FORD WSL-M98D29-A-2016 COMPOSITE FUEL TANK HIGH DENSITY POLYETHYLENE (PE-HD) LINEAR LOW DENSITY POLYETHYLENE (PE-LLD) TIE LAYERS ETHYLENE VINYL ALCOHOL (E VAL) BARRIER TO BE USED .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 03 2016 02 02 Revised See Summary of Revisions A. Reaume, NA 2010 03 04 Revised See Summary of Revisions J. Souza, SA 1996 02 08 Activated J.D. Rehkopf L.R. Gullen Controlled document at www.MATS Copyright 2016, Ford Global Technologies,

2、 LLC Page 1 of 7 COMPOSITE, FUEL TANK HIGH DENSITY WSL-M98D29-A POLYETHYLENE (PE-HD), LINEAR LOW DENSITY POLYETHYLENE (PE-LLD) TIE LAYERS, ETHYLENE VINYL ALCOHOL (E/VAL) BARRIER 1. SCOPE The material defined by this specification is a thermoplastic blow molded composite based on high molecular weigh

3、t PE-HD, E/VAL and PE-LLD tie layers (Figure 1). This specification defines a composite material used in manufacturing of blow molded fuel tanks and similar articles. The composite consists of a coextruded and blow molded high density polyethylene, barrier layer of ethylene/vinyl alcohol and tie lay

4、ers of linear low density polyethylene, and has excellent chemical resistance and low fuel permeation characteristics. 2. APPLICATION This specification was released originally for materials used for composite fuel tanks which meet CARB/EPA Clean Air Act Requirements in Passenger Car and Truck Appli

5、cations. 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 when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is locate

6、d within Ford at or available externally through a Ford Materials Engineer. 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 50 +/- 5% relative humidity. Testing of the materi

7、al should occur in the conditioning environment or soon after removal. 3.3 INFRARED 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 materia

8、l 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 MOLDED TEST SPECIMEN 3.4.1 Preparation of Test Specimens The following tests shall be performed

9、on test specimens cut (in accordance with the ISO methods specified) from blow molded fuel tanks. Specimens are tested with the as-molded thickness of the fuel tank and are not machined to meet the thickness ENGINEERING MATERIAL SPECIFICATION WSL-M98D29-A Copyright 2016, Ford Global Technologies, LL

10、C Page 2 of 7 requirements of the Standard Test Methods except where necessary for fixturing. Greater variation in test values can be anticipated when evaluating materials that are thinner than recommended by an applicable Industry Standard/Test Method. The following dimensions are required: A. 150

11、min x 20/10 +/- 0.2 mm (Tensile Bar, ISO 527) B. 80 x 10 +/- 0.2 mm (Flexure Bar, ISO 178) C. 60 x 10/3, r = 15 mm (Tensile Impact Bar, ISO 8256) Refer to Table 1 for number of samples required for each test to establish specification compliance. 3.4.2 Density 0.940 - 0.960 g/cm3 (ISO 1183, Method A

12、) 3.4.3 Tensile Properties (ISO 527, 50 mm/minute test speed, 150 min x 20/10 +/- 0.2 mm specimen) 3.4.3.1 Tensile Strength at Yield 20 MPa min (Test Method according to para 3.4.3) 3.4.3.2 Elongation at Yield 8% min (Test Method according to para 3.4.3) 3.4.3.3 Elongation at Break of E/VAL Layer 25

13、% min (Test Method according to para 3.4.3, noting that E/VAL layer typically fractures before PE layers) 3.4.3.4 Elongation at Break of PE-HD Layer 40% min (Test Method according to para 3.4.3, reflecting first fracture of one of the PE-HD layers) Note: Yield is defined as the first point on the en

14、gineering stress-strain curve at which the stress does not increase with increasing strain. Break of PE-HD layer (para 3.4.3.4) is the first fracture of the regrind or PE-HD layers. 3.4.4 Heat Deflection Temperature (ISO 75, 120 x 10 +/- 0.2 mm specimen, 0.32 +/- 0.01 mm deflection) 3.4.4.1 At 1.82

15、MPa 35 C min 3.4.5 Heat Aging Performance (ISO 188, except 150 +/- 50 air changes/ h, 1000 h at 120 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.4.5.1 Tensile Strength at Yield +/- 25% change (Test Method per para 3.4.3.1) ENGINEERING MATERI

