FORD WSS-M99P32-C-2015 PERFORMANCE ACOUSTICAL AND THERMAL ASSEMBLIES TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 04 2015 02 20 N Status Replaced by WSS-M99P32-D1/2/3/4/5/6 C. Kay, NA 2014 10 16 Revised See Summary of Revisions K. Mueller, NA 2013 07 30 Revised Editorial updates to Flammability K. Mueller, FNA 2009 03 31 Activated B. Witkowski, FNA,

2、 J. Williams FoE Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 11 PERFORMANCE, ACOUSTICAL AND THERMAL ASSEMBLIES WSS-M99P32-C NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines the minimum durability requirements of all thermal, foam gasket an

3、d sound absorption/insulation applications, where various materials are combined to provide an assembly having thermal and/or acoustical (sound absorption/barrier/insulation) and/or functional features. This includes interior passenger, luggage compartment, and engine compartment thermal and/or acou

4、stical (sound absorbing/barrier/ insulation) parts. This document also includes high temperature applications such as exhaust shields. In addition, ultra high temperature parts exposed to heat from turbochargers, EGR systems and exhaust pipes are also included. Acoustical wheel arch/well liners and

5、underbody/engine shields are not in scope for this performance specification. Use WSS-M99P32-D2/D3/D4/D5. 2. APPLICATION This specification was released originally for materials used as interior, luggage compartment, and engine compartment thermal and/or sound absorbing insulators. Acoustical wheel

6、arch/well liners and underbody/engine shields are not in scope for this performance specification. Use WSS-M99P32-D2/D3/D4/D5. 3. REQUIREMENTS Interior adhesive backed products must also meet WSS-M11P62-A. Materials used in interior applications must meet the requirements outlined in WSS-M99P2222-D1

7、*, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be included in material submission package. *Use the latest levels of the performance specifications listed above. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers

8、must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 FINISHED PART REQUIREMENTS Detailed part construction must be submitted along with test data. Design Verification (DV) is done on the material and Product Verification Testing (PV) is done on production

9、 parts. DV/PV and sample sizes are defined in Table 1. In addition to the following minimum requirements, production assemblies must withstand normal handling during shipping, installation, use, and service, without tearing, breaking, or permanently deforming. Specific sampling areas may be required

10、; these will be highlighted on the Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Copyright 2015, Ford Global Technologies, LLC Page 2 of 11 3.3 APPEARANCE (FLTM BI 109-01) All appearance properties of exposed materials shall meet the requirements of the relevant Engineering De

11、partment. 3.4 WEIGHT (FLTM BN 106-01) The fiber/foam weight and total weight shall be as specified on the Engineering Drawing. 3.5 ODOR Rating 3 max (FLTM BO 131-03) 3.6 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min The formation of a cl

12、ear (oily) film, droplets or crystals is cause for rejection. 3.7 RESISTANCE TO MILDEW The material shall exhibit no visible evidence of mildew growth and/or objectionable odor after 7 days exposure in a humidity cabinet maintained at 98 +/- 2% relative humidity and 38 +/- 2 C. 3.8 ENVIRONMENTAL TES

13、TING The assembly, after the test, shall exhibit no visible and objectionable appearance such, distortion, blistering, delamination, expansion, shrinkage or warpage which will interfere with normal function or cause objectionable and unsightly gaps. Any engine side insulator shall not sag vertically

14、 or horizontally more than 5 mm at any point after the test. No mold formation present. In addition, any objectionable appearance observed during the test should be reported. Test Method: Conduct with the NVH or approved surrogate assembly mounted on an actual or simulated production support foundat

15、ion with the approved retention methods. The assemblies shall be subjected to the environmental cycles specified in paragraph 3.8.1 and 3.8.2. Confirm with the affected Materials Engineering Activity for agreement prior to using test chambers with automated programmable test cycles for the listed te

16、st conditions below. Ramp speed 1 to 5 C per minute (record actual ramp speed on data sheet). 3.8.1 Short Term Heat, Humidity and Cold 3.8.1.1 Interior/Luggage Compartment Parts 5 h at -30 +/- 2 C 30 minutes at 23 +/- 2 C and 50% R.H. 5 h at 80 +/- 2 C 30 minutes at 23 +/- 2 C and 50% R.H. 2 h at 50

17、 +/- 2 C and 95 +/- 5% R.H. 30 minutes at 23 +/- 2 C and 50 % R.H. 5 h at -30 +/- 2 C 30 minutes at 23 +/- 2 C and 50% R.H. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Copyright 2015, Ford Global Technologies, LLC Page 3 of 11 5 h at 80 +/- 2 C 3.8.1.2 Engine Maximum temperature of exposure will

18、 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 maximum temperature. Maximum temperature Components exposed to engine oil: 150 C Components bolted to engine (away from exhaust manifold): 1

