x 3.2 mm Specimen G 90 mm x 200 mm Specimen H 50 +/- 1 mm diameter x 3.2 +/
16、- 0.2 mm Specimen I 100 mm x 150 mm, min 3.6 APPEARANCE 3.6.1 Accelerated Weathering Resistance Preferred Method 3.6.1.1 Standard Practice for Xenon Arc Exposure Test Requirements per Table with Enhanced Light and Water Exposure for Transportation Coatings (ASTM D7869, Use an ungrained, non-polished
17、, tool to prepare specimen for C through N gloss, use a smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) or 3.6.1.2 Performance Based Standard for Accelerated Requirements per Table Exposure of Automotive Exterior Materials Using Controlled Irra
18、diance Xenon-Arc Apparatus ENGINEERING MATERIAL SPECIFICATION WSS-M4D1057-A1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 9 (Boro/Boro, SAE J2527, Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant exposure m
19、onitored at 340 nm, Specimen C, ungrained, non-polished mold, use a smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) Type ASTM D7869 (preferred) SAE J2527 Boro/Boro Requirements New Color 2250 h 3000 h Fade Resistance: Rating 4 min There shall b
20、e no cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss Change 25% max (FLTM BI 110-01) *New Material Supplier or New Material Grade 2250 h 3000 h Fade Resistance: Rating 4 min There shall be no cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss
21、Change 25% max (FLTM BI 110-01) 3000 h and 3750 h 4000 h, 5000 h, and 6000 h Fade Resistance: Report Only Report any cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Report Gloss Change (FLTM BI 110-01) *New Material Supplier or New Material Grade: New resin from unknown or kn
22、own Material Supplier. New Manufacturing Locations (new GSDB) for previously approved materials and existing colors are not required to test exterior weathering. All initial approvals may be based on the the above accelerated weathering exposure. Results from Florida Outdoor Weathering (3.3.2) takes
23、 precedence over Accelerated Weathering. 3.6.2 Outdoor Weathering of Exterior Materials - Florida Initial Qualification for new resin technology (SAE J1976, 5 South, direct weathering inland, Specimen I, use an ungrained, non- olished, tool to prepare specimen for C through N gloss, use a smooth pol
24、ished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) 3.6.2.1 1 and 3 year Florida Rating 4 min Florida Submission Required for Approval to ASL ENGINEERING MATERIAL SPECIFICATION WSS-M4D1057-A1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 9 3.6.2.2 5
25、 year Florida Report Only After exposure the material shall show no color change in excess of the specified AATCC Rating. In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss or chalking will be allowed provided an acceptable appearance can be achieved as s
26、pecified below by washing with mild detergents and water (ratio 5:95 by volume) or equivalent after the outdoor exposure only. 3.6.3 Resistance to Scratch and Mar (FLTM BO 162-01, Specimen I) Scratch Rating 2 at 2 N, max Whitening/Color Change Rating 1 at 7 N, max Marring Rating 2 at 2 N, max 3.7 MA
27、TERIAL PROPERTIES 3.7.1 Melt Flow Rate 19-23 g/10 minutes (ISO 1133 230 C, 2.16 kg) 3.7.2 Determination of Ash 24 +/- 1.5% (ISO 3451-1, Method A, talc filler, 3 h at 650 +/- 25 C) 3.7.3 Density 1.06-1.09 g/cm3 (ISO 1183, Method A) 3.7.4 Tensile Strength at Yield 17 MPa min (ISO 527-1 & ISO 527-2, sp
28、ecimen A, 50 mm/minute test speed) 3.7.5 Tensile Modulus 1.8 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.6 Flexural Modulus 1.9 GPa min (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.7.7 Standard Test Method for High Speed Puncture Properties of Pla
29、stic Using Load and Displacement Sensors (ASTM D3763, Impact velocity: 2.2 m/s, Specimen E, smooth surface) 3.7.7.1 Max Load Energy at 23 +/- 2 C Report J Energy Absorbed 100% Ductile Failure 3.7.7.2 Max Load Energy at 0 +/- 2 C Report J Energy Absorbed 100% Ductile Failure, min 3.7.7.3 Max Load Ene
30、rgy at -20 +/- 2 C Report J Energy Absorbed 80% Ductile Failure, min Test specimens must be conditioned for minimum of 6 h at test temperature prior to impact testing. Low temperature testing shall be conducted within the same environmental chamber as the clamp mechanism of the impact device. Specim
