FORD WSS-M4D1056-A1-2015 POLYCARBONATE COPOLYMER MOLD IN COLOR UV STABLE A GLOSS EXTERIOR TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions REV 00 2015 10 15 Released M. Katz, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 10 POLYCARBONATE COPOLYMER, MOLD IN COLOR, UV STABLE, WSS-M4D1056-A1 A GLOSS, EXTERIOR 1. SCOPE The material define

2、d by this specification is a thermoplastic injection molded compound based on a polycarbonate copolymer and contains UV stabilization. 2. APPLICATION This specification was originally released for materials used for exterior components that require high gloss and exterior weathering performance with

3、out need for a coating, such as grilles. 2.1 LIMITATIONS This material should be evaluated for potential incompatibility with other materials that it may come in contact with. Refer to the appropriate performance specification. Materials approved to this specification may contain additives which inh

4、ibit adhesion, and therefore should not be used in painted applications. 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

5、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 TEST CONDITIONS All test values are based on material conditioned for not less than 24 h prior to testing in a controlled environment of 2

6、3 +/- 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 THERMAL ANALYSIS IR spectra and thermograms from initial material approval shall constitute the reference standard and shall be

7、 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 thermograms that correspond to the reference standard when tested under the same conditions. 3.4 STANDARD REQUIREMENTS FOR PRODU

8、CTION 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 to be reported. The specification minimum, maximum or range was established using 3 sigma data. For 2011 and beyond, refer

9、to Table 1 for number of samples required for each test. 3.4.2 This specification is based on virgin material and does not allow the addition of recycled content (PIR/PCR). ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 10 3.4.3 Performance

10、Criteria: Parts using this specification shall meet the appropriate performance specifications, WSS-M98P13-E/Latest. 3.4.4 Ford Materials Engineering may request a Control Plan and Certificate of Analysis (C of A) containing lot testing requirements which must include, but are not limited to: Melt F

11、low Rate Impact Strength, Notched Charpy at 23C Tensile Modulus 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 Engi

12、neering. Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test specimens. The test specimens A and D shall be molded using molding conditions defined in ISO 7391-2. No additional annealing is allowed. See Tables 1 for the number of samples required. Specim

13、ens shall be as follows: Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, Specimen Type 1A) 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

14、 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 mm Specimen I 100 mm x 150 mm, min For Appearance Testing: Use an ungrained, non-polished, tool to prepare specimens for C through N gloss surfaces. Use a smooth, polished tool to prepare specimens for A

15、 and B gloss surfaces. 3.6 APPEARANCE 3.6.1 Gloss Rating 92 min (FLTM BI 110-01, ASTM D523, Specimen I) Use a smooth, polished tool to prepare specimens for A and B gloss surfaces. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 10 Gloss Desc

16、ription Gloss Code* Gloss Level Very High A 92 min B 76 - 84 High C 66 - 74 D 58 - 66 E 47 - 53 F 33 - 38 Medium G 17 - 23 H 7 - 13 J 4 - 6 Low K 2 - 4 L 0.5 - 2.0 N 1.8-2.4 *A use 20 degree, B-N use 60 degree 3.6.2 Accelerated Weathering Resistance Preferred Method 3.6.2.1 Standard Practice for Xen

17、on Arc Exposure Test Requirements per Table with Enhanced Light and Water Exposure for Transportation Coatings (ASTM D7869, Use a smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) or 3.6.2.2 Performance Based Standard for Accelerated Requirements

18、 per Table Exposure of Automotive Exterior Materials Using Controlled Irradiance Xenon-Arc Apparatus (Boro/Boro, SAE J2527, Atlas Water Cooled, Rotary Drum Xenon-Arc Apparatus only. Modified Type “S“ borosilicate inner and outer filters, 0.55 W/m2 radiant exposure monitored at 340 nm, Specimen C, un

19、grained, non-polished mold, use a smooth, polished tool to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 10 Type ASTM D7869 (preferred) SAE J2527 Boro/Boro Requi

20、rements New Color 2250 h 3000 h Fade Resistance: Rating 4 min There shall be no cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss Change 25% max (FLTM BI 110-01) *New Material Supplier or New Material Grade 2250 h 3000 h Fade Resistance: Rating 4 min There shall be no cra

21、cking, crazing, dulling, or other deterioration A&B Gloss Materials: Gloss Change 25% max (FLTM BI 110-01) 3000 h and 3750 h 4000 h, 5000 h, and 6000 h Fade Resistance: Report Only Report any cracking, crazing, dulling, or other deterioration A&B Gloss Materials: Report Gloss Change (FLTM BI 110-01)

