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1、 ENGINEERING MATERIAL SPECIFICATION Material NameSpecification Number DateRelease No.Release/Revision 1993 08 02 EP00E10258823000 Completely Revised L. Rodigas 1992 09 01 EP00E10176304000 Revised P. Kuntze 1990 06 01 EP00E01031536000 Released P. Kuntze WP 3948-aPage 1 of 11 PLASTIC BUMPER, RIGID WSK
2、-M98P7-A 1.SCOPE This specification defines the requirements for self-coloured as well as painted plastic bumpers with in situ foamed reinforcements. 2.APPLICATION This specification was released originally to define the performance requirements for plastic bumpers. 3.REQUIREMENTS 3.1STATISTICAL PRO
3、CESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to analyze process/product data so that variation in the final product i
4、s continuously reduced. 3.2INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the referen
5、ce standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3CONDITIONING AND TEST CONDITIONS The part shall be conditioned for a minimum of 24 h a
6、t 23 +/- 2 C and 50 +/- 5 % relative humidity prior to test and tested under the same conditions unless otherwise specified. Painted parts shall be conditioned 16 h at 45 +/- 2 C or 72 h at 23 +/- 2 C prior to above conditioning, unless otherwise specified. 3.4APPEARANCE (FLTM BI 109-01) Color, glos
7、s and surface shall match the Master Appearance Sample as approved by the Design Department. ENGINEERING MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 2 of 11 3.5ADHESION Adhesion shall be tested on the original part and 15 to 30 minutes after the relevant aging tests according to para 3.6, 3.7,
8、3.8. and 3.19. Test Methods: Choice of the test method shall be made according to the design of the bumper and shall be shown on the Engineering Drawing. 3.5.1Coating Adhesion (EAO only) (FLTM BI 106-01, Method B) Applicable to painted surfaces only; must be tested in accordiance with paint performa
9、nce specification WSK-M2P145-A or as defined on the Engineering Drawing. 3.5.2Coating Adhesion (NAAO only) (FLTM BI 106-01, Method D) Applicable to painted surfaces only; must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing. 3.5.3Peel S
10、trengthAs specified on (ASTM D 1000)Engrg. Drawing Applicable to laminated and/or attachments (EAO only). . For applied moldings with single and/or double coated pressure sensitive tapes, test and evaluate according to the Engineering Drawing. . For in situ foamed bumper reinforcements or fixing par
11、ts covered by foam and/or overmoulded or welded applications, the adhesion of the foam to all components of bumper beam shall be greater then the cohesive strength of the structure. . Overmoulded or welded applications (profiles, spoilers etc.) must not be separable by mechanical means at joint area
12、s. The bond strength (adhesion) shall be greater than the structures cohesive strength. 3.5.4Visual Evaluation The finished part shall show no evidence of blisters or delamination. 3.6PAINT REPAIR OVEN RESISTANCE (EAO only) The finished part shall show no deformation or other changes which will inte
13、rfere with assembly to mating parts or affect its appearance, as specified on the Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 3 of 11 Test Method: Mount the finished part according vehicle installation on a suitable fixture and place it in car position in a mech
14、anical convection oven maintained at 120 +/- 2 C for 30 minutes. Evaluate after conditioning at 23 +/- 2 C and a storage of 24 h at 23 +/- 2 C. Painted surfaces must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing. 3.7ENVIRONMENTAL CYCL
15、ING (FLTM BQ 104-07, Procedure 1/FLTM BQ 104-07, Procedure 5, 3 cycles, applicable to painted surfaces only; must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing) The finished part shall show no evidence of warpage, deformation, cracks,
16、 delamination or other failures to an extent that would affect its use in the ultimate assembly. The finished part shall show no changes in appearance when compared with the original finished part. The adhesion of the individual surface coating shall meet the requirements of paragraph 3.5. 3.8SHOCK
17、TEST The finished part shall show no breaks, cracks or other failures. The adhesion of the individual surface coating shall meet the requirements of paragraph 3.5. Test Method: Maintain the finished part or section of it at - 40 +/- 2 C for 16 h. Then immediately immerse part in water at 70 +/- 2 C
