WSS-M99P32-C

ENGINEERING MATERIAL SPECIFICATION Date Action Revisions REV 01 2011 03 01 Revised See Summary of revisions S. Stanciu FNA J. Williams FoE 2009 03 31 Activated B. Witkowski FNA J. Williams FoE Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 1 of 11 PERFORMANCE, ACOUSTICAL AND THERMAL ASSEMBLIES WSS-M99P32-C 1. SCOPE This specification defines the minimum durability requirements of all thermal, foam gasket and sound absorption/insulation applications, where various materials are combined to provide an assembly having thermal and/or acoustical (sound absorption/barrier/insulation) and/or functional features. This includes interior passenger, luggage compartment, engine compartment and underbody thermal and/or acoustical (sound absorbing/barrier/ insulation) parts. This document also includes high temperature applications such as exhaust shields. In addition, ultra high temperature parts exposed to heat from turbochargers, EGR systems and exhaust pipes are also included. 2. APPLICATION This specification was released originally for materials used as interior, luggage compartment, engine compartment and underbody thermal and/or sound absorbing insulators. 3. REQUIREMENTS Adhesive backed products must meet WSS-M11P62-A. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Company's Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 FINISHED PART REQUIREMENTS Detailed part construction must be submitted along with test data. Design Verification (DV) is done on the material and Product Verification Testing (PV) is done on production parts. DV/PV and sample sizes are defined in Table 1. In addition to the following minimum requirements, production assemblies must withstand normal handling during shipping, installation, use, and service, without tearing, breaking, or permanently deforming. Specific sampling areas may be required; these will be highlighted on the Engineering Drawing. 3.3 APPEARANCE (FLTM BI 109-01) All appearance properties of exposed materials shall meet the requirements of the relevant Engineering Department. 3.4 WEIGHT (FLTM BN 106-01) The fiber/foam weight and total weight shall be as specified on the Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 2 of 11 3.5 ODOR Rating 3 max (FLTM BO 131-03) 3.6 FOGGING (SAE J1756, 3 h at 100 °C heating, 21 °C cooling plate, post test conditioning 16 h) Fog Number 70 min The formation of a clear (oily) film, droplets or crystals is cause for rejection. 3.7 RESISTANCE TO MILDEW The material shall exhibit no visible evidence of mildew growth and/or objectionable odor after 7 days exposure in a humidity cabinet maintained at 98 +/- 2% relative humidity and 38 +/- 2 °C. 3.8 ENVIRONMENTAL TESTING The assembly, after the test, shall exhibit no visible and objectionable appearance such as: . Wrinkling . Distortion . Blistering . Delamination . Expansion, shrinkage or warpage which will interfere with normal function or cause objectionable and unsightly gaps. In addition, any objectionable appearance observed during the test should be reported. Test Method: Conduct with the NVH or approved surrogate assembly mounted on an actual or simulated production support foundation with the approved retention methods. The assemblies shall be subjected to the environmental cycles specified in paragraph 3.8.1 and 3.8.2. Confirm with the affected Materials Engineering Activity for agreement prior to using test chambers with automated programmable test cycles for the listed test conditions below. Ramp speed 1 to 5 °C per minute (record actual ramp speed on data sheet). 3.8.1 Short Term Heat, Humidity and Cold 3.8.1.1 Interior/Luggage Compartment Parts 5 h at -30 +/- 2 °C 30 minutes at 23 +/- 2 °C and 50% R.H. 5 h at 80 +/- 2 °C 30 minutes at 23 +/- 2 °C and 50% R.H. 2 h at 50 +/- 2 °C and 95 +/- 5% R.H. 30 minutes at 23 +/- 2 °C and 50 % R.H. 5 h at -30 +/- 2 °C 30 minutes at 23 +/- 2 °C and 50% R.H. 5 h at 80 +/- 2 °C ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 3 of 11 3.8.1.2 Engine/Underbody Parts 5 h at -40 +/- 2 °C 48 h at 38 +/- 2 °C and 95% R.H. 48 h at 150 +/- 2 °C 5 h at -40 +/- 2 °C 48 h at 38 +/- 2 °C and 95% R.H. . 