ENGINEERING MATERIAL SPECIFICATION

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 applications, where various materials are combined to provide an assembly having thermal
and/or acoustical (sound absorption/barrier) 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. Adhesive backed products must meet WSS-
M11P62-A.

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

Material specification requirements are to be used for initial qualification of materials.

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
System Engineering Department.

3.4 WEIGHT
(FLTM BN 106-01)

The fiber/foam weight and total weight shall be as specified on the Engineering Drawing.

3.5 ODOUR, max

(FLTM BO 131-03) Rating 3
Date Action Revisions

2009 03 31 Activated B. Witkowski FNA J. Williams FoE

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

Fog Number, min 70

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.

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).

3.8.1 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

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

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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

Test one previously unexposed assembly:

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

Insulation and covering materials shall not crack, warp, flame, glow,
smolder, degrade, delaminate, develop an objectionable odor or exhibit
any exothermic reaction when tested at the maximum vehicle use
temperature as determined from applicable vehicle tests.

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.)

Insulation materials shall not crack, warp, flame, glow, smolder, degrade,
delaminate, develop an objectionable odor or exhibit any exothermic
reaction when tested at the maximum vehicle use temperature as
determined from applicable vehicle tests.

3.8.2.4.2 Radiant Heat Exposure, max Nominally 340 +/- 2 °C

(SAE J1361)

The number of heating and cooling cycles and duration to be supplied by

the Ford Heat Management Team. Cycle times/temperatures to be
specified on the Engineering Drawing.

(This requirement is shown as an example, actual maximum average

component temperatures as defined by the Ford Heat Management
Team shall be used.)

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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 D 5034)

Specimens to be cut from flat areas of the finished part. Speed of testing
25 mm/minute; distance between clamps at beginning of test should be 100 mm.

3.9.1.1 Original, min 10 N/cm2

Specific values will be reported with

the data submission package.

3.9.1.2 Change After Humidity Aging, max -30%

(48 h at 38 +/- 2 °C and 95
+/- 2% R.H.; 1 h at
room temperature)

3.9.1.3 Change After Heat Ageing, max -30%

(para.3.8.2)

3.9.1.4 Change After Immersion In Water, max -30%

(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, max 50%

(For foam materials only)
(ISO 1856, Method A/ASTM D 3574, Test D)

3.9.4 Tear Strength, min

(ASTM D 5733 for non-woven materials) 50 N/m
(ASTM D 3574, Test F for foam materials) 10 N/m

Specimens to be cut from flat areas of finished parts.

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3.9.5 Peel Strength (Laminates only), min 9N/50mm

(For interior materials only)
(FLTM BN 151-05)

Samples must also meet following requirement:

. Adhesion of the cover material shall exceed the cohesive strength of the fabric
substrate.

3.9.6 Peel Strength (Laminates only), min 9N/50mm

(For engine and underbody materials only)
(FLTM BN 151-05, 30 minute immersion)

Samples are cut to 250 mm lengths. Each material should be tested to the fluids
quoted in 3.10.

. Must have cohesive failure at the interface

3.10 RESISTANCE OF INSULATORS TO VARIOUS TEST REAGENTS

(ASTM D 896)

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.

3.11 MOISTURE ABSORPTION, max 30%

1. Cut a 200 x 200 +/-10mm specimen from the part to be tested and seal any cut edges,
e.g. with wax.

2. Weigh the specimen nearest to 0.1 g.

3. Condition part/section in suspended position at 38 +/- 2 °C and 95 +/- 2% R.H. for 24 h.

4. 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.

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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, (W/M/°K) Report

(ASTM C 518, C 177)

3.13.2 Floor Heat Insulation, max 60 °C on the

(Interior acoustical 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 Report

(SAE J2302)

3.14 FLAMMABILITY (For Interior Components)

(SAE J369/ISO 3795, Flammability is affected by the material
thickness and density, conduct testing on full range of material
thicknesses and densities on part)

3.14.1 Burn Rate, max 100 mm/minute

3.15 FLAMMABILITY (For Engine/Underbody Components)

(SAE J369/ISO 3795, Flammability is affected by the material
thickness and density, conduct testing on full range of material
thicknesses and densities on part)

3.15.1 Burn Rate SE 10 seconds

3.15.2 Burn Rate SE 20 seconds

After heat ageing acc 3.8.2.2 or 3.8.2.3 or 3.8.2.4

The flame must extinguish within the specified time.

