ENGINEERING MATERIAL SPECIFICATION

ASSEMBLY PERFORMANCE, HARD MOLD-IN-COLOR WSS-M15P4-F

INTERIOR COMPONENTS

1. SCOPE

This specification defines the minimum durability and performance requirements of hard, mold-in-color
interior trim panels, moldings, overhead and floor consoles, and hard instrument panels where various
materials are combined to provide a trim assembly having decorative and/or functional features.

2. APPLICATION

This specification was originally released for plastic mold-in-color and non-visible interior trim items
such as door panels, center and overhead consoles, quarter panels, A-, B-, C-, and D-pillar moldings,
hard instrument panels, instrument panel components and garnish molding.

Testing for mold-in-color components is detailed in Table 1 unless specified otherwise by Ford
Engineering. Testing for non-visible components is detailed in Table 2 unless otherwise specified by
Ford Engineering Testing must be done on parts unless part geometry does not allow. If that is the
case, appropriate plaques with production grain and color can be used.

2.1 LIMITATIONS

Excluded from this specification are soft instrument panels, interior soft trim and wrapped parts
(WSS-M15P45-B/latest), package trays (WSS-M15P6-D/latest), steering wheels (WSS-98P12-
B/latest), headliners (WSS-M15P27-F/latest), carpeted substrate (WSS-M8P16-B/latest),
molded armrests and headrests (WSS-M15P39-B/latest), appliqués (WSS-M15P34-D/latest),
visors (WSS-M98P3-B/latest), painted interior components (WSS-M2P188-A1/latest), chrome
plated components (WSS-M1P83-D1/latest) and interior elastomer (WSS-M9P8-B/latest) or
whose performance is specified separately.

3. REQUIREMENTS

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).

Materials with recycled content as defined by WRS-M99P42-A1 (post-consumer and/or post

industrial recyclates and repolymerised recycled materials) should be used whenever
technically feasible and following all materials and PV testing required by Ford Materials
Engineering. The use of regrind is permitted, for economic / environmental reasons, with
compliance as indicated in WSS-M99P1111-A.

3.1.1 Vehicle Interior Environment Quality Materials/Component Performance Requirements

Materials used in interior applications must meet the requirements outlined in WSS-
M99P2222-C1/latest.

Date Action Revisions Rev 02

2012 11 21 Editorial See Summary of revisions Y. Bankowski,
NA
2012 03 06 Revised See Summary of revisions L. Schmalz, NA
2009 10 14 Activated L. Schmalz, NA
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 ENGINEERING MATERIAL SPECIFICATION

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3.2 APPEARANCE

Color, gloss, grain, tactile effect shall match master Trim Sample and/or Master Appearance
Sample as approved by Corporate Design.

3.2.1 Color
(FLTM BI 109-02 Visual Assessment and/or
SAE J1545, MA58 Three-Angle CMC)

Shall match the Master Approved Sample

.
3.2.2 Gloss
(FLTM BI 110-01, ASTM F 523)

As released by Engineering:

Gloss A: 20o Glossmeter min 92

B: 60o Glossmeter 76-84
C: 60o Glossmeter 66-74
D: 60o Glossmeter 58-66
E: 60o Glossmeter 47-53
F: 60o Glossmeter 33-38
G: 60o Glossmeter 17-23
H: 60o Glossmeter 7-13
o
J: 60 Glossmeter 4-6
K: 60o Glossmeter 2-4
L: 60o Glossmeter 0.5-2.0
N: 60o Glossmeter 1.8-2.4

3.3 ENVIRONMENTAL TESTING

Sample Preparation

All parts shall be fully trimmed including all components packaged in the environment (eg.
speakers, hardware, wiring, etc.) and assembled onto actual or representative production
support foundations. This includes not only all attaching points, but also any boundary
conditions that may restrict movement, unless otherwise specified by the affected Materials
Engineering Activity. The retention methods, attachments, and supporting garnish moldings (if
any), shall be the same as proposed for production.

Measurement Locations

. Every twenty centimeters and at the points of greatest movement between the twenty
centimeter marks along the part's outside edges and internal openings or defined by PD
Engineering.

. The "significant characteristics locations" specified on the engineering drawing.

Measurement Technique

The movement at each measurement point shall be recorded in two directions: (1) in the x/y
plane from the observers view, and (2) in the z-dimension direction into or out of the x/y plane
from the observers view. The observer's view shall remain consistent always viewing from the
front side of the part.

