FORD WSS-M15P50-C2-2018 PERFORMANCE PLASTIC COMPONENTS UNDERBODY UNDERHOOD ENGINE TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M15P50-C1).pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2018 05 23 Revised See Summary of revisions H. Santos, SA 2017 06 27 Editorial Corrected footer A. Collins, NA 2017 01 06 Released K. Mueller, FNA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of

2、 10 PERFORMANCE, PLASTIC COMPONENTS, ENGINE PRECONDITIONING WSS-M15P50-C1 PERFORMANCE, PLASTIC COMPONENTS, UNDERBODY, UNDERHOOD, ENGINE WSS-M15P50-C2 1. SCOPE This specification addresses material durability for engine compartment and underbody plastic components that are not covered by other Ford p

3、erformance specifications. This specification does not include fuel system components. 2. APPLICATION WSS-M15P50-C1: This specification is intended for Engine Released plastic parts. These preconditioned parts will go through full DV/PV testing. (Examples: intake manifolds, air induction components,

4、 etc.). Testing must be done on parts as detailed in Table 1.0, unless specified by Ford Design and Release and Ford Materials Engineering Activities. In addition, this specification may be used when color matching is required for engine plastic components. WSS-M15P50-C2: This specification is inten

5、ded for parts that do not require preconditioning. It addresses material durability of parts, such as washer bottles, battery trays, underbody/aeroshields, belly pans, wheel arch liners, AGS/GOR/FEM/Bolster, air deflectors, etc. Testing requirements are referenced in paragraph 3.4. In addition, this

6、 specification may be used when color matching is required for underhood/underbody/engine plastic components. Excluded from this specification are underbonnet labels (WSS-M99P41-latest), thermal and acoustic assembly (WSS-M99P32-latest), exterior lighting (WSK-M98P10-latest), painted parts (WSS-M2P1

7、80-latest, or WSS-M2P181-latest), exterior plastics (WSS-M9P13-latest), Windshield Washer Solvent Performance (WSS-M14P19-latest), and Fuel System Parts Performance (WSS-M98P14-latest) whose performance is specified separately. 3. REQUIREMENTS Material specification requirements are to be used for i

8、nitial qualification of materials. 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources Data must be submitted to Ford Engineering upon completion of testing and before PPAP or SREA approval, see appendix A. 3.2 MATERIAL REQUIREMENTS Data must be submitted

9、via the Ford Materials Database (FMD) template. 3.2.1 Density (ISO 1183, Method A) Report Value, g/cm3 ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2018, Ford Global Technologies, LLC Page 2 of 10 3.2.2 Melt Flow Rate Report Value, (ISO 1133 190 C, 21.6 kg) g/10 minutes 3

10、.3 WSS-M15P50-C1: ENGINE PRE-CONDITIONING Unless otherwise noted, the cycled part, if appearance item, shall show no color change in excess of Grey Scale rating 4 (AATCC Evaluation Procedure 1/ISO 105-A02) when compared with the original part. (A color tone shift to the yellow direction is allowed u

11、p to Grey Scale rating 4. No other tone change (e.g. pink) is allowed.) For visible and non visible parts no visible cracks, blisters, softening, dulling, or evidence of material degradation when observed with the unaided eye from a distance of 300 +/- 30 mm. Except for paragraph 3.3.5, the pass/fai

12、l criteria for this section are successfully passing the DV/PV testing. The sample size will be dependent on the DV/PV test plan. Subject the minimum number of parts (see Table 1.0) to one cycle as described below: 3.3.1 Short Term Heat, Humidity and Cold Cycle (FLTM BQ 104-07 for conditioning guide

13、lines) High temperature will be dependent on location of the component. The values below are estimates, if a component is exposed to a higher temperature based on historical data, use the higher temperature. Ramp speed 1 to 5 C per minute. Record actual ramp speed on data sheet. High Temperature (us

14、e maximum TASE temperature). If maximum TASE temperature is not known, use the following: Components exposed to engine oil: 150 C Components exposed to engine coolant: 120 C Components bolted to engine (away from exhaust manifold): 150 C Under hood components not directly bolted to engine: 110 C Par

15、ts exposed to power steering fluid or transmission fluid: 135 C Short Term Heat, Humidity and Cold Cycle . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at High Temperature +/- 2 C . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +/- 2 C and 50

16、% R.H. . 5 h at -40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at High Temperature +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. 3.3.2 Short Term Heat, Condensing Humidity and Cold Cycle Substitute this test for parts that may be damaged by moisture ingression/freeze damage such as bonded or ov

17、er molded parts with different coefficients of expansion. Ramp speed 1 to 5 C per minute. This test requires 50 cycles of the following program: ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2018, Ford Global Technologies, LLC Page 3 of 10 Short Term Heat, Condensing Humid