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3.16 FLAMMABILITY (For Engine/Underbody Components) Flame shall extinguish

(IEC 60695-2-10, Glow wire temperature: 750 °C, within 10 seconds
Flammability is affected by the material thickness and density, after removal of the
conduct testing on full range of material thicknesses wire
and densities of part)

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 test method for materials
IEC 60695-2-13 Glow wire ignitability test method for materials

3.17 CORROSIVENESS TO STEEL, min Rating 4

(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)

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.

4.2 Purchase departments will ensure that materials defined in this specification and one assembly
plant will be produced by one supplier only.

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 ENGINEERING MATERIAL SPECIFICATION

TABLE 1

Material Category

A1: Felt

A2: PU Foam

Temperature Foam
A3: High

A4: EPP Foam

Fleece
A5: Polyester

A6: Mineral Fibre

A7: Glass Fibre

Interior Applications

Applications
Engine/Underbody

Applications
High Temperature

Applications
Temperature
Ultra High
Test method:
Sample Size required for DV and PV: Noted in Table

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 3.8.1. 3.8.1.1 Interior/Luggage
3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x
Environmental Short Compartment
Testing Term 3.8.1.2 Engine/Underbody
Heat, 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x x
Humidity, 3.8.1.3 High Temperature
Cold Applications 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x x

3.8.2 3.8.2.1 Interior/Luggage

Long Compartment 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x
Term
3.8.2.2 Engine/Underbody
Heat 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x x
Exposure
3.8.2.3 High Temperature
3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x x
Applications
Long 3.8.2.4.1 Ultra High temperature
Term Applications
3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x
Heat
Exposure
Radiant 3.8.2.4.2 Ultra High temperature
Heat Applications
Exposure 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x

TABLE 1: continued

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Material Category

A1: Felt

A2: PU Foam

Temperature Foam
A3: High

A4: EPP Foam

Fleece
A5: Polyester

A6: Mineral Fibre

A7: Glass Fibre

Interior Applications

Applications
Engine/Underbody

Applications
High Temperature

Applications
Temperature
Ultra High
Test method:
Sample Size required for DV and PV: Noted in Table

3.9 3.9.1 3.9.1.1 Original (N/cm2)

Physical Tensile 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) x x x x
Properties Strength
(ASTM D 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
5034)
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

3.9.1.4 Change after Immersion in

5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) 5(PV) x x x x
Water %
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 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x x x x
D)
3.9.4 3.9.4.1 ASTM D5733 3(PV) 3(PV) 3(PV) 3(PV) x x x x
Tear
Strength 3.9.4.2 ASTM D3574 Test F 3(PV) 3(PV) x x
3.9.5 Peel Strength Laminates only (FLTM
BN105-04) Interior 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) 3(PV) x

3.9.6 Peel Strength Laminates only (FLTM

BN105-05) 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 D696) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) x x 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

TABLE 1: continued

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Material Category

A1: Felt

A2: PU Foam

Temperature Foam
A3: High

A4: EPP Foam

Fleece
A5: Polyester

A6: Mineral Fibre

A7: Glass Fibre

Interior Applications

Applications
Engine/Underbody

Applications
High Temperature

Applications
Temperature
Ultra High
Test method:

Sample Size required for DV and PV: Noted in Table

3.13 3.13.1 Thermal Conductivity

Thermal 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) x x x x
Properties
3.13.2 Floor Heat Insulation
1(DV) 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) x x x x

3.13.3 Thermal Sleeve Heat Insulation

1(DV) 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) 1(DV) x x x

3.14 Flammability 3.14.1 Burn Rate 100mm/min maximum

Performance
5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) x
Interior

3.15 Flammability 3.15.1 No Burn Rate: Sample must

Performance extinguish within 10 seconds 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) x x x
Engine and
Underbody 3.15.2 No Burn Rate: Sample must
extinguish within 20 seconds 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) x x x
(after heat ageing)
0
3.15.3 Hot Wire Ignition @ 750 C
3.16 Flammability: Sample must self extinguish after
5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) 5(DV+PV) x x x
Glow Wire removal of the wire

3.16 Corrosiveness to Steel (SAE J1369)

1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) 1(PV) x x x

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