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Test Procedure

Visually evaluate the part before, during, and after the test. Measure the part and record data
at all specified locations at room temperature before and after cycling on the production
support foundation or test fixture. Also, during paragraph. 3.3.1 "Short Term Heat and Cold
Cycle" testing, visually evaluate the part and measure any significant characteristic locations
only, during the last half-hour of each cold and hot extreme temperature period.

Subject the number of assemblies specified to each of the cycles that follow in paragraphs
3.3.1 and 3.3.2.

Automated programmable test cycles based on the listed test conditions may be accepted by
prior agreement with the affected Materials Engineering Activity. Ramp speed 1 to 5 °C per
minute. Record actual ramp speed on data sheet.

3.3.1 Short Term Heat, Humidity and Cold Cycle

3.3.1.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. sail;

A-, B-, C-, and D-pillars; upper quarter panels; hard
instrument panels, and window garnish moldings):

. 5 h at -30 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at 100+/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 2 h at 50 +/- 2 °C and 95 +/- 5% R.H.
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at -30 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at 100 +/- 2 °C

3.3.1.2 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels,
lower quarter trim panels, floor and overhead consoles, and glove box
doors.)

. 5 h at -30 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at 90 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 2 h at 50 +/- 2 °C and 95 +/- 5% R.H.
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at -30 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at 90 +/- 2 °C

3.3.1.3 Scuff plates, kick panels, and other non-sun loaded floor level parts.

. 5 h at -30 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at 80 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 2 h at 50 +/- 2 °C and 95 +/- 5% R.H.
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at -30 +/- 2 °C
. 30 min at 23 +/- 2 °C and 50% R.H.
. 5 h at 80 +/- 2 °C

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3.3.2 Long Term Heat Exposure/Sun Load

3.3.2.1 All hard instrument panels (with or without integrated floor consoles)

Sun Load per IP-0105, 107°C surface temperature via heat lamps with a
chamber temperature of 90°C for 240 hours

3.3.2.2 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. sail; A-

, B-, C-, and D-pillars; upper quarter panels; and window garnish
moldings):

. 7 days at 100 +/- 2 °C

3.3.2.3 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels,
lower quarter trim panels, glove box doors, overhead consoles, and floor
consoles that are not integrated with the instrument panel and the unit
stands alone):

. 7 days at 90 +/- 2 °C

3.3.2.4 Non-sun loaded floor level parts (e.g., scuff plates and kick panels)

. 7 days at 80 +/- 2 °C

Requirements:

The trimmed assemblies shall remain relatively unaffected by the exposure cycles during and
after the tests as demonstrated:

(1) Tactually/visually - no excessive tackiness, loss in surface-grain, or surface-color change

(AATCC Procedure 1, Rating 4, min); no wrinkling, distortion, blistering, warping, delamination,
blushing, hazing, milking, staining, waviness, or other objectionable visual appearance.

(2) Functionally - no excessive expansion, shrinking, or warping that will interfere with normal
functional operations.

(3) Dimensionally - no movement exceeding what is required on the Engineering drawing

from the original installed position during or after the test.

3.4 IMPACT RESISTANCE*

Required for scuff plates, floor consoles, load floors, seating components,
door map pockets or any other parts as required by Ford Engineering.

3.4.1 Rubber Ball

4.5 kg weight, 127 mm dia, 60 +/- 5 Durometer "A"
(ISO 868/ASTM D 2240)

Test Method: Conduct this test with the trim assembly mounted on an actual or
simulated production support foundation using the approved retention methods. Drop
the rubber ball from the height specified below at the impact locations indicated on the
Engineering Drawing.

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Drop Height

. Scuff Plates 610 mm

Load Floor 500 mm
Below belt line 460 mm
Above the belt line 305 mm

The assembly shall show no evidence of cracking or breaking and shall fully recover
from indentation.

3.4.1.1 Room Temperature Impact

(23 +/-2 °C)

3.4.1.2 Cold Temperature Impact

(-30 +/-2 °C)

Expose the mounted assembly for 24 h at 80 +/-2 °C and then for 5 h

at -30 +/-2 °C. Drop the rubber ball while the part is in the cold box or
within 10 seconds of its removal from the cold box.

* Exceptions to temperature or drop height must be specified in the component SDS.

