FORD WSS-M15P4-G-2016 ASSEMBLY PERFORMANCE HARD MOLD-IN-COLOR INTERIOR COMPONENTS TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2016 07 08 Editorial See Summary of revisions L. Schmalz, NA 2016 05 24 Editorial See Summary of Revisions L. Schmalz, NA 2016 04 05 Released L. Schmalz, NA Controlled document at www.MATS Copyright 2016, Ford Global Technologies, LLC

2、 Page 1 of 10 ASSEMBLY PERFORMANCE, HARD MOLD-IN-COLOR WSS-M15P4-G INTERIOR COMPONENTS 1. SCOPE This specification defines the minimum durability and performance requirements of hard, mold-in-color interior trim panels, moldings, overhead and floor consoles, and hard instrument panels where various

3、materials are combined to provide a trim assembly having decorative and/or functional features. 2. APPLICATION This specification was originally released for plastic mold-in-color and non-visible interior trim items such as door panels, center and overhead consoles, quarter panels, A-, B-, C-, and D

4、-pillar moldings, hard instrument panels, instrument panel components and garnish molding. Testing for mold-in-color components is detailed in Table 1 unless specified otherwise by Ford Engineering. Testing for non-visible components is detailed in Table 2 unless otherwise specified by Ford Engineer

5、ing. Testing must be done on parts unless part geometry does not allow. If that is the case, appropriate plaques with production grain and color can be used. 2.1 LIMITATIONS Excluded from this specification are the non resin components within the following assembly performance specifications; soft i

6、nstrument panels, interior soft trim and wrapped parts (WSS-M15P45-B/latest), package trays (WSS-M15P6-E/latest), steering wheels (WSS-M98P12-B/latest), headliners (WSS-M15P27-G/latest), carpeted substrate (WSS-M8P16-B/latest), molded armrests and headrests (WSS-M15P20-B1/B2/latest), appliqus (WSS-M

7、15P34-E/latest), visors (WSS-M98P3-B/latest), painted interior components (WSS-M2P188-B1/latest), chrome plated components (WSS-M1P83-E1/latest), interior elastomers (WSS-M9P8-B/latest), instrument clusters (WSS-M15P52-A) interior NVH components (WSS-M99P32-D1/latest) or whose performance is specifi

8、ed separately. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 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

9、 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 APPEARANCE Color, gloss, grain, tactile effect shall match master Trim Sample and/or Master Appearance Sample as approved by Color and Materials. ENGINEERING MATERIAL SPECIFI

10、CATION WSS-M15P4-G Copyright 2016, Ford Global Technologies, LLC Page 2 of 10 3.3.1 Gloss As released by Engineering: Gloss A: 20o Glossmeter min 92 B: 60o Glossmeter 76-84 C: 60o Glossmeter 66-74 D: 60o Glossmeter 58-66 E: 60o Glossmeter 47-53 F: 60o Glossmeter 33-38 G: 60o Glossmeter 17-23 H: 60o

11、Glossmeter 7-13 J: 60o Glossmeter 4-6 K: 60o Glossmeter 2-4 L: 60o Glossmeter 0.5-2.0 N: 60o Glossmeter 1.8-2.4 R: 60 Glossmeter 1.2-1.6 3.4 ENVIRONMENTAL TESTING Sample Preparation All parts shall be fully trimmed including all components packaged in the environment (eg. speakers, hardware, wiring,

12、 etc.) and assembled onto actual or representative production support foundations. This includes not only all attaching points, but also any boundary conditions that may restrict movement, unless otherwise specified by the responsible PD Engineer. The retention methods, attachments, and supporting g

13、arnish moldings (if any), shall be the same as proposed for production. Measurement Locations Every twenty centimeters and at the points of greatest movement between the twenty centimeter marks along the parts outside edges and internal openings or as defined by PD Engineering. Some parts may have s

14、pecific measurement locations required by PD Engineering, which will override the 20 cm required. Part specific measurement locations to be signed off by PD Engineering prior to test. The “significant characteristics locations“ specified on the engineering drawing. For Upper A-Pillars: In addition t

15、o the locations defined above, measurement locations should be every 5 centimeters starting at the upper zero location and running along the glass and the weather seal edges (See diagram below). Applies to paragraphs 3.3.1 and 3.3.2. ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-G Copyright 2016, For

