FORD WSS-M4D1028-A3-2018 POLYPROPYLENE (PP) COPOLYMER IMPACT MODIFIED COMPOUND MOLD IN COLOR INTERIOR TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M4D1028-A2).pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 1 2018 05 03 Released A3 See Summary of Revisions D. Stark, NA 2013 12 09 Released R. Harris, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 8 POLYPROPYLENE (PP) COPOLYMER, WSS-M4D1028-A2 IMPAC

2、T MODIFIED COMPOUND, NON VISIBLE, INTERIOR POLYPROPYLENE (PP) COPOLYMER, IMPACT MODIFIED COMPOUND, MOLD IN COLOR, INTERIOR WSS-M4D1028-A3 1. SCOPE The material defined by this specification is a formed sheet, vacuum formed or injection molded thermoplastic material based on polypropylene copolymer.

3、2. APPLICATION WSS-M4D1028-A2: This specification was released originally for material used for B pillar reinforcement applications. WSS-M4D1028-A3: This specification was released originally for material used for seat belt buckle covers. 2.1 LIMITATIONS WSS-M4D1028-A2: This material does not contai

4、n UV stabilizers, long term exposure to direct sunlight will cause chalking and loss of gloss. WSS-M4D1028-A3: This material is UV stable only when molded with color concentrate containing UV stabilizers. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. O

5、nly 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 or available externally through a Ford Materials Engineer. 3.2 CONDITIONING AND TESTIN

6、G 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 material should occur in the conditioning environment or soon after removal. 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THE

7、RMAL 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 material supplier shall ensure that all future material supplied to the specification shall produce IR spectra and ther

8、mograms that correspond to the reference standard when tested under the same conditions. 3.4 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.4.1 Many 4D resin specifications prior to 2011, identified certain requirements with the symbol (s), which indicated that the mean and +/- 3 sigma values were

9、 to be reported. The specification minimum, maximum or range was established using 3 sigma data. For 2011 ENGINEERING MATERIAL SPECIFICATION WSS-M4D1028-A2/A3 Copyright 2018, Ford Global Technologies, LLC Page 2 of 8 and beyond, refer to Table 1 for number of samples required for each test. 3.4.2 Th

10、is specification is based on virgin material and does not allow the addition of recycled content (PIR/PCR). 3.4.3 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 an

11、d the maximum allowable regrind content must be specified on the 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) or Engineering Notice.

12、 3.4.4 Performance Criteria Parts using these specifications shall meet the appropriate performance specification, WSS-M15P4-H / Latest. 3.4.5 Ford Materials Engineering may request a Control Plan and Certificate of Analysis (C of A) containing lot testing requirements which must include, but are no

13、t limited to: Melt Flow Rate Impact Strength, Notched Charpy at 23C Flexural Modulus 3.5 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 Ford Materials

14、Engineering. Specimens are tested with the as-molded thickness of the part and are not machined to meet the thickness 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 re

15、commended by an applicable Industry Standard/Test Method. The test specimens A and D shall be molded using molding conditions defined in ISO 1873-2. See Table 1 for the number of samples required. Specimens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, Specimen Type 1

16、A) 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 3.2 mm Specimen G 90 mm x 200 mm Specimen H 50 +/- 1 mm diameter x 3.2 +/- 0.2

17、mm Specimen I 100 mm x 150 mm, min 3.6 APPEARANCE (WSS-M4D1028-A3 ONLY) 3.6.1 Resistance to Interior Weathering Rating 4 min (FLTM BO 116-01, 2406.4 kJ/m2 exposure Specimen C, ungrained, non-polished mold, ISO 105-A02 / AATCC Evaluation Procedure 1) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1028-A2/

18、A3 Copyright 2018, Ford Global Technologies, LLC Page 3 of 8 Every week* remove the samples from the weatherometer and allow 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 sha

19、ll show no fading or color change in excess of the specified AATCC rating. In addition, there shall be no cracking, crazing or other deterioration. Use regional choice for initial approval and report the color house used. See Table 2 for additional color durability submission requirements. *When set

