FORD WRS-M4D993-B3-2015 POLYAMIDE (PA) 6 HEAT STABILIZED 30% GLASS FIBER REINFORCED MOLDING COMPOUND 100% PCR AND OR PIR RESIN CONTENT 70% RECYCLED MATERIAL BY WEIGHT TO BE USED W.pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 04 2015 11 23 Revised Combined B1, B2, and B3 into one specification G. Kowalski, FNA 2011 10 05 Revised Editorial updates to 3.1.3 2011 01 07 Released B1 (2011-01-07), B2 (2011 03 14) B3 (2014 08 01) V Cerato, FOE Controlled document at

2、 www.MATS Copyright 2015 Ford Global Technologies, LLC Page 1 of 9 POLYAMIDE (PA) 6, HEAT STABILIZED 30% GLASS WSS-M4D993-B1 FIBER REINFORCED MOLDING COMPOUND POLYAMIDE (PA) 6, HEAT STABILIZED 30% GLASS WRS-M4D993-B2 FIBER REINFORCED MOLDING COMPOUND, 25% PCR AND/OR PIR RESIN CONTENT, 18% RECYCLED M

3、ATERIAL BY WEIGHT POLYAMIDE (PA) 6, HEAT STABILIZED 30% GLASS WRS-M4D993-B3 FIBER REINFORCED MOLDING COMPOUND, 100% PCR AND/OR PIR RESIN CONTENT 70% RECYCLED MATERIAL BY WEIGHT 1. SCOPE The materials defined by this specification are a thermoplastic 30% glass fiber reinforced, heat stabilized moldin

4、g compound based on polyamide 6. Material with recycled content should be used whenever feasible. 2. APPLICATION WSS-M4D993-B1 This specification was released originally for material used for intake manifolds and GOR/FEM. This material is formulated to have enhanced welding properties. WRS-M4D993-B2

5、/B3 This specification was released originally for materials containing post consumer or post industrial recycled resin content. This material is used for intake manifolds. 2.1 LIMITATIONS This material absorbs and retains moisture. Part design and tolerances must accommodate changes in part dimensi

6、ons and physical properties due to moisture absorption or loss in the service/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 exposure to engine coolan

7、t, or direct exposure to strong acids or bases. It is not sutable for use above 150 C. 3. REQUIREMENTS 3.1 APPROVED SOURCES 3.1.1 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

8、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. ENGINEERING MATERIAL SPECIFICATION WSS-M4D993-B1 WRS-M4D993-B2/B3 Copyright 2015, Ford Global Technologies, LLC Page 2 of 9 3.1.2 This spec

9、ification is part of the Ford Co-Managed Buy (CMB) agreement. Tier 1 Molders who are participating under the CMB agreement must use one the following approved sources (deviations require approval from Raw Materials Purchasing and Materials Engineering): North American and European Programs: WSS-M4D9

10、93-B1 BASF Ultramid B3WG6 Lanxess Durethan BKV 30 H2.0 DuPont Zytel 73G30HSL WRS-M4D993-B2 BASF Nypel RC6030F WRS-M4D993-B3 Wellman Ecolon GF3030 Molders not on the CMB program or regions without CMB are encouraged to use the CMB sources listed above. 3.2 STANDARD REQUIREMENTS FOR PRODUCTION MATERIA

11、LS 3.2.1 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 Table 1 fo

12、r number of samples required for each test. 3.2.2 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 specified on the

13、 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). 3.2.3 WSS-M4D993-B1 is based on virgin materials. 3.2.4 WRS-M4D993-B2 must contain 25

14、% Post Consumer Recycled (PCR) and/or Post Industrial Recycled (PIR) resin content as defined by WRS-M99P42-A1. The remaining portion of the material can come from virgin sources. 3.2.5 WRS-M4D993-B3 must contain 100% Post Consumer Recycled (PCR) and/or Post Industrial Recycled (PIR) resin content a

15、s defined by WRS-M99P42-A1. 3.2.6 Dry as molded: All test values indicated herein are based on material and specimens with moisture content not exceeding 0.2% except where noted (Moisture Conditioned, see paragraph 3.7.9) (test according to ISO 15512 Method B/ASTM D6869). All test materials have to

