Requirements

NAVISTAR, INC.
NUMBER:
Material, Parts, and Process Specifications
MPAPS D-22
(MPAPS) Former Designation:
CEMS D-22
TITLE: CURRENT REV No.: DATE:
Fiber Glass Reinforced Polymer Materials 1402 Feb. 2014
WRITTEN/EDITED BY: APPROVED BY: SUPERSEDES:

Materials Engineering Materials Engineering CEMS D-22 - April 2004
PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION
This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of
the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine
the applicability of regulatory limits prior to use.
Change Notice: Changes to Table 4 tensile strength test method description; editorial changes.
1.0 SCOPE
This specification covers requirements for molded plastics based on fiberglass reinforced polymer (FRP)
materials used in the Corporation’s products.
2.0 CONTENTS
PAGE
RESTRICTED CHEMICAL SUBSTANCES 1
REFERENCE DOCUMENTS 1
CLASSIFICATION OF COMPOUNDS 2
PROPERTY REQUIREMENTS 3
QUALITY 7
METHODS OF TEST 9
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SOURCE APPROVAL AND QUALITY CONTROL 11
DESIGNATION ON DRAWINGS AND PURCHASE ORDERS 11
PACKING AND SHIPPING 11
TECHNICAL INFORMATION 12
APPENDIX – GENERAL INFORMATION (Not A Requirement) Green Sheets
3.0 RESTRICTED CHEMICAL SUBSTANCES

Effective January 1, 2007, all product supplied to the requirements of this specification must comply
with the requirements of the MPAPS B-50 specification.
4.0 REFERENCE DOCUMENTS

Unless otherwise specified the latest issue of all referenced standards shall apply. The following
specifications, standards, and regulations are referenced in this specification.
Quality System Standard ISO 9001 or TS-16949 ASTM D 638
CFR Title 29, Part 1910 ASTM G 53 ASTM D 790
NAVISTAR Manufacturing Standard D-13 ASTM D 149 ASTM D 792
NAVISTAR CEMS DT-2 and DT-8 ASTM D 150 ASTM D 2132
This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. 2014 by Navistar, Inc.
February 2014 Page 1 of 12
Copyright Navistar International Corporation
Provided by IHS under license with INTERN Licensee=Core Molding Tech/5946063001, User=Leal, Ruben
No reproduction or networking permitted without license from IHS Not for Resale, 10/12/2015 14:32:47 MDT
NUMBER: TITLE: REVISION:
MPAPS D-22 Fiber Glass Reinforced Polymer Materials 1402
NAVISTAR CEMS G-5 ASTM D 495 ASTM D 570

NAVISTAR TMS-7095 ASTM D 618 ASTM D 2583
Federal Motor Vehicle Safety Std. FMVSS-302
5.0 CLASSIFICATION OF COMPOUNDS

Molded fiberglass reinforced polymer (FRP) materials are designated by Type and Grade. The Type
defines a particular molding process. The Grade designates the physical properties required within the
Type. Suffixes are used to specify additional requirements dictated by the application. See “Appendix –
General Information” for a more complete discussion of materials.
5.1 Types
5.1.1 Type I - Light duty nonstructural parts made of premix or bulk molding compound (BMC) by matched die
compression or injection molding.
5.1.2 Type II -Decorative and/or Structural parts made by compression molded sheet molding compound (SMC).
5.1.3 Type III -Decorative and/or Structural parts made by an “open mold” process, such as hand-layup, spray-up
or bag molding.
5.1.4 Type IV -Decorative and/or Structural parts made from low pressure closed mold systems, such as cold
molding or resin transfer molding (RTM).
5.1.5 Type V -Special purpose moldings constructed with high-performance resins and/or oriented glass or
specialty reinforcements.
5.1.6 Type VI- Thermoplastic composites (GMT) made from low pressure compression mold systems, such as
Azdel®, Quadrant or StaMax®.
5.2 Grades
5.2.1 Grade A – Light Duty
5.2.2 Grade B – Medium strength, general purpose
5.2.3 Grade C – High Strength
5.2.4 Grade D – Extra High Strength
5.2.5 Grade E – Special purpose – moldings constructed with high performance resins and/or oriented glass or
specialty reinforcements – grade requirements will be shown on the part drawing.
5.3 Suffix letters
Suffix letters indicate materials or molded part requirements in addition to those shown in Table 2 –
Basic Property Requirements. Specific limitations are shown in Table 3 – Suffix Requirements; for a
discussion of suffix requirements, see “Appendix – General Information”. The following suffix letters
will be used to indicate the additional properties required:
5.3.1 A - Surface Finish Quality
5.3.2 B - Surface Finish Compatibility
5.3.3 C - Weather and Sunlight Resistance
5.3.4 D - High Temperature Resistance
5.3.5 E - Oil, Fuel or Solvent Resistance
5.3.6 F - High Temperature Properties
5.3.7 G - Matrix Crazing
5.3.8 K - Adhesion Properties
5.3.9 L - Water or Coolant Resistance
5.3.10 M - Flame Resistance
5.3.11 N - Chemical Resistance
5.3.12 P - Impact Resistance
5.3.13 R - Resin Control
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5.3.14 S - Electrical Properties

5.3.15 T - Translucency or Light Transmission
5.3.16 Z - Special Requirements
TABLE 1 CROSS REFERENCE TO OBSOLETE CLASSIFICATIONS

