ENGINEERING MATERIAL SPECIFICATION

POLYCARBONATE/ACRYLONITRILE BUTADIENE WSS-M4D924-B1

STYRENE BLEND (PC+ABS) MEDIUM IMPACT
MOLDING COMPOUND, INTERIOR

1. SCOPE

The material defined by this specification is a thermoplastic UV stabilized, medium impact molding
compound based on a blend of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) for mold-
in-color interior applications.

2. APPLICATION

This specification was released originally for material used in interior instrument panel applications for
small bezels in non-head impact and medium UV exposure (977.6kJ/m2) areas.

2.1 LIMITATIONS

The use of HALS (Hindered Amine Light Stabilizers) is prohibited in PC+ABS materials.

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).

3.1.1 Many 4D resin specifications prior to 2011, identified certain requirements with the
symbol(s), which indicated that the mean and +/- 3 sigma values were to be reported.
The specification minimum, maximum or range was established using 3 sigma data.
For 2011 and beyond, refer to Table 1 for number of samples required for each test to
establish specification limits.

3.1.2 This specification is based on virgin materials. Materials with post-consumer, post
industrial, or repolymerised recycled materials as defined by WRS-M99P42-A1 are
preferred and should be used whenever feasible.

3.1.3 The use of regrind is permitted, for economic / environmental reasons, with compliance
as indicated in Ford Engineering CAD and Drafting Standard E-4

3.1.4 Materials used in interior applications must meet the requirements outlined in WSS-
M99P2222-D1/Latest, Performance, Vehicle Interior Environment Quality
Material/Component Requirements. Data must be included in material submission
package.

3.1.5 Performance Criteria:

Parts using this specification shall meet the appropriate performance specifications:
WSS-M15P4-F/Latest, for interior mold-in-color applications. Parts must fulfill
applicable SDS/CDS requirements.

Date Action Revisions Rev. 0

2012 12 04 Activated L. Shen, APA

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 ENGINEERING MATERIAL SPECIFICATION

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3.2 SAMPLE PREPERATION

Unless otherwise specified all tests shall be carried out on injection molded, one-end gated test
specimens. The test specimens A and D shall be molded using molding conditions defined in
ISO 2580-2. No annealing is allowed. See Table 1 and 2 for the number of specimens required.

Specimens shall be as follows:

Specimen A 150 minimum x 10 x 4.0 +/- 0.2 mm (ISO 527-2, Specimen Type 1A)
Specimen B 355 x 100 x 1.0 +/- 0.1 mm (ISO 3795)
Specimen C 145 x 60 x 3.2 +/- 0.2 mm
Specimen D Center of Specimen A. 80 x 10 x 4.0 +/- 0.2 mm
Specimen E 100 mm diameter x 3.2 mm
Specimen F 80 mm diameter x 3.2 mm
Specimen G 90 mm x 200 mm
Specimen H 50 +/- 1 mm diameter x 3.2 +/- 0.2 mm
Specimen I 100 mm x 150 mm, min

3.3 APPEARANCE

3.3.1 Weathering Resistance Rating 4 min

2
(FLTM BO 116-01, 977.6 kJ/m exposure,
Specimen C from smooth polished mold,
ISO 105-A02 / AATCC Evaluation Procedure 1)

Every 526.4 kJ/m2 remove the samples from the weather-

ometer and allow them to cool for one hour. Conduct a tactile
evaluation and report any tackiness. Visually evaluate and
report any spewing or other exudation.

After exposure the material shall show no fading or color

change in excess of the specified AATCC rating. In addition,
there shall be no cracking, crazing or other deterioration.

Use regional choice for initial approval and report the color
house used. See Table 2 for additional color durability
submission requirements.

3.4 MATERIAL PROPERTIES

3.4.1 Density 1.08 - 1.20 g/cm3

(ISO 1183, Method A)

3.4.2 Tensile Strength at Yield 48 MPa min

(ISO 527-1 & ISO 527-2, Specimen A,
50 mm/minute test speed)

3.4.3 Elongation at Yield 3.0 % min

(ISO 527-1 & ISO 527-2, Specimen A,
50 mm/minute test speed)

3.4.4 Tensile Modulus 2.3 GPa min

(ISO 527-1 & ISO 527-2, Specimen A,
1 mm/minute test speed)

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3.4.5 Flexural Modulus 2.0 GPa min

(ISO 178, Specimen D,
64 mm support span, 2 mm/minute test speed)

3.4.6 Impact Strength, Notched Charpy

(ISO 179-1/1eA, Specimen D)
2
3.4.6.1 At 23 +/- 2 °C 28 kJ/m , min
Report Break Type
2
3.4.6.2 At -40 +/- 2 °C 9 kJ/m , min
Report Break Type

The test specimen must be conditioned for minimum of 6

hours at the above specified temperature prior to impact
test. Low temperature testing shall be done within the cold
chamber, if not possible, test may be conducted outside,
but within 5 seconds.

