Klass.-Nr. 55 15 4
The English translation is believed to be accurate. In case of discrepancies the German version shall govern.
Test Scope for Material Data Sheets Konzernnorm Descriptors: thermoplastics, mounting bracket, material data sheet
TL 526 25
This technical supply specification (TL) specifies the component requirements of mounting brackets made from thermoplastics and hybrid technology (e.g. PP GMT, long-glass-fiber-reinforced PP, PP injection molding LFT, polyamide 6 in hybrid technology). The limit-value and tolerance requirements can be found in the component-, material- and supplierspecific material data sheets. 2 Designation
Refer to the material data sheet. 3 3.1 Requirements General requirements
Approval of first supply and changes according to Volkswagen standard VW 011 55. Avoidance of hazardous substances according to VW 911 01. The required minimum for complete testing is three parts; this number may increase depending on the component design. 3.2 Material
Refer to the material data sheet and section 5.1. In terms of their technological material characteristics, the materials used for the components must ensure the function and safety of the vehicle for the entire service life. Fillers such as glass fibers and modifying agents for heat stabilization are permitted. In the case of combined components (metal/plastic) compatibility of the materials shall be ensured. If necessary, the materials shall be matched to each other by means of pretreatments (e.g. bonding agent).
Material qualities which have not yet been recorded in the material data sheets must be released by Design Engineering after testing and fulfill the general requirements of the component. Then, the new material qualities can be included in the material data sheets. Material data sheets (MDs for short) for the various designs are available from department K-QS31 and can be requested by the responsible Quality Assurance departments of the producing factories, as required (example of a material data sheet, see Appendix A).
Form FE 41 - 01.03
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Fachverantwortung/Responsibility K-QS-31 Achtzehner Tel. 76414 Dr. Wohlfarth Normung/Standards (EZTD, 1733) Frau Krenz Tel: +49-5361-9-48869 Sobanski
Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group. Parties to a contract can only obtain this standard via the responsible procurement department.
? VOLKSWAGEN AG
If the material for the finished part is changed during development or during ongoing standard production, this change must be presented and examined in all cases. A new technical engineering release may be necessary.
Norm vor Anwendung auf Aktualit?t prüfen / Check standard for current issue prior to usage.
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Identification according to VDA 260
Refer to the material data sheet. 3.4 Types
According to drawing. 3.5 Manufacturing method
Injection molding, thermo extrusion procedure, hybrid technology, IMC procedure. 3.6 Appearance
Surface and interior of the components shall be free of flaws and processing defects, such as flow lines, voids, cracks or similar faults. Sink marks at the base of ribs and reinforcements are permissible only if they do not adversely affect the part’s function or appearance. 3.7 Conditioning
The components, and the specimens taken, shall be conditioned for at least 48 h before the test in the DIN 50 014 - 23/50-2 standard climate (deviating conditioning methods are described in the relevant material data sheets depending on the type of material). 3.8 Validity of requirements
The required numerical values apply to each individual measurement. 3.9 Types according to material data sheet
The mechanical material data specified in a material data sheet are exclusively valid for this type as produced by one or several suppliers, and which has been evaluated positively in terms of the material and released by the laboratory (according to section 1.1 of the material data sheet). 4 Requirements for the finished part
The general requirements apply to every material quality and material combination. The mechanical properties described in the material data sheets can vary individually, depending on the additionally set requirements. In every case, both the general requirements and the material-specific requirements must be met in order to describe the material quality actually used on a componentspecific basis. 4.1 Temperature resistance
The component must be resistant to temperatures from -40°C to +110°C and be functional for the entire service life of the vehicle. If necessary, deviating limit temperatures shall be determined and shall always be specified as well.
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See section 5.1. The components must exhibit no changes in shape, color and surface that would adversely affect the function and/or appearance. 4.3 Low-temperature behavior
See section 5.2. The components must remain fully functional and free of damage when exposed to cold and subsequently heated to (23 ± 2)°C. 4.4 Resistance to agents
Any media that could come in contact with the finished part must also be listed (e.g. oil, coolant). Tests to determine resistance to agents are therefore performed only as needed (type and procedure are added to the drawing if necessary). 4.5 Aging resistance
The temperature level is based on the temperatures that will actually occur at the finished part. Thus, different requirements could be made on the component depending on the engine version. As the aging behavior is heavily dependent on the material, it is described in the relevant material data sheet. If there is no information available on the actually occurring temperatures, the principle shall apply that aging must take place for 1,000 h at +150°C (mechanical circulation oven). Refer to the material data sheets or the relevant drawings for the corresponding instructions. 5 5.1 Notes on testing Elevated-temperature behavior
Aging at elevated temperatures according to DIN 53 497, method B, to be performed with at least one complete component. Aging period: (24 ± 2) h Aging temperature: (110 ± 1)°C 5.2 Low-temperature behavior
Aging of at least one complete component in mechanically circulated air. Aging period: (24 ± 2) h Aging temperature: (-40 ± 1)°C The evaluation is conducted after heating to (23 ± 2)°C. 5.3 Material
Identification can take place using the attenuated total reflection variant of the FTIR (Fourier transform infrared spectroscopy) procedure.