16、d Global Technologies, LLC Page 3 of 10 Measurement Technique The movement at each measurement point shall be recorded in two directions: (1) in the x/y plane from the observers view, and (2) in the z-dimension direction into or out of the x/y plane from the observers view. The observers view shall

17、remain consistent always viewing from the front side of the part. Test Procedure Visually evaluate the part before, during, and after the test. Measure the part and record data at all specified locations at room temperature before and after cycling on the production support foundation or test fixtur

18、e. Any visual defects/imperfections must be noted in the test report, and signed off by PD Engineering for compliance. Upper A-Pillars: For 3.4.1 Short Term Heat, Humidity, and Cold cycle: Within the last 2 hours of the final cycle of high heat, photograph the parts with the same camera angle as on

19、the pre-test photo. For 3.4.2 Long Term heat: Within the last 24 hours of high heat test, photograph the parts with the same camera angle as on the pre-test photo. Subject the number of assemblies specified to each of the cycles that follow in paragraphs 3.4.1 and 3.4.2. Use test chambers with autom

20、ated programmable test cycles for the listed test conditions below. Typical ramp time between stages is 30 minutes unless otherwise agreed upon by Materials Engineering. 3.4.1 Short Term Heat, Humidity and Cold Cycle 3.4.1.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. sail; A-, B-,

21、C-, and D-pillars; upper quarter panels; hard instrument panels, and window garnish moldings): 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100+/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H. 5 h at -30 +/- 2 C 30 min at

22、23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C 3.4.1.2 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels, lower quarter trim panels, floor and overhead consoles, and glove box doors.) 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 90 +/- 2 C 30 min at 23 +/- 2 C and 50% R.

23、H. 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H. 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 90 +/- 2 C ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-G Copyright 2016, Ford Global Technologies, LLC Page 4 of 10 3.4.1.3 Scuff plates, kick panels, and other non-

24、sun loaded floor level parts. 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 80 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H. 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 80 +/- 2 C 3.4.2 Long Term Heat Ex

25、posure/Sun Load 3.4.2.1 All hard instrument panels (with or without integrated floor consoles) Sun Load per IP-0105, 107 C surface temperature via heat lamps with a chamber temperature of 90 C for 240 hours 3.4.2.2 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. sail; A-, B-, C-, and D-

26、pillars; upper quarter panels; and window garnish moldings): 7 days at 100 +/- 2 C 3.4.2.3 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels, lower quarter trim panels, glove box doors, overhead consoles, and floor consoles that are not integrated with the instrument panel and the

27、unit stands alone): 7 days at 90 +/- 2 C 3.4.2.4 Non-sun loaded floor level parts (e.g., scuff plates and kick panels) 7 days at 80 +/- 2 C Requirements: The trimmed assemblies shall remain relatively unaffected by the exposure cycles during and after the tests as demonstrated by: (1) Tactually/visu

28、ally - no excessive tackiness, loss in surface-grain, or surface-color change (ISO 105-A02 AATCC Procedure 1, Rating 4, min); no wrinkling, distortion, blistering, warping, delamination, blushing, hazing, milking, staining, waviness, or other objectionable visual appearance. (2) Functionally - no ex

29、cessive expansion, shrinking, or warping that will interfere with normal functional operations. (3) Dimensionally - no movement exceeding what is required on the Engineering drawing from the original installed position during or after the test. 3.5 IMPACT RESISTANCE- ROOM TEMPERATURE (23 +/-2 C) Req

30、uired for scuff plates, floor consoles, load floors, seating components, door map pockets or any other parts as required by Ford Engineering. Rubber Ball, 4.5 kg weight, 127 mm diameter, 60 +/- 5 Durometer “A“ ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-G Copyright 2016, Ford Global Technologies, L

31、LC Page 5 of 10 Test Method: Conduct this test with the trim assembly mounted on an actual or simulated production support foundation using the approved retention methods. Drop the rubber ball from the height specified below at the impact locations indicated on the Engineering Drawing. Drop Height S

32、cuff Plates 610 mm Load Floor 500 mm Below belt line 460 mm Above the belt line 305 mm The assembly shall show no evidence of cracking or breaking and shall fully recover from indentation. 3.6 RESISTANCE TO INTERIOR WEATHERING (FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1) In Vehicle Su