3.4.7 Heat Deflection Temperature 92 °C min

(ISO 75-1 & ISO 75-2, Specimen D, flatwise,
0.34 +/- 0.1 mm deflection at 1.80 MPa)

All specimens dry as molded. If not tested immediately after molding, specimens must
be stored in a sealed, moisture-proof container filled with silica gel.

3.4.8 Vicat Softening Temperature 116 °C min

(ISO 306, Specimen D, Bath - silicone oil,
temperature raise 50 +/- 5 °C/h.
Dial gage reset to 'O' after addition
of 5 kg weight, at 50 N load)

All specimens dry as molded. If not tested immediately after molding, specimens must
be stored in a sealed, moisture-proof container filled with silica gel.

3.4.9 Heat Aging Performance

(ISO 188, 150 +/- 50 air
changes/h, 1000 h at 90+/- 2 °C.
After heat aging test specimens are
to be conditioned in a desiccator for
3 - 5 h at 23 +/- 2 °C. Unaged property
values shall be determined at the time
of the aged properties determination)

3.4.9.1 Tensile Strength at Yield, Change +/- 25% max

(Test method per para 3.4.2)

3.4.9.2 Impact Strength, Notched Charpy, Change +/- 25% max

(Test Method per para 3.4.6.1,
specimens to be notched before
heat aging)

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3.4.10 Hydrolytic Stability

(ISO 188, humidity aging at 90 °C/70% RH
for 500 h or 80 °C/70% RH for 1000 h
After humidity aging test specimens are
to be conditioned for 24 h at 23 +/- 2 °C
50% RH. Unaged property values shall be determined
at the time of the aged properties determination)

3.4.10.1 Impact Strength, Notched Charpy, Change +/- 50% max

(Test Method per para 3.4.6.1,
specimens to be notched before
humidity aging)

3.4.11 Odor Rating 3 max

(FLTM BO 131-03, Specimen G)

3.4.12 Fogging Photometric

(SAE J1756, Specimen F, 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.

3.4.13 Flammability
(ISO 3795/SAE J369,
Specimen B smooth surface)

Burn Rate 100 mm/minute max

3.5 MATERIAL PROPERTIES – REPORT ONLY

Values are retained in Ford Materials Database www.fmd.ford.com.

3.5.1 Melt Flow Rate Report Value, g/10 minutes

(ISO 1133, 260 °C, 5 kg)

The material shall be dried for 4 h minimum at 100 °C in a mechanical convection

oven immediately preceding the test.

3.5.2 Coefficient of Linear Thermal Expansion

(ISO 11359-2, -30°C to 30°C)
-5
Flow Report Value, E mm/mm/ °C
Cross Flow Report Value, E-5 mm/mm/ °C

3.5.3 Molding Shrinkage

(Report method used, sample size and value)

After 48 h at 23 +/- 2 °C

Flow Report Value, %

Cross Flow Report Value, %

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 ENGINEERING MATERIAL SPECIFICATION

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3.5.4 Impact Strength, Notched Izod

(ISO 180/1A, Specimen D)

3.5.4.1 At 23 +/- 2 °C Report Value, kJ/m2

Report Break Type

3.5.4.2 At -40 +/- 2 °C Report Value, kJ/m2

Report Break Type

The test specimen must be conditioned for minimum of 6 hours at the above specified
temperature prior to impact test. Low temperature testing shall be done within the cold
chamber, if not possible, test may be conducted outside, but within 5 seconds.
3.5.5 Impact Strength Multi-axial
(ASTM D 3763, Impact velocity: 6.6 m/s
Specimen E, smooth surface injection molded specimen)

Max Load Energy at 23 +/- 2 ºC Report J Energy Absorbed

100 % Ductile

Max Load Energy at -10 +/- 2 ºC Report J Energy Absorbed

80 % Ductile min

A ductile failure is defined as a crack that does not radiate more than 10 mm from the
center of the impact point.

Test specimens must be conditioned for minimum of 6 h at test temperature prior to

impact testing. Low temperature testing shall be conducted within the same
environmental chamber as the clamp mechanism of the impact device. Specimens can
be transported from the conditioning environment to the testing environment, provided
the transfer is within 5 seconds.