48 h at 150 +/- 2 °C 3.8.1.3 High Temperature Applications 5 h at -40 +/- 2 °C 48 h at 38 +/- 2 °C and 95% R.H. 48 h at 200 +/- 2 °C 5 h at -40 +/- 2 °C 48 h at 38 +/- 2 °C and 95% R.H. 48 h at 200 +/- 2 °C 3.8.2 Long Term Heat Exposure In addition to no visible and objectionable appearance after the test requirements listed above, insulation and covering 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 one previously unexposed assembly to one of the following: 3.8.2.1 Interior/Luggage Compartment Parts (7 days at 80 +/- 2 °C) 3.8.2.2 Engine/Underbody Parts (7 days at 150 +/- 2 °C) 3.8.2.3 High Temperature Applications (7 days at 200 +/- 2 °C) 3.8.2.4 Ultra High Temperature Applications 3.8.2.4.1 Long Term Heat Exposure (7 days at 280 +/- 2 °C) (This requirement is shown as an example, actual maximum average component temperatures as defined by the Ford Heat Management Team shall be used.) ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 4 of 11 3.8.2.4.2 Radiant Heat Exposure Nominally (SAE J1361) 340 +/- 2 °C max (This requirement is shown as an example, actual maximum average component temperatures as defined by the Ford Heat Management Team shall be used.) The number of heating and cooling cycles and duration is to be supplied by the Ford Heat Management Team. Cycle times/temperatures to be specified on the Engineering Drawing. Test at the maximum component surface temperature, as determined by heat mapping studies conducted by the Ford Heat Management Team. The heat resistance for any other application would be as specified on the Engineering Drawing. 3.9 PHYSICAL PROPERTIES 3.9.1 Tensile Strength (ASTM D5034, speed 25 mm/minute) Specimens to be cut from flat areas of the finished part and distance between clamps at beginning of test should be 100 mm. 3.9.1.1 Original 10 N/cm2 min Specific values to be reported with the data submission package. 3.9.1.2 Change After Humidity Ageing -30% max (48 h at 38 +/- 2 °C and 95 +/- 2% R.H.; 1 h at room temperature) 3.9.1.3 Change After Long Term Heat Exposure -30% max (Conditions per para.3.8.2) 3.9.1.4 Change After Immersion In Water -30% max (48 h in distilled water at room temperature) 3.9.2 Compression and Recovery (For padding and foam gasket materials only) (SAE J1352 or equivalent) Shall not compress more than 70% of the original thickness, after loading with 35 kg. Upon removing the load, the material shall recover at least 65% of the compressed distance. 3.9.3 Compression Set (For foam materials only) 50% max (ISO 1856, Method A/ASTM D3574, Test D) ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 5 of 11 3.9.4 Tear Strength 3.9.4.1 Non Woven Materials 50 N min (ISO 9073-4, 300 mm/min speed) 3.9.4.2 Fiberglass/Mineral Fiber Materials 25 N min (ASTM D2261) 3.9.4.3 Foam Materials 250 N/m min (ASTM D3574, Test F) Specimens to be cut from flat areas of finished parts. Conduct testing on full range of material thicknesses on part. 3.9.5 Peel Strength (Interior Laminates only) 9N/50 mm min (FLTM BN 151-05) Samples also must meet the following requirement: - Must have cohesive failure at the interface. For laminates with foam where both requirements cannot be met tested samples must have cohesive failure at the interface and the actual peel strength values shall be reported. 3.9.6 Peel Strength (Engine and Underbody Laminates only) 9N/50 mm min (FLTM BN 151-05, 250 mm length sample, 30 min. immersion). Each material should be tested to the fluids quoted in 3.10. - Must have cohesive failure at the interface. For laminates with foam where both requirements cannot be met tested samples must have cohesive failure at the interface and the actual peel strength values shall be reported. 3.10 RESISTANCE OF INSULATORS TO VARIOUS TEST REAGENTS (ASTM D896) The finished or surrogate part shall not dissolve, exhibit tackiness or delaminate when immersed in each of the following test reagents for a 4 hour period. Use a separate specimen for each test reagent. Test Reagents: 1. Deionized Water 2. 3% Salt (NaCl) Solution in Deionized Water 3. Engine Oil Resistance ASTM SF 105* 4. Brake Fluid FMVSS DOT 3 or 4* 5. Sulfuric Acid (2.5% by weight in Deionized Water) 6. Long Life Coolant WSS-M97B51-A1* (50/50% vol. Coolant/Deionized Water) 7. Transmission/Power Steering Fluid WSS-M2C938-A* 8. Windshield Washer Fluid Resistance WSS-M8B16-A3* *Or currently released equivalent fluid. ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 6 of 11 3.10.1 Short Term Resistance to Fuels (Splash contact for engine/underbody applications including splash shields) (FLTM BO 101-05, except substitute test fluid with fluids below) Fuel C of ASTM D471 with 10 % Ethanol by volume. Fuel F of ASTM D471 The part shall not dissolve, exhibit tackiness, delaminate, crack, or craze when exposed to the test fluid. Record condition of parts after each test interval. Proper safety precautions must be followed when handling hot and/or flammable fluids. 3.11 MOISTURE ABSORPTION 30% max Cut a 200 x 200 +/-10mm specimen from the part to be tested and seal any cut edges, e.g. with wax. Weigh the specimen nearest to 0.1 g. Condition part/section in suspended position at 38 +/- 2 °C and 95 +/- 2% R.H. for 24 h. After 1 h at 23 +/- 2 °C and 50 +/- 2% RH weigh the part/section to the nearest 0.1 g and determine increase of weight in percent based on the original weight. 3.12 LOW TEMPERATURE FLEXIBILITY (FLTM BN 102-01) No sign of cracking or delamination of the laminate after conditioning at -40 +/- 2 °C for 5 h, and then wrapped around a mandrel which is 2 times the nominal diameter of the sleeve (for heat sleeve applications) or a 12.7 mm diameter mandrel (for flat laminates). Sample size as noted in the FLTM. 3.13 THERMAL PROPERTIES The surface of the part/material being protected shall not reach its maximum use temperature when tested at the maximum vehicle use temperature as determined from applicable vehicle tests. 3.13.1 Thermal Conductivity (Thermal Insulators Only) Report W/M/°K (ASTM C518, ASTM C177) 3.13.2 Floor Heat Insulation (Interior Acoustical 60 °C max on the and Thermal Insulators) top surface of (SAE J1361, 2h) floor systems Test at the maximum vehicle floor pan temperature (without throw in mats) as determined from floor heat mapping studies conducted by the Ford Heat Management Team. The heat resistance for any other application would be as specified on the Engineering Drawing. 3.13.3 Thermal Sleeve Heat Insulation (Wire Harness Only) Report (SAE J2302) ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 7 of 11 3.14 FLAMMABILITY 3.14.1 Interior Components (SAE J369/ISO 3795) Burn Rate 100 mm/minute max Flammability is affected by the material thickness and density, conduct testing on full range of material thicknesses and densities on part. 3.14.2 Engine/Underbody Components (SAE J369/ISO 3795) 3.14.2.1 Burn Rate SE 10 seconds 3.14.2.2 Burn Rate SE 20 seconds After Long Term Heat Exposure per 3.8.2.2 or 3.8.2.3 or 3.8.2.4, the flame must extinguish within the specified time. Flammability is affected by the material thickness and density. Conduct testing on the full range of material thicknesses and densities on part) 3.14.3 Engine/Underbody Components Flame shall extinguish (IEC 60695-2-10, Glow wire temperature: 750 °C) within 10 seconds after removal of the wire IEC 60695-2-10 Glow wire apparatus and common test procedure 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 Flammability is affected by the material thickness and density. Conduct testing on the full range of material thicknesses and densities of part. 3.15 CORROSIVENESS TO STEEL Rating 4 min (SAE J1389) 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification 4.1 FUNCTIONAL REQUIREMENTS Material supplier shall furnish applicable Vehicle Engineering (NVH) team with the following data for their material 4.1.1 Absorption Properties (Alpha Cabinet, frequency range 400 - 10,000 Hz) 4.1.2 Sound Insulation Properties (Apamat II Cabinet, frequency range 100 - 6300 Hz) ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 8 of 11 4.1.3 Airborne Noise Reduction (for sound barriers only) (SAE J1400) Noise reduction should be as specified on the Engineering Drawings. 4.1.4 Sound Absorption (for sound absorbers only) (ASTM C 384/ASTM E 1050) Sound absorbed should be as specified on the Engineering Drawings. 4.1.5 Vibration Damping (For Vibration Dampers only) (ASTM E 756/SAE J1637) Vibration damping should be as specified on the Engineering Drawing. 