FORD WRS-M4D1062-A1-2017 POLYAMIDE (PA66) HEAT STABILIZED 40% SHORT CARBON FIBER FILLED MOLDING COMPOUND 40% RECYCLED MATERIAL BY WEIGHT TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 01 11 Released L. Rabideau, NA Controlled document at www.MATS.com Copyright 2017, Ford Global Technologies, LLC Page 1 of 8 POLYAMIDE (PA66), HEAT STABILIZED, 40% SHORT WRS-M4D1062-A1 CARBON FIBER FILLED, MOLDING COMPOUND, 40% R

2、ECYCLED MATERIAL BY WEIGHT 1. SCOPE The material defined by this specification is a composite with a PA66 matrix with 40% PI recycled short carbon fiber filler content. Type of Material % Material Type by Weight Virgin Resin 60 Recycled Carbon Fiber PCR/PIR 40 Minimum % Recyclable Material 40 2. APP

3、LICATION This specification was released originally as a material replacement for steel in the IP cross-car beam, and may also be used in most underhood applications (see limitations for specifics). 2.1 LIMITATIONS This material absorbs and retains moisture. Part design and tolerances must accommoda

4、te changes in part dimensions and physical properties due to moisture absorption or loss in theservice/assembly environment. This material does not contain UV stabilizers, long term exposure to direct sunlight will cause chalking and loss of gloss. This material is not suitable for direct long term

5、exposure to engine coolant, or direct exposure to strong acids or bases. It is not suitable for continuous use above 150 C. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used whe

6、n 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 CONDITIONING AND TEST CONDITIONS Dry as molded: All test values indicated herein are based on material a

7、nd specimens with moisture content not exceeding 0.2% except where noted (Moisture Conditioned, see paragraph 3.7.6) (test according to ISO 15512 Method B/ASTM D6869). All test materials have to be sealed in moisture-proof containers and stored at 23 +/- 2 C for at least 24 h immediately after proce

8、ssing. If the moisture content exceeds 0.2%, condition the material for a minimum of 16 h at 40 50 C at a reduced pressure below 133 kPa. ENGINEERING MATERIAL SPECIFICATION WRS-M4D1062-A1 Copyright 2017, Ford Global Technologies, LLC Page 2 of 8 Conduct tests in a controlled atmosphere of 23 +/- 2 C

9、 and 50 +/- 5% relative humidity. Individual specimens shall not be removed from closed containers until immediately before testing. 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms from initial material approval shall constitute the reference standard and shall be k

10、ept on file at the designated material laboratory. The material supplier shall ensure that all future material supplied to the specification shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 STANDARD REQUIREMENTS FOR PRODUCT

11、ION MATERIALS 3.4.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicated that the mean 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

12、 Table 1 for number of samples required for each test. 3.4.2 The use of regrind is permitted, for economic/environmental reasons. Part manufacturers using this specification must complete DV and PV testing with the allowable amount of regrind and the maximum allowable regrind content must be specifi

13、ed on the engineering drawing. Any changes to what is specified on the drawing (no specific amount implies zero regrind) must be approved by Materials and PD Engineering through the formal Ford Motor Company process (SREA). 3.4.3 Materials requiring High Strain Rate, Creep or fiber oriented Tensile

14、Modulus may be required to test to the requirements of WSS-M99D68-A1/Latest, Thermoplastic Property Determination For CAE, High Strain Rate Tensile, Creep and Tensile Modulus. Material suppliers should be prepared to submit data upon request. 3.4.4 Performance Criteria: Parts using this specificatio

15、n for non-visible interior applications must meet the appropriate performance specification: WSS-M15P4-G/Latest. Parts using this specification for underhood applications must meet the appropriate performance specification: WSS-M15P50-B/Latest. 3.4.5 Ford Materials Engineering may request a Control

16、Plan and Certificate of Analysis (CofA) containing lot testing requirements which must include, but are not limited to: Filler Content Impact Strength, Notched Charpy at 23 C Tensile Modulus 3.5 SAMPLE PREPARATION All tests shall be carried out on production materials manufactured from the productio

17、n 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 molded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defi