20、ting machine for automatic shutoff, every 526.4 kJ/m2 is recommended. 3.6.1.2 Determining the Tackiness of Interior Materials Rating 4 min (FLTM BO 061-01, Specimen C, ungrained, on-polished mold. Expose per para. 3.5.1) Evaluate the test specimens every 526.4 kJ/m2. If Rating falls below a Rating 4

21、 at any interval this is cause for rejection. Report any spewing or other exudation. This is used to find any incompatibility of stabilizers in polypropylenes or other polymers. 3.7 MATERIAL PROPERTIES 3.7.1 Melt Flow Rate 0.9 1.7 (ISO 1133, 230 C, 2.16 kg) g/10 minutes 3.7.2 Density 0.88 0.92 g/cm3

22、 (ISO 1183, Method A) 3.7.3 Tensile Strength at Yield 21 MPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.7.4 Tensile Modulus 0.9 GPa min (ISO 527-1 and ISO 527-2, Specimen A, 50 mm/minute test speed) 3.7.5 Flexural Modulus 1100 - 1250 MPa (ISO 178, Specimen D, 64 mm support

23、span, 2 mm/minute test speed) 3.7.6 Impact Strength, Notched Charpy (ISO 179-1/1eA, Specimen D) 3.7.6.1 At 23 +/- 2 C 45 kJ/m2 min Report Break Type 3.7.6.2 At -40 +/- 2 C 2.0 kJ/m2 min Report Break Type ENGINEERING MATERIAL SPECIFICATION WSS-M4D1028-A2/A3 Copyright 2018, Ford Global Technologies, L

24、LC Page 4 of 8 The test specimen must be conditioned for minimum 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

25、 Materials Engineering. 3.7.7 Heat Deflection Temperature 44C min (ISO 75-1 and ISO 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 1.80 MPa) 3.7.8 Heat Aging Performance (ISO 188, 150 +/- 50 air changes/h, 1000 h at 120 +/- 2 C. After heat aging test specimens are to be conditioned in a

26、desiccator for 3 - 5 h at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.7.8.1 Tensile Strength at Yield, Change +/- 25% max (Test Method per Para 3.7.3) 3.7.8.2 Impact Strength, Notched Charpy, Change - 25% max (Test Method per Para 3.7.6,

27、 specimens to be notched before Heat Aging) 3.7.9 Interior Odor Test Rating 3 max (FLTM BO 131-03, Variant C, Specimen G) 3.7.10 Determination of the Fogging Characteristics of Interior Automotive Materials Photometric (SAE J1756, Specimen F, 3 h at 100 C heating, 21 C cooling plate, post test condi

28、tioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. For shipping, all materials or parts shall be sampled immediately after manufacture, then bagged in a zipper- or slide-sealed polyethylene (PE) bag, PE-coated aluminum bag or wrapped in aluminum foi

29、l prior to bagging. Test specimens shall be cut, then stored in a clean, open environment for 14-28 days. After 14-28 days of air exposure, the specimens shall be tested immediately or re-bagged until testing can be performed. Bagged materials or parts must be labelled on the outside of the bag with

30、 the following information, and included in the test report: supplier, contact information, product code/trade name or part number, manufacturing location, date of manufacture, shipping date, start and end dates of conditioning period and test date. 3.7.11 Flammability (ISO 3795/SAE J369, Specimen B

31、, smooth surface) Burn Rate 100 mm/minute max ENGINEERING MATERIAL SPECIFICATION WSS-M4D1028-A2/A3 Copyright 2018, Ford Global Technologies, LLC Page 5 of 8 3.8 MATERIAL PROPERTIES REPORT ONLY 3.8.1 Molding Shrinkage (ISO 294-3 and 294-4/ISO 2577, 60 x 60 x 2.0 +/- 0.1 mm injection molded specimen B

32、) After 48 h at 23 +/- 2 C Flow Report Value, % Cross Flow Report Value, % 3.8.2 Coefficient of Linear Thermal Expansion (ISO 11359-2 TMA, -30 +/- 2 C to 100 +/- 2 C) Flow Report Value, mm/mm/ C Cross Flow Report Value, mm/mm/ C 3.8.3 Heat Deflection Temperature Report Value, C min (ISO 75-1 and ISO

