FORD WSS-M99P32-D5-2014 PERFORMANCE ACOUSTICAL HEAVY DUTY UNDERBODY ENGINE SHIELDS TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M99P32-D2).pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 01 2014 11 25 Editorial Corrected acoustical spelling in title D. Murtonen, NA 2014 10 16 Released K. Mueller, NA Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 1 of 13 PERFORMANCE, ACOUSTICAL WHEEL ARC

2、H/WELL LINERS WSS-M99P32-D2 PERFORMANCE, ACOUSTICAL HEAVY DUTY WHEEL ARCH/WELL LINERS WSS-M99P32-D3 PERFORMANCE, ACOUSTICAL UNDERBODY/ENGINE SHIELDS WSS-M99P32-D4 PERFORMANCE, ACOUSTICAL HEAVY DUTY UNDERBODY/ENGINE SHIELDS WSS-M99P32-D5 1. SCOPE This specification defines the minimum durability requ

3、irements of composite acoustical underbody and under-engine shields, including wheel arch/well liners, where various materials may be combined to provide acoustical (sound absorption/barrier/insulation) features. Examples include PET nonwoven fabric, Glass/PP fiber nonwoven fabric, Glass/PP wet laid

4、 nonwoven composite. Materials are also called Light Weight Reinforced Thermoplastic (LWRT). 2. APPLICATION This specification was released originally for NVH absorbers, barriers, or insulators, specific to materials used in the under-engine and underbody shields, as well as wheel arch/well liner ap

5、plications. There are four subsets of the standard (D2, D3, D4 Report N, min Testing speed: 100 mm/min, samples at unconsolidated And consolidated thicknesses) Report Method, MD/CMD, thickness of samples 3.3.10.1 Change After Humidity Ageing -30% max (48 h at 38 +/- 2 C and 95 +/- 2% R.H.; 1 h at ro

6、om temperature) 3.3.10.2 Change After Long Term Heat Exposure -30% max 7 days for: Components exposed to engine fluids or bolted to the engine: 150 C Components not bolted to engine (as agreed by engineering): 120 C 3.3.10.3 Change After Immersion In Water -30% max (48 h in distilled water at room t

7、emperature) ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5 Copyright 2014, Ford Global Technologies, LLC Page 4 of 13 3.3.11 Flexural Modulus Report MPa, min (ISO 178, Method A, at unconsolidated thickness, Include specimen sizes 12.7mm/min compression rate) 3.3.12 Peel Strength (Laminate

8、s only) 20 N/50mm, min (FLTM BN 151-05, 250 mm length or sample, 30 min. immersion). Adhesion of the covering material must exceed cohesive strength of the substrate Each material should be tested to the fluids quoted in 3.3.8. 3.3.13 Resistance to Water Wicking 5 mm, max (SAE J913, using solution A

9、, 16 hours) 3.3.14 Resistance to Bolt Pull - Thru Report Method A, N (FLTM BA 116-01, Method A (Out-of-Plane) Report Method B, N and Method B (In-Plane), 5 specimens/method) 3.4 FINISHED COMPOSITE/PART REQUIREMENTS This material shall be molded and formed to the specific geometry of the wheel arch/w

10、ell or vehicle underbody or under-engine shield as appropriate. The material shall be a moldable, self-supporting composite with a solid black color (as agreed by engineering), if visible by the customer (D2 these will be highlighted on the Engineering Drawing. 3.4.1 Construction Report Detailed com

11、posite construction must be submitted along with test data. Tier 1 Tier 2 Material Supplier Type of part Ford Production Part Example(s) Trade Name Made in-house or purchased Manufacturing process Number of Layers (including scrims) Min, Max. if a component is exposed to a higher temperature based o

12、n historical data, use the maximum temperature. Maximum temperature: Components exposed to engine fluids or bolted to the engine: 150 C Components not directly bolted to engine (as agreed by engineering): 120 C 3.4.4.1 Short Term Heat, Humidity and Cold 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95%

