FORD WRS-M4D625-A3-2016 POLYESTER MOLDING COMPOUND (PBT+PET) 40% GLASS MINERAL FILLED MOLDED-IN-COLOR INTERIOR 25% PCR RESIN CONTENT 15% RECYCLED MATERIAL BY WEIGHT TO BE USED WIT.pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions REV. 01 2016 07 25 Revised See Summary of Revisions A. Wagenhals, NA 2015 09 16 Released B. Haggart, FNA Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC Page 1 of 7 POLYESTER MOLDING COMPOUND (PBT+PET), WRS-M4D62

2、5-A3 40% GLASS/MINERAL FILLED, MOLDED-IN-COLOR, INTERIOR, 25% PCR RESIN CONTENT, 15% RECYCLED MATERIAL BY WEIGHT 1. SCOPE The materials defined by this specification are for straight shade colors of 40% glass fiber and mineral filled thermoplastics polyester resins with 25% post consumer resin recyc

3、late, good dimensional stability and interior weathering performance. 2. APPLICATION This specification was released originally for material used for interior molded-in-color HVAC register vanes. 2.1 LIMITATIONS These materials are not intended for painted applications, no dusting allowed. 3. REQUIR

4、EMENTS 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 when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at

5、or available externally through a Ford Materials Engineer. The approved source for this specification is Ticona Celanex 6402R. 3.2 CONDITIONING 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

6、50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.3.1 Materials approved to these specifications require testing to WSS-M99P2222-D1/latest Performance, Vehicle Interior Environ

7、ment Quality Material/Component Requirements. If collective parts exceed 100 cm2 or 100 g then testing will be required per the appropriate performance specification. 3.3.2 Materials requiring High Strain Rate, Creep or fiber oriented Tensile Modulus must test to the requirements of WSS-M99D68-A1/La

8、test, Thermoplastic Property Determination. For CAE, High Strain Rate Tensile, Creep and Tensile Modulus. Data must be included in the material submission package. 3.3.3 Performance Criteria: Parts using this specification shall meet the appropriate performance specification, WSS-M15P4-F/Latest for

9、Hard, Interior, Molded-in-Color component performance. ENGINEERING MATERIAL SPECIFICATION WRS-M4D625-A3 Copyright 2016, Ford Global Technologies, LLC Page 2 of 7 3.4 SAMPLE PREPARATION Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens. The te

10、st specimens A and D shall be molded using molding conditions defined in ISO 9988-2. Annealing is allowed for unaged specimens for property comparison to Heat Aging samples only. See Table 1 for the number of specimens required. Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.

11、2 mm (ISO 527-2, 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 d

12、iameter x 3.2 +/- 0.2 mm Specimen I 100 mm x 150 mm, min 3.5 APPEARANCE 3.5.1 Weathering Resistance Rating 4 min (FLTM BO 116-01, 2406.4 kJ/m2 exposure Specimen C from smooth polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) Every 526.4kJ/m2 remove the samples from the weatherometer and all

13、ow them to cool for one hour. Conduct a tactile evaluation and report any tackiness. Visually evaluate and report any spewing or other exudation. After exposure the material shall show no fading or color change in excess of specified AATCC rating. In addition, there shall be no cracking, crazing or

14、other deterioration. Use regional choice colors for initial approval and report color house used. For color durability submissions, test all program colors. 3.6 MATERIAL PROPERTIES 3.6.1 Determination of Ash 37 42% (ISO 3451-2, Method A, 1h at 750 +/- 25 C, Test portion 2 2.5 g) 3.6.2 Density 1.60 1

15、.7 g/cm3 (ISO 1183, Method A) 3.6.3 Tensile Strength at Break 110 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 5 mm/minute test speed) 3.6.4 Tensile Modulus 11 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.6.5 Flexural Modulus 10 GPa min (ISO 178, Specimen D, 64 mm support

16、 span, 2 mm/minute test speed) ENGINEERING MATERIAL SPECIFICATION WRS-M4D625-A3 Copyright 2016, Ford Global Technologies, LLC Page 3 of 7 3.6.6 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.6.6.1 At 23 +/- 2 C 5.0 kJ/m2 min Report Break Type 3.6.6.2 At -40 +/- 2 C 5.0 kJ/m2 min Repor

17、t Break Type The test specimens must be conditioned for min of 6 h at the above specified temperature prior to impact test. Low temperature testing shall be done within the cold box, if not possible, test can be conducted outside, but within 5 seconds. 3.6.7 Heat Deflection Temperature 195 C min (IS

18、O 75-1 and ISO 75-2, Specimen D flatwise, 0.34 +/- 0.1 mm deflection, at 1.80 MPa) 3.6.8 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 110 +/- 2 C) 3.6.8.1 Tensile Strength at Yield Change +/- 25% max (Test Method per para 3.6.3) 3.6.8.2 Impact Strength, Notched Charpy, Change

19、 +/- 25% max (Test Method per para 3.6.6.1, specimens to be notched before Heat Aging) 3.6.9 Odor (FLTM BO 131-03, Specimen G, Variant B) Condition 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.6.10 Fogging Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling p

