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1、Page #TL 526 25: 2003-10.nrevoorans nn5lev na 円eG enl sotunaDBICSKafo esac pMoun ti ng BracketTest Scope for Material Data SheetsTL526 25VOLKSWAGEN AGKonzernnormDescriptors:thermoplastics, mounting bracket, material data sheet3nlu - 14 moeowsu nr r nrrp e usort nfiFUC r rr dcaa nflr s k cehcr npupc?
2、_a3t<f ua gnudne wnA rov S-ONOctober 2003Klass.-Nr. 55 15 41 ScopeThis tech ni cal supply specificati on (TL) specifies the comp onent requireme nts of moun ti ng brackets made from thermoplastics and hybrid tech no logy (e.g. PP GMT, lo ng-glass-fiber-rei nforced PP, PP in jecti on moldi ng LFT,
3、 polyamide 6 in hybrid tech no logy).The limit-value and toleranee requirements can be found in the component-, material- and supplierspecific material data sheets.2 Desig nati onRefer to the material data sheet.3 Requireme nts3.1 Gen eralrequireme ntsApproval of first supply and cha nges accordi ng
4、 to Volkswage n sta ndard VW 011 55.Avoida nee of hazardous substa nces accord ing to VW 911 01.The required minimum for complete testi ng is three parts; this nu mber may in crease depe nding on the comp onent desig n.3.2 MaterialRefer to the material data sheet and sect ion 5.1.In terms of their t
5、ech no logical material characteristics, the materials used for the comp onents must ensure the function and safety of the vehicle for the entire service life. Fillers such as glass fibers and modifying agents for heat stabilization are permitted.In the case of comb ined comp onents (metal/plastic)
6、compatibility of the materials shall be en sured. If n ecessary, the materials shall be matched to each other by means of pretreatme nts (e.g. bonding age nt).If the material for the fini shed part is cha nged duri ng developme nt or duri ng ongoing sta ndard product ion, this cha nge must be prese
7、nted and exam ined in all cases. A new tech ni cal engin eer ing release may be n ecessary.Material qualities which have not yet bee n recorded in the material data sheets must be released by Design Engineering after testing and fulfill the general requirements of the component. Then, the new materi
8、al qualities can be included in the material data sheets.Material data sheets (MDs for short) for the various desig ns are available from department K-QS- 31 and can be requested by the resp on sible Quality Assura nee departme nts of the produc ing factories, as required (example of a material data
9、 sheet, see Appe ndix A).Page 1 of 7Fachverantwortung/ResponsibilityNormung/Standards (EZTD, 1733)K-QS-31 AchtzehnerTel. 76414Dr. WohlfarthFrau Krenz Tel: +49-5361-9-48869SobanskiCon fide ntial. All rights reserved. No part of this docume nt may be tra nsmitted or reproduced without the prior writte
10、 n permissi on of a Stan dards Departme nt of the Volkswage n Group. Parties to a con tract can on ly obtai n this sta ndard via the resp on sible procureme nt departme nt.3.3 Ide ntificatio n accordi ng to VDA 260Refer to the material data sheet.3.4 TypesAccordi ng to draw ing.3.5 Manu facturi ngme
11、thodInjectio n moldi ng, thermo extrusi on procedure, hybrid tech no logy, IMC procedure.3.6 Appeara neeSurface and in terior of the comp onents shall be free of flaws and process ing defects, such as flow lin es, voids, cracks or similar faults. Sink marks at the base of ribs and rein forceme nts a
12、re permissible only if they do not adversely affect the part' s function or appearanee.3.7 Con diti oningThe comp onen ts, and the specime ns take n, shall be con diti oned for at least 48 h before the test in the DIN 50 014 - 23/50-2 standard climate (deviating conditioning methods are describe
13、d in the releva nt material data sheets depe nding on the type of material).3.8 Validity of requireme ntsThe required nu merical values apply to each in dividual measureme nt.3.9 Types accord ing to material data sheetThe mecha ni cal material data specified in a material data sheet are exclusively
14、valid for this type as produced by one or several suppliers, and which has bee n evaluated positively in terms of the material and released by the laboratory (accord ing to sect ion 1.1 of the material data sheet).4 Requireme nts for the fini shed partThe gen eral requireme nts apply toevery materia