13、R.H. 48 h at Maximum Temperature +/- 2 C 5 h at -40 +/- 2 C 48 h at 38 +/- 2 C and 95% R.H. . 48 h at Maximum Temperature +/- 2 C 3.4.4.2 Long Term Heat Exposure ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5 Copyright 2014, Ford Global Technologies, LLC Page 6 of 13 In addition to no vis

14、ible and objectionable appearance after the test requirements listed above, 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 from applicable vehicle tests. Test

15、previously unexposed composite to the following (as applicable): 7 days at 150 C: Components exposed to engine fluids or bolted to the engine. 7 days at 120 C: Components not directly bolted to engine (as agreed by engineering). 3.4.4.3 Radiant Heat Cycling, if near exhaust or exceed 150 C (SAE J136

16、1, *test at max.temp for specified number 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 the Engineering Drawing. One cycle = 30 minutes at max

17、. temperature and 30 minutes at ambient temperature. Example of radiant heat cycling: 71 hours trailer tow: 71 cycles = (maximum temperature for 30 min. + ambient temperature for 30 min.) x 71 3.4.5 Breaking Force Report, N, min (ASTM D5034, 100 mm between clamps, speed 25mm/min, sample size 25mm x

18、150mm, at unconsolidated and consolidated thicknesses) Or (ISO 527-4 Type 2, Sample size 25 x 250 mm; Report, N, min Testing speed: 100 mm/min, samples at unconsolidated And consolidated thicknesses) Report Method, MD/CMD, thickness of samples 3.4.6 Flexural Modulus Report MPa, min (ISO 178, Method

19、A, at unconsolidated thickness, Include specimen sizes 12.7mm/min compression rate) 3.4.7 Peel Strength,(Laminates only) 20 N/50 mm, min (FLTM BN 151-05, 250 mm length or sample, 30 min. immersion) Adhesion of the covering material must exceed cohesive strength of the substrate Each material should

20、be tested to the fluids quoted in 3.3.8. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5 Copyright 2014, Ford Global Technologies, LLC Page 7 of 13 3.4.8 Salt Staining, (Wheel Arch/Well Liners Only D2 & D3) Report (CETP 00.00-L-467, 6 weeks) There shall be no physical deterioration or perm

21、anent staining. 3.4.9 Resistance to Car Wash, (Wheel Arch/Well Liners Only D2 & D3) Report (Ford Test Method 01.08-L-2619) 1) Install the composite on vehicle in design position (or simulated vehicle position). 2) Measure and record torque of all attachments. 3) Inspect the components visible surfac

22、e for dents, cracks, scratches and functionality and document all defects prior of testing. 4) Subject the composite to 10 cycles through a high pressure treatment for pre-cleaning with 10 liters/minute at 10 MPa and 60 +/-1 C for 2 minutes, using a jet with an opening angle of 25 degrees applied at

23、 the most unfavorable angularity of impingement in a true distance of 300 mm to the critical area. 5) Inspect the visible surfaces after the test for any damage such as dents, cracks and scratches. 6) Measure fasteners torques. 7) Photograph and document any damage to the components tested. 3.4.10 G

24、ravelometer, (Mid-rocker Underbody Shields and Report 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

25、 holes, fuzziness upon approach, separation, or other changes that impact the function or reduce the perceived quality of the vehicle. 3.4.11 Flammability Flammability is affected by the material thickness and density. Conduct testing on the full range of material thicknesses and densities on part.

