FORD WSS-M4D1052-B3-2018 POLYCARBONATE (PC) OPTICAL GRADE LOW MELT FLOW INTERIOR TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M4D1052-B1).pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2018 03 06 Released C. Wilson, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 10 POLYCARBONATE (PC), OPTICAL GRADE, HIGH MELT FLOW, EXTERIOR WSS-M4D1052-B1 POLYCARBONATE (PC), OPTICAL GRADE,

2、LOW MELT FLOW, EXTERIOR WSS-M4D1052-B2 POLYCARBONATE (PC), OPTICAL GRADE, LOW MELT FLOW, INTERIOR WSS-M4D1052-B3 1. SCOPE The material defined by this specification is a thermoplastic injected molded compound based on polycarbonate. These are non UV-stable materials. 2. APPLICATION WSS-M4D1052-B1 th

3、erefore it requires a UV stable coating for exterior applications. Long term exposure to direct sunlight will cause yellowing. This material should be evaluated for potential incompatibility with other materials that they may come in contact with. Refer to the appropriate performance specification.

4、HALS (Hindered Amine Light Stabilizers) IS PROHIBITED IN PC AND PC/ABS RESINS. HALS UV stabilizer degrades the polymer in the presence of moisture causing cracking/crazing of the resin. WSS-M4D1052-B1 only: These materials should not be considered for parts with snap-in features or features that are

5、 notch-sensitive, as they tend to break in these types of applications. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification 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 req

6、uire approval from Raw Materials Purchasing and Materials Engineering). Molders not on the CMB program or regions without CMB are required to use materials listed on the Ford Approved Source List (ASL), and are encouraged to use the CMB sources. Only the sources identified on the Approved Source Lis

7、t 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. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-B1/B2/B3 Copyright 2018, Ford Global Technol

8、ogies, LLC Page 2 of 10 Approval of new sources requires the completion of the latest version of the FMD template. Data should be submitted at the time as the specification data package. Only one FMD package is required per trade name approved, FMD is not required for each manufacturing site. FMD is

9、 required for new site approvals that do not have an existing FMD record. 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 material

10、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 material s

11、upplier 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 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS 3.4.1 Many 4D resin specifications prior to 2011, i

12、dentified 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 for number of samples required for each test. 3.4.2 This

13、 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 maximum allowable amount of regr

14、ind and 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 N

15、otice. 3.4.4 Performance Criteria: WSS-M4D1052-B1 split screen at 2000 cm-1, Strongest absorption band in the spectrum should bottom out in the 10 to 20 % transmittance range. Supplied spectrum should span a standard sheet of copy paper, preferably in landscape mode, with the x-axis delineated well

16、so that the location of the absorption bands in cm-1 can be determined. TGA (% by weight, Room temperature to 900 C in nitrogen at 15 C /minute, cool to 600 C then 900 C in air at 15 C /minute, on plot, report Weight % loss in Nitrogen, Weight % loss in Air, and % Ash) Specific Heat Capacity, Cp (J/

17、kg K) (Differential Scanning Calorimetry (DSC), ASTM E1269, ISO 11357-4) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-B1/B2/B3 Copyright 2018, Ford Global Technologies, LLC Page 7 of 10 Graphs of 1st and 2nd heat cycles, report Tg. Specific Heat Capacity (J/kgK) x-y data from 0C to 30-50 C above m

18、elt temp Also report Glass Transition Onset, Glass Transition Inflection, Melt Point Onset, and Melt Point Peak Engineering Stress/Strain x-y data (max 100 data points) at 23 C, -40 C, and a high temperature (recommend heat age temperature). 4. GENERAL INFORMATION The information given below is prov

19、ided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design

20、 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 test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested mat

21、erial 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 Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.2 SUPPLIERS ONGOING RESPONSIBILIT

22、Y 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, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall n

23、otify the affected Supplier 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

24、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. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to th

25、e 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 standard on a continuing basis through IMDS and or GMAP reporting. 4.4 ENVIRONMENTAL