5. SUMMARY OF REVISIONS 03/01/2011 • Clarified Tear Strength – added requirement for fiberglass and mineral fiber materials • Clarified Peel Strength – added foam applications minimum requirement • Added Short Term Resistance to Fuels • Clarified requirements for Thermal Properties • Updated Table 1 • Deleted 4.2, guideline for purchase departments ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 9 of11 TABLE 1 Material Category Test method: Sample Size required for DV and PV: Noted in Table A1 : F elt A2 : PU F oa m A3 : H igh T e m p e ratu re F oa m A4 : EPP F o a m A5 : P olyeste r Fle ece A6 : M in e ral Fib re A7 : G lass Fib re Inte rio r Applicatio ns E ngin e/U nd e rb ody Applicatio ns H igh T e m p e ratu re Applicatio ns U ltra H igh T e m p e ratu re Applicatio ns 3.4 Weight FLTM BN106-01: Substrate and Total Weight 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x x x x 3.5 Odour FLTM BO131-03 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x 3.6 Fogging SAE J1756 (Photometric): 3 hours @ 100C 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x 3.7 Resistance to Mildew 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x x x x 3.8.1.1 Interior/Luggage Compartment 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x 3.8.1.2 Engine/Underbody 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x x 3.8.1. Short Term Heat, Humidity, Cold 3.8.1.3 High Temperature Applications 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x x 3.8.2.1 Interior/Luggage Compartment 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x 3.8.2.2 Engine/Underbody 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x x 3.8.2 Long Term Heat Exposure 3.8.2.3 High Temperature Applications 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x x Long Term Heat Exposure 3.8.2.4.1 Ultra High temperature Applications 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x 3.8 Environmental Testing Radiant Heat Exposure 3.8.2.4.2 Ultra High temperature Applications 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) 3(DV+PV) x ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 10 of 11 TABLE 1: continued Material Category Test method: Sample Size required for DV and PV: Noted in Table A1 : F elt A2 : PU F oa m A3 : H igh T e m p e ratu re F oa m A4 : EPP F o a m A5 : P olyeste r Fle ece A6 : M in e ral Fib re A7 : G lass Fib re Inte rio r Applicatio ns E ngin e/U nd e rb ody Applicatio ns H igh T e m p e ratu re Applicatio ns U ltra H igh T e m p e ratu re Applicatio ns 3.9.1.1 Original (N/cm2) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) x x x x 3.9.1.2 Change after Humidity Ageing% 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) x x x x 3.9.1.3 Change after Heat Ageing % 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) x x x x 3.9.1 Tensile Strength (ASTM D 5034) 3.9.1.4 Change after Immersion in Water % 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) x x x x 3.9.2 Compression and Recovery 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) x x x x 3.9.3 Compression Set % (ISO 1856 Method A/ASTM D3574 Test D) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x x x x 3.9.4.1 (ISO 9073-4) 3(PV) 3(PV) x x x x 3.9.4.2 (ASTM D2261) 3(PV) 3(PV) x 3.9.4 Tear Strength 3.9.4.3 (ASTM D3574 Test F) 3(PV) 3(PV) x x 3.9.5 Peel Strength Laminates only (FLTM BN151-05) Interior 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x 3.9 Physical Properties 3.9.6 Peel Strength Laminates only (FLTM BN 151-05) Engine and Underbody 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x x x 3.10 Resistance to Test Reagents (ASTM D896) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) x x x 3.10.1 Short Term Resistance to fluids (splash contact) (FLTM BO 101-05) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) x 3.11 Moisture Absorption max % 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) x x x x 3.12 Low Temperature Flexibility 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) x x x x ENGINEERING MATERIAL SPECIFICATION WSS-M99P32-C Printed copies are uncontrolled Copyright © 2011, Ford Global Technologies, LLC Page 11 of 11 TABLE 1: continued Material Category Test method: Sample Size required for D