26、3.4.11.1 All Components (D2, D3, D4, D5) SE/NBR max (ISO 3795/SAE J369) The material shall not glow or smolder after the flame extinguishes. Flame should be applied to the road side of the component. Supplier shall document test conditions in their Control Plan (for PV). 3.4.11.2 Glow Wire Flammabil

27、ity (IEC 60695-2-10, Glow wire temperature: 750 C) Only applicable when electrical wiring is going thru or attached to the component. Flame shall extinguish within 10 sec. after removal of the wire IEC 60695-2-10 Glow wire apparatus and common test procedure ENGINEERING MATERIAL SPECIFICATION WSS-M9

28、9P32-D2/D3/D4/D5 Copyright 2014, Ford Global Technologies, LLC Page 8 of 13 IEC 60695-2-11 Glow wire flammability test 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 F

29、lame 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). 3.4.11.3 Under Engine Shields Only SE/NBR max (ISO 3795 / SAE J369) Cut specimens from shield per ISO

30、3795 / SAE J369. Suspend specimens (vehicle position) over a pan to catch flow through oil. Pour 100 mL of engine oil* at room temperature over the top surface of the shield. After 10 minutes place shield in a vertical position and drain oil off for 20 minutes. Test ISO 3795/SAE J369 immediately fol

31、lowing 20 minute oil drain. The material shall not glow or smolder after the flame extinguishes. Flame should be applied to the road side of the component (at the specimen end where the oil dripped in vertical position). Supplier shall document test conditions in their Control Plan (for PV). *Engine

32、 oil is SAE 5W-20: WSS-M2C945-A 3.4.12 Water Absorption +10% max After weighing the production composite, completely immerse it in a 23 C water bath for 1 hour. Place composite in vehicle position for 24 hours. Re-weigh the production composite. 3.4.13 Resistance to Bolt Pull Thru Report Method A, N

33、 (FLTM BA 116-01, Method A (Out-of-Plane) Report Method B, N and Method B (In-Plane), 5 specimens/method) 3.5 ADDITIONAL FMD REQUIRED INFORMATION Mechanical Curves: - Breaking Force - Flexural Modulus - Bolt Pull Thru (3.3 and 3.4) Material Characterization Curves (3.3): - FTIR - DSC (1st and 2nd he

34、ats) - TGA 3.6 FUNCTIONAL REQUIREMENTS Component supplier shall meet the NVH program specific targets as directed by Ford D&R activity through the Request for Quote document. These targets are program dependent and run at Ford NVH facilities. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/D3/D4/D5

35、 Copyright 2014, Ford Global Technologies, LLC Page 9 of 13 3.6.1 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 Alpha Cabin. The target curve s

36、hould be specified on the Engineering Drawing. 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. 5. SUMMARY OF REVISIONS ENGINEERING

37、 MATERIAL SPECIFICATION WSS-M99P32-D2/3/4/5 Copyright 2014, Ford Global Technologies, LLC Page 10 of13 TABLE 1: Material and Physical Property Requirements Material Category D2: Wheel Arch/Well Liners D3: Heavy Duty Wheel Arch/Well Liners D4: Underbody/ Engine Shields D5: Heavy Duty Underbody/ Engin

38、e Shields Test Method Sample Size: Noted in Table 3.3.1 Thickness Fully Consolidated 3 3 3 3 3.3.2 Thickness Unconsolidated 3 3 3 3 3.3.3 Area Weight (Fully Consolidated) 3 3 3 3 3.3.3 Area Weight (Unconsolidated) 3 3 3 3 3.3.4 Fiber Reinforcement (Fully Consolidated) 1 1 1 1 3.3.4 Fiber Reinforceme

39、nt (Unconsolidated) 1 1 1 1 3.3.5 Resistance to Mildew (Fully Consolidated) 3 3 3 3 3.3.5 Resistance to Mildew (Unconsolidated) 3 3 3 3 3.3.6 Moisture Absorption (Fully Consolidated) 3 3 3 3 3.3.6 Moisture Absorption (Unconsolidated) 3 3 3 3 3.3.7 Gravelometer (Mid-Rocker Underbody Shields and Front

40、 Wheel Arch/Well Liners Only) (Fully Consolidated) 3 3 3 3 3.3.7 Gravelometer (Mid-Rocker Underbody Shields and Front Wheel Arch/Well Liners Only) (UnConsolidated) 3 3 3 3 3.3.8 Water and Splash Resistance (Fully Consolidated) 3 3 3 3 3.3.8 Water and Splash Resistance (Unconsolidated) 3 3 3 3 3.3.9

