NAVISTAR TMS 7119-2005 Plastic Aerodynamic Components (Revision F).pdf

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1、 INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION)NUMBER: TMS-7119 TITLE: Plastic Aerodynamic Components REVISION: F WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: June 2005 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CUR

2、RENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability

3、of regulatory limits prior to use. Change Notice: Added QUV specification in Table 2. Reference: File 30-14 Keywords: Aerodynamic components, plastic parts. 1.0 APPLICATION This specification covers five types of polymeric materials used for bumper FASCIA and aerodynamic components. Current parts us

4、e thermoplastic materials produced by injection molding, blow molding, or thermo forming. Applications include: bumpers, bumper extensions, fuel tank skirts, fairings, and valance panels. Note: Parts used in future applications of aerodynamic components may be produced by Reaction-Injection-Molding

5、(RIM) of thermosetting plastic materials. New material types and property requirements will be added as they become necessary. 2.0 SCOPE This specification covers basic materials and mechanical property requirements for five types of thermoplastic materials. Requirements for finished parts, painting

6、, quality and identification/marking are also covered. Qualification, Quality Control and Source Approval procedures are included. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following specifications and standards are referenced i

7、n this specification: Quality System Standard QS-9000 (ISO 9000 or TS-16949) INTERNATIONAL TMS-9008 ASTM D 790 INTERNATIONAL IQR Quality Standard CFR 29, Part 1910 ASTM D 792 INTERNATIONAL Manufacturing Std. D-13 ASTM D 256 ASTM D 955 INTERNATIONAL CEMS D-28 ASTM D 638 ASTM D 1238 INTERNATIONAL CEMS

8、 G-5, Parts I, and II ASTM D 746 ASTM G 53 INTERNATIONAL CEMS DT-4 SAE J 1344 INTERNATIONAL CEMS GT-31 4.0 GENERAL REQUIREMENTS 4.1 Material Type General characteristics of the five material types are shown in Table 1. 4.2 Molding Compound This document is restricted and may not be sent outside Inte

9、rnational Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine Corporation JUNE 2005 Page 1 of 5 NUMBER: TMS-7119 TITLE Plastic Aerodynamic Components REVISION F

10、 Infrared spectra and rheometric analysis of molding compound and material taken from molded production parts must match standards developed during initial qualification. TABLE 1 - GENERAL CHARACTERISTICS TYPE BASE MATERIAL* STIFFNESS UV RESISTANCE 1 TPO FLEXIBLE YES 2 TPO SEMI-RIGID YES3 ABS RIGID

11、NO4 PA + PPE RIGID NO 5 PC + ABS RIGID NO * Refer to CEMS D-28. 4.2.1 Filler type and amount in molding compound and material taken from molded parts must correspond (1.0%) to standards developed during initial qualification. 4.3 Mechanical Properties Test plaques measuring 4x6x.125 inch, (100x150x3

12、mm) prepared using virgin compound, shall meet the minimum requirements shown in Table 2. Impact and UV resistance requirements, when specified, must be determined on each specific color being qualified. 4.4 Finished Part Requirements 4.4.1 Identification/Marking Parts supplied to the requirements o

13、f this specification shall be permanently marked to identify the material the part is from. Marking shall be in accordance with SAE J 1344. Examples are: Type 1 Type 2 Type 3 Type 4 Type 5 4.4.1.1 Marking Symbol: TPO TPO ABS PA + PPE PC + ABS 4.4.1.2 Marking is not permitted on the cosmetic surface

14、of the part. 4.4.1.3 Wherever practical, the marking should be located in an area where it will not be seen when the part is attached to the vehicle, but it must be readable when the part is disassembled. 4.4.1.4 Markings applied with inks, dyes, paint, etc. shall be nonstaining to the part and to o

15、ther contacted materials or parts. 4.4.1.5 Marking must remain legible during the life of the part. 4.4.1.6 Markings which are molded into the part shall not create a stress concentration site which could result in premature cracking of the part. 4.4.2 Surface Finish Surface finish of untextured mol

16、ded parts shall be such that, after painting, there shall be no visible waviness, gate blush, flow lines, flash, knit lines, sink, warpage or other cosmetic defects. 4.4.3 Texture Finish - E Suffix Textured finish, when required, shall be specified separately on the part drawing, using the E Suffix.

17、 4.4.4 Resin Pigmentation - D1 Suffix Parts requiring molded-in-color shall exhibit uniform pigmentation throughout the molded part. Color shall be specified separately on the part drawing, using the D1 Suffix. Color of parts supplied must match International Paint Chip Color Standards, available fr

18、om Materials Engineering at the Truck This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine

19、Corporation JUNE 2005 Page 2 of 5 NUMBER: TMS-7119 TITLE Plastic Aerodynamic Components REVISION F Development and Technology Center. Chemical analyses of pigments in the molding compound and in molded production parts must correspond in type and amount to standards developed during initial qualific

20、ation. 4.4.5 Finish Paint Requirements - D2 Suffix Where finish painting is required, the color shall be specified separately on the part drawing using the D2 Suffix. Color of paint must match International Paint Chip Color Standards, available from Materials Engineering at the Truck Development and

21、 Technology Center. Painted parts shall meet exterior paint requirements as shown in TMS-9008 (Finished Painting-Plastics, Interior and Exterior). 4.4.6 Prime Paint Requirements - D3 Suffix Parts to be supplied in prime paint only shall be specified using the D3 Suffix. A minimum of 25 m (1.0 mil) o

22、f dry film is required on all primed parts. The quality of the primer material and application shall be the responsibility of the supplier. Primed parts shall be compatible with the paint finishing operations employed by the using International plant or outside topcoat paint source, and shall be of