26、 STRESS CRACKING (FLTM BO 127-03) Note: Not tested for initial application of this resin. Resin must be tested for resistance to stress cracking when used for applications that come into contact with oil, grease, cleaners, PVC, etc. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-B1/B2/B3 Copyright 2

27、018, Ford Global Technologies, LLC Page 8 of 10 4.5 TYPICAL PROPERTIES USING METHODS IN SECTION 3.8 Para. Test Typical Value Units 3.8.1 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering) Flow Cross Flow 0.8 0.81 - 0.83 % % 3.8.2 Coefficie

28、nt of Linear Thermal Expansion Flow Cross Flow 7.1 6.4 6.8 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.3 3.8.3.1 3.8.3.2 Impact Strength, Charpy, Notched, mean At 23 +/- 2 C At - 40 +/- 2 C B1 B2/B3 9 58 7 6 kJ/m2 min/ Break Type kJ/m2 min/ Break Type 3.8.4 Poissons Ratio 0.35 - 0.38 N/A 4.3 GENERIC IDENTIFICATIO

29、N AND MARKING OF PLASTIC PRODUCTS PC (ISO 1043/11469/18064) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1052-B1/B2/B3 Copyright 2018, Ford Global Technologies, LLC Page 9 of 10 Table 1: Minimum Sample Size Initial Approval New Manufacturing Location for Previously Approved Material Para. Test Minimum

30、Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4 WSS-M99P1111-A 3.4.4 WSK-M98P10-A/Latest Reference performance specification 3.4.4 WSS-M15P4-G/Latest Reference performance specification 3.6.1 Weathering Resistance 1 1 1 3.7.1 Melt Flow Rate* 3 1 3 1 1 1 3.

31、7.2 Density 1 3 3 1 3 3 3.7.3 Tensile Strength at Yield * 3 5 15 1 5 5 3.7.4 Elongation at Yield * 3 5 15 1 5 5 3.7.5 Tensile Modulus 1 10 10 3.7.6 Flexural Modulus* 3 10 30 1 10 10 3.7.7 Standard Test Method for High Speed Puncture (per condition)* 3 10 30 1 10 10 3.7.8 Heat Deflection Temperature*

32、 3 2 6 1 2 2 3.7.9 Vicat Softening Temperature* 3 2 6 1 2 2 3.7.10 Heat Aging Performance 3.7.10.1 Tensile Strength at Yield, Change 1 5 5 3.7.10.2 Standard Test Method for High Speed Puncture, Change 1 10 10 3.7.11 Odor 1 9 9 3.7.12 Fogging Photometric 1 3 3 3.7.13 Flammability 1 5 5 3.7.14.1 Lumin

33、ous Transmittance 1 3 3 3.7.14.2 Haze 1 3 3 3.7.15 Yellowness Index 1 3 3 3.8.1 Mold Shrinkage 1 5 5 1 5 5 3.8.2 Coefficient of Linear Thermal Expansion (per condition) 1 3 3 3.8.3 Impact Strength, Notched Charpy (per condition) 1 10 10 3.8.4 Poissons Ratio 1 2 2 1 2 2 3.8.5 Curves - IR - TGA - DSC(

34、first and second heat) - CLTE (3 flow and 3 cross flow) - Stress Strain Curves 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-M4D1052-B1/B2/B3 Copyright 2018, Ford Global Technologies, LLC Page 10 o

35、f 10 Table 2: Minimum Color Property Testing 5. SUMMARY OF REVISIONS Para. Test Lots Specimens per Lot Total Test Specimens Color Test Direction 3.6.1 Weathering Resistance (WSS-M4D1052-B3 only) 1 1 1 Every color 3.7.2 Tensile Strength at Yield 1 5 5 As directed by Materials Engineering 3.7.5 Flexur

36、al Modulus 1 10 10 As directed by Materials Engineering 3.7.7.1 Standard Test Method for High Speed Puncture at 23 +/- 2C 1 10 10 As directed by Materials Engineering 3.7.11 Odor (WSS-M4D1052-B3 only) 1 9 9 As directed by Materials Engineering 3.7.12 Fogging Photometric 1 3 3 As directed by Materials Engineering 3.7.13 Flammability 1 5 5 Every color