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1、 Mercedes-Benz DBL 5408 Supply Specification Date Published: 2006-11 Total No. of Pages (incl. Annex): 10 Person in Charge: Dr. Rainer Capellmann Plant 010; Dept.: PWT/VEW Phone: +49(0)711 17-55796 Thermoplastic parts for engine air management Thermoplastic parts for engine air management Preface DB
2、L 5408 describes the requirements for thermoplastics and components manufactured from these materials for use in engine air management. It supersedes DBL 5403 and DBL 5404 for new de- signs with regard to application in engine air management. Changes ? Additions regarding the production of the notch
3、 for unfilled materials (Sections 4.2 and 4.3.2) ? Adaptation of required limits for tensile strain at break for PV 07 Copyright DaimlerChrysler 2006 DBL 5408, 2006-11, page 2 Copyright DaimlerChrysler 2006 Table 1: Product versions and application examples PV Material Material description Applicati
4、on examples 00 PP Polypropylene (copolymer) with increased impact strength Raw air line 05 PP Polypropylene (homopolymer) Raw air line, air intake 07 PP-TD20 Polypropylene with 20 % talcum powder Raw air line 10 PP-GF30 Polypropylene with 30 % glass fibers Air cleaner/intake silencer housing, air in
5、take, air duct housing 15 PA6 Polyamide 6 Bearing elements, brackets, raw air line, charge air manifold, air cleaner housing 18 PA6-I Polyamide 6, impact-modified (extrusion blowing type) Raw air line, charge air manifold 21 PA6-HI Polyamide 6, high-impact-modified (extrusion blowing type) Raw air l
6、ine 24 PA6-GF15 Polyamide 6 with 15 % glass fibers Charge air manifold 27 PA6-I-GF15 Polyamide 6 with 15% glass fibers, impact modified (extrusion blowing type) Raw air line 30 PA6-GF30 Polyamide 6 with 30 % glass fibers Air cleaner/intake silencer housing, intake manifold, air intake connection, ch
7、arge air manifold, charge air distribution line, vac- uum reservoir 33 PA6-GF35 Polyamide 6 with 35 % glass fibers Air cleaner/intake silencer housing, intake manifold, charge air distribution line 36 PA6-(GF10+MD20) Polyamide 6 with 10% glass fibers and 20% mineral powder Air cleaner/intake silence
8、r housing 40 PA6-MD30 Polyamide 6 with 30 % mineral powder (Distortion-minimized) housing 45 PA66-GF30 Polyamide 66 with 30 % glass fi- bers Air cleaner/intake silencer housing, charge air manifold, charge air distribution line, breather pipe, vacuum control, shifter shaft, charge air cooler box 50
9、PA66-GF35 Polyamide 66 with 35 % glass fi- bers Air cleaner/intake silencer housing, charge air manifold, charge air distribution line, air duct housing, intake air throttling, intake manifold, silencer (resonator) 55 (PA66+PA6)-GF50 Polyamide 66 / Polyamide 6 blend with 50% glass fibers Charge air
10、cooler box 60 PPA-GF30 Polyphtalamide with 30 % glass fibers Charge air manifold (incl. EGR infeed) 65 PPA-GF35 Polyphtalamide with 35 % glass fibers Silencer (resonator) 70 PPA-GF45 Polyphtalamide with 45 % glass fibers Charge air cooler box 75 PA46 Polyamide 46 Bearing elements 80 PA46-GF30 Polyam
11、ide 46 with 30 % glass fi- bers Charge air cooler box, housing, shafts 83 PPS-GF30 Polyphenylene sulfide with 30 % glass fibers Inlet port shutoff, throttle modules 86 PPS-GF40 Polyphenylene sulfide with 40 % glass fibers Charge air cooler box, inlet port shutoff, throttle modules PV = Product versi
12、on All PVs within the material group PA are heat stabilized in accordance with requirements. Abbreviated designations On drawings, in the block for materials, e.g. Thermoplastic PA66-GF30 + DBL 5408.45 DBL 5408, 2006-11, page 3 Copyright DaimlerChrysler 2006 1 Scope DBL 5408 describes the requiremen
13、ts for thermoplastics and components manufactured from these mate- rials for use in engine air management. The product versions, materials, material descriptions and application examples are listed in Table 1. 2 Reference to other standards and supply specifications DBL 5408 supersedes DBL 5403 and