19、50 C Hood/fender insulators: 150C Parts exposed to power steering fluid or transmission fluid: 135 C Components exposed to engine coolant: 120 C Under hood components not directly bolted to engine: 110 C 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. 48 h at Maximum Temperature +/- 2 C 5 h at -4

20、0 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. . 48 h at Maximum Temperature +/- 2 C 3.8.1.3 High Temperature Applications 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. 48 h at 200 +/- 2 C 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. 48 h at 200 +/- 2 C 3.8.2 Long Term Heat Exposure In additio

21、n to no visible and objectionable appearance after the test requirements listed above, insulation and covering materials shall not crack, flame, glow, smolder, degrade, develop an objectionable odor or exhibit any exothermic reaction when tested at the maximum vehicle use temperature as determined f

22、rom applicable vehicle tests. Test one previously unexposed assembly to one of the following: 3.8.2.1 Interior/Luggage Compartment Parts (7 days at 80 +/- 2 C) 3.8.2.2 Engine Parts (7 days at maximum temperature per para 3.8.1.2 +/- 2 C) 3.8.2.3 High Temperature Applications (7 days at 200 +/- 2 C)

23、3.8.2.4 Radiant Heat Cycling (engine parts only) (SAE J1361, *test at max.temp for specified no of cycles) * The number of heating and cooling cycles and the actual maximum component surface temperatures is to be supplied by the Ford Heat Management Team. Cycle times/temperatures to be specified on

24、the Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Copyright 2015, Ford Global Technologies, LLC Page 4 of 11 One cycle = 30 minutes at max. temperature and 30 minutes at ambient temperature. Example of radiant heat cycling: 71 hours trailer tow: 71 cycles = (maximum temperatur

25、e for 30 min. + ambient temperature for 30 min.) x 71 3.9 PHYSICAL PROPERTIES 3.9.1 Tensile Strength (ASTM D5034, speed 25 mm/minute) Specimens to be cut from flat areas of the finished part and distance between clamps at beginning of test should be 100 mm. 3.9.1.1 Original 10 N/cm2 min Specific val

26、ues to be reported with the data submission package. 3.9.1.2 Change After Humidity Ageing -30% max (48 h at 38 +/- 2 C and 95 +/- 2% R.H.; 1 h at room temperature) 3.9.1.3 Change After Long Term Heat Exposure -30% max (Conditions per para.3.8.2) 3.9.1.4 Change After Immersion In Water -30% max (48 h

27、 in distilled water at room temperature) 3.9.2 Compression and Recovery (For padding and foam gasket materials only) (SAE J1352 or equivalent) Shall not compress more than 70% of the original thickness, after loading with 35 kg. Upon removing the load, the material shall recover at least 65% of the

28、compressed distance. 3.9.3 Compression Set (For foam materials only) 50% max (ISO 1856, Method A/ASTM D3574, Test D) 3.9.4 Tear Strength 3.9.4.1 Non Woven Materials 50 N min (ISO 9073-4, 300 mm/min speed) 3.9.4.2 Fiberglass/Mineral Fiber Materials 25 N min (ASTM D2261) 3.9.4.3 Foam Materials 250 N/m

29、 min (ASTM D3574, Test F) Specimens to be cut from flat areas of finished parts. Conduct testing on full range of material thicknesses on part. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Copyright 2015, Ford Global Technologies, LLC Page 5 of 11 3.9.5 Peel Strength (Interior Laminates only) (FL

30、TM BN 151-05) Samples must meet at least one of the following requirements: . - Achieve peel strength value of 9 N/50 mm, min - Adhesion of the covering material must exceed cohesive strength of the substrate 3.9.6 Peel Strength (Engine Laminates only) (FLTM BN 151-05, 250 mm length sample, 30 min.

31、immersion). Each material should be tested to the fluids quoted in 3.10. Samples must meet at least one of the following requirements: . - Achieve peel strength value of 9 N/50 mm, min - Adhesion of the covering material must exceed cohesive strength of the substrate 3.10 RESISTANCE OF INSULATORS TO

32、 VARIOUS TEST REAGENTS (ASTM D896) The finished or surrogate part shall not dissolve, exhibit tackiness or delaminate when immersed in each of the following test reagents for a 4 hour period. Use a separate specimen for each test reagent. Test Reagents: 1. Deionized Water 2. 3% Salt (NaCl) Solution

33、in Deionized Water 3. Engine Oil Resistance ASTM SF 105* 4. Brake Fluid FMVSS DOT 3 or 4* 5. Sulfuric Acid (2.5% by weight in Deionized Water) 6. Long Life Coolant WSS-M97B51-A1* (50/50% vol. Coolant/Deionized Water) 7. Transmission/Power Steering Fluid WSS-M2C938-A* 8. Windshield Washer Fluid Resis