3.5.6 Poisson's Ratio Report Ratio

(ISO 527-1/2, Specimen A
1 mm/minute test speed)

3.5.7 Supplemental Information

The following curves are to be submitted with the data packages:

FTIR
TGA
DSC
CLTE
Engineering Stress/Strain at 23 °C

4. GENERAL INFORMATION

The 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.

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 ENGINEERING MATERIAL SPECIFICATION

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4.1 TYPICAL PROPERTIES USING TEST METHODS IN SECTION 3.5

Typical
Para. Test Units
Values
3.5.1 Melt Flow Rate 3 g/10 minutes
3.5.2 Coefficient of Linear Thermal Expansion;
-5
Flow 7.9 E mm/mm/ºC
Cross Flow 7.8 E-5 mm/mm/ºC
3.5.3 Molding Shrinkage after 48 h at 23 +/- 2
°C;
(For specific method and sample size,
contact Materials Engineering)
Flow 0.96 %
Cross Flow 0.84 %
3.5.4.1 Impact Strength, Notched Izod;
45 kJ/m2
At 23 +/- 2 °C
3.5.4.2 Impact Strength, Notched Izod; 2
17 kJ/m
At -40 +/- 2 °C
3.5.5 Impact Strength, Multiaxial; Max Load
Energy at 23 +/- 2 °C; 44.9 J
6.6 m/s
3.5.5 Impact Strength, Multiaxial; Max Load
Energy at -10 +/- 2 °C; 50.1 J
6.6 m/s
3.5.6 Poisson's Ratio 0.35 N/A

4.2 MATERIAL IDENTIFICATION FOR RECYCLING PURPOSES >PC+ABS<

(ISO 1043/11469)

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Table 1: Minimum Sample Size

New Manufacturing Location for

Initial Approval
Previously Approved Material
Minimum Specimens Total Test Specimens Total Test
Para. Test Lots per Lot Specimens
Lots
per lot Specimens
3.1 WSS-M99P1111-A
WSS-M99P2222-B1/Latest – Total 1 1 1 per test
Carbon, Hazardous Substances,
3.1.4 Formaldehyde, Acraldehyde,
Acetaldehyde (See below for Odor and
Fogging)
3.3.1 Weathering Resistance 1 1 1
3.4.1 Density 1 3 3
3.4.2 Tensile Strength at Yield * 3 5 15 1 5 5
3.4.3 Elongation at Yield * 3 5 15 1 5 5
3.4.4 Tensile Modulus 1 10 10
3.4.5 Flexural Modulus* 3 10 30 1 10 10
Impact Strength, Notched Charpy (per 3 10 30 1 10 10
3.4.6
condition)*
3.4.7 Heat Deflection Temperature* 3 2 6 1 2 2
3.4.8 Vicat Softening Temperature* 3 2 6 1 2 2
3.4.9 Heat Aging Performance
3.4.9.1 Tensile Strength at Yield, Change 1 5 5
Impact Strength, Notched Charpy, 1 10 10
3.4.9.2
Change
3.4.10 Hydrolytic Stability 1 10 10
3.4.11 Odor 1 9 9
3.4.12 Fogging Photometric 1 3 3
3.4.13 Flammability 1 5 5
3.5.1 Melt Flow Rate 1 1 1
Coefficient of Linear Thermal Expansion 1 3 3
3.5.2
(per condition)
3.5.3 Molding Shrinkage 1 5 5 1 5 5
Impact Strength, Notched Izod (per 1 10 10
3.5.4
condition)
Impact Strength, Multiaxial (per 3 10 30 1 10 10
3.5.5
condition)*
3.5.6 Poisson's Ratio 1 5 5
Curves
- IR
- TGA 1 1 1 per test
3.5.7
- DSC
- CLTE
- Stress/Strain Curves at 23 °C

* For these requirements the 3 sigma value from the raw data is used to meet the requirements.

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Table 2: Minimum Color Property Testing

Specimens Total Test Color Test

Para. Test Method Lots
per Lot Specimens Direction
3.3.1 Weathering Resistance Every color
1 1 1
3.4.2 Tensile Strength at Yield As directed by
1 5 5 Materials
Engineering
3.4.5 Flexural Modulus As directed by
1 10 10 Materials
Engineering
3.4.6.1 Impact Strength, Notched Charpy As directed by
At 23 +/- 2 °C 1 10 10 Materials
Engineering
3.4.11 Odor As directed by
1 9 9 Materials
Engineering
3.4.13 Flammability 1 5 5 Every color

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