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Density is measured using the buoyancy method. If possible, the same specimens as those intended to determine the glass fiber content shall be used. For this reason, the density measurement shall be conducted before the glass fiber content determination (ignition residue). In order to avoid oven-drying the specimens after the density measurement, the weight of the specific specimen in air prior to the density measurement shall be used as the weigh-in for the ignition loss. 5.5 Glass fiber content
Specimen (50 x 50) mm. Five individual measurements shall be taken from different areas of the finished part (see also section 5.4). 5.6 Flexural strength
Specimens: length (80 ± 1) mm; width (30 ± 1) mm; thickness corresponding to product thickness. Support separation: 60 mm; test rate: 1 mm/min; evaluation between 0.2% and 0.4% edge fiber elongation. The specimens shall be placed on the supports of the test device so that the specimen surface corresponding to the front or exterior of the finished part is subjected to compression stress. Rigid supports that are aligned in parallel with the pressure fin and cannot move during the test shall be used for the test. It is permissible to measure the modulus of elasticity in connection with the determination of the flexural stress at maximum load on the same specimen. The specimens shall be removed on the basis of a specimen removal plan, if available. A sample specimen removal plan is provided in the appendix. If possible, subsequent mounting brackets should follow according to a similar diagram, if the geometry allows. 5.7 Impact resistance
Test according to DIN EN ISO 179-1/1fU, but specimens: length (120 ± 1) mm; width (15 ± 1) mm; thickness corresponding to product thickness. Test equipment: 7.5 J according to DIN 51 222; support separation: 70 mm. The specimens shall be placed on the mounting flanges of the test device so that the specimen surface corresponding to the front or exterior of the finished part faces the hammer edge. For specimen removal see section 5.6. 5.8 Aging resistance
Continuous aging in mechanically circulated air at (150 ± 2)°C. The test is preferably performed on complete finished parts. It is permissible to perform it on sections of finished parts. Brittling is achieved when the specimen exhibits signs of disintegration typical for decomposed PP (material starts to crumble, glass fibers emerge). The aging duration is generally 1,000 h; a reduction in the aging resistance is only possible if a lower temperature level is determined in temperature measurements (performed for those engine versions that radiate the greatest amount of heat relevant for the component), as specified under section 5.1. This must always be indicated! A temperature of +150°C is set in order to keep the test duration brief. The test temperature has nothing to do with the temperatures actually occurring at the part in the vehicle. The reserves of the aging stabilizer are to be determined using the aging test. The maximum temperature at the finished part in the installed condition may not exceed +120°C, as otherwise another material quality must be used.
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Referenced standards*) Vehicle Supply Parts, General; Approval of First Supply and Changes Vehicle Environmental Standard; Vehicle Parts, Materials, Operating Fluids; Avoidance of Hazardous Substances Climates and their Technical Application; Standard Atmospheres Materials Testing Machines – Impact Test – Particular Requirements on Pendulum Impact Testing Machines with a Capacity of Nominal Energy ≤ 50 J and Verification Testing of Plastics; Hot Storage Test on Mouldings Made of Thermoplastic Moulding Materials without External Mechanical Stressing Plastics – Methods of Determining the Density and Relative Density of NonCellular Plastics Plastics – Determination of Flexural Properties
VW 011 55 VW 911 01 DIN 50 014 DIN 51 222
DIN 53 497 ISO 1183 A DIN EN ISO 178
DIN EN ISO 179-1 Plastics – Determination of Charpy Impact Properties – Part 1: NonInstrumented Impact Test DIN EN ISO 1172 Textile-Glass-Reinforced Plastics - Prepregs, Moulding Compounds and Laminates – Determination of the Textile-Glass and Mineral-Filler Content; Calcination Methods Vehicles – Identification of Components made from Polymer Materials
In this section terminological inconsistencies may occur as the original titles are used.
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Appendix A A 1. Example of a material data sheet
Material Data Sheet re TL 526 25 Plastic Mounting Bracket
1 1.1 1.2 1.3 1.4 Material quality Material base see section 5.3 Manufacturing method
Long-glass fiber reinforced PP (30 ± 5)% Injection molding
Designation for use in draw- 30% long-glass fiber reinforced PP, heat stabilized ings acc. to TL 526 25 – MD 01 Identification according to VDA 260 Properties requirements Property Density acc. to ISO 1183 A see section 5.4 Glass fiber content acc. to DIN EN ISO 1172 see section 5.5 Melting temperature DSC Flexural strength acc. to DIN EN ISO 178 see section 5.6 Modulus of elasticity acc. to DIN EN ISO 178 see section 5.6 Impact resistance acc. to DIN EN ISO 179-1 see section 5.7 Aging resistance time until brittling see section 5.8 Unit g/cm
2 No. 2.1
Requirement 1.12 ± 0.05
30 ± 5
≥ 158 Average of at least 5 individual values: ≥ 85 No individual value less than 60 Average of at least 5 individual values: ≥ 3,500 No individual value less than 2,000 Average of at least 5 individual values: 25 No individual value less than 20 ≥ 1,000
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Example of a specimen removal plan
Legend: F1 to F4: S1 to S5: B1 to B5: D1 to D5: Specimens for filler content Specimens for impact resistance Specimens for flexural strength Specimens for impact penetration test (currently not a required TL test) Figure 1 – Specimen removal plan taking the Golf A5 as an example