14、DBL 5404 for new designs with regard to applications in engine air management. For overlaps with product versions of DBL 5403 and DBL 5404, refer to Table 2. Cited standards are listed in Table 3. The general conditions laid down in DBL 5555 and DBL 8585 shall also be observed. In addition, the “Pur
15、chase Conditions for Production Materials and Spare Parts for Motor Vehi- cles“ and “MB Special Terms“ are deemed constituent parts of the agreement. For a description of the requirements for thermoplastic elastomers (TPE), refer to DBL 5562. Table 2: Relationship to other Mercedes-Benz Supply Speci
16、fications Product version (PV) Material Applications with the excep- tion of engine air management 5408.07 PP-TD20 5404.00 5408.10 PP-GF30 5404.00 5408.15 PA6 5403.00 5408.24 PA6-GF15 5404.00 5408.30 PA6-GF30 5403.00 5408.36 PA6-(GF10+MD20) 5403.00 5408.40 PA6-MD30 5403.00 5408.50 PA66-GF35 5403.00
17、5408.70 PPA-GF45 5403.00 5408.75 PA46 5403.00 Table 3: Cited standards DC standards Other standards DBL 5403 DBL 5404 DBL 5555 DBL 5562 DBL 8585 MB Special Terms DIN EN ISO 179-1 DIN EN ISO 527-1 DIN EN ISO 527-2 DIN EN ISO 1110 DIN EN ISO 1183 A DIN EN ISO 1874-2 DIN EN ISO 3167 DIN EN ISO 3451-1 D
18、IN EN ISO 11469 ISO 188 3 Constituents and recyclability All materials, components, processes and systems shall conform to current statutory requirements regard- ing controlled substances and recyclability. The negative substance list in accordance with DBL 8585 (or MB Special Terms Nos. 30/3 and 36
19、/1) shall be observed. DBL 5408, 2006-11, page 4 Copyright DaimlerChrysler 2006 4 Tests Criteria, test standards and test conditions are described in Annex A.1. The tests described in the following paragraphs 4.1 to 4.3 are summarized in Annex A.2. 4.1 Molded material value For the requirements for
20、the relevant product versions in new condition, refer to Annex A.3. In addition, the stipulations regarding hot air resistance (Section 4.3) shall be observed. For the production of test speci- mens, refer to DIN EN ISO 3167 and for polyamides to DIN EN ISO 1874-2, among others. 4.2 Component To ass
21、ess the material properties of the component, the impact resistance (filled materials) or notched impact resistance (unfilled materials) at 23C in accordance with DIN EN ISO 179-1 shall be tested. The test consists of at least 10 individual tests. If the test specimen type 1 (in accordance with DIN
22、EN ISO 179-1) cannot be removed from the compo- nent due to its dimensions, test specimen 3 shall be used in deviation from DIN EN ISO 179-1. In this ca- se, notches of notch type A shall be applied for unreinforced components. With regard to the machining of the notch, DIN EN ISO 179-1 Para. 6.1.5.
23、1 (edition May 2006) shall be observed. The test specimens shall be removed from the finished component taking into account DBL 5555 Part II Section 1.3. During initial sampling, the supplier shall indicate the sample value of the (notched) impact strength at 23C in new condition in a materials test
24、 report, trial sample inspection report or initial sample inspection report. For PVs 15 to 86, the sample value of the (notched) impact resistance at 23C following hot air storage (refer to Section 4.3.2) shall be indicated in addition. These sample values are assigned a permis- sible tolerance of 2
25、0 %. 4.3 Notes on the examination of the resistance to oxidative degradation (hot air resis- tance) Care shall be taken to ensure that a material is selected with adequate heat stabilization for the applica- tion. 4.3.1 Examination of hot air resistance of polypropylene (PVs 00, 05, 07, 10) Within t
26、he context of component development, the hot air resistance shall be verified on the component. For this purpose, store the component in an air-circulating oven in accordance with ISO 188 Section 4.1.3 at constant temperature. The following marginal conditions apply with regard to the hot air storag
27、e: PP, not reinforced: 450 h, (150 2) C PP, reinforced with mineral: 550 h, (150 2) C PP, reinforced with glass fibers: 1000 h, (150 2) C Following storage, no cracks or visible changes (degradation) shall be discernible on the component. DBL 5408, 2006-11, page 5 Copyright DaimlerChrysler 2006 4.3.