OBSOLETE INTERNATIONAL CLASSIFICATION NEW NAVISTAR CLASSIFICATION
Type – Grade Type – Grade
Type 2 – Grade A Type IV – Grade A
Type 2 – Grade B Type IV – Grade B
Type 2 – Grade BB Type II – Grade B
Type 2 – Grade C Type IV – Grade C
Type 2 – Grade CC Type II – Grade C
Type 2 – Grade D Type IV – Grade D
Type 2 – Grade DD Type II – Grade D
Type 4 – Grade A Deleted – No Usage of Centrifugally
(Centrifugally Cast) Cast Parts in International Systems
6.0 PROPERTY REQUIREMENTS
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Material purchased to this specification will meet the basic property requirements shown in Table 2, and
the applicable suffix requirements shown in Table 3. Evaluation criteria are defined in “Methods of
Test”, Section 8 and Table 4.
TABLE 2 – BASIC PROPERTY REQUIREMENTS

TYPE I TYPE II
Property Grade Grade
A B C B C D
Water Absorption, % max, average 1.5 1.0 0.6 0.5 0.5 0.5
Specific Gravity, g/cc, max 2.2 2.2 2.0 2.0 2.0 2.0
psi - - 5000 8000 10500 13500
average
Tensile Strength, Mpa - - 34.5 55.2 72.4 93.1
min psi - - 3500 5600 7350 9450
single value*
Mpa 0 0 24.1 38.6 50.7 65.2
Tensile Modulus, 103 psi - - - 1200 1500 1750
min, average Gpa - - - 8.3 10.3 12.0
psi 6000 8000 14000 20000 24000 28000
average
Flexural Strength, Mpa 41.4 55.2 96.5 137.9 165.5 193.1
min psi 4200 5600 9800 14000 16800 19600
single value*
Mpa 29.0 38.6 67.6 96.5 115.8 135.1
Flexural Modulus of 103 psi 800 900 1200 1200 1400 1600
Elasticity, min, average Gpa 5.52 6.31 8.27 8.27 9.65 11.03
Flexural Strength Retention, min, psi - - - 14000 16800 19600
average Mpa - - - 96.5 115.8 135.1
Flexural Modulus of Elasticity 103 psi - - - 840 980 1120
Retention, min, average Gpa - - - 5.79 6.76 7.72
Hardness, Barcol, min, average 40 45 45 45 45 45
In-lbs - - - 6 6 6
tested as room temp
mm - - - 150 150 150
Reverse received and
-20°F In-lbs - - - 6 6 6
Impact, drop conditioned
(-29°C) mm - - - 150 150 150
height, min
tested after room In-lbs - - - 6 6 6
aging temp mm - - - 150 150 150
TABLE 2 – BASIC PROPERTY REQUIREMENTS (Continued)

TYPE III TYPE IV TYPE V TYPE VI
Property Grade Grade Grade Grade
A B C ** A B C D A A B C**
Water Absorption, % max, average 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Specific Gravity, g/cc, max 1.5 1.6 1.7 1.8 1.8 1.7 1.7 1.5
psi 7000 10000 14000 7000 10000 13500 15000 7000
average
Tensile Strength, Mpa 48.3 68.9 96.5 48.3 68.9 93.1 103.4 48.2
min psi 4900 7000 9800 4900 7000 9450 10500 4900
single value*
Mpa 33.8 48.3 67.6 33.8 48.3 65.2 72.4 33.8
Tensile Modulus, 103 psi 800 1000 1200 800 1000 1200 1500 700
min, average Gpa 5.5 6.9 8.3 5.5 6.9 8.3 10.3 4.8
psi 12000 18000 25000 12000 18000 25000 28000 12000
average
Flexural Strength, Mpa 82.7 124.1 172.4 82.7 124.1 172.4 193.1 As specified 82.7
on part
min psi 8400 12600 17500 8400 12600 17500 19600 8000
single value* drawing.
Mpa 57.9 86.9 120.7 57.9 86.9 120.7 135.1 55.2
Contact
Flexural Modulus of 103 psi 600 800 1100 600 800 1100 1300 600
Materials
Elasticity, min, average Gpa 4.14 5.52 7.58 4.14 5.52 7.58 8.96 Engineering 4.14
Flexural Strength Retention, min, psi 8400 12600 17500 8400 12600 17500 19600 for further 8000
average Mpa 57.9 86.9 120.7 57.9 86.9 120.7 135.1 information 55.2
Flexural Modulus of Elasticity 103 psi 420 560 770 420 560 770 1120 420
Retention, min, average Gpa 2.90 3.86 5.31 2.90 3.8 5.31 7.72 2.90
Hardness, Barcol, min, average 45 45 45 45 45 45 45
In-lbs 7 8 8 6 7 7 8 36
Reverse tested as room temp
mm 180 200 200 150 180 180 200 914
Impact, received and
-20°F In-lbs 5 6 6 5 6 6 6 30
drop conditioned
(-29°C) mm 130 150 150 130 150 150 150 762
height,
tested after In-lbs 7 8 8 6 7 7 8 30
min room temp
aging mm 180 200 200 150 180 180 200 762
* NOTE: In certain cases, due to part configuration, the vendor will not be able to totally avoid knit lines or severe flow. This will
result in limited areas of lower single value strength. Such areas will not be allowed where they may detract from the performance of
the component. Therefore, the vendor will request and receive permission for such deviations from the Appropriate International
engineering department prior to qualification of the molded part. Such request will detail the location(s), extent of orientation and
minimum strength value of all such deviations.
** Type III and VI, C normally cannot be achieved by spray-up process.
TABLE 3 – SUFFIX REQUIREMENTS

