DBL_5418_2003-10

October 2003

Mercedes-Benz

Supply Specification

Injection moulded parts manufactured from fibre reinforced thermoplastics for structural requirements

DBL 5418

BQF available o

Additional DaimlerChrysler standards required: MB Special Terms, DBL 5555, 5306, 5307, 8585

Supersedes edition:Refer to Section Changes

Fortsetzung Seite 2 bis 8

Issued by:

DaimlerChrysler AG 70546 Stuttgart

Standards (EP/QIN)Technical responsibility (Name): Ilzh?fer/Schmid

Department: PWT/VWK Plant: 050Telephone: +49(0)7031 90-44268/2006 HPC:X685Technical coordination by PWT / Materials and Process Engineering Plant 050, Department PWT/VWK Name: Dr. Wittig Telephone +49(0)7031 90-44270

In case of doubt, the German language original should be consulted as the authoritative text.Product versions and examples

Product version Material Material description Application examples

00PA6 GF30

Assembly carrier front module (hybrid)00PP GF20 Long glass fibre Underfloor panelling 00PP GF30 Long glass fibre Instrument panel carrier

PP GF40 Long glass fibre

Assembly carrier, flexible bumper bracket MKV

Abbreviated designations

For drawings, in the block for materials

e.g. : Thermoplastic PA6 GF30in the block for design and delivery

e.g. : +DBL 5418.00

1 Field of application, general requirements

DBL 5418 applies to components manufactured from fibre-reinforced thermoplastics with increased mechanical strength and stiffness requirements in order to fully exploit the light-weight design potential. The temperature and ageing-dependent properties of the materials used shall be specifically taken into account in the component design. It is expedient that a specifications book with the materials engineering requirements for each component is compiled.

The application of this DBL is mandatory as early as the development phase - e.g. for trial samples - as the results achieved form the basis for the component approval.

2 General properties of the materials, raw materials and supply condition

The parts shall be free of manufacturing defects of any type which have a more than an insignificant impact on appearance and serviceability characteristics. In order to ensure that long fibre material (fibre length > 500 μm,e.g. PPGF30 PV00 and PPGF20 PV00) is processed with minimum damage to the fibres, suitable processing plant technologies shall be used.

Assessment of the mechanical properties of the components is difficult, as the fibre orientation and the fibre length (and, in case of PA, the moisture content) have an influence on the test results. The quality status of a component sample can only be determined on the basis of a well-produced reference component. In addition,the results of a filling analysis and a relevant FEM calculation (taking into account the fibre orientation) shall be used. Only parts shall therefore be used for trials whose processing quality is known (e.g. evidence using a trial sample report in analogy to an initial sample inspection report in accordance with DBL 5418).

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DBL 5418 : October 2003

Where components are subjected to specific environmental conditions (e.g. UV radiation or service fluids), suitable test criteria shall be defined (refer to e.g. DBL 5555) to ensure the capability of the materials used (refer to the specifications book for the materials engineering requirements above).

Long fibre-reinforced plastic:

Injection moulding of long fibre-reinforced materials is a particularly sensitive process. Important process parameters such as dynamic pressure, screw speed, nozzle geometry or sprue design affect the resulting fibre length distribution in the finished part. The fibre length in turn has an influence on the strength properties of the material, in particular with regard to the creep stress and higher temperatures. During the development process, all process parameters shall therefore be documented and the trial parts examined in accordance with this DBL (refer to Sections 1 and 5.2.4). For critical applications, the retention of back-up samples can prove useful.

3 Dimensions and tolerances / Form of supply

Refer to DBL 5555

data

4 Technical

Material characterization on test panels: for minimum values for test panels, refer to Table 1, page 7

for values for components (for fibres with transverse orientation), refer to Table 2, page 8

5 Tests

5.1Preliminary material assessment using test panels (Table 1)

For assessing and assuring new materials / methods (refer to DBL 5555, Sections 5 to 8), test panels (dimensions, sprue design and sampling plan to be agreed with Deptm. PWT/VWK)

shall be used to determine test values in coordination with department PWT/VWK in accordance with the materials and process specifications book.

Manufacturing parameters and the resulting degree of orientation of the test panels shall be indicated when supplying samples. Sufficient statistical evidence shall be ensured.

We reserve the right to sample granulate in the PWT technology centre.