3.5 WEATHERING RESISTANCE

Resistance to Fade
(FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1)

FLTM BO AATCC Rating After

In Vehicle Sunlight Exposure Level 116-01 Test Exposure, min.
Exposure
Severe Exposure: Instrument panel top,
3609.6 kJ/m2 Rating 4
defroster grille,
Heavy Exposure: Instrument panel lower
top cover, 2 tone IP, IP bezel, IP registers,
airbag, steering wheel, message center, 2406.4 kJ/m2 Rating 4
appliqués, parcel shelf assembly/package
tray and center finish panel.
Medium Exposure: Instrument panel
lower, door trim, interior trim, pillars,
garnish moldings, seats, head rest,
sunshade, sun visor, seat belt webbing & 977.6 kJ/m2 Rating 4
loops, exposed load floor trim, and
luggage cover, interior rear view mirror
housing.
Mild Exposure: Floor console, radio, 2
601.6 kJ/m Rating 4
radio bezel and lower floor molding.
Low Exposure: Lower trim panels,
overhead console, headliner, moon roof, 225.6 kJ/m2 Rating 4
carpet and floor mats.

Slight change in gloss is acceptable.

The Xenon Arc sample size shall be approximately 60 x 150 mm

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3.6 ADHESION AND BONDING PROPERTIES

Bonded Strength, minimum average
(FLTM BN 151-05, except age per
Para. 3.3.1 and 3.3.2)

3.6.1 Original Bond Strength 0.48 N/mm width

3.6.2 Aged Bond Strength 75% of original result,

no visual change in
appearance,

The above method is to be used for all adhesive bonded materials to the hard plastic part.

3.7 SOILING ANDCLEANABILITY

(FLTM BN 112-08, ISO 105-A03/
AATCC Evaluation Procedure 2)

Cleanability Rating 3 min

3.8 SCRATCH RESISTANCE

Samples are to be taken from flat areas of part. When flat areas of the part do not exist,
surrogate plaques with identical color, grain and processing conditions may be used.

3.8.1 Resistance to Scratch and Mar

(FLTM BO 162-01, visual evaluation,
1 mm scratch balls at 2.0 N, 3.0 N, 7.0 N, 10.0 N, and 15.0 N load)

Hard Instrument Panel areas as directed by Materials Engineering, Design and

Release Engineering, Studio and Color and Mastering,

Scratch 2 N, Rating 2 max

Whitening/Color Change 15 N, Rating 1 max
Marring 2 N, Rating 2 max

Hard Trim

Scratch 2 N, Rating 2 max

Whitening/Color Change 7 N, Rating 1 max
Marring 2 N, Rating 2 max

Seat side shields/recliner handles

Scratch 2 N, Rating 2 max

Whitening/Color Change 2 N, Rating 1 max
Marring 2 N, Rating 2 max

3.9 FOGGING
(SAE J1756, 3 h at 100 °C heating, 21 °C cooling
plate, post test conditioning 16 h)

Fog Number 70 min

Formation of clear film, droplets or crystals is cause for rejection.

3.10 ODOR
(FLTM BO 131-03) Rating 3 max
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3.11 FLAMMABILITY
(ISO 3795/SAE J369)

Burn Rate 100 mm/minute max

3.12 ENVIRONMENTAL STRESS CRACKING

(FLTM BO 127-03 for stressed parts. For unstressed parts, do not assemble test bars in the
test fixture to achieve the 1% strain level.)

All amorphous materials (such as PC, PC/ABS ABS, SMA, ASA, PPO) must be evaluated for
potential incompatibility with other materials listed in the Bill of Material (BOM) that come in
continuous contact with the plastic components. For example, polycarbonate must be tested
with grease used on fasteners; vinyl must be tested for compatibility with the substrate material
they are covering.

No cracking or crazing allowed.

4. GENERAL INFORMATION

This information given below is provided for clarification and assistance in meeting the requirements of
this specification. Contact gmfs@ford.com for questions concerning Engineering Material
Specifications.

Rubber Ball Contact Information

Sean Djuricic, seand@ardl.com
Akron Rubber Development Laboratory, Inc.
2887 Gilchrist Rd. Akron, Ohio 44305
Ph: 330-794-6600
Fax: 330-794-6610
Cell: 330-554-6824

5. SUMMARY OF REVISIONS

2012 11 21
- Moved interior rear view mirror housing from severe exposure to medium exposure in section 3.5
Resistance to fade.