41、Resistance to Test Reagents (Fully Consolidated) 1 1 1 1 3.3.9.1 Short Term Resistance to fluids (splash contact) (Fully Consolidated) 1 1 1 1 3.3.9 Resistance to Test Reagents (Unconsolidated) 1 1 1 1 3.3.9.1 Short Term Resistance to fluids (splash contact) 1 1 1 1 ENGINEERING MATERIAL SPECIFICATIO

42、N WSS-M99P32-D2/3/4/5 Copyright 2014, Ford Global Technologies, LLC Page 11 of 13 (Unconsolidated) 3.3.10 Corrosiveness to Steel 1 1 1 1 3.3.11 Breaking Force MD (Fully Consolidated) 5 5 5 5 3.3.11 Breaking Force MD (Unconsolidated) 5 5 5 5 3.3.11 Breaking Force CMD (Fully Consolidated) 5 5 5 5 3.3.

43、11 Breaking Force CMD (Unconsolidated) 5 5 5 5 3.3.11.2 Change After Humidity Aging (for all conditions 3.3.11) 5 5 5 5 3.3.11.3 Change After Long Term Heat Exposure (for all conditions 3.3.11) 5 5 5 5 3.3.11.4 Change After Water Immersion (for all conditions 3.3.11) 5 5 5 5 3.3.12 Flexural Modulus

44、MD (Unconsolidated) 5 5 5 5 3.3.12 Flexural Modulus CMD (Unconsolidated) 5 5 5 5 3.3.13 Peel Strength MD (Fully Consolidated) 3 3 3 3 3.3.13 Peel Strength MD (Unconsolidated) 3 3 3 3 3.3.13 Peel Strength CMD (Fully Consolidated) 3 3 3 3 3.3.13 Peel Strength CMD (Unconsolidated) 3 3 3 3 3.3.14 Water

45、Wicking MD (Fully Consolidated) 3 3 3 3 3.3.13 Water Wicking MD (Unconsolidated) 3 3 3 3 3.3.14 Water Wicking CMD (Fully Consolidated) 3 3 3 3 3.3.14 Water Wicking CMD (Unconsolidated) 3 3 3 3 3.3.15 Resistance to Bolt Pull-Thru, Method A (Fully Consolidated) 5 5 5 5 3.3.15 Resistance to Bolt Pull-T

46、hru , Method B, MD (Fully Consolidated) 5 5 5 5 3.3.15 Resistance to Bolt Pull-Thru , Method B, CMD (Fully Consolidated) 5 5 5 5 ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-D2/3/4/5 Copyright 2014, Ford Global Technologies, LLC Page 12 of 13 TABLE 2: Finished Composite/Part Requirements Test Metho

47、d Sample Size: Noted in Table Material Category D2: Wheel Arch/Well Liners, D3: Heavy Duty Wheel Arch/Well Liners , D4: Underbody/ Engine Shields, D5: Heavy Duty Underbody/ Engine Shields 3.4.1 Construction Description Tier 1 Tier 2 / Material Supplier Type of Part Ford Production Part (examples) 3.

48、4.1 Construction Description (continued) Trade name Made in house or Purchased Manufacturing Process # of Layers (scrims, etc.) Min, Max, Average, Denier GSM of each layer % Recycled Content 3.4.1 Construction Description (continued) Main material Composition(s) for each layer D2: Wheel Arch/Well Li

49、ners D3: Heavy Duty Wheel Arch/Well Liners D4: Underbody/ Engine Shields D5: Heavy Duty Underbody/ Engine Shields 3.4.1.1 Part Layout CAD for all test specimens in 3.4 X X X X 3.4.2 Thickness Fully Consolidated 3 3 3 3 3.4.2 Thickness Unconsolidated 3 3 3 3 3.4.3.1 Area Weight and Total Part Weight on Drawing X X X X 3.4.3.2 Area Weight (critical sections) As defined by Engineering As defined by Engineering As defined by Engineering As defined by Engineering 3.4.4