5.2Finished components (Table 2)

The values under Sections 4.2.3.1 to 4.2.10.3 are requirements for the finished part. The test specimens shall be removed from the finished component taking into account DBL 5555 Part II Section 1.3. The sampling points shall be agreed between the buyer and the supplier.

capability

5.2.1 Process

Verification of process capability with regard to materials engineering, e.g. by means of DOE (design of experiments), based on material properties is a precondition for approval of the production process by PWT after discussion with the receiving plant.

The criteria and relevant parameters shall be defined within the framework of the development process and documented. [For long fibre materials, the cold impact resistance and the tensile test at 120°C (refer to Table 2: Sections 4.2.5.1, 4.2.6.1, 4.2.7.1) shall be used as criteria for verification.] In case of any changes in the relevant production parameters, renewed sampling is required (refer to DBL 5555, Section 4).

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DBL 5418 : October 2003 5.2.2 Sampling

Due to the directional character of the properties of injection moulded materials, the test specimens shall be taken from unambiguously defined sampling points of at least five components. The sampling plan (sampling longitudinally and transversely to the fibre orientation) shall be conducted by PWT in agreement with the receiving plant, the responsible development department and the supplier (failure-critical areas shall be included in the drawing, if applicable). If required for the assessment of the microstructure, X-rays and microsections (refer to Section 5.2.3) of the component shall be produced.

5.2.3 Examination of microstructure

In areas subject to high mechanical stress or in failure-critical areas, verification of the microstructure shall be provided (e.g. micrographs). The removal points of the samples for the examination of the microstructure shall be specified following agreement with PWT and the relevant development department. Alternatively, if the microstructure examination is not meaningful, mechanical component testing may be performed. The way in which this verification is to be performed shall be agreed with PWT.

5.2.4 Evaluation

Each sampling point shall be statistically evaluated separately. The values indicated in Table 2 must be achieved. Any deviation of the properties (variance) from the successfully tested development sample, even at higher values, shall be recorded and defined in view of the verification of the process capability (refer to 5.2.1). The property values of the development samples shall be submitted to the materials testing department of the responsible DC receiving plant without further request when supplying initial samples.

5.2.5Flame-retardant properties (FMVSS 302), emissions, fogging, odour, hot light ageing Components for vehicle interiors shall comply with the requirements regarding flame-retardant properties, emissions, fogging, odour and hot light ageing. For other components depending of the requirement on the functional instructions.

Flame retardant properties for interior parts in accordance with DBL 5307.10

Emission: VDA 278 (2002), DBL 8585

Fogging: DBL 5306, method B max. 0,7mg

Odour: VDA 270 Grade ≤ 3

Hot light ageing: DBL 5555 min. grade 4

6 Test

methods

Immediately before the mechanical tests are performed, the test specimens shall be stored for 48 hours in standard atmosphere in accordance with DIN EN ISO 291 and then tested. For PA materials, the moisture content of the test specimens at the time of testing shall be recorded.

6.1Density

ISO 1183, buoyancy method

6.2 Residue on ignition

DIN EN ISO 1172 refers to glass fibres and mineral fillers; for carbon fibres, DIN 2564 method A shall be used.

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DBL 5418 : October 2003

6.3 Bending test

DIN EN ISO 178

Test specimens: 80 x 10 x d (in mm), or in agreement with PWT,

Test specimens (long fibre material): 80 x 25 x d (in mm) (deviating from standard)

Test speed: 10 mm/min

Test speed modulus in flexure : 1 mm/min

Determination of modulus of elasticity : between 0,05 and 0,25 % elongation

Distance between supports: 64 mm or L = (16±1) x h (in agreement with the relevant materials

testing department of the receiving plant)

Bending direction: in agreement with PWT and the development department

6.4Impact resistance test, unnotched

DIN EN ISO 179

Test specimens: 80 x 10 x d (in mm), or in agreement with PWT

Distance between supports: 62 mm

Test specimens (long fibre material): 120 x 15 x d (in mm) (instrument panel/deviating from standard) Distance between supports: 70 mm

Direction of impact: on broad side, determine tensile zone together with PWT

Fracture assessment and evaluation: in accordance with DIN EN ISO 179

6.5 Tensile test

DIN EN ISO 527 1-3

Test specimens: Standard bar type 1B, (type 5A only for component testing, where

type 1B cannot be used)

Test specimens (long fibre material): 170 x 25 x d (in mm) (deviating from standard)

Test speed: 5 mm/min

Determination of modulus of elasticity : between 0,05 and 0,25 % elongation

Test speed: 5 mm/min

Test speed modulus in flexure : 1 mm/min

Distance between grips: 100 mm or 50 mm

Gauge length: 50 mm or 20 mm

6.6Puncture impact test

DIN EN ISO 6603-2

Test specimen diameter : 60 mm, specimen thickness corresponding to component thickness

or test panel thickness of 2,5 or 3 mm ±0,1

Clamp diameter: 40mm

Puncture body diamete: 20mm

Test speed: 4 m/s

Evaluation: Visual assessment of fracture pattern

Maximum force F max

Total penetration energy to F max

Important: Grease ram before each individual test!