18、for 5 minutes. Evaluate after conditioning at 23 +/- 2 C. Painted surfaces must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing. 3.9RESISTANCE TO COLD IMPACT (Bumper Shell Only) The finished part shall show no breaks, cracks or other fa
19、ilures. Test Method as specified on Engineering Drawing. Painted surfaces must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 4 of 11 3.10CHANGE OF MELT FLOW RATE (MFR) or M
20、ELT VOLUME RATE (MVR) - (EAO only) Applicable for bumper bars and reinforcements made of PC+PBT moulding compound without painted surface only. Test Method: ISO 1133, except 250 +/- 0.5 C with a weight force of 5 kg, or according to released material specification. The material shall be dried for 2
21、h at 123 +/- 2 C in a mechanical convection oven. The MFR/MVR shall be tested immediately after drying. 3.10.1Procedure for a Fundamental Determination of the MFR/MVR Control-Regions on Bumper Bars and the MFR/MVR Testing in Line with Acceptance Testing (NOTE: Same procedure for reinforcements) 1)Af
22、ter having the moulding machine and the tool in optimized and constant condition take 10 g of the dried granule from the bottom of the hopper immediately before the screw feed. 2)Wait for a further three shots, then take the next 5 bumper bars in sequence for numbering and testing. 3)The bumper bar
23、No. 1 serves as fundamental testing with appropriate many MFR/MVR-control regions. Subdivide the regions into areas with knitlines and between knitlines and other critical areas and number accordingly. The individual MFR/MVR sample areas should normally not exceed 40 g. 4)Mark the 5th bumper with th
24、e same regions and numbers. This bumper serves as Master Bumper Bar. 5)Cut bumper No. 1 into the individual marked MFR/MVR regions and granulate. Mix the granule of each region properly to get a representative value. 6)Determine: a) the MFR or MVR of the original granule according to para. 1, b) the
25、 MFR or MVR of each region of bumper bar No. 1 and mark the result on bumper bar No.5 accordingly. 7)Calculate the % change in MFR or MVR for each region compared to the original granule and mark these figures too on bumper bar No. 5. 8)Identify for each “hot runner“ fill region the -,-,- ENGINEERIN
26、G MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 5 of 11 lowest change in MFR or MVR and mark only those future control regions on bumper bars No. 2, 3 and 4. 9)Cut out the control regions from bumper 2, 3 and 4 (as defined in para. 8) and granule. The granules of the individual regions again shou
27、ld be mixed properly. Determine the MFR/MVR and the change of MFR/MVR compared to the original granule (para 1). 10)The control regions should show less than 25 % change in MFR/MVR or as shown on drawing. Note: To control the influence of further changes in processing conditions only the control reg
28、ions (according to para. 8) have to be tested. In case of change of wall thickness or cold runners the procedure according to para. 1 has to be repeated. The frequence of testing the change in MFI or MVI has to be carried out according to Q-101. 3.10.2Change of MFI or MVI on Bumper Bars before estab
29、lishing the “Acceptance Testing“ according to para. 3.10.1 . The process conditions have to be optimized in such a way that the change in MFI/MVI - compared with theoriginal granule - does not exceed 35 %. Test regions have to be taken from characteristic sensitive areas, e.g. impact or welding area
30、s. 3.11WEATHERING RESISTANCE (Preferable for visible unpainted parts) NAAO only: Applicable to parts using materials without previous weathering approval. After exposure in accordance with 3.11.1, 3.11.2 and 3.11.3, the material shall show no color change in excess of specified AATCC rating (AATCC G
31、ray Scale for Evaluating Change in Color, 10 step). In addition, there shall be no cracking, crazing or other deterioration. A slight loss of gloss or chalking will be allowed provided an acceptable appearance can be achieved by polishing with Ford car polish (auto wax) at permission of the affected
32、 Product Development Materials Activity. All initial approvals will be based on the preliminary Weatherometer exposure (para 3.11.1), pending Florida exposure results for final approval. -,-,- ENGINEERING MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 6 of 11 3.11.1Xenon Arc Weatherometer Rating 4