28、2 Examination of hot air resistance of the other product versions The marginal conditions of hot air storage (time, temperature) shall be agreed with PWT and the respon- sible development unit at DC. On the one hand, material characteristics (molded material values) shall be documented and submitted
29、 to DC within the context of component development. The results of the following tests shall be indicated: Tensile test to determine the tensile modulus, Tensile test for tensile stress at failure and tensile stress at yield and relevant strain values, Impact resistance test to determine the notched
30、 and unnotched impact strength at 23C, -30C. For unfilled materials, the notches shall be applied to the test specimens before hot air storage. With re- gard to the machining, reference is once more made DIN EN ISO 179-1 Para. 6.1.5.1 (edition May 2006). On the other hand, the impact resistance test
31、 shall be carried out at 23C on component specimens fol- lowing hot air storage to generate the sample value according to Section 4.2. In this case, too, the notch shall be applied before commencement of storage for unfilled materials. The detailed component requirements in the requirement specifica
32、tions, e.g. hot air storage of the compo- nent with subsequent component testing, shall also be observed. 4.4 Note on the examination of the resistance to substances Changes to plastics for the use in engine air management caused by exposure to substances such as blow-by gas / engine condensation or
33、 exhaust gas shall not result in any functional impairment of the component. For detailed requirements, refer to the relevant requirement specifications of the component. 5 Marking (for components) In accordance with DIN EN ISO 11469 6 Requirements / Technical data For the requirements for the relev
34、ant product versions in new condition, refer to Annex A.3. End of main document # # # # # DBL 5408, 2006-11, page 6 Copyright DaimlerChrysler 2006 Annex A Criteria, test methods and technical data A.1 Criteria and test methods Table 4: Criteria and test methods Criteria Units Test standards Remarks
35、Tensile modulus at 23C MPa DIN EN ISO 527-1/-2 Standard bar 1A test rate 1 mm/min; Tensile stress at yield at 23C MPa DIN EN ISO 527-1/-2 Tensile stress at break at 23C MPa DIN EN ISO 527-1/-2 Tensile strain at break at 23C % DIN EN ISO 527-1/-2 Tensile strain at yield at 23C % DIN EN ISO 527-1/-2 S
36、tandard bar 1A Test rate 50 mm/min for unfilled materials Test rate 5 mm/min for filled materials (PP: 50 mm/min also permitted) For unfilled PP and PA materi- als, the data in Annex A.3 in line “Tensile strain at break“ are minimum requirements for the tensile strain at yield Impact strength (Charp
37、y), unnotched at 23C kJ/m2DIN EN ISO 179-1/1eU Impact strength (Charpy), unnotched at -30C kJ/m2DIN EN ISO 179-1/1eU Impact strength (Charpy), notched at 23C kJ/m2DIN EN ISO 179-1/1eA Impact strength (Charpy), notched at -30C kJ/m2DIN EN ISO 179-1/1eA Hot storage temperature C DBL 5555 P2, Section 8
38、 Density g/cm3DIN EN ISO 1183 A Residue on ignition % DIN EN ISO 3451-1 Note on conditioning of PA6, PA66, PA46 and PPA Conditioning in accordance with DIN EN ISO 1110 (70C, 62 % r.h.). Before testing, store the test speci- men in a closed container for at least 16 hours at 23C, 50 % r.h. DBL 5408,