33、nlight Exposure Level FLTM BO 116-01 Test Exposure AATCC Rating After Exposure, min. Severe Exposure: Instrument panel top, defroster grille, 3609.6 kJ/m2 Rating 4 Heavy Exposure: Instrument panel lower top cover, 2 tone IP, IP bezel, IP registers, airbag, steering wheel, message center, appliqus, p

34、arcel shelf assembly/package tray and center finish panel, door trim top rollover 2406.4 kJ/m2 Rating 4 Medium Exposure: Instrument panel lower, door trim, interior trim, pillars/grab handles, garnish moldings, seat back plastics, head rest plastics, sunshade, sun visor, seat belt webbing resins tha

35、t come in contact with the vinyl and/or foam. No cracking or crazing allowed. ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-G Copyright 2016, Ford Global Technologies, LLC Page 7 of 10 4. GENERAL INFORMATION This information given below is provided for clarification and assistance in meeting the requ

36、irements of this specification. Contact for questions concerning Engineering Material Specifications. Rubber Ball Contact Information Dave Clow, Schap Specialty Machine, Inc. 17309 Taft Street Spring Lake, MI 49456, USA Phone:1-616-846-6530 4.1 SUPPLIERS ONGOING RESPONSIBILITY All materials must

37、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 affected Su

38、pplier 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

39、 specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.2 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed

40、 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 standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2016 07 08 Edi

41、torial Clarified note for short and long term environmental in table 1 for PV testing. 2016 05 24 Editorial Table 1 under PV added back in testing exception for 3.4.1 and 3.4.2ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-G Copyright 2016, Ford Global Technologies, LLC Page 8 of 10 TABLE 1 TESTING RE

42、QUIREMENTS NOTE: This table is only for APPROVED RESIN technologies as shown on the Ford Approved Source List. Otherwise full WSS-M15P4-G specification testing is required. Sample size/color New Color (Data from MCDCC approval can be used as surrogate) DV Required for New part geometry or new materi

43、al Technology (post FDJ) PV Must use production tools Molder/resin supplier change Comments Components 3.3 Appearance All colors X X 3.4.1 Short Term Heat Exposure 1/part- darkest color 2 parts/new technology X Required in assembly X * *Key life testing can be used in lieu. Bonded parts must be prod

44、uction representative. 3.4.2 Long Term Heat Exposure 1/part-darkest color 2 parts/new technology X Required in assembly X * For IP-Sunload testing per IP-105. Bonded parts must be production representative. 3.5.1.1 Impact Resistance-Room Temp 2/parts lightest and darkest color X Required in assembly

45、 Grained Plaque/Part tests 3.7 Soiling and Cleanability* 1 per media/ per grain/per color X X Production intent resin, grain and colorant to complete testing by FEC for all new colors and grains Concentrate letdown ratio must be production representative 3.8.1 Scratch and Mar Resistance* 3 per grain

46、/per color X X Testing on plaques with Production intent resin, grain and color (with production intent colorant) if available X Testing on production parts if they differ in grain, material, color and/or processing from plaques tested at DV or if unavailable at DV. Concentrate letdown ratio must be

47、 production representative 3.8.2 Micro Scratch (A/B gloss only) 3 per color X X Testing on plaques with Production intent resin, grain and X Testing on production parts if they differ in grain, material, color and/or processing ENGINEERING MATERIAL SPECIFICATION WSS-M15P4-G Copyright 2016, Ford Glob

48、al Technologies, LLC Page 9 of 10 Sample size/color New Color (Data from MCDCC approval can be used as surrogate) DV Required for New part geometry or new material Technology (post FDJ) PV Must use production tools Molder/resin supplier change Comments color (with production intent colorant) if avai

49、lable from plaques tested at DV or if unavailable at DV. Material Tests (ungrained/ grained parts or plaques) 3.6 Resistance to Fade 1 per color X X Production intent resin and colorant to complete testing by PEC MCDCC form may be used as evidence Concentrate letdown ratio must be production representative 3.9 Fogging 1 any color X Prototype parts Contact Materials Engineering if surrogate data is acceptable