Property Suffix Requirements
Best surface on parts to be painted. Surface quality will be such that, after painting,
the finish is equivalent to that of painted sheet metal normal to the using International plant. There
will be no visible fiber pattern, pinholing, cratering, waviness or other defects. Type II and Type
IV will be made using “low-profile” resin systems. Type I and III will use gel coat and/or “low-
profile” resin systems.
Surface Achievement of the A1 surface finish requirement may necessitate the use of in-mold coatings.
A1 Where the use on in-mold coatings is required by Engineering it will be specified on the
Finish
A1n engineering drawing by means of a “Z” suffix requirement.
Quality
Control of production parts will be accomplished through comparison with master samples retained
from the initial qualification of molded parts or by means of written acceptance standards for the
individual part.
When a second suffix numeral is shown, this designates a maximum surface finish of 100 times the
second digit in microinches. [A15 requires a finish of 500 µin (13µm).]
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TABLE 3 – SUFFIX REQUIREMENTS (continued)

Good surface on parts to be painted. After painting, surface will exhibit a finish approaching that
A2 of painted sheet metal. However, a very faint fiber pattern will not be cause for rejection.
Minimum surface on parts to be painted. Surface preparation need only be sufficient to meet paint
A3 compatibility requirements. Fiber pattern and/or slight pinholing will not be cause for rejection.
Best surface on parts not to be painted. Parts will be free from fiber pattern (color or roughness),
waviness or other defects when viewed with the unaided eye. Type I & II will be made of “low-
A4 profile” resin systems.
Surface A4n Type III material will use gel coat and/or “low-profile” resin systems. When a second suffix
Finish numeral is shown, this designates a maximum surface finish of 100 times the second digit in
Quality microinches. Parts will meet any 60 glossmeter requirement stated on the drawing.
Good surface on parts not to be painted. Parts will exhibit a uniformly attractive surface with no
more than a faint fiber pattern. Such parts may be made of BMC or SMC, highly filled but not
A5 necessarily “low-profile” , or by use of surface veil on “wet-system”, Types II, III and IV parts.
Parts will meet any 60 glossmeter requirement stated on the drawing.
A7 Minimum surface on parts not to be painted. Surface will be uniformly attractive; Prominent fiber
pattern will be allowable.
A9 Special finish; requirements will be stated on the part drawing.
Parts will be compatible with paint finishing operations employed by the using Navistar plant.
Surface preparation will be sufficient to allow finishing paint top coat to meet dry film
requirements, as well as the finish requirements of Suffix A. The suffix B1n indicates priming is
not specifically required. However, priming is not precluded where necessary to meet the above
requirements.
After being subjected to standard NAVISTAR finishing operations wherein paint baking
B1n temperatures do not exceed the temperature designated by the second suffix numeral as shown
below, parts will not delaminate, blister, shrink, warp or sag to the extent that function or
appearance is impaired. The finish paint will not exhibit craters or pinholes. There will be no failure
in adhesive bonded joints. The second suffix numerals indicate paint bake temperatures as follows:
0 – as stated on drawing 5 - 310 F (154 C)
1 - 190 F (88 C) 6 - 340 F (171 C)
2 - 220 F (104 C) 7 - 370 F (188 C)
Surface 3 – 250 F (121 C) 8 - 400 F (204 C)
Finish
4 – 280 F (138 C)
Compat-
Example: B13 indicates a paint bake not exceeding 250 F (121 C).
ibility
B2n Same as B1n except that priming is specifically required. Dry film properties will
meet the requirements of CEMS G-5, Grade – 52, or other stated requirements.
B3n Same as B2n except that primed surface will be electrically conductive as necessary for
electrostatic painting.
B4n Same as B2n except that top coat of primer system will have a 60 gloss of 85 minimum for use as
an inspection aid.
B5n Same as B1n except that primed surface will be electrically conductive as required for electrostatic
painting.
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Same as B1n except that surface preparation will be as specially detailed on the drawing or in
B8n referenced documents.
Parts will be finish painted by the vendor to match color or colors specified on the drawing. Dry
B9n film properties will meet the requirements of the specified Grade per CEMS G-5 or other stated
requirements.