18、ned in ISO 1874-2. No additional annealing is allowed. ENGINEERING MATERIAL SPECIFICATION WRS-M4D1062-A1 Copyright 2017, Ford Global Technologies, LLC Page 3 of 8 Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, Specimen Type 1A) Specimen B 355 x 100 x 1.0 +/-

19、0.1 mm Specimen C 145 x 60 x 3.2 +/- 0.2 mm Specimen D 80 x 10 x 4.0 +/- 0.2 mm (may be cut from the center of Specimen A) 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 +/- 0.2 mm Specimen I 100 mm x 150 mm, min

20、 3.6 MATERIAL PROPERTIES 3.6.1 Melt Temperature 255-265 C (ISO 11357, 10 C/min heating rate) 3.6.2 Determination of Ash (Filler Content) 38-42 % (FLTM BO 134-01) 3.6.3 Density 1.30-1.35 g/cm3 (ISO 1183, Method A) 3.6.4 Tensile Strength at Break 245 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 5 mm/

21、minute test speed) 3.6.5 Tensile Modulus 30 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.6.6 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.6.6.1 At 23 +/- 2 C 6.5 kJ/m2 min Report Break Type 3.6.6.2 At -40 +/- 2 C 5.5 kJ/m2 min Report Break Type The test sp

22、ecimen 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, but within 5 seconds. Test specimens must be reviewed by Materials Engineering. 3.

23、6.7 Heat Deflection Temperature (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection) 3.6.7.1 at 0.45 MPa 258 C min 3.6.7.2 at 1.80 MPa 250 C min All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moistur

24、e-proof container filled with silica gel. ENGINEERING MATERIAL SPECIFICATION WRS-M4D1062-A1 Copyright 2017, Ford Global Technologies, LLC Page 4 of 8 3.6.8 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 140 C +/- 2 C. After heat aging test specimens are to be conditioned in a d

25、esiccator for 3 - 5 h at 23 C +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.6.8.1 Tensile Strength at Break, Change +/- 25% max (ISO 527-1 and ISO 527-2, Specimen A, 5 mm/minute test speed) 3.6.8.2 Impact Strength, Notched Charpy, Change +/-

26、25% max (ISO 179-1/1eA, Specimen D, specimens to be notched before Heat Aging) 3.6.9 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max 3.7 MATERIAL PROPERTIES REPORT ONLY All specimens dry as molded. If not tested immediately after molding, specimens must be st

27、ored in a sealed, moisture-proof container filled with silica gel. Values are retained in Ford Materials Database . 3.7.1 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.7.2 Coefficient of Linear Thermal Expansi

28、on (ISO 11359-2 TMA) -30 +/- 2 C to 60 +/- 2 C Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C60 +/- 2 C to 120 +/- 2 C Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.7.3 Water Absorption Report Value, % (ISO 62, 24 h immersion, Specimen H, 50 +/- 1 mm

29、diameter, 3.2 +/- 0.2 mm thick specimen) 3.7.4 Flexural Modulus Report Value, GPa (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.7.5 Poissons Ratio Report Ratio ENGINEERING MATERIAL SPECIFICATION WRS-M4D1062-A1 Copyright 2017, Ford Global Technologies, LLC Page 5 of 8 (ISO 527-1

30、 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.6 Moisture Conditioned: The specimens shall be conditioned to a moisture content of 1.0 to 2.0 wt% moisture then place the specimens in standard atmosphere of 23 +/- 2 C and 50 +/- 5% relative humidity for at least 1 h before testing (according

31、 to ISO 1110). Moisture content shall be reported to verify the moisture level. 3.7.6.1 Moisture Content Report Value, Wt% (ISO 15512, Karl Fisher, or ASTM D756-93) Note: Moisture content must be between 1.0 2.0 wt% before testing para 3.7.6.2, 3.7.6.3, 3.7.6.4, and 3.7.6.5. 3.7.6.2 Tensile Strength

32、 at Break Report Value, MPa (ISO 527-1 and ISO 527-2, Specimen A, 5 mm/minute test speed, 23 +/- 2 C) 3.7.6.3 Tensile Modulus Report Value, GPa (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.7.6.4 Impact Strength, Notched Charpy Report Value, kJ/m2 (ISO 179-1/1eA, Specimen D, 23 +/-

33、 2 C) Report Break Type 3.7.6.5 Flexural Modulus Report Value, GPa (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.7.7 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC first and second heat CLTE Engineering Stress/Strain at 23

34、 C, 120C, -40 C 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their mat

35、erials shall first obtain an expression of interest from Purchasing, Design or Product Development, 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 com

36、pliance with all the requirements of the Material Specification. Tested material samples 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 P

37、lans, ENGINEERING MATERIAL SPECIFICATION WRS-M4D1062-A1 Copyright 2017, Ford Global Technologies, LLC Page 6 of 8 Certification testing) with Ford. 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted.