16、be sealed in moisture-proof containers and stored at 23 +/- 2 C for at least 24 h immediately after processing. 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. Conduct tests in a controlled atmosphere of 23 +/- 2 C an

17、d 50 +/- 5% relative humidity. Individual specimens shall not be removed from closed containers until immediately before testing. ENGINEERING MATERIAL SPECIFICATION WSS-M4D993-B1 WRS-M4D993-B2/B3 Copyright 2015, Ford Global Technologies, LLC Page 3 of 9 3.2.7 Materials requiring High Strain Rate, Cr

18、eep or fiber oriented Tensile 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. 3.2.8 Performance Criteria:

19、 Parts using this specification shall meet the appropriate performance specifications, WSS-M15P50-B/Latest 3.2.9 Ford Materials Engineering may request a Control Plan and Certificate of Analysis (C of A) containing lot testing requirements which must include, but are not limited to: Melt Flow Rate (

20、not for filled materials) Filler Content Impact Strength, Notched Charpy at 23 C Flexural Modulus 3.3 SAMPLE PREPARATION 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 Fo

21、rd 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 defined in ISO 1874-2. See Table 1 for the number of samples required. Specimens shall be as foll

22、ows: 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 +/- 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.

23、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 For Appearance Testing: Use an ungrained, non-polished, tool to prepare specimens for C through N gloss surfaces. Use a smooth, polished tool to prepare specimens for A and B gloss surface

24、s. 3.4 MATERIAL PROPERTIES B1 B2 / B3 3.4.1 Melt Temperature 215 - 225 C 218 - 224 C (ISO 11357, 10 C/min heating rate) 3.4.2 Glass Fiber Content 28 32 28 - 32 (ISO 3451-4, test temperature 600 +/- 25C, test portion 2 to 2.5 g) 3.4.3 Density 1.32 1.39 g/cm3 1.33 1.42 g/cm3 (ISO 1183, Method A) ENGIN

25、EERING MATERIAL SPECIFICATION WSS-M4D993-B1 WRS-M4D993-B2/B3 Copyright 2015, Ford Global Technologies, LLC Page 4 of 9 B1 B2 / B3 3.4.4 Tensile Strength at Break 150 MPa min 140 MPa min (ISO 527-1 and ISO 527-2, Specimen A 5 mm/minute test speed) 3.4.5 Tensile Modulus 8.3 GPa min 8.3 GPa min ISO 527

26、-1 and ISO 527-2, Specimen A 1 mm/minute test speed) 3.4.6 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.4.6.1 At 23 +/- 2 C 7.4 kJ/m2 min 6.9 kJ/m2 min Report Break Type 3.4.6.2 At -40 +/- 2 C 5.2 kJ/m2 min 5.2 kJ/m2 min Report Break Type The test specimen must be conditioned for mi

27、nimum 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. 3.4.7 Heat Deflection Temperature 1

28、90 C min 190 C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.4.8 Heat Aging P

29、erformance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 140 +/- 2 C. After heat aging test specimens are to be conditioned 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) Impact Strength, Notched Charpy, Change

30、+/- 25% max +/- 25% max (Test Method per para 3.4.6.1, specimens to be notched before Heat Aging) 3.4.9 Flammability (ISO 3795/SAE J369, Specimen B, smooth surface) Burn Rate 100 mm/minute max100 mm/minute max 3.5 MATERIAL PROPERTIES REPORT ONLY All specimens dry as molded. If not tested immediately

31、 after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. Values are retained in Ford Materials Database . B1 / B2 / B3 3.5.1 Percent Recycled Resin Content (PIR/PCR) Report Value, % (WRS specifications only) ENGINEERING MATERIAL SPECIFICATION WSS-M4D993-

32、B1 WRS-M4D993-B2/B3 Copyright 2015, Ford Global Technologies, LLC Page 5 of 9 B1 / B2 / B3 3.5.2 Molding Shrinkage Report method used, sample size and value) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.5.3 Coefficient of Linear Thermal Expansion (ISO 11359-2 TMA) 30 +/