22、 *New Material Supplier or New Material Grade: New resin from unknown or known Material Supplier. New Manufacturing Locations (new GSDB) for previously approved materials and existing colors are not required to test exterior weathering. All initial approvals may be based on the above accelerated wea

23、thering exposure. Results from Florida Outdoor Weathering (3.3.3) takes precedence over Accelerated Weathering. 3.6.3 Outdoor Weathering of Exterior Materials - Florida Initial Qualification for new resin technology (SAE J1976, 5 South, direct weathering inland, Specimen I, use a smooth polished too

24、l to prepare specimens for A and B gloss, ISO 105-A02/AATCC Evaluation Procedure 1) 3.6.3.1 1 and 3 year Florida Rating 4 min Florida Submission Required for Approval to ASL 3.6.3.2 5 year Florida Report Only After exposure the material shall show no color change in excess of the specified AATCC Rat

25、ing. In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss or chalking will be allowed provided an acceptable ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 10 appearance can be achieved as specified

26、 below by washing with mild detergents and water (ratio 5:95 by volume) or equivalent after the outdoor exposure only. 3.6.4 Resistance to Scratch and Mar (FLTM BO 162-01, Specimen I) Scratch Rating 2 at 2 N, max Whitening/Color Change Rating 1 at 7 N, max Marring Rating 2 at 2 N, max These values a

27、re derived from colored and grained samples in agreement with Materials Engineering. Details regarding color house, let down ratio, colors, grain, etc can be found in the approval package. 3.6.5 Resistance to Mar 70% Gloss Retention A & B gloss materials only with a smooth surface (FLTM BI 161-01, S

28、pecimen I) No visual gloss change at all angles. 3.7 MATERIAL PROPERTIES 3.7.1 Melt Flow Rate 12 - 22 g/10 minutes (ISO 1133 300 C, 1.2 kg) The material shall be dried for 4hr minimum at 120C in a mechanical convection oven immediately preceding the test. 3.7.2 Density 1.18 - 1.23 g/cm3 (ISO 1183, M

29、ethod A) 3.7.3 Tensile Strength at Yield 60 MPa min (ISO 527-1 & ISO 527-2, Specimen A, 50mm/minute test speed) 3.7.4 Elongation at Yield 5% min (ISO 527-1 & 527-2, Specimen A, 50mm/minute test speed) 3.7.5 Tensile Modulus 2.2 GPa min (ISO 527-1 & ISO 527-2, Specimen A 1mm/min test speed) 3.7.6 Flex

30、ural Modulus 2.1 GPa min (ISO 178, Specimen D, 64mm support span, 2mm/min test speed) 3.7.7 Impact Strength Charpy, notched (ISO 179-1/1eA, Specimen D) 3.7.7.1 At 23 +/- 2 C 7 kJ/m2 min Report Break Type 3.7.7.2 At -40 +/- 2 C 3 kJ/m2 min Report Break TypeThe test specimen must be conditioned for mi

31、nimum 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. ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1 Copyright 2015, Ford Global Technologies, L

32、LC Page 6 of 10 3.7.8 Standard Test Method for High Speed Puncture Properties of Plastic Using Load and Displacement Sensors (ASTM D3763, Impact velocity: 2.2 m/s, Specimen E, smooth surface) 3.7.8.1 Max Load Energy at 23 +/- 2 C Report J Energy Absorbed 100% Ductile Failure 3.7.8.2 Max Load Energy

33、at 0 +/- 2 C Report J Energy Absorbed 80% Ductile Failure 3.7.8.3 Max Load Energy at -15 +/- 2 C Report J Energy Absorbed 80% Ductile Failure 3.7.8.4 Max Load Energy at -30 +/- 2 C Report J Energy Absorbed 80% Ductile Failure Test specimens must be conditioned for minimum of 6 h at test temperature

34、prior to impact testing. Low temperature testing shall be conducted within the same environmental chamber as the clamp mechanism of the impact device. Specimens can be transported from the conditioning environment to the testing environment, provided the transfer is within 5 seconds. Ductile is defi

35、ned as a failure in which plastic deformation precedes fracture sample does not fracture into two or more pieces sample does not show cracks radiating more than 10 mm beyond the center of the impact point In borderline cases Ford Materials Engineering can use additional data such as load versus defl