18、ity and Cold Cycle . 30 min at 23 +/- 2 C and 50% R.H. . 3 h at High Temperature +/- 2 C . 3 h at 65 +/- 2 C and 90 +/- 5% R.H. . 3 h at - 30 +/- 2 C 3.3.3 Long Term Heat Exposure 3.3.3.1 Short 7 days at 5C above High Temperature +/- 2 C (as defined in 3.3.1) (as defined in 3.3.1, except use 100 +/-

19、 2 C for HDPE applications) 3.3.3.2 Extended 1000 Hours at High Temperature +/- 2 C (as defined in 3.3.1) (as defined in 3.3.1, except use 100 +/- 2 C for HDPE applications) 3.3.4 Long Term Resistance to Fluids (continuous use) Test only materials that will be continuously exposed to the fluids list

20、ed below. Note the time and temperature for each fluid exposure. Samples are to be immersed in, or filled with (depending on the part environment), the fluid for the time and temperature listed. Proper safety precautions must be followed when handling hot and/or flammable fluids. 3.3.4.1 Cooling Age

21、nt Resistance (1000 h at 125 +/- 2 C, 50/50 % vol coolant/water, engine coolant: WSS-M97B51-A1*) 3.3.4.2 Engine Oil Resistance (1000 h at 150 +/- 2 C, ASTM SF 105) 3.3.4.3 Brake Fluid Resistance (1000 h at 100 +/- 2 C, FMVSS DOT 3 or 4*) 3.3.4.4 Windshield Washer Fluid Resistance (1000 h at 50 +/- 2

22、 C, Motorcraft ZC-32 fluid, 1:1 dilution*) 3.3.4.5 Power Steering Fluid Resistance (1000 h at 135 +/- 2 C, WSA-M2C195-A*) 3.3.4.6 Automatic Transmission Fluid Resistance (1000 h at 135 +/- 2 C, WSS-M2C938-A*) *Or currently released equivalent fluid 3.3.5 Short Term Resistance to Fluids (Splash Conta

23、ct) (FLTM BI 168-01, Expose 1 part, or section of a part, per fluid. Exposed parts are evaluated per FLTM BI 168-01 and do not need to undergo PV/DV tests.) Parts where liquid exposure to battery acid is likely, parts near or under battery, substitute battery acid (6% by weight H2SO4) with battery a

24、cid ( 37% by weight H2SO4 with a density of 1.28 g/cm3). Paragraph 1. of procedure warming of test specimen shall be omitted. ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2018, Ford Global Technologies, LLC Page 4 of 10 3.4 WSS-M15P50-C2: UNDERBODY, UNDERHOOD, ENGINE PERF

25、ORMANCE This includes plastic underbody/aeroshields, wheel arch liners, washer bottles, underhood deflectors, AGS/GOR/FEM/Bolster, and other plastic engine compartment parts. See Table 2.0 for test sample description: Type (plaques or part/component) and Quantity. Test Plaques Testing: Test plaques

26、must be prepared with the production material (density and melt flow rate) using the production process (injection molding or vacuum forming) conditions. Part/Component Testing is applicable per judgment of Ford Product Development Engineering Activity: Parts shall be fully trimmed including all com

27、ponents packaged in the environment 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,

28、attachments, and supporting garnish moldings (if any), shall be the same as proposed for production. All test values are based on a part conditioned for not less than 24 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. 3.4.1 Environmental Testing Measurem

29、ent: Once the assembly is mounted onto a fixture, measure all critical dimensions including attachment points, package space and critical GDT tolerances. Test Procedure Visually evaluate the part before, during, and after the test. Measure the part and record data at all specified locations at room

30、temperature before and after cycling on the production support foundation or test fixture. For 3.4.1.1 “Short Term Heat and Cold Cycle“ testing, visually evaluate the part and measure any significant characteristic locations only, after each cold, extreme humidity and extreme hot temperature period.

31、 For 3.4.1.2 “Short Term Heat, Condensing Humidity and Cold Cycle“ visually evaluate the part before the test and after the last test cycle. Measure the part and record data at all specified locations at room temperature before and after cycling on the production support foundation or test fixture.

32、Subject the number of assemblies specified (see Table 2.0) to each of the cycles that follow in paragraphs 3.4.1.1, 3.4.1.2 and 3.4.1.3. Automated programmable test cycles based on the listed test conditions may be accepted by prior agreement with the affected Materials Engineering Activity. Ramp sp

33、eed 1 to 5 C per minute. Record actual ramp speed on data sheet. Acceptance Criteria: No cracking, crazing, tackiness, surface-color change, wrinkling, blistering, warping, delamination, permanent surface distortion, or softening. After testing is complete, part must be able to function (as reviewed

34、 by Ford Design and Release Engineering Activity). ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2018, Ford Global Technologies, LLC Page 5 of 10 3.4.1.1 Short Term Heat, Humidity and Cold Cycle High temperature will be dependent on part location. The values below are esti