Exterior parts not to be painted will not show visual color change, loss of translucency, where
Weather C1 applicable, or degradation of surface appearance or physical properties after subjection to 500
and hours of QUV-B exposure as per ASTM G 53.
Sunlight Interior parts, painted or unpainted, which are exposed to sunlight under glass will not show visual
Resistance C2 color change, loss of translucency, where applicable, or degradation of surface appearance or
physical properties after subjection to 200 hours of QUV-A exposure as per ASTM G 53
After being mounted in the assembly, or fixture simulating the same, and subjected to three hours at
D1 190 F(88 C), parts will not shrink, warp, craze, blister, delaminate, sag or change color to the
extent that appearance or function is impaired. No failure in adhesive bonded joints is allowed.
D2 Same as D1 except temperature will be 220 F(104 C).
High D4 Same as D1 except temperature will be 280 F(138 C).
Temperature
Resistance
D8 Same as D1 except temperature will be 400 F(204 C)
D9 Same as D1 except temperature will be as stated on the drawing.
Will be resistant to leakage or excessive loss of strength or rigidity upon exposure to fluids and
Oil, Fuel temperatures required by the application.
Or Solvent E Specific requirements and test methods will be shown on drawing. This resistance may typically be
Resistance obtained through use of a resin-rich surface, such as surface veil, gel coat or equivalent, on side
exposed to fluid.
Flexural strength and flexural modulus, when tested at a temperature of 180 F(82 C), will be a
F1 minimum of 70% and 60%, respectively, of the room temperature requirements for the grade of
High material specified.
Temperature Flexural strength and flexural modulus, when tested at a temperature of 230 F(121 C), will be a
Properties F2 minimum of 50% and 40%, respectively of the room temperature requirements for the grade of
material specified.
Matrix . The laminate should exhibit a minimum of n% elongation in the mandrel bend test.
Gn
Crazing
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Silicone release agents or other materials that interfere with subsequent joining or bonding
K
operations will not be used.
Assembly will be neatly and securely bonded using adhesives and techniques suitable to the thermal
requirements stated in Suffix D. Bond line will be free from voids or gaps. Visible joints will be
K1 neatly finished and free from irregularities and excess adhesive. Sealed joints will meet any
Adhesion
pressure test shown on the drawing. Samples cut from the bonded joint will provide an average
Properties
strength of 150 lbf/inch (26 N/mm), with a minimum value of 50 lbf/inch (9N/mm).
Same as K1 except average bond strength will be 500 lbf/inch (88 N/mm), with a minimum value
K2 of 300 lbf/inch (52 N/mm). In addition, bond adhesion will be sufficient to cause failure in the base
laminate (“pull fibers” at the minimum).
Same as K2 except average bond strength will be 700 lbf/inch (122 N/mm), with a minimum value
K3
of 500 lbf/inch (88 N/mm).
Winter or Will be resistant to leakage or excessive loss of strength or rigidity upon exposure to water or
Coolant L coolant fluids at temperatures required by the application. Specific requirements and test methods
Resistance will be shown on the drawing.

M1 Parts will meet the requirements of the latest issue of the Federal Motor Vehicle Safety Standard
Flame No. 302 – Flammability of Interior Materials.
Resistance M2n Will have a flame retardancy rating of ten times the second (or second and third) digit. (M28
requires a rating of 80: M210 requires a rating of 100.)
N Will be resistant to excessive degradation upon exposure to chemical environment required by
Chemical application. Specific requirements and test methods will be shown on drawing. Resistance to
chemical environments may typically be obtained through use of a resin-rich surface, such as
Resistance
surface veil, gel coat or equivalent, on side exposed to chemicals.
Pn Parts will not fracture when impact tested at point or points indicated on the drawing. Impact
Impact energy will be equal to the suffix number in foot-pounds [P12 indicates no fracture at 12 ft lbf
(16N·m)]. Since this test is intended for the detection of improperly molded parts with a heavy
Resistance
impact, failure is defined as a definite crack more than 0.5 inch (12.7 mm) in length. Minor cracks
or crazing will not be cause for rejection.
Chemical Resin component of parts intended for use in critical environmental conditions will correspond to
Resistance R resin component of qualification sample as determined by gas chromatography or equivalent
analytical means.
S1 120 seconds, min. arc resistance: 300 volts per mil, min, short-time perpendicular dielectric
Electrical strength. This suffix is applicable only to Type I materials.
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Properties S2 180 seconds, min arc resistance: 350 volts per mil, min. short-time perpendicular dielectric
Electrical strength. This suffix is applicable only to Type I materials.
S3 Same as S2: additional requirements – 300 hours, min. track resistance.
Translucency
or Light
T Color and degree of translucency will be equivalent to those of qualification
Transmission sample. Special requirements, where applicable, will be shown on drawing.
Special Z Special requirement will be shown on drawing.
Requirements
6.1 Part Marking Requirements