36、ection curves or maximum load data to establish ductility. Summarize testing at each condition by providing the following information: a. Detailed description of specimen preparation if different then Specimen E. b. Molding conditions: melt and mold surface temperatures, and average injection veloci

37、ty. c. All force versus deflection curves for each impact event. d. Original samples are to be submitted for review or, in agreement with Ford Materials Engineering, photos of the tested samples. 3.7.9 Heat Deflection Temperature, 114 C min (ISO 75-1 & ISO 75-2, Specimen D, flatwise, Bath- silicone

38、oil, 0.34 +/- 0.1mm deflection. At 1.80 MPa and 0.45 MPa) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.7.10 Vicat Softening Temperature, 132 C min (ISO 306, Method B50, Specimen D, Bath

39、- silicone oil) All specimens dry as molded. If not tested immediately after molding, specimens must be stored in a sealed, moisture-proof container filled with silica gel. 3.7.11 Heat Aging Performance (ISO 188, except 150 +/- 50 air ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1 Copyright 2015,

40、 Ford Global Technologies, LLC Page 7 of 10 changes/h, 1000 h at 90 +/- 2 C. After heat aging test specimens are To be conditioned in a desiccator for 3 5 h at 23 +/- 2 C. Unaged property values shall be determined at the time of the aged properties determination) 3.7.11.1 Tensile Strength at Yield,

41、 Change +/- 25% max (Test method per para 3.7.3) 3.7.11.2 Impact Strength, Notched Charpy, Change +/- 25% max (Test Method per para 3.7.7, specimens to be notched before heat aging) 3.7.12 Flammability (ISO 3795/SAE J369 Specimen B, smooth surface) Burn Rate 100 mm/min max 3.8 MATERIAL PROPERTIES RE

42、PORT ONLY Values are retained in Ford Materials Database . 3.8.1 Molding Shrinkage (Report method used, sample size and value) After 48 h at 23 +/- 2 C 3.8.1.1 Flow Report Value, % 3.8.1.2 Cross Flow Report Value, % 3.8.2 Coefficient of Linear Thermal Expansion (ISO 11359-2, -30 +/- 2 C to 100 +/- 2

43、 C, 3 curves per direction, flow and cross flow) 3.8.2.1 Flow Report Value, E-5 mm/mm/ C 3.8.2.2 Across Flow Report Value, E-5 mm/mm/ C 3.8.3 Stress Cracking Test for Plastics Report evidence (FLTM BO 127-03, 1%, Coolant, Oil, cracking or crazing Windshield Wash Fluid, Bug and Tar Remover, IPA 1:1 w

44、ith water, Multipurpose Cleaner) 3.8.4 Poissons Ratio Report Value (ISO 527-1 & ISO 527-2, Specimen A, test speed 1mm/min) 3.8.5 Supplemental Information The following curves are to be submitted with the data packages: FTIR TGA DSC CLTE Engineering Stress/Strain at 23 C (additional temperatures requ

45、ired depending on the material and or application) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1 Copyright 2015, Ford Global Technologies, LLC Page 8 of 10 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specific

46、ation. Contact for questions concerning Engineering Material Specifications. 4.1 TYPICAL PROPERTIES USING METHODS IN SECTION 3.8 Para. Test Typical Value Units 3.8.1 3.8.1.1 3.8.1.2 Molding Shrinkage After 48 h at 23 +/- 2 C (For specific method and sample size, contact Materials Engineering) Flow

47、Cross Flow 0.89 0.91 % % 3.8.2 3.8.2.1 3.8.2.2 Coefficient of Linear Thermal Expansion Flow Cross Flow 6.7 - 7.4 6.8 - 7.4 E-5 mm/mm/ C E-5 mm/mm/ C 3.8.4 Poissons Ratio 0.38 N/A 4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES PC (ISO 1043/11469) ENGINEERING MATERIAL SPECIFICATION WSS-M4D1056-A1

48、Copyright 2015, 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 Lots Specimens per Lot Total Test Specimens Lots Specimens per lot Total Test Specimens 3.4.3 WSS-M98P13-E/Latest Re

49、ference performance specification 3.6.1 Gloss 1 1 1 3.6.2 Weathering Resistance 1 1 1 3.6.3 1, 3, and 5 year Florida 1 3 3 3.6.4 Scratch Resistance 1 3 3 3.6.5 Mar Resistance 1 3 3 3.7.1 Melt Flow Rate 3 1 3 1 1 1 3.7.2 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 Impact Strength Notched Charpy (per condition)* 3 10 30 1 1