34、tance WSS-M8B16-A3* *Or currently released equivalent fluid. 3.10.1 Short Term Resistance to Fuels (Splash contact for engine/underbody applications including splash shields) (FLTM BO 101-05, except substitute test fluid with fluids below) Fuel C of ASTM D471 with 10 % Ethanol by volume. Fuel F of A

35、STM D471 The part shall not dissolve, exhibit tackiness, delaminate, crack, or craze when exposed to the test fluid. Record condition of parts after each test interval. Proper safety precautions must be followed when handling hot and/or flammable fluids. 3.11 MOISTURE ABSORPTION 30% max Cut a 200 x

36、200 +/-10mm specimen from the part to be tested and seal any cut edges, e.g. with wax. Weigh the specimen nearest to 0.1 g. Condition part/section in suspended position at 38 +/- 2 C and 95 +/- 2% R.H. for 24 h. After 1 h at 23 +/- 2 C and 50 +/- 2% RH weigh the part/section to the nearest 0.1 g and

37、 determine increase of weight in percent based on the original weight. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Copyright 2015, Ford Global Technologies, LLC Page 6 of 11 3.12 LOW TEMPERATURE FLEXIBILITY (FLTM BN 102-01) No sign of cracking or delamination of the laminate after conditioning a

38、t -40 +/- 2 C for 5 h, and then wrapped around a mandrel which is 2 times the nominal diameter of the sleeve (for heat sleeve applications) or a 12.7 mm diameter mandrel (for flat laminates). Sample size as noted in the FLTM. 3.13 THERMAL PROPERTIES The surface of the part/material being protected s

39、hall not reach its maximum use temperature when tested at the maximum vehicle use temperature as determined from applicable vehicle tests. 3.13.1 Thermal Conductivity (Thermal Insulators Only) Report W/M/K (ASTM C518, ASTM C177) 3.13.2 Thermal Sleeve Heat Insulation (Wire Harness Only) Report (SAE J

40、2302) 3.14 FLAMMABILITY Flammability is affected by the material thickness and density. Conduct testing on the full range of material thicknesses and densities on part) 3.14.1 Interior Components (SAE J369/ISO 3795) Burn Rate 100 mm/minute max 3.14.2 Engine Components (SAE J369/ISO 3795) Burn Rate S

41、E/NBR max The material shall not glow or smolder after the flame extinguishes. Flame should be applied to the exposed side of the component, which under certain conditions may include inner/outer surfaces. Supplier shall document test conditions in their Control Plan (for PV). 3.14.3 Engine Componen

42、ts (IEC 60695-2-10, Glow wire temperature: 750 C) Flame shall extinguish within 10 sec. after removal of the wire Only applicable when electrical wiring is going thru or attached to the component. IEC 60695-2-10 Glow wire apparatus and common test procedure IEC 60695-2-11 Glow wire flammability test

43、 method for end products IEC 60695-2-12 Glow wire flammability index (GWFI) test method for materials IEC 60695-2-13 Glow wire ignition temperature (GWIT) test method for materials ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Copyright 2015, Ford Global Technologies, LLC Page 7 of 11 Flame should

44、 be applied to the exposed side of the component, which under certain conditions may include inner/outer surfaces. Supplier shall document test conditions in their Control Plan (for PV). 3.15 CORROSIVENESS TO STEEL Rating 4 min (SAE J1389) 4. GENERAL INFORMATION The information given below is provid

45、ed for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 FUNCTIONAL REQUIREMENTS Component supplier shall meet the NVH program specific targets as directed by Ford D&R activity through the Reques

46、t for Quote document. These targets are program dependent and run at Ford NVH facilities. 4.1.1 Sound Absorption: The component shall meet the Sound Absorption Target Curve in the 400Hz to 10KHz frequency range as specified in the Request for Quote. The measurements should be conducted in the Ford A

47、lpha Cabin. The target curve should be specified on the Engineering Drawing. 4.1.2 Sound Transmission Loss: The component shall meet the Sound Transmission Loss Target Curve in the 200Hz to 10KHz frequency range as specified in the Request for Quote. The measurements should be conducted in the Ford

48、Sound Transmission Loss Chamber. The target curve should be specified on the Engineering Drawing. 4.1.3 Sound Insulation: The component shall meet the Sound Insulation Loss Target Curve in the 100Hz to 10KHz frequency range as specified in the Request for Quote. The measurements should be conducted

49、in the Ford APAMAT Chamber. The target curve should be specified on the Engineering Drawing. 5. SUMMARY OF REVISIONS 2014 10 16 Removed Acoustical Underbody Shields and Wheel Arch/Well Liners applications. WSS-M99P32-D2/D3/D4/D5 should be used for these applications. 7/30/2013 Updated WSS-M99P2222-C1 to WSS-M99P2222-D1 Added clarification to Flammability 3.14.2 and 3.14.3 10/21/2011 Modified 3.8.2.2 Deleted 3.8.2.4 Re