16、AL SPECIFICATION WSL-M98D29-A Copyright 2016, Ford Global Technologies, LLC Page 3 of 7 3.4.6 Adhesion Strength 3 N/mm min (FLTM BO 101-06, T-Peel test, 127 x 12.7 mm specimen, 50 mm/min) 3.4.7 Resistance to Fuel (ISO 1817, complete immersion in fuel C + 15% Methanol at 40 +/- 2 C for 1000 h) Testin

17、g is to be completed within 30 minutes after the coupons have been removed from the fuel. Coupons should be wrapped in aluminum foil as long as practical between removal and testing to minimize drying. 3.4.7.1 Tensile Strength at Yield 16 MPa min (Test Method per para 3.4.3.1) 3.4.7.2 Elongation at

18、Yield 10% min (Test Method per para 3.3.3.2) 3.4.7.3 Adhesion Strength 2 N/mm min (Test Method per para 3.4.6) In addition, there shall be no evidence of delamination after fuel soak. 3.4.8 Fuel Swell (ASTM D471, 75 x 25 mm specimen, immersed in Fuel C +15% Methanol at 40 +/- 2 C for 1000 h) 3.4.8.1

19、 Linear Swell 8% max (average of length, width and thickness % change) 3.4.8.2 Weight Gain 15% max 3.5 FLAMMABILITY (ISO 3795, Sample size per ISO 3795) Burn Rate 100 mm/minute max 3.6 ENVIRONMENTAL STRESS CRACKING RESISTANCE (ASTM D1693, Sample Type A F50, 10% Igepal at 50 +/- 0.5 C) Across Flow 10

20、00 h min Specimen dimensions to be as specified in the ASTM procedure. Tank coupons which are thicker than this specification are to be milled or ground down on the inner HDPE surface to the proper thickness. Notch is to be applied to the exterior HDPE surface (see Figure 1). 3.7 E/VAL BARRIER LAYER

21、, % of total composite 1 - 5% Thickness Or Specified on Engineering Drawing 3.8 TIE LAYER, % of total composite thickness 1.5 +/- 0.75% (on each side of E/VAL barrier layer) 3.9 REGRIND Regrind material from production sources of WSL-M98D29-A fuel tank material. The regrind material may only be used

22、 in the second-most exterior layer of the composite, on the exterior side of the outer tie layer (see Figure 1). ENGINEERING MATERIAL SPECIFICATION WSL-M98D29-A Copyright 2016, Ford Global Technologies, LLC Page 4 of 7 3.9.1 Regrind Layer Thickness, % of total 45% max fuel tank wall thickness 3.9.2

23、Agglomerate Particle Size of E/VAL Within Regrind (blow molded part) (Compare with Visual Master provided in the Control Plan) Note: Agglomerate E/VAL particle size and shape are significant characteristics. Using a microtome, obtain thin sections (approx 40 micrometer thick) of the composite struct

24、ure and mount on glass slides using Canada Balsam. View at 350 - 500 x magnification using an optical microscope which has a calibrated scale. E/VAL particles appear dark and may be more distinct if stained with iodine solution prior to microtoming. E/VAL particles in the regrind layer must be unifo

25、rmly dispersed (Compare with Visual Master provided in the Control Plan). Max dimension of agglomerate E/VAL particles 15 micrometer 3.10 PERFORMANCE CRITERIA Polyethylene materials approved to this specification must also be approved to the fuel system polymeric materials performance standard: WSS-

26、M98P14-A1. 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 TENSILE STRENGTH AT BREAK Report only (ISO 527, 50 mm/min test spee

27、d, 150 min x 20/10 +/- 0.2 mm specimen) Break is complete fracture of the entire composite specimen. 4.2 RESISTANCE TO FUEL (ISO 1817, complete immersion in fuel at 40 +/- 2 C for 1000 h) Testing is to be completed within 30 minutes after the coupons have been removed from the fuel. Coupons should b

28、e wrapped in aluminum foil as long as practical between removal and testing to minimize drying. The following requirements shall be met for: Fuel C +15% Methanol 4.2.1 Tensile Strength at Break Report only (Test Method per para 4.2) 4.3 HEAT DEFLECTION TEMPERATURE (ISO 75, 120 x 10 +/- 0.2 mm specim

29、en, 0.32 +/- 0.01 mm deflection) 4.3.1 At 0.45 MPa Report only 4.4 COEFFICIENT OF LINEAR THERMAL EXPANSION (ISO 11359-2 TMA, temperature range -30 C to +100 C, tested on plaque samples) ENGINEERING MATERIAL SPECIFICATION WSL-M98D29-A Copyright 2016, Ford Global Technologies, LLC Page 5 of 7 PE-HD, i