31、ens can be transported ENGINEERING MATERIAL SPECIFICATION WSS-M4D1057-A1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 9 from the conditioning environment to the testing environment, provided the transfer is within 5 seconds. Ductile is defined as a failure in which plastic deformation pre
32、cedes fracture sample does not fracture into two or more pieces sample does not show cracks radiating more than 10 mm beyond the center of the impact point In borderline cases Ford Materials Engineering can use additional data such as load versus deflection curves or maximum load data to establish d
33、uctility. Summarize testing at each condition by providing the following information: a. Detailed description of specimen preparation if different then Specimen E. b. Molding conditions: melt and mold surface temperatures, and average injection velocity. c. All force versus deflection curves for eac
34、h impact event. d. Original samples are to be submitted for review or, in agreement with Ford Materials Engineering, photos of the tested samples. 3.7.8 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.7.8.1 At 23 +/- 2 C 35 kJ/m2 min Report Break Type 3.7.8.2 At -40 +/- 2 C 1.8 kJ/m2 m
35、in Report Break Type 3.7.8.3 At 0 +/- 2 C 20 kJ/m2 min Report Break Type The test specimen must be conditioned for minimum of 6 hours at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold chamber, if not possible, test may be conducted outside
36、, but within 5 seconds. 3.7.9 Heat Deflection Temperature 49 C min (ISO 75-1 and ISO 75-2 Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.7.10 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. After heat aging test specimens are to be condition
37、ed in a desiccator for 3 - 5 h at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.7.10.1 Tensile Strength at Yield, Change +/- 25% max (Test method per para 3.7.4) 3.7.10.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per
38、 para 3.7.8.1, specimens to be notched before heat aging) 3.7.11 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to Tg, Tg to 100 +/- 2 C, ENGINEERING MATERIAL SPECIFICATION WSS-M4D1057-A1 Copyright 2015, Ford Global Technologies, LLC Page 6 of 9 3 curves per directions, flow and c
39、ross flow) Plaque size is 100 x 150 minimum at 3.2 +/- 0.2 mm thickness. Plaque to be fan or edge gated. Specimens to be water jet or die cut from the center of plaque, minimum of three samples each direction. Conditioning procedure consists of steps 1-4. Start at 23 C. 1. Ramp 5 C/minute to -40 C 2
40、. Isothermal hold for 5 minutes 3. Ramp 5 C/minute to 110 C 4. Isothermal hold for 10 minutes Leave the test specimen in the equipment and run steps 5-7 5. Ramp 5 C/minute to -40 C 6. Isothermal hold for 10 minutes 7. Ramp 5 C/minute to 110 C Report CLTE value after Step 4 (un-annealed value) for bo
41、th Flow and Cross Flow directions. 3.7.11.1 Flow Report Only, E-5 mm/mm/ C 3.7.11.2 Across Flow Report Only, E-5 mm/mm/ C Report CLTE value again after Step 7 (annealed value) for both Flow and Cross Flow directions. 3.7.11.3 Flow 4.8-6.7 E-5 mm/mm/ C 3.7.11.4 Across Flow 4.8-6.7 E-5 mm/mm/ C 3.7.12
42、 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.7.13 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C 3.7.13.1 Flow 0.425 0.625 % 3.7.13.2 Cross Flow 0.425 0.625 % 3.8 MATERIAL PROPERTIES REPORT ONLY Values are retaine
43、d in Ford Materials Database . 3.8.1 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.8.2 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC CLTE ENGINEERING MATERIAL SPECIFICATION WSS-M4D1057-A1 Copyright
44、 2015, Ford Global Technologies, LLC Page 7 of 9 Engineering Stress/Strain at 23 C 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.8 Para. Test Typical
45、 Value Units 3.8.1 Poissons Ratio 0.39 N/A 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS TPO-(PP+EPDM) (ISO 1043/11469/18064) -MD24 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product De
46、velopment, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples
47、must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.4 SUPPLIERS ONGOING RESPONSIBILITY All material
48、s must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affe
49、cted Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign of