39、2006-04, page 7 A.2 Overview of the molded material and component tests Table 5: Overview of the molded material and component tests I- tem PV / Material Test Molded material Molded material Compo- nent Compo- nent New Aged New Aged 1 All PVs According to Section A.3 X X* 2 PVs 00, 05, 07, 10 (PP) V
40、isual assessment for cracks or similar following hot air storage, refer to Sec- tion 4.3.1 X 3 from PV 15 (PA, PPA, PPS) Tensile test following hot air storage, refer to Section 4.3.2 X 4 from PV 15 (PA, PPA, PPS) (Notched) impact test at 23C X* X X X 5 from PV 15 (PA, PPA, PPS) (Notched) impact tes
41、t at -30C X* X *) included in test plan according to line 1 *) hot storage temperature DBL 5408, 2006-11, page 8 A.3 Requirements / Technical data Table 6: Requirements / Technical data dry PV 00 05 07 10 15 18 21 24 conditioned Material PP PP PP-TD20 PP-GF30 PA6 PA6-I PA6-HI PA6-GF15 Units Tensile
42、modulus MPa 1.000 1.200 2.500 6.000 2.900 1.800 200 5.500 - - - - 1.000 550 150 2.800 Tensile stress at yield at 23C MPa 22 25 30 70 80 55 - - - - - - 40 40 - - Tensile stress at break at 23C MPa - - - 70 - 50 20 110 - - - - - 50 15 65 Tensile strain at break at 23C % 10* 5* 6 2 3* 50 50 2 - - - - 1
43、5* 50 50 5 Charpy impact strength at 23C kJ/m2- - 30 35 - - - 40 - - - - - - - 55 Charpy impact strength at -30C kJ/m2- - 10 30 - - - 30 - - - - - - - 35 Charpy impact strength, notched at 23C kJ/m2 30 4 - - 4 10 NB - - - - - 25 150 NB - Charpy impact strength, notched at -30C kJ/m2 2,5 1,5 - - 3 8
44、NB - - - - - 5 8 NB - Hot storage temperature C 100 100 120 120 120 120 120 150 Density g/cm30,9 0,02 0,9 0,02 1,04 0,03 1,13 0,03 1,13 0,02 1,05 0,06 1,05 0,07 1,23 0,02 Residue on ignition % - - 20 2 30 2 - - - 15 2 *) For unfilled PP and PA6 materials, the values listed in the table are minimum r
45、equirements for the tensile strain at yield NB = no breakage Copyright DaimlerChrysler 2006 DBL 5408, 2006-11, page 9 Table 7: Requirements / Technical data dry PV 27 30 33 36 40 45 50 conditioned Material PA6-I-GF15 PA6-GF30 PA6-GF35 PA6-(GF10+MD20) PA6-MD30 PA66-GF30 PA66-GF35 Units Tensile modulu
46、s MPa 5.000 9.000 10.000 6.000 5.000 9.000 10.500 2.300 5.500 6.500 2.300 2.000 6.500 7.000 Tensile stress at break at 23C MPa 85 170 180 95 75 170 180 55 100 110 45 40 110 120 Tensile strain at break at 23C % 3 3 3 2,5 5 3 2,5 10 4,5 4 5 10 5 4 Charpy impact strength at 23C kJ/m2 60 80 80 40 45 70
47、80 90 90 90 50 50 80 85 Charpy impact strength at -30C kJ/m2 60 55 70 40 40 60 70 70 70 70 35 30 60 70 Hot storage temperature C 150 150 150 150 130 150 150 Density g/cm31,2 0,02 1,35 0,02 1,39 0,02 1,35 0,02 1,38 0,03 1,36 0,02 1,41 0,02 Residue on ignition % 15 2 30 2 35 2 30 2 30 2 30 2 35 2 Copy
48、right DaimlerChrysler 2006 DBL 5408, 2006-11, page 10 Table 8: Requirements / Technical data dry PV 55 60 65 70 75 80 83 86 conditioned Material (PA66+PA6)-GF50PPA-GF30 PPA-GF35 PPA-GF45 PA46 PA46-GF30 PPS-GF30 PPS-GF40 Units Tensile modulus MPa 16.000 11.000 12.000 15.500 3.300 10.000 11.000 14.000 12.000 11.000 12.000 15.000 1.000 6.000 - - Tensile stress at yield at 23C MPa - - - - 100 - - - - - - - 55 - - - Tensile stress at break at 23