23、such quality as to allow finishing topcoats to meet the dry film requirements for adhesion, gloss, and durability of current topcoat paints as described in CEMS G-5, Part II. 4.4.7 Non-Primed Parts Requiring International Painting - D4 Suffix Parts to be supplied without prime, for painting in Inter

24、national plants, shall be specified using the D4 Suffix. The quality and condition of the part surface shall be compatible with the paint finishing operations employed by the using International plant or outside topcoat paint source. The surface quality and condition shall be such as to allow finish

25、ing topcoats to meet the dry film requirements for adhesion, gloss, and durability of current topcoat paints as described in CEMS G-5, Part II. 4.4.8 Weatherability - Y-Suffix Type 1 and Type 2 materials are available with optional UV stabilization additives. When required, UV resistance of the base

26、 material shall be specified on the drawing using the Y Suffix. Molded parts shall meet the UV resistance requirements of this specification as described in Table 2. 4.4.9 Special Requirements - Z Suffix Special requirements shall be designated on the drawing using the Z Suffix. 5.0 QUALITY Producti

27、on parts shall maintain the same pattern, color, and finish as approved on preproduction samples. No voids in the material, surface defects, flash, or flow patterns are permissible. 5.1 Qualification Prior to use in production, materials and/or finished parts must be formally qualified by Materials

28、Engineering at TDTC. The general qualification procedure is outlined below. Any changes or modifications in the qualification procedure must be approved by Materials Engineering. 5.1.1 Initial Submission Initial submission of test plaques shall be in natural colored compound (without pigment). These

29、 samples shall be accompanied by a detailed test report indicating conformance to all property requirements shown in Table 2 with the exception of UV resistance. Thirty untextured plaques measuring 4x6x.125 inch (100x150x3 mm) and ten untextured plaques measuring 8.5x11x.100 inch (215x280x2.5 mm) ar

30、e required for International tests. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine Co

31、rporation JUNE 2005 Page 3 of 5 NUMBER: TMS-7119 TITLE Plastic Aerodynamic Components REVISION F 5.1.2 Color Approval: Following notification of successful confirmation testing, ten plaques in each color of interest shall be submitted to the Industrial Design Department at TDTC for color approval. P

32、anel size and surface texture are to be established prior to submission. 5.1.3 Impact Resistance: Following color match approval, ten untextured plaques measuring 4x6x.125 inch (100x150x3 mm) shall be submitted in each color under consideration for final impact and UV resistance qualification testin

33、g. 5.1.4 Painted Parts: In applications where painting of the parts is required, Step 3 of the procedure shall be followed by qualification testing as outlined in TMS-9008. Panels and parts supplied at this stage are to reflect material/paint color combinations planned for production. 5.1.5 Molding

34、Trials: Following the successful completion of the laboratory evaluation, a molding trial may be required by Engineering prior to granting final material approval. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to INTERNATIONAL Truck and Engine are required to be reg

35、istered to QS-9000 Quality System Requirements. INTERNATIONAL will also accept ISO 9000 or TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accr

36、edited registrar and must furnish copies of registration certificates to the INTERNATIONAL Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchase

37、r. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering, TDTC and International Purchasi

38、ng and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for chan

39、ge. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplie

40、r and the plant metallurgist and/or the quality control manager of the using International plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing and identification shall be in accordance with Manufacturing Std. D-13. 8.

41、0 DESIGNATION ON DRAWINGS Material shall be specified on drawings as in the following examples: Example #1: Type 2, D1, Y, TMS-7119 D1 = material color to match NAV 8678, gray Example #2 Type 1, D1, D2, TMS-7119 This document is restricted and may not be sent outside International Truck and Engine C

42、orporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine Corporation JUNE 2005 Page 4 of 5 NUMBER: TMS-7119 TITLE Plastic Aerodynamic Components REVISION F D1 = material color to be b

43、lack D2 = topcoat paint to match NAV 0004, black 9.0 APPROVED MATERIALS 9.1 Type 1: Montell ETA 3131, Montell ETA 3131-E, and Dexflex D-160 9.2 Type 2: Montell RTA 3262-EUV 9.3 Type 3: General Electric Cycolac LXB 9.3 Type 4: General Electric Noryl GTX-626 9.3 Type 5: General Electric Cycoloy MC-810

44、0 TABLE 2 PHYSICAL AND MECHANICAL PROPERTIES PROPERTY TEST METHOD (1) TYPE 1 TYPE 2 TYPE 3 TYPE 4 TYPE 5 Specific Gravity D792 .910.010 1.100.05 1.020.01 1.06.05 1.120.01 (Method A) Typical Mold Shrinkage,in./in. D955 .014 .008 .008 .014 .006 Ultimate Tensile Strength, psi, min. D638 (type I bar) 2,

45、600 2,500 5,000 7,000 7,000 Tangent Modulus of Elasticity, ksi, min. D790 (0.5x.250 x 5 in., bar) 125 150 260 260 260 Gardner Impact, CEMS 240 240 240 240 240 in-lbs, min.,-20F DT-4 (2) Brittleness Temp.F, max. D746 -40 F -7 F - - - QUV-B Resistance, hrs, min (4) CEMS GT-31 (3) 1,200 x Lifecycle 1,2

46、00 x Lifecycle Not UV Resistant Not UV Resistant Not UV Resistant (1) ASTM method unless otherwise specified (2) 6 pound dart, 40 inch drop, 0.125 in. specimen (3) QUV Testing Cycle - There shall not be any color alteration greater than E of 3. (4) Must be specified on the part drawing using the “Y“

47、 suffix. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine Corporation JUNE 2005 Page 5 of 5