Parts supplied to the requirements of this specification shall be marked to identify the specific polymeric
material that the part is made from. The material identification marking shall be in accordance with SAE
J1344. Marking of plastic parts aids the field repair and repainting of the part as necessary during the
service life of the part and aids in the separation, recovery, and recycling of the part at the eventual end-
of-life.
6.1.1 Additional Marking: When specified on the Engineering drawing, or purchase order, or other
controlling specification, the part shall also be identified so as to provide traceability to the resin
lot/batch, mold and cavity number, manufacturing date, and operator, or other identification specified.
7.0 QUALITY
All materials and workmanship will be in accordance with good commercial practice. Parts will be free
from visible porosity, voids, exposed surface fibers and delaminated areas. Parts must be uniform in
appearance and thickness without resin-rich or resin-starved areas detrimental to performance. There
will be no evidence of cracking, crazing, alligatoring or poorly finished parting lines. Color will be
specified on the drawing. Where exact matching or a molded-in color to an International standard color
chip is not required, the color will be subject to engineering approval during qualification; the color of
subsequent production parts will match the color of the qualification samples receiving engineering
approval.
7.1 Qualification
7.1.1 Production material can be furnished under this specification only after formal qualification. When
requested, the supplier will furnish to Materials Engineering for engineering qualification, the following
sample panels, manufactured with the materials and processes to be used in production:
7.1.2 Types I, II, III, and IV material - Four panels, 12 x 12 x 1/8 inches (305 x 305 x 3 mm)
Material submitted for qualification will be accompanied by detailed test information, and by a diagram
indicating the lay-out of test specimens taken from the panels, and also by verification that the materials
meet all requirements of this specification.
7.1.3 For material designations which do not specify surface finish requirements (any “A”suffix and/or
paint compatibility requirements (any “B” suffix), engineering qualification for the type and grade of
material with applicable suffixes will be granted by Materials Engineering after testing the samples for
conformance to all specification requirements.
7.1.4 For material designations which contain an “A” suffix, a “B”suffix or both, conditional
engineering qualification will be granted by Materials Engineering after testing the samples for
conformance to all specification requirements except surface finish and/or paint compatibility. After
receiving conditional engineering qualification, the supplier will furnish four additional panels of the
applicable size above to each of the appropriate engineering departments. Where relevant, two of these
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four additional panels will be subjected to the paint finishing operations of the using International plant.
The appropriate engineering and/or styling personnel will test these panels for compliance with the
surface finish and/or paint compatibility requirements and will notify Materials Engineering of their
findings. Upon receipt of notification signifying acceptance, Materials Engineering will grant full
engineering qualification for the type and grade of material with applicable suffixes.
7.1.5 At the time engineering qualification is granted, the initial qualification samples to be retained by
Materials Engineering and the appropriate NAVISTAR engineering departments will be agreed upon by
NAVISTAR and the supplier.
7.1.6 Where sample panels of the above dimensions would not be representative of production material,
suitable molded shapes may be requested by Materials Engineering or the appropriate Engineering
Department in lieu of, or in addition to, standard panels.
7.1.7 The supplier will receive engineering qualification (based upon flat panels) for the type and grade
of material with applicable suffixes prior to the time the job is placed with him.
7.1.8 The supplier will have and maintain sufficient equipment, facilities and personnel commensurate
with the processes and material formulations involved. He will also maintain an adequate quality
control program with suitable (technical) personnel and test equipment, and assure that the material
meets all drawing and specification requirements prior to shipping. The supplier will keep adequate
records of his quality control program; copies of such records will be made available, upon request, to
Materials Engineering, the appropriate NAVISTAR inspection facility or both.
7.1.9 After production tooling is completed, the supplier will submit the initial production molded parts
for qualification according to the procedure defined in the NAVISTAR ISO 9001 Quality System
Standard. Further samples may be selected at this time for the quality control of pertinent features of
production moldings. If required, written acceptance standards for appearance control will be
established at this time. Any modification to the original material specification will be made at this time
to insure that all aspects of the part are known and controlled.
7.1.10 It will be the responsibility of the supplier to submit samples and receive engineering
qualification without delaying any other engineering or manufacturing sample programs. After approval
is granted, neither the raw material supplier nor the fabricator will make any change in formulation or
processing without the prior approval of Materials Engineering.
8.0 METHODS OF TEST

8.1 Sample Requirements
8.1.1 Flat Panels for Initial Engineering Qualification
8.1.1.1 Test panels for Type I materials will be produced by charging a ball of material into the center of
the mold.
8.1.1.2 Test panels for Type II materials made with SMC will be molded in such a manner to minimize
flow. 12” x 12”x 1/8” panels are to be charged with a minimum 8” x 8” square charge placed in the
center of the mold.
8.1.1.3 The tensile, flexural and impact values of all types of panels will be determined by testing five
samples each taken parallel and perpendicular to the flow (radial) direction. Unless otherwise noted, the
average of all ten samples will be not less than the specified value, with the further requirement that the
minimum single value of the ten samples will not be less than 70% of the specified value as shown in
Table 2.
8.1.2 Molded Parts
8.1.2.1 Where feasible, samples will be taken from the molded part for initial qualification of
production parts and for routine quality control thereafter. A minimum of ten test samples for each
requirement will be taken from representative locations on the part. Half of the samples will be taken in
the flow direction and half at 90° to this. As with flat panels above, the average of all samples will meet
the specification requirement, with the lowest single value not less than 70% of this requirement unless
approved by deviation as discussed in the note in Table 2.
8.1.2.2 In cases where it is not feasible to take samples from the part, such as with small Type I parts, a
”Z” suffix and special mechanical testing requirements will be specified on the drawing.
8.2 Master Samples And Acceptance Standards
Quality control of appearance requirements, such as defined by “A” or “C” suffixes, will be
accomplished through comparison of the test samples with master samples retained from the initial
qualification of molded parts or through well defined written acceptance standards established for each
individual part at the time of the initial qualification of production parts. The appropriate inspection
facilities will maintain master samples or standards required for quality control purposes.
8.3 Conditioning
Tests will be conducted at least seven days after molding. Hardness, reverse impact, as received and
conditioned, arc resistance, dielectric strength, dielectric constant, track resistance and light transmission
characteristics will be determined on test specimens which have been conditioned 48/23/50 per ASTM D
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618. The remaining properties will be determined on test specimens which have been conditioned
according to the procedures specified in the applicable test method shown in Table 4.
TABLE 4 - METHODS OF TEST