2012 03 06
- Updated application and limitation sections
- Added gloss ranges
- Section 3.3, modified dimensional requirements to allow engineering to define acceptable movement
after test.
- Section 3.4 modified load floor drop height to line up with M15P6
- Removed 3.6.3 cold bond strength
- Section 3.8 added requirement for seating components removed definitions.
- Modified wording in section 3.12 environmental stress cracking
- Added general information section and rubber ball contact information.
- Revised Table 1 and created Table 2

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 ENGINEERING MATERIAL SPECIFICATION

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TABLE 1
TESTING REQUIREMENTS

NOTE: This table is only for APPROVED RESIN technologies as shown on Ford Approved Source List
otherwise full WSS-M15P4-F specification testing is required.

Sample New Color DV PV Comments

size/color
(Data from Required for Must use
MCDCC New part production
approval geometry or tools
can be new
used as material Molder/resin
surrogate) Technology supplier
(post FDJ) change
Components
3.2 Appearance All colors X X
3.3.1 Short Term 1/part- X *Key life testing
Heat Exposure darkest Required in can be used in
color assembly lieu. Bonded
2 parts/new parts must be
technology production
representative.
3.3.2 Long Term 1/part- X For IP-Sunload
Heat Exposure darkest Required in testing per IP-105.
color assembly Bonded parts
2 parts/new must be
technology production
representative.
3.4.1.1 Impact 1/part- X
Resistance-Room darkest Required in
Temp color assembly
3.4.1.2 Impact 1/part- X
Resistance-Cold darkest Required in
Temp color assembly
3.6.1 Original 3/part-any X X Must be bonded
Bond Strength color using production
process. If not,
retest at PV.
3.6.2 Aged Bond 3/part-any X X Must be bonded
Strength color using production
process. If not,
retest at PV
Grained
Plaque/Part tests
3.7 Soiling and 3 per X X Concentrate
Cleanability* grain/per Production letdown ratio must
color intent resin, be production
grain and representative
colorant to
complete
testing by
FEC for all
new colors
and grains

3.8 Scratch 3 per X X X Concentrate

Resistance* grain/per Testing on Testing on letdown ratio must
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Sample New Color DV PV Comments

size/color
(Data from Required for Must use
MCDCC New part production
approval geometry or tools
can be new
used as material Molder/resin
surrogate) Technology supplier
(post FDJ) change
color plaques production be production
with parts if they representative
Production differ in
intent grain,
resin, grain material,
and color color and/or
(with processing
production from
intent plaques
colorant if tested at DV
applicable) or if
unavailable
at DV.
Material Tests
(ungrained parts
or plaques)
3.5 Resistance to 1 per color X X Concentrate
Fade Production letdown ratio must
intent resin be production
and representative
colorant to
complete
testing by
FEC .
3.9 Fogging 1 X X Contact Materials
component Prototype Can be Engineering if
darkest parts used for surrogate data is
color M99P2222 acceptable
compliance
3.10 Odor 1 X X Contact Materials
component Prototype Can be Engineering if
darkest parts used for surrogate data is
color M99P2222 acceptable.
3.11 Flammability 5 X X X Testing is
specimens Production Certified at dependent on part
intent resin PPAP and size (355x100 mm
to annually. min). FMVSS 302
complete can be used as
testing by surrogate
FEC
3.12 1 X Required for all
Environmental component Prototype amorphous
Stress Cracking any color parts or materials that
plaques come in
continuous
contact with
grease, oil etc.

*As agreed upon by Ford Design & Release and Materials Engineering.
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Table 2
Non-Visible Components

Component tests Sample size Non-Visible Comments

Application
Requirement
s

3.3.1 Short Term DV *Key life testing

Heat Exposure can be used in lieu.
1 component Bonded parts must
/assembly be production
representative.
3.3.2 Long Term DV For IP-Sunload
Heat Exposure testing per IP-105.
1 component/ Bonded parts must
assembly be production
representative.
3.9 Fogging 1 component DV Contact Materials
Engineering if
surrogate data is
acceptable
3.10 Odor 1 component DV Contact Materials
Engineering if
surrogate data is
acceptable.
3.11 Flammability 5 samples PV Testing is
dependent on part
size (355x100 mm
min). FMVSS 302
can be used as
surrogate
3.12 1 component DV Required for all
Environmental amorphous
Stress Cracking materials that
come in continuous
contact with
grease, oil etc.

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