6.7Hot storage

To be tested according to the relevant functional instructions.

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DBL 5418 : October 2003 ageing

6.8 Heat

Heating cabinet in accordance with DIN 50011

Store the sample panels/component sections for 1000 hours at temperatures conforming to Tables 1 and 2. Then remove the test specimens, store in standard atmosphere in accordance with DIN EN ISO 291 for 48 hours and then perform the mechanical tests. Report the water content of the test specimens at the time of testing.

6.9Flame-retardant properties (FMVSS 302), emissions, fogging, odour, hot light ageing

Components for vehicle interiors shall comply with the requirements regarding flame-retardant properties, emissions, fogging, odour and hot light ageing. For other components depending on the requirements of the functional instructions.

Flame retardant properties for interior parts in accordance with DBL 5307.10

Emissions: VDA 278 (2002)

Fogging: DBL 5306, method B max. 0,7mg

Odour: VDA 270 Grade ≤ 3

Hot light ageing: DBL 5555 min. grade 4

6.10Viscosity number

DIN EN ISO 307

content

6.11 Water

DBL 5555, 72h drying at 105°C

The water content shall be determined on delivery, after exposure to constant condensed water climate and after heat ageing following the tests (PA materials, PA blends).

6.12 Constant condensed water climate

DIN 50017

Store the sample panels/component sections for 1000 hours at 40 °C, 98% humidity

Then remove the test specimens, dry at 105 °C for 72 h, store in standard atmosphere in accordance with

DIN EN ISO 291 for 48 hours and then perform the mechanical tests. Report the water content of the test specimens at the time of testing.

6.13 Resistance to chemicals and service fluids

The resistance requirements for each component shall be defined in the relevant materials specifications book. 7Duties of the supplier

Refer to Special Purchase Conditions and MB Special Terms No. 13 and No. 16

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DBL 5418 : October 2003

8Samples

Refer to MB Special Terms

9Deliveries

Refer to MB Special Terms

10Marking

Refer to MBN 33015 and VDA 260 as well as MB Special Terms

11Packaging

Refer to MB Special Terms

12Storability

Refer to MB Special Terms

13Special instructions

Refer to order

14 Complaints

Refer to MB Special Terms and Special Purchase Conditions

15Environmental protection regulations/Industrial safety

Refer to negative substance list for material selection in accordance with DBL 8585 (or MB Special Terms)

16Other applicable standards

MB Special Terms, Special Purchase Conditions

DBL 5306, 5307, 5555, 8585, MBN 33015

DIN 50011

DIN 50017

DIN EN ISO 178

DIN EN ISO 179

DIN EN ISO 291

DIN EN ISO 307

DIN EN ISO 527 1-3

DIN EN ISO 1172

DIN EN 2564

DIN EN ISO 6603-2

ISO 1183

FMVSS 302

VDA 260

VDA 270

VDA 278 (2002)

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DBL 5418 : October 2003

Table 1

4.1. Technical data test panel (minimum values except 4.1.1, 4.1.2)

Unit

PA6 GF30

PP GF30 Long glass fibres PP GF20 Long glass fibres

Product version

0000Test method 4.1.1Density acc. to sample, guideline value g/cm31,36 ± 0,02****ISO 11834.1.2Residue on ignition acc. to sample,guideline value

30 ± 330 ± 320 ± 3DIN EN ISO 11724.1.3.1Modulus in tension in new condition 3000**

**DIN EN ISO 527 1-3

4.1.3.2After const. condensed water climate 3)2700

--4.1.3.3After ageing

4100 1)

** 2)** 2)4.1.4.1Bending strength in new condition 160 *****DIN EN ISO 178

4.1.4.2After const. condensed water climate 3)80 *

--4.1.4.3After ageing

MPa

185 * 1)

** 2)** 2)4.1.5.1Impact strength in new condition RT -25°C 5020****DIN EN ISO 179

4.1.