38、 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 affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the propo

39、sed 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 A

40、pproval Process (PPAP) sign off must be kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standa

41、rd WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 4.4 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS (ISO 1043/11469) PA66-CF40 4.5 TYPICAL PROPERTIES USING METHODS IN SECTION

42、3.7 Para. Test Typical Value Units 3.7.1 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Cross Flow 0.004 0.006 % % 3.7.2 Coefficient of Linear Thermal Expansion -30 to 60 C Flow Cross Flow 60 to 120 C Flow Cross Flow 0.2 7.4 0.2 14.0 E-5 mm/mm/ C E-5 mm/m

43、m/ C E-5 mm/mm/ C E-5 mm/mm/ C 3.7.3 Water Absorption 1.0 % 3.7.4 Flexural Modulus 35.0 GPa 3.7.5 Poissons Ratio 0.42 N/A 3.7.6.1 Moisture Content 1.0 Weight % ENGINEERING MATERIAL SPECIFICATION WRS-M4D1062-A1 Copyright 2017, Ford Global Technologies, LLC Page 7 of 8 3.7.6.2 Moisture Conditioned Ten

44、sile Strength at Break 230.0 MPa 3.7.6.3 Moisture Conditioned Tensile Modulus 24.0 GPa 3.7.6.4 Moisture Conditioned Notched Charpy Impact 11.0 kJ/m2 3.7.6.5 Moisture Conditioned Flexural Modulus 28.0 GPa ENGINEERING MATERIAL SPECIFICATION WRS-M4D1062-A1 Copyright 2017, Ford Global Technologies, LLC

45、Page 8 of 8 Table 1: Minimum Sample Size Initial Approval and New Manufacturing Location Approval New Manufacturing Location for Previously Approved Material Para. Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4.3 Thermoplastic Property Determ

46、ination For CAE WSS-M99D68-A1 Reference the Performance Specification 3.4.4 WSS-M15P4-G/Latest (interior non-visible applications) WSS-M15P50-B/Latest (underhood applications) Reference the Performance Specification 3.6.1 Melt Temperature 3 1 3 3.6.2 Determination of Ash/Filler Content * 3 1 3 1 1 1

47、 3.6.3 Density 1 3 3 1 3 3 3.6.4 Tensile Strength at Break * 3 5 15 1 5 5 3.6.5 Tensile Modulus 1 10 10 3.6.6 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.6.7.1 Heat Deflection Temperature (0.45 MPa)* 3 2 6 1 2 2 3.6.7.2 Heat Deflection Temperature (1.80 MPa)* 3 2 6 1 2 2 3.6.8

48、Heat Aging Performance 3.6.8.1 Tensile Strength at Break, Change 1 5 5 3.6.8.2 Impact Strength, Notched Charpy, Change 1 10 10 3.6.9 Flammability 1 5 5 3.7.1 Mold Shrinkage 1 5 5 1 5 5 3.7.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.7.3 Water Absorption 1 3 3 3.7.4 Flexural Mod

49、ulus * 3 10 30 1 10 10 3.7.5 Poissons Ratio 1 2 2 1 2 2 3.7.6.1 Moisture Content 1 1 1 1 1 1 3.7.6.2 Moisture Conditioned Tensile Strength at Break 1 5 5 1 5 5 3.7.6.3 Moisture Conditioned Tensile Modulus 1 10 10 3.7.6.4 Moisture Conditioned Notched Charpy Impact 1 10 10 1 10 10 3.7.6.5 Moisture Conditioned Flexural Modulus 1 10 10 1 10 10 3.7.7 Curves - IR - TGA - DSC (first and second heat) - CLTE (3 flow and 3 cross flow) Stress/Strain Curves at 23