33、 75-2, Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. At 0.45 MPa) 3.8.4 Poissons Ratio Report Ratio (ISO 527-1 and ISO 527-2, Specimen A 1 mm/minute test speed) 3.8.5 Supplemental Information The following curves are to be submitted with the data packages: TGA FTIR DSC CLTE Engineering Stress/St

34、rain at 23 C, -40 C, 80 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 Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.7 Para

35、. Test Typical Value Units 3.8.1 Molding Shrinkage After 48 h at 23 +/- 2 C Flow Cross Flow 1.4 1.4 % % 3.8.2 Coefficient of Linear Thermal Expansion -30 to 100C Flow Cross Flow 13.1 14.9 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.3 Heat Deflection Temperature At 0.45 MPa 69 - 85 C 3.8.4 Poissons Ratio 0.4 N/A E

36、NGINEERING MATERIAL SPECIFICATION WSS-M4D1028-A2/A3 Copyright 2018, Ford Global Technologies, LLC Page 6 of 8 4.2 GENERIC IDENTIFICATION AND MARKING OF PLASTIC PRODUCTS (ISO 1043/11469) PP Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Previously Approved Material Para.

37、 Test Minimum Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4.4 Performance Criteria Reference Performance Specification 3.6.1 Resistance to Interior Weathering WSS-M4D1028-A3 ONLY 1 1 1 3.7.1 Melt Flow* 3 1 3 1 1 1 3.7.2 Density 1 3 3 1 3 3 3.7.3 Tensile

38、Strength at Yield* 3 5 15 1 5 5 3.7.4 Tensile Modulus* 3 10 30 1 10 10 3.7.5 Flexural Modulus* 3 10 30 1 10 10 3.7.6 Impact Strength Notched Charpy (per condition)* 3 10 30 1 10 10 3.7.7 Heat Deflection Temperature* at 1.80 MPa 3 2 6 1 2 2 3.7.8 Heat Aging Performance 3.7.8.1 Tensile Strength at Yie

39、ld, Change 1 5 5 3.7.8.2 Impact Strength, Notched Charpy, Change 1 10 10 3.7.9 Interior Odor Testing 1 9 9 3.7.10 Fogging (Photometric) 1 3 3 3.7.11 Flammability 1 5 5 3.8.1 Mold Shrinkage 1 5 5 1 5 5 3.8.2 Coefficient of Linear Thermal Expansion 1 3 3 3.8.3 Heat Deflection Temperature at 0.45 MPa 3

40、 2 6 3.8.4 Poissons Ratio 1 2 2 3.8.5 Curves - FTIR - TGA - DSC - CLTE - Stress / Strain 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 WSS-M4D1028-A2/A3 Copyright 2018, Ford Global Technologies, LLC Pa

41、ge 7 of 8 Table 2: Minimum Color Property Testing - Contact Materials Engineering for Color Test Work Plan (WSS-M4D1028-A3 ONLY) 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 M

42、aterials Engineering. The supplier shall submit a completed copy of their laboratory 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 availabl

43、e for review upon request and kept for a minimum 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 equiva

44、lent 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 Supplier Te

45、chnical 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 specific

46、ations for Design Verification (DV), Production 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

47、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. 4.6 ADDITIONAL REQUIREMENTS Requirements beyo

48、nd those explicitly stated in this document and the material specification may be specified on the Engineering drawing, Engineering specification (ES), performance specification, System Design Specification (SDS) and/or Attribute Requirement List (ARL). Para. Test Lots Specimens per Lot Total Test S

49、pecimens Color Test Direction 3.6.1 Resistance to Interior Weathering 1 1 1 Every color 3.7.6 Impact Strength, Notched Charpy at 23 +/- 2 C 1 10 10 As directed by Materials Engineering 3.7.11 Flammability 1 5 5 As directed by Materials Engineering ENGINEERING MATERIAL SPECIFICATION WSS-M4D1028-A2/A3 Copyright 2018, Ford Global Technologies, LLC Page 8 of 8 5. SUMMARY OF REVISIONS 2018 05 03 Updated WSS-M4D1028-A2 title for clarif