33、 (SAE J1960, 660 kJ/m2 exposureexcept Rating 4-5 minimum or higher if defined infor PP must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing. -,-,- ENGINEERING MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 8 of 11 3.15RESISTANCE TO WA
34、TER IMMERSION (FLTM BI 104-01) The part shall not show any surface changes, loss of gloss or adhesion. The adhesion of the individual surface shall meet the requirements of para 3.5 within 15 to 30 minutes of water immersion. Applicable to painted surfaces only, must be tested in accordiance with pa
35、int performance specification WSK-M2P145-A or as defined on Engineering Drawing. 3.16CONTACT & MIGRATION STAINING (FLTM BN 103-01, except 72 h at 80 +/- 2 C) Released contact materials shall not cause migration staining, embrittlement or stress cracks in the finished part. Slight contact staining is
36、 permitted. Test Method: Place on the finished part or critical sections a suitable large piece of released contact material. Apply a load so that the molding is in close contact with the finished part as released. Expose this assembly in a mechanical convection oven. Remove contact material and eva
37、luate the part after cooling at 23 +/- 2 C. Applicable for painted areas and areas with appliques of foam substrates. Painted surfaces must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing. 3.17RESISTANCE TO WAXING AND DEWAXING COMPOUNDS
38、 (FLTM BO 155-01, for NAAO applications use ESB-M99J371-A1/A2 instead of specified material) The part shall show no breaks, cracks or other failures. The adhesion of the individual surface coating shall meet the requirements of paragraph 3.5. Painted surfaces must be tested in accordiance with paint
39、 performance specification WSK-M2P145-A or as defined on Engineering Drawing. 3.18FUEL RESISTANCE (FLTM BO 101-05, except test at 23 +/- 2 C) The part (bumper or section of bumper) shall show no significant staining, change in color, loss of gloss or adhesion. The adhesion of the indivisual surface
40、shall meet the requirements of para 3.5. Treatment of the part with a soft cloth prior to evaluation is permitted. Visual evaluation is to be carried out with the finished part mounted in vehicle position and viewed from a distance of 1.5 m. The part shall show no fading or color change in excess of
41、 Rating 4 of AATCC rating (AATCC Gray Scale for Evaluating Change in color, 10 step). -,-,- ENGINEERING MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 9 of 11 Painted surfaces must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing. Test
42、 Fuels: 3.18.185 % Fuel C + 15 % Methanol (ISO 1817) 3.18.2Diesel Fuel (ISO 1817, Fuel F) 3.18.3Fuel as specified on Engineering Drawing. 3.19SCRATCH RESISTANCE 3.19.1Test Method A (FLTM BN 108-13, 1 mm scratch balls, instrumental evaluation of 3.0 N scratch mark) Percentage of Marking, max30 % or a
43、s defined on Engineering Drawing 3.19.2Test Method B (FLTM BN 108-13, 1 mm scratch balls, visual evaluation) Rating 1 at 2 N scratch mark or as defined on Engineering Drawing. 3.20HEAT RESISTANCE (7 days at 80 +/- 2 C, a part or section of it) No color change, blistering, delamination, deformation o
44、r any other failures. Adhesion shall meet para 3.5. 3.21CLEANABILITY (Applicable to visible unpainted parts/areas only) The applied car polish wax must remove easily without any residue. Test Method: The finish part or section of the part shall be treated with a car polish wax (Simonize) according t
45、o the direction of use. After drying period of 4 h remove the polish wax with a smooth cloth. SOURCE: Car polish wax Simonize GT, (soft paste formula), Messr. Simonize Ltd. England 3.22RESISTANCE TO ABRASION (FLTM BN 154-01, 1000 cycles, applicable for hot stamped/metallized/laminated areas or attac
46、hments) The abraded area shall be compatible with the adjacent unabraded area. -,-,- ENGINEERING MATERIAL SPECIFICATION WSK-M98P7-A WP 3948-bPage 10 of 11 Tests carried out on original parts and after heat aging (para 3.19) and environmental cycling (para 3.7). 3.23MATERIALS 3.22.1Base MaterialAs sp
47、ecified on Engineering Drawing 3.22.2Use of Regrind Material is only allowed if specified on Engineering Drawing. 3.24PAINT MATERIAL REQUIREMENTS Painted surfaces must be tested in accordiance with paint performance specification WSK-M2P145-A or as defined on Engineering Drawing and as crossreferenc
48、ed on the applied requirements of this specification. 3.25SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, constructio
49、n, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approva