30、nner layer, flow direction Report only PE-HD, inner layer, cross-flow direction Report only PE-HD, outer layer, flow direction Report only PE-HD, outer layer, cross-flow direction Report only 4.5 RAW MATERIALS The raw materials (PE-HD, E/VAL, and PE-LLD - based tie layer), which are formulated to co

31、mprise the blow molded composite fuel tank material, are controlled in the Control Plan. The Control Plan is on file at the materials activity in the manufacturing plant. 4.6 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS (ISO 1043/11469/18064) PE-HD,PE-LLD,E/VAL 4.7 APPROVAL OF MATERIALS Su

32、ppliers 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 test reports, signed by a qualified and authorized Representative of the

33、 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 supplier will review the associated quality control documents (Process Failur

34、e Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.8 SUPPLIERS ONGOING RESPONSIBILITY All materials 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, whet

35、her 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 proposed changes (with reasons) by submission of a completed Suppliers Requ

36、est 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 off must be kept until Job 1. 4.9 RESTRICT

37、ED 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 respon

38、sibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 4.10 ADDITIONAL REQUIREMENTS Requirements beyond those explicitly stated in this document and the material specification may bespecified on the Engineering drawing, Engineering specification (ES), perform

39、ance specification,System Design Specification (SDS) and/or Attribute Requirement List (ARL). ENGINEERING MATERIAL SPECIFICATION WSL-M98D29-A Copyright 2016, Ford Global Technologies, LLC Page 6 of 7 PE-HD w/ carbon blackRegrind (optional)PE-HDE/VAL BarrierTie LayerTie LayerFIGURE 1 ENGINEERING MATE

40、RIAL SPECIFICATION WSL-M98D29-A Copyright 2016, Ford Global Technologies, LLC Page 7 of 7 Table 1: Minimum Sample Size Initial Approval and/or Initial Approval in a New Region Additional Manufacturing Location for Previously Approved Materials Para. Test Total Test Specimens Total Test Specimens 3.4

41、.2 Density 3 0 3.4.3.1 Tensile Strength, Yield 5 5 3.4.3.2 Elongation, Yield 5 5 3.4.3.4 Elongation, Break, PE-HD Layer 5 5 3.4.4 HDT 3 3 3.4.5 Heat Aging Performance 3.4.5.1 Tensile Strength, Yield 5 0 3.4.6 Adhesion Strength 5 3 3.4.7 Resistance to Fuel 3.4.7.1 Tensile Strength, Yield 5 5 3.4.7.2

42、Elongation, Yield 5 5 3.4.7.3 Adhesion Strength 5 3 3.4.8 Fuel Swell 3.4.8.1 Linear Swell 5 3 3.4.8.2 Weight Gain 5 3 3.5 Flammability 3 3 3.6 Environmental Stress Cracking Resistance 10 10 3.7 E/VAL Barrier Layer Thickness 8 8 3.8 Tie Layer Thickness 8 8 3.9 Regrind 3.9.1 Regrind Layer Thickness 3

43、3 3.9.2 Agglomerate Particle Size 1 1 4 General Information 4.1 Tensile Strength, Break 5 5 4.2 Resistance to Fuel 4.2.1 Tensile Strength, Break 5 5 4.3 Heat Deflection Temperature 3 3 4.4 Coefficient of Linear Thermal Expansion 4 4 5. SUMMARY OF REVISIONS 2016 02 02 Added WSS-M99P1111-A requirement

44、s, updated 4.4 Removed 3.4.4 Flex Mod., 3.4.5 Tensile impact, 5.1 Shear Modulus, and 3.4.3.3 Elongation of E/VAL layer. Clarified 3.3.8.1. Lowered 3.3.3.2 Elongation at yield from 10% to 8%. Added Table 1. Revised 3.6 E/Val thickness to 1 5% from 2 5%, Added 3.10 and table of sample sizes 2010 03 04

45、 Revised Item 3.4.2 Density lower limit Added ASTM D1822 methodology to 3.4.5 Tensile Impact Strength, min Added 10% Igepal concentration to 3.6 Environmental Stress Cracking Resistance Changed No cracking to F50, 10% Igepal, Across Flow to specify to 3.6 Environmental Stress Cracking Resistance 2006 09 29 Inserted 3.0; Deleted 3.1, 3.2, 3.3, 3.10 & 4