ASTM Test
Test Description and Modification
Designation
Water Absorption D 570 24 hour immersion – specimens to be 3 inches x 1 inch (75 mm x 25 mm).
Specific Gravity,g/cc, max D 792 Specimens to be 1 inch x 1 inch (25 mm x 25 mm).
The reduced section of the test specimen will be 0.5 inches (13 mm) wide
Tensile Strength D 638 by materials thickness unless otherwise specified. Testing will be done at
5mm/min. Specimen to be 6.5 inches x 0.75 inch (165 mm x 19 mm).
Flexural Strength and Flexural Test according to Procedure A; maximum stress will be on the nongel-
D 790
Modulus of Elasticity coated side.
Retention of Flexural Strength
Conditioning: as received specimens will be immersed in boiling water for
and Flexural Modulus of D 790
two hours, cooled in water to room temperature and tested wet.
Elasticity
Hardness D 2583
Barcol Type 934-1 instrument.
A conditioned specimen will be supported and clamped securely with
finished side down in a 5 inch (125 m) diameter frame. The center of the
as received and specimen will be subjected to the impact of a 1.5 inch (38 mm) diameter
-
conditioned steel ball weighing 0.5 lb. (225g) dropped from the specified height.
Reverse Impact Finished side will be exhibit cracking or crazing when wiped with a
penetrant dye and observed with the unaided eye.
As received specimens will be aged for seven days at 212°F (100°C) and
aged - cooled to room temperature. Testing will then follow the same procedure
as in “as received and conditioned” above.
Glass Content - Run per CEMS DT-8.
Select four flat areas on appearance surfaces of panel or part. Using a
“Microrecorder” (Micrometrical Division of Bendix Corp.), or equivalent,
pass the remote stylus over a 2 inch (51 mm) line, taking separate readings
Surface Finish -
for each of four 0.5 inch (12.7 mm) segments of the trace. Average the
four readings in each area to determine the surface finish for that area. All
areas will meet the requirements.
Weather and Sunlight Resistance G 53 -
A minimum of five lap shear specimens will be cut from the part across the
bond line. Width will be approximately 1 inch (25 mm) and length about 6
inches (150 mm) where possible with the lap centered in the length.
Adhesive Bond Strength - Cutting will be done with a very fine tooth (preferably diamond grit) saw to
avoid stressing the bond. Samples will be tested at 0.1 inch (2.5 mm) per
minute. Report average strength per unit of width in lbf/inch (N/m), the
lowest single value and whether any laminate failure occurred.
Flame Resistance M1 Suffix FMVSS #302 -
Flame Resistance M2 Suffix CEMS DT-2 -
The molded part will be mounted in the assembly, or fixture simulating
same, and impacted at point(s) indicated on the drawing with 2 inch (50
mm) diameter metal cylinder with a 1 inch (25 mm) radius nose. The
Impact Resistance P Suffix - specified energy may be applied by the weight in a free vertical fall or by
the same impacting weight swung in an arc (as a pendulum). The
impacting weight used with 3 lbf (13 N) unless very low or high specified
impact energies dictate the use of reduced or added weight.
Arc Resistance D 495 -
Dielectric Strength D 149 -
Dielectric Constant D 150 -
Track Resistance D 2132 -
Mandrel Bend - Use the Mandrel Bend Test procedure described in TMS-7095.
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9.0 SOURCE APPROVAL AND QUALITY CONTROL

9.1 Supplier Requirements
All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements.
NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG
PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must
maintain their certification with an accredited registrar and must furnish copies of registration
certificates to their Corporate Buyer upon request.
9.2 Approval
Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all
respects to those samples which were approved by the purchaser. No changes in formulation or
processing practices are permitted without approval. In the event that changes in material, properties,
processing practices, construction, color, or labeling of the product are required, the supplier shall
notify Materials Engineering and Purchasing and Supplier Development of the proposed change(s).
Test data indicating conformance to all requirements of this specification, test samples, and new or
amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part
1910 shall be submitted with the request for change.
9.3 Process Control
The supplier shall either perform and report results of tests on specific lots of parts produced using ISO
9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of
statistical control and with a process capable of providing all required properties. The part supplier
and/or the quality control manager of the using NAVISTAR plant may determine testing and reporting
requirements on specific products.
10.0 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS

10.1 Drawings
Material designation on drawings will specify type, grade, suffixes, color and special requirements
applicable.
Example: FRP, Type II Grade B-A6C2TZ, color similar to NAV 901 White; suffix T requires
62-70% light transmission; suffix Z requires 250 lbf (1.11 kN) min single bolt hole
pullout, per MPAPS D-22.
FRP, Type II C-A15B53D2F1P12 per MPAPS D-22
10.2 Purchase Orders

The designation on purchase orders will consist of the NAVISTAR part number and applicable drawing
revision.
NOTE: When specifying assemblies such as tanks, each component (shell, end caps, fittings) will
be specified separately.
11.0 PACKING AND SHIPPING

Packing, shipping and identification shall be in accordance with Manufacturing Standard MS-D-13.
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Page 11 of 12
12.0 TECHNICAL INFORMATION
For further information related to the technical Suppliers may purchase controlled copies
content of this specification, contact: of this specification by contacting:
Materials Engineering and Technology Dept. IHS Global Inc.
15 Inverness Way East
10400 W. North Avenue
Englewood CO 80112-5776
Melrose Park, IL 60160 Phone: 1-800-854-7179
E-mail: MaterialsEngineering@Navistar.com E-mail: Automotive@IHS.com
Website: http://global.ihs.com
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NAVISTAR, INC.
NUMBER:
Material, Parts, and Process Specifications
MPAPS D-22 APPENDIX
(MPAPS) Former Designation:
CEMS D-22 APPENDIX
TITLE: CURRENT REV No.: DATE:
Fiber Glass Reinforced Polymer Materials - Appendix 1402 Feb. 2014
WRITTEN/EDITED BY: APPROVED BY: SUPERSEDES:

Materials Engineering Materials Engineering CEMS D-22 APPX – Dec. 2003
PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION

This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of
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the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine
the applicability of regulatory limits prior to use.
Change Notice: New format.
APPENDIX
GENERAL INFORMATION (Not a Requirement)
CONTENTS
PAGE
INTRODUCTION 1
TYPES OF FRP 1
APPROXIMATE RELATIVE COSTS 3
MATERIAL AND MOLDED PART CHARACTERISTICS 3
DESIGN 5
A.1 INTRODUCTION
This Appendix is intended to provide engineers with a brief description of the types of fiber glass
reinforced polymeric materials (FRP and GMT) available and their properties and uses. Familiarity with
plastics materials is not generally widespread within the Corporation; therefore, consultation between
engineers and International plastics specialists on specific projects is usually desirable.
A.1.1 FRP materials share, with other plastics, the properties of corrosion resistance, resiliency, and the
ability to be molded in complex shapes at relatively low cost. In general, FRP has high strength
properties that exceed those of other commonly used plastics, and compares favorably with common
metals, particularly on a strength-to-weight basis. When properly compounded for the particular
application, FRP exhibits good resistance to chemicals, fuels, lubricants, and outdoor weathering. It can
be compounded for both electrical and bearing applications; however, it is not normally suitable for use
under conditions involving severe abrasive wear or high ambient temperatures.
A.1.2 The combination of properties available with FRP materials makes them highly suitable for
structural and semi-structural applications, such as hoods, fenders, shrouds, aero components, tanks, and
electrical components.
MPAPS D-22 Fiber Glass Reinforced Polymer Materials - 1402
APPENDIX Appendix
A.2 TYPES OF FRP

A.2.1 TYPE I is a premix compound normally molded in matched steel dies. Premix is composed of a
uniform mixture of polymeric resin, chopped reinforcing fibers, and inert fillers which form a putty-like
material prior to molding. During molding, the flow of this compound can cause some alignment of the
fibers in the flow direction, particularly on thin walled or large parts, which results in unequal strength
properties in different directions. Proper design and molding technique can minimize this.
A.2.1.1 Type I FRP is most suitable for nonstructural shapes incorporating ribs, bosses, side cores, and
variable thicknesses, as found in shrouds, fittings, and electrical components. Small to medium sized
parts and medium to large quantities (over 2,000/year) are generally most feasible. Parts have a molded
surface on all sides with a finish varying from poor to good. Typically Type I parts are not recommended
for class “A” surface requirements.
A.2.2 TYPE II parts are compression molded using sheet molding compound (SMC). This type exhibits
good physical properties and excellent surface finish, suitable for use in parts such as hoods, fenders,
aero devices and cabs.
A.2.2.1 Similar to Type I, SMC will flow during the molding process. Unequal property distribution in
the parts will occur due to orientation of the glass fibers. Care must be taken in the design of the part and
the molding operation in order to minimize the effects of flow.
A.2.2.2 The size of Type II parts is limited only by press size and tooling cost. Economical quantities are
in the medium to high range (generally 2,000 to 50,000+/yr). Parts will have a molded surface on all
sides (see “Surface Finish,” Section A.4.1)
A.2.2.3 Grades “b” through “d” will typically contain 20-25%, 25-30%, and 30-35% glass respectively.
Special purpose higher strength grades which utilize glass reinforcement in the form of fabric or cross-
plied roving can also be provided. Such grades will be more costly.
A.2.3 TYPE III moldings are made by an open mold process such as hand lay-up, spray-up, or bag
molding. Normally fiberglass in the form of mat or chopped fibers is employed. Cloth or woven roving
may also be used. Fillers in the resin are not common. Strength is nondirectional. Because of this open
mold process, greater inherent variation in wall thickness will occur than in the other material types.
A.2.3.1 The size of Type III parts is almost unlimited. This process is most suited for lower quantities
(under 2000/yr). A gel coat (resin-filler mixture) is normally used to provide a good surface on
appearance parts. However, Type III parts are not recommended where the best surface finish (Class ‘A’)
is required (see “Surface Finish,” Section A.4.1). Grades “a” through “c” will typically contain 25%, 30-
35%, and 40% glass, respectively. Special purpose, high strength grades which utilize glass
reinforcement in the form of fabric, woven roving, or cross-plied roving can also be provided.
A.2.4 TYPE IV parts are made from a closed mold using either resin transfer molding (RTM) or “cold
molding.” Generally, glass mat or preforms are preplaced in the mold. The resin can be poured into the
mold prior to closing or injected after the mold is closed. Strength is nondirectional. Sometimes vacuum
is used to aid in removing entrapped air in the mold, assisting in resin flow, and for mold clamping.
A.2.4.1 The size of Type IV parts is almost unlimited. Economical quantities are in the low to medium
range (generally 1000 to 5000/yr). Excellent surface finish can be obtained (see “Surface Finish,”
Section A.4.1). Depending on volume and surface finish requirements, parts can be molded in matched
metal or polymer molds. However, for the best finish, molds must be capable of being heated to a
minimum of 150 °F.
February 2014 --``,,,`,```,,`````,`,`,`,``,,`,-`-`,,`,,`,`,,`---
Page 2 of 6
APPENDIX Appendix
A.2.4.2 Grades “a” through “d” will typically contain 15-20%, 20-25%, 25-30%, and 30-35% glass,
respectively. Strength is nondirectional. Special purpose, higher strength laminates can be obtained with
the use of fabric or cross-plied rovings. These materials can be applied generally or used locally to
reinforce specified areas.
A.2.5 TYPE V materials are suitable for special applications utilizing high-performance resins and/or
oriented glass or specialty reinforcements. Material properties may vary with the direction of test
samples. In some very special cases, other resins may be specified. Because of many possible
combinations of physical properties, requirements will be shown on the drawing. Moldings may be made
using matched dies, open molding, continuous pultrusion, or filament winding.
A.2.6 TYPE VI materials are thermoplastic materials, sometimes called glass mat thermoplastics
(GMT) that are plastic materials reinforced with glass fibers. Most frequently this will be a glass-
reinforced polypropylene under the trade name of Azdel® or StaMax® but may include other
thermoplastic reinforced materials. These materials are often used in non-appearance parts where impact
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resistance is desired.
A.3 APPROXIMATE RELATIVE COSTS
Relative tooling and part costs for types of FRP are shown below. These figures are very rough
approximations due to variations in part size, complexity, construction, and so forth. Higher grades
within each type will increase cost slightly. Special requirements such as high quality surface finish to
match sheet metal can increase cost significantly. The relative costs are shown for as-molded parts using
a cost index of 100 for Type II as a base.
RELATIVE COSTS FOR AS-MOLDED PARTS