33、- 2 C to 60 +/- 2 C Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 60 +/- 2 C to 120 +/- 2 C Flow Report Value, E-5 mm/mm/ C Cross Flow Report Value, E-5 mm/mm/ C 3.5.4 Water Absorption Report Value, % (ISO 62, 24 h immersion, Specimen H, 50 +/- 1 mm diameter, 3.2 +/- 0.2 mm t

34、hick specimen) 3.5.5 Flexural Modulus Report Value, GPa (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.5.6 Heat Deflection Temperature Report Value, C (ISO 75-1 and ISO 75-2, Specimen D, flatwise, Bath silicone oil, 0.34 +/- 0.1 mm deflection. At 0.45 MPa) 3.5.7 Poissons Ratio R

35、eport Ratio (ISO 527-1 and ISO 527-2, Specimen A, 1 mm/minute test speed) 3.5.8 Determination of Creep Behavior (ISO 899-1, Specimen A, Flow Direction) 1 hour Report Value, MPa 1000 hours Report Value, MPa Provide data creep plots (% Strain vs. Time in hours), individual data points at each stress l

36、evel and Isochronous Stress-Strain Plot 3.5.9 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 to ISO 1110

37、). Moisture content shall be reported to verifly the moisture level. ENGINEERING MATERIAL SPECIFICATION WSS-M4D993-B1 WRS-M4D993-B2/B3 Copyright 2015, Ford Global Technologies, LLC Page 6 of 9 B1 / B2 / B3 3.5.9.1 Moisture Content Report Value, Weight% (ISO 15512, Karl Fisher, or ASTM D756-93) Note:

38、 Moisture content must be between 1.0 2.0 wt% before testing para 3.5.9.2, , 3.5.9.3, 3.5.9.4, and 3.5.9.5. 3.5.9.2 Tensile Strength at Break Report Value, MPa (ISO 527-1 and ISO 527-2, Specimen A, 5 mm/minute test speed, 23 +/- 2 C) 3.5.9.3 Tensile Modulus Report Value, GPa (ISO 527-1 and ISO 527-2

39、, Specimen A, 1 mm/minute test speed) 3.5.9.4 Impact Strength, Notched Charpy Report Value, kJ/m2 (ISO 179-1/1eA, Specimen D, 23 +/- 2 C) Report Break Type 3.5.9.5 Flexural Modulus Report Value, GPa (ISO 178, Specimen D, 64 mm support span, 2 mm/minute test speed) 3.5.10 Determination of Ash (Minera

40、l Filler+Glass Fiber) Report Value, % (ISO 3451-1, Method A, or ISO 3451-2, 1 h at 650 +/- 25 C) 3.5.11 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC first and second heat Engineering Stress/Strain at 23 C and -40 C 4. GENERAL INFORMATION The

41、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 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS PA6 GF30 4 stress levels 4 stress levels 1 1 2 3 2

42、 3 3.5.9.1 Moisture Content 1 1 1 1 1 1 3.5.9.2 Moisture Conditioned Tensile Strength at Break 1 5 5 1 5 5 3.5.9.3 Moisture Conditioned Tensile Modulus 1 10 10 3.5.9.4 Moisture Conditioned Notched Charpy Impact 1 10 10 1 10 10 3.5.9.5 Moisture Conditioned Flexural Modulus 1 10 10 1 10 10 3.5.10 Dete

43、rmination of Ash 3 1 3 1 1 1 3.5.11 Curves - IR - TGA - DSC (first and second heat) - CLTE (3 flow and 3 cross flow) - Stress/Strain Curves (as required) 1 1 1 per test * For these requirements the 3 sigma value from the raw data is used to meet the requirements. ENGINEERING MATERIAL SPECIFICATION W

44、SS-M4D993-B1 WRS-M4D993-B2/B3 Copyright 2015, Ford Global Technologies, LLC Page 9 of 9 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

45、submit a completed copy of their laboratory test reports, signed by a qualified and authorized representativeof 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 m

46、inimum 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 materials must be equivalent in all characteristics to the materia

47、l 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 affected Supplier Technical Assistance (STA), Purchasing, and

48、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), Produ

49、ction Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.5 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 Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standar