35、mates, if a component sees a higher temperature based on historical data, use the higher temperature. Subject the minimum number of parts (see Table 2.0) to one cycle as described below: High Temperature (use maximum TASE temperature). If maximum TASE temperature is not known, use the following: Und

36、erbody Shields, Wheel Arch Liners, 100 C Washer Reservoirs/Bottles 90 C (The reservoir to be filled With H2O to its design capacity) AGS/GOR/FEM/Bolster 110 C Components exposed to engine oil: 150 C Components exposed to engine coolant: 120 C Components bolted to engine (away from exhaust manifold):

37、 150 C Under hood components not directly bolted to engine: 110 C Parts exposed to power steering fluid or transmission fluid: 135 C Short Term Heat, Humidity and Cold Cycle . 5 h at -40 +/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record results) . 5 h at High Temperature

38、+/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record results) . 2 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record results) . 5 h at - 40 +/- 2 C . 30 minutes (minimum) at 23 +/- 2 C and 50% R.H. (observe and record res

39、ults) 3.4.1.2 Short Term Heat, Condensing Humidity and Cold Cycle (Use only for parts that may be damaged by moisture ingression/freeze damage such as bonded or over molded parts with different coefficients of expansion). Ramp speed 1 to 5 C per minute. Evaluate after 25 cycles and at end of test. T

40、his test requires 50 cycles of the following program: ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2018, Ford Global Technologies, LLC Page 6 of 10 Short Term Heat, Condensing Humidity and Cold Cycle . 30 min at 23 +/- 2 C and 50% R.H. . 3 h at High Temperature +/- 2 C .

41、3 h at 65 +/- 2 C and 90 +/- 5% R.H. . 3 h at -30 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. 3.4.1.3 Long Term Heat Exposure (See Table 2.0 for minimum sample size) 3.4.1.3.1 Short 7 days at 5 C above High Temperature +/- 2 C (as defined in 3.4.1, except use 90 C for washer Reservoirs/Bottles. All

42、other HDPE applications use 100 +/- 2 C). 3.4.1.3.2 Extended - Not required if material is already approved 1000 Hours at High Temperature +/- 2 C (as defined in 3.4.1, except use except use 90 C for washer Reservoirs/Bottles. All other HDPE applications use 100 +/- 2 C). 3.4.2 Gravelometer Report (

43、Mid-rocker Underbody Shields and Front Wheel Arch/Well Liners Only) (SAE J400 / ISO 20567-1, 5 cycles of 700g (473ml), at 23 +/- 2 C and -30 +/- 2 C, test specimens size 100 x 305 mm (4 x 12 in), impingement angle at 45 degrees with edge-supported backer plate) There shall be no holes, separation, o

44、r other changes that impact the function or reduce the perceived quality of the vehicle. 3.4.3 Short Term Resistance to Fluids (Splash Contact) Report (FLTM BI 168-01) The part shall not dissolve, exhibit tackiness, delaminate, crack, or craze when exposed to each of the fluids listed below. Use a n

45、ew part for each test reagent. Record condition of parts after each test interval. Parts where liquid exposure to battery acid is likely, parts near or under battery, substitute Battery Acid (6% by weight H2SO4) with Battery Acid ( 37% by weight H2SO4 with a density of 1.28 g/cm3). Paragraph 1. of p

46、rocedure warming of test specimen shall be omitted. ENGINEERING MATERIAL SPECIFICATION WSS-M15P50-C1 WSS-M15P50-C2 Copyright 2018, Ford Global Technologies, LLC Page 7 of 10 Underhood/Underbody Parts use: Gasoline: Any commercially available lead free product with 20% laboratory grade ethanol. Winds

47、hield wash fluid, methanol based. 1 part Motorcraft fluid to 1.5 parts water Motorcraft ZC-20 Engine Shampoo and Degreaser Diesel: Any commercially available low sulfur diesel, grade 2 with 20% (by volume) biodiesel added. (any commercially available type) Transmission Fluid (Mercon or Ford brand) C

48、oolant: Motorcraft full OAT 50/50 dilution Battery Acid (6% by weight H2SO4) Engine Oil: Any commercially available engine oil meeting the latest API-ILSAC requirements. Brake Fluid (DOT 3 or DOT 4) Deionized Water with 3% sodium chloride (w/w) 3.4.4 Long Term Resistance to Fluids (Continuous Use On

49、ly) (Impact Strength, Notched Charpy, ISO 179-1/1eA, specimen D mm specimen use center section of specimen A, 10 specimens for each test, specimens to be notched before immersion) Test materials that will be continuously exposed to the fluids below. Record the time and temperature for each fluid exposure. Samples are to be immersed in the fluid for the time and temperature specified. Report the loss of impact strength ve