20、late, post test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. 3.6.11 Flammability (ISO 3795/SAE J369 Specimen B smooth surface) Burn Rate 100 mm/minute max ENGINEERING MATERIAL SPECIFICATION WRS-M4D625-A3 Copyright 2016, Ford Global Techno

21、logies, LLC Page 4 of 7 3.7 MATERIAL PROPERTIES REPORT ONLY Values are retained in Ford Material Database . 3.7.1 Percent Recycled Resin Content (PCR) Report, % 3.7.2 Melt Flow Rate Report g/10 minutes (ISO 1133, 265 C, 2.16 kg) 3.7.3 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 C to 15

22、0 +/- 2 C) Flow Report E-5 mm/mm/ C Cross Flow Report E-5 mm/mm/ C 3.7.4 Mold Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C Report Range, % 3.7.5 Poissons Ratio Report Ratio (ISO 527-1/2, Specimen A, test speed 1 mm/minute) 3.7.6 Supplemental Information The followin

23、g curves are to be submitted with the data packages: FTIR TGA DSC CLTE 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. Contact for questions concerning Engineering Ma

24、terial Specifications. 4.1 TYPICAL PROPERTIES USING TEST METHODS IN SECTION 3.5 Para. Test Typical Values Units 3.7.1 Percent Recycled Resin Content 25 % 3.7.2 Melt Flow Rate 21 - 28 g/10 minutes 3.7.3 Coefficient of Linear Thermal Expansion; Flow Cross Flow 2 - 3 6 - 7 E-5 mm/mm/ C E-5 mm/mm/ C 3.7

25、.4 Mold Shrinkage (Method used: ISO 294, 48 h at 23 +/- 2 C, 60 x 60 x 2.0 +/- 0.1 mm specimen) Parallel Perpendicular 0.1 0.5 % 3.7.5 Poissons Ratio 0.40 N/A ENGINEERING MATERIAL SPECIFICATION WRS-M4D625-A3 Copyright 2016, Ford Global Technologies, LLC Page 5 of 7 4.2 MATERIAL IDENTIFICATION FOR RE

26、CYCLING PURPOSES (ISO 1043) PBT+PET(GF+M)40 4.3 APPROVAL OF MATERIALS Suppliers desiring approval of their materials 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

27、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 must be available for review upon request and kept for a minimum of one year. Upon request, the suppl

28、ier 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 materials must be equivalent in all characteristics to the material upon which approval was originally grante

29、d. 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 pro

30、posed 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

31、 Approval Process (PPAP) sign off must be kept until Job 1. 4.4 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 Stan

32、dard 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. ENGINEERING MATERIAL SPECIFICATION WRS-M4D625-A3 Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 Table 1: Minimum Sample S

33、ize Initial Approval Para. Test Lots Specimens per lot Total Test Specimens 3.3.1 WSS-M99P2222-D1 Total Carbon, Hazardous Substances, Formaldehyde, Acraldehyde, Acetaldehyde (See below for odor and fogging) 1 1 1 per test 3.3.2 WSS-M99D68-A1 See Specification 3.3.3 WSS-M15P4-F See Performance Specif

34、ication 3.5.1 Weathering Resistance 1 1 1 3.6.1 Determination of Ash 3 1 3 3.6.2 Density 1 3 3 3.6.3 Tensile Strength at Break* 3 5 15 3.6.4 Tensile Modulus 1 10 10 3.6.5 Flexural Modulus* 3 10 30 3.6.6 Impact Strength, Notched Charpy (per condition) 1 10 10 3.6.7 Heat Deflection Temperature* 3 2 6

35、3.6.8 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 Odor 1 9 9 3.6.10 Fogging Photometric 1 3 3 3.6.11 Flammability 1 5 5 3.7.1 Percent Recycled Resin Content 1 1 1 3.7.2 Melt Flow Rate 1 1 1 3.7.3 Coefficient of Li

36、near Thermal Expansion (per condition) 1 3 3 3.7.4 Mold Shrinkage 1 5 5 3.7.5 Poissons Ratio 1 5 5 3.7.6 Curves - IR - TGA - DSC - CLTE Stress/Strain Curves 1 1 1 per test * For these requirements, the 3 Sigma value from the raw data is used to meet the requirements. ENGINEERING MATERIAL SPECIFICATI

37、ON WRS-M4D625-A3 Copyright 2016, Ford Global Technologies, LLC Page 7 of 7 Table 2: Minimum Color Property Testing 5. SUMMARY OF REVISIONS 2016 07 25 Reduced minimum requirements for density, tensile modulus, flexural modulus, charpy impact, and heat deflection. Para. Test Method Lots Specimens per

38、Lot Total Test Specimens Color Test Direction 3.5.1 Weathering Resistance 1 1 1 Every color 3.6.3 Tensile Strength at Break 1 5 5 As directed by Materials Engineering 3.6.5 Flexural Modulus 1 10 10 As directed by Materials Engineering 3.6.6.1 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering 3.6.9 Odor 1 9 9 As directed by Materials Engineering 3.6.10 Fogging Photometric 1 3 3 As directed by Materials Engineering 3.6.11 Flammability 1 5 5 Every Color