15、l quality and material comb in ati on. The mecha ni-cal properties described in the material data sheets can vary in dividually, depe nding on the additionally set requirements. In every case, both the general requirements and the material-specific requirements must be met in order to describe the m
16、aterial quality actually used on a componentspecific basis.4.1 Temperatureresista neeThe comp onent must be resista nt to temperatures from -40° C to +110 ° C and be fun ctio nal for theentire service life of the vehicle. If necessary, deviating limit temperatures shall be determined and s
17、hall always be specified as well.Page 3TL 526 25: 2003-104.2 Elevated-temperature behaviorSee section 5.1.The components must exhibit no changes in shape, color and surface that would adversely affect the function and/or appearance.4.3 Low-temperature behaviorSee section 5.2.The components must rema
18、in fully functional and free of damage when exposed to cold and subsequently heated to (23 ±2) ° C.4.4 Resistance to agentsAny media that could come in contact with the finished part must also be listed (e.g. oil, coolant).Tests to determine resistance to agents are therefore performed onl
19、y as needed (type and procedure are added to the drawing if necessary).4.5 Aging resistanceThe temperature level is based on the temperatures that will actually occur at the finished part.Thus, different requirements could be made on the component depending on the engine version. As the aging behavi
20、or is heavily dependent on the material, it is described in the relevant material data sheet. If there is no information available on the actually occurring temperatures, the principle shall apply that aging must take place for 1,000 h at +150° C (mechanical circulation oven).Refer to the mater
21、ial data sheets or the relevant drawings for the corresponding instructions.5 Notes on testing5.1 Elevated-temperature behaviorAging at elevated temperatures according to DIN 53 497, method B, to be performed with at least one complete component.Aging period: (24 ±2) hAging temperature: (110 &#
22、177;1) ° C5.2 Low-temperature behaviorAging of at least one complete component in mechanically circulated air.Aging period: (24 ±2) hAging temperature: (-40 ±1) ° CThe evaluation is conducted after heating to (23±2) ° C.5.3 MaterialIdentification can take place using th
23、e attenuated total reflection variant of the FTIR (Fourier transform infrared spectroscopy) procedure.5.4 DensityDensity is measured using the buoyancy method. If possible, the same specimens as those intended to determine the glass fiber content shall be used. For this reason, the density measureme
24、nt shall be conducted before the glass fiber content determination (ignition residue). In order to avoid oven-drying the specimens after the density measurement, the weight of the specific specimen in air prior to the density measurement shall be used as the weigh-in for the ignition loss.5.5 Glass
25、fiber contentSpecimen (50 x 50) mm. Five individual measurements shall be taken from different areas of the finished part (see also section 5.4).5.6 Flexural strengthSpecimens: length (80 ±1) mm; width (30 ±1) mm; thickness corresponding to product thickness. Support separation: 60 mm; tes
26、t rate: 1 mm/min; evaluation between 0.2% and 0.4% edge fiber elongation. The specimens shall be placed on the supports of the test device so that the specimen surface corresponding to the front or exterior of the finished part is subjected to compression stress. Rigid supports that are aligned in p
27、arallel with the pressure fin and cannot move during the test shall be used for the test. It is permissible to measure the modulus of elasticity in connection with the determination of the flexural stress at maximum load on the same specimen.The specimens shall be removed on the basis of a specimen
28、removal plan, if available. A sample specimen removal plan is provided in the appendix. If possible, subsequent mounting brackets should follow according to a similar diagram, if the geometry allows.5.7 Impact resistanceTest according to DIN EN ISO 179-1/1fU, but specimens: length (120±1) mm; w