5.2After const. cond. water climate 3) RT -25°C 60***--4.1.5.3After ageing RT -25°C kJ/m2

1)**

** 2)** 2)** 2)** 2)4.1.6.1Tensile strength in new condition 65** 5)** 5)DIN EN ISO 527 1-3

4.1.6.2After const. condensed water climate 3)45*--4.1.6.3After ageing

MPa

80 1)** 2)** 2)4.1.7.1Elongation at break in new condition 2** 5)** 5)DIN EN ISO 527 1-3

4.1.7.2After const. condensed water climate 3)3,5*--4.1.7.3After ageing

1 1)** 2)** 2)4.1.8.1Viscosity number in new condition 120-150--DIN EN ISO 307

4.1.8.2After const. condensed water climate 3)max. -5%

--4.1.8.3After ageing

ml/g max. -5%

--4.1.9.1Penetration max. force new condition

RT and -25°C N ******DIN EN ISO 6603-2

4.1.9.2After const.cond.water climate 3) RT,-25°C N **--4.1.9.3After ageing RT,-25°C

N ** 1)** 2)** 2)4.1.10.1Total penetration energy new condition

RT, -25°C

kJ ******DIN EN ISO 6603-24.1.10.2After const. condensed water climate 3)

RT and -25°C

kJ **--4.1.10.3

After ageing RT and -25°C kJ

** 2)

1) 42 days at 140 °C hot air 5) Values at a test temperature of RT/ 120°C

2) 42 days at 120 °C hot air

3) Constant condensed water climate 42 days at 40°C, 98% humidity * preliminary values

4) Water content ≤ 0,7%

** values still to be specified

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DBL 5418 : October 2003

Table 2

4.2. Technical data component

Unit

PA6 GF30

PP GF30 Long glass fibres PP GF20 Long glass fibres

Product version

000000Test method 4.2.1Density acc. to sample, guideline value g/cm31,36 ± 0,021,12 ± 0,03**ISO 11834.2.2Residue on ignition acc. to sample,guideline value

%30 ± 330 ± 320±3DIN EN ISO 11724.2.3.1Modulus in tension in new condition 30003000

**DIN EN ISO 527 1-3

4.2.3.2After constant condensed water climate 3)2700*

--4.2.3.3After ageing

MPa

4100 1)

** 2)** 2)4.2.4.1Bending strength in new condition

160 *70**DIN EN ISO 178

4.2.4.2After constant condensed water climate 3)80 *

--4.2.4.3After ageing

185 * 1)

** 2)** 2)4.2.5.1Impact strength in new condition RT -25°C 50204530****DIN EN ISO 179

4.2.

5.2After const. cond. water climate 3) RT -25°C 60***----4.2.5.3After ageing RT -25°C kJ/m2

1) ** 1) ** 2) ** 2)** 2)** 2)4.2.6.1Tensile strength in new condition

6540/** 5)

** 5)DIN EN ISO 527 1-3

4.2.6.2After constant condensed water climate 3)45*--4.2.6.3After ageing

MPa

801) ** 2)** 2)4.2.7.1Elongation at break in new condition 21,6/** 5)

** 5)DIN EN ISO 527 1-3

4.2.7.2After constant condensed water climate 3)3,5*--4.2.7.3After ageing

% 1 1) ** 2)** 2)4.2.8.1Viscosity number in new condition

115-155--DIN EN ISO 307

4.2.8.2After constant condensed water climate 3)ml/g

max. -5%

--4.2.8.3After ageing

max. -5%

--4.2.9.1Penetration max. force in new condition RT and -25°C

N ******DIN 6603-2

4.2.9.2After const.cond.water climate 3) RT, -25°C N **--4.2.9.3After ageing RT, -25°C N ** 1) ** 2)** 2)4.2.10.1Total penetration energy in new condition RT and -25°C

kJ ******DIN 6603-24.2.10.2After const.cond. water climate 3) RT, -25°C kJ **--4.2.10.3

After ageing RT, -25°C

1) ** 2)

** 2)

1) 42 days at 140 °C hot air 5) Values at a test temperature of RT/ 120°C

2) 42 days at 120 °C hot air

3) Constant condensed water climate 42 days at 40°C, 98% humidity * preliminary values

4) Water content ≤ 0,7%

** values still to be specified