29、idth (15 ±1) mm;thickness corresponding to product thickness. Test equipment: 7.5 J according to DIN 51 222; support separation: 70 mm. The specimens shall be placed on the mounting flanges of the test device so that the specimen surface corresponding to the front or exterior of the finished pa
30、rt faces the hammer edge.For specimen removal see section 5.6.5.8 Aging resistanceContinuous aging in mechanically circulated air at (150±2) ° C. The test is preferably performed oncomplete finished parts. It is permissible to perform it on sections of finished parts. Brittling is achieved
31、 when the specimen exhibits signs of disintegration typical for decomposed PP (material starts to crumble, glass fibers emerge). The aging duration is generally 1,000 h; a reduction in the aging resistance is only possible if a lower temperature level is determined in temperature measurements (perfo
32、rmed for those engine versions that radiate the greatest amount of heat relevant for the component), as specified under section 5.1. This must always be indicated!A temperature of +150 ° C is set in order to keep the test duration brief. The test temperature has nothing to do with the temperatu
33、res actually occurring at the part in the vehicle. The reserves of the aging stabilizer are to be determined using the aging test.The maximum temperature at the finished part in the installed condition may not exceed +120° C,as otherwise another material quality must be used.Page 5TL 526 25: 20
34、03-106 Referenced*)standardsVW 011 55Vehicle Supply Parts, General; Approval of First Supply and ChangesVW 911 01Vehicle Environmental Standard; Vehicle Parts, Materials, Operating Fluids; Avoidance of Hazardous SubstancesDIN 50 014Climates and their Technical Application; Standard AtmospheresDIN 51
35、 222Materials Testi ng Machi nes Impact Test Particular Requireme nts on Pendulum Impact Test ing Machi nes with a Capacity of Nominal En ergy<50 J andVerificationDIN 53 497Testing of Plastics; Hot Storage Test on Mouldings Made of Thermoplastic Moulding Materials without External Mechanical Stre
36、ssingISO 1183 APlastics Methods of Determi ning the Den sity and Relative Den sity of Non-Cellular PlasticsDIN EN ISO 178Plastics Determ in ati on of Flexural PropertiesDIN EN ISO 179-1Plastics Determ in ati on of Charpy Impact Properties Part 1: NonInstrumented Impact TestDIN EN ISO 1172Textile-Gla
37、ss-Reinforced Plastics - Prepregs, Moulding Compounds and Lamin ates Determ in ati on of the Textile-Glass and Min eral-Filler Content; Calci nation MethodsVDA 260Vehicles Ide ntificati on of Comp onents made from Polymer Materials*) In this section terminological inconsistencies may occur as the or
38、iginal titles are used.Page #TL 526 25: 2003-10Appendix AA 1. Example of a material data sheetMD01Material Data Sheet re TL 526 25Plastic Mounting Bracket1 Material quality1.1Material base see section 5.3Long-glass fiber reinforced PP (30±5)%1.2Manufacturing methodInjection molding1.3Designatio
39、n for use in drawings30% long-glass fiber reinforced PP, heat stabilizedacc. to TL 526 25- MD 011.4Identificationaccording to VDA 260>PP-GF30<2 Properties requirementsNo. PropertyUnitRequirement2.1Densityacc. to ISO 1183 Asee section 5.4g/cm 31.12 ±0.052.2Glass fiber contentacc. to DIN EN
40、 ISO 1172see section 5.5%30 ±52.3Melting temperatureDSC°C>1582.4Flexural strengthacc. to DIN EN ISO 178 see section 5.6MPaAverage of at least5 individual values: >85No individual value less than 602.5Modulus of elasticity acc. to DIN EN ISO 178 see section 5.6MPaAverage of at least5
41、individual values: >3,500No individual value less than 2,0002.6Impact resistance acc. to DIN EN ISO 179-1 see section 5.7kJ/m2Average of at least5 individual values: 25No individual value less than 202.7Aging resistance time until brittling see section 5.8h>1,000Page 7TL 526 25: 2003-10A 2. Ex
42、ample of a specime n removal pla nLegend:F1 to F4:Specimens for filler contentS1 to S5:Specime ns for impact resista neeB1 to B5:Specimens for flexural strengthD1 to D5:Specime ns for impact pen etrati on test (curre ntly not a required TL test)Figure 1- Specimen removal plan taking the Golf A5 as an example