Relative Relative
FRP Material Piece Cost Tool Cost
(Type II = 100) (Type II = 100)
Type I 80 110
Type II 100 100
Type III 200 10
Type IV 150 - 200 20 - 60
A.3.1 Type V is difficult to compare with other types due to its unique properties. However costs are
generally competitive on a performance basis in the proper application.
A.4 MATERIAL AND MOLDED PART CHARACTERISTICS
A.4.1 Surface Finish
The surface finish of FRP parts is one of the more difficult characteristics to specify and control. This is
true largely because of the lack of clear and concise definitions of acceptable finish and the lack of
generally accepted standards and/or test methods to quantify surface finish. Class A surface is generally
defined as “equivalent” to finished painted sheet metal. The best surface finishes in FRP are obtained
using low-profile resin systems. Typically, low-profile SMC (Type II) surfaces are generally accepted as
APPENDIX Appendix
equivalent to sheet metal. Also, recent resin developments make Type IV laminates excellent candidates
for class “A” surface.
A.4.1.1 A gel coat finish is normally specified for Type III and IV parts where appearance is a factor.
High paint bake temperatures may increase the severity of glass and bond reinforcement print-through.
Additional light sanding and priming may be necessary to achieve the desired surface finish. It is
generally not possible to obtain a class “A” surface with Type III parts.
A.4.2 Compatibility with Paint Finishing Operations
When FRP parts are to be painted at the NAVISTAR facilities, certain precautions must be taken by the
vendor to insure compatibility with finishing operations. He must avoid the use of mold release materials
which impair adhesion. Light sanding to enhance adhesion may be necessary. The vendor must also
develop his product to withstand paint baking cycles encountered at the using Plants. He should be
allowed sufficient time to correct defects found in the initial molded parts submitted for qualification
before full production begins. Possible problems include, pin holes and/or porosity, warpage due to relief
of molded-in stresses and blisters due to expansion of entrapped air bubbles in the laminate. Porosity is a
primary problem of Type II parts. Primer systems which allow for detection and repair of the porosity
and/or in-mold coating (IMC) are recommended to minimize rejects due to porosity at the finish paint
facility.
A.4.2.1 Warpage and air entrapment (blisters) are more common to Type III and IV parts. The use of
primer bake temperatures higher than the using plants finish bake oven should reveal defects prior to
finish paint.
A.4.2.2 Repair materials and procedures must be such that all FRP repairs are compatible with the using
plants’ finishing system.
A.4.3 Resistance to Weathering and Sunlight
Parts which are to be exposed to ultraviolet light from the sun will require special compounding unless
protected by painting. Resins are normally compounded with ultraviolet stabilizers. In some cases,
special resins or crosslinking monomers may be used. Generally, the use of a surfacing veil or gel coat is
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recommended to avoid premature exposure of glass fibers at the surface. Premature exposure causes a
poor appearance, leads to moisture absorption, and tends to accelerate the weathering process. Exposure
of glass fibers due to weathering can also cause skin irritation. Therefore, special care should be taken
when specifying and controlling arm rests. Abrasion alone has not been known to cause skin irritation.
Pigments used for molded-in colors must also be stable. Cost of ultraviolet protection is usually nominal.
A.4.4 Heat Resistance
General purpose isophthalic resins are normally compounded to provide a balance of good resiliency
(resistance to impact and fatigue crazing) with moderate resistance to high temperatures [from 180° to
240°F (82 to 116°C)] depending on glass content, environment, and loading. It is possible to compound
resins for resistance to 400°F (205°C) or higher at a sacrifice in resiliency and some increase in cost.
A.4.5 Resistance To Fuels, Lubricants, Coolants, And Chemicals
Polymeric resins can be supplied to provide resistance to fuels, lubricants, and common solvents, or to
common aqueous chemicals (salts, acids, alkalis, coolants, and the like). As a rule, maximum protection
against both environments is not possible in a single resin system. Parts exposed to such fluids or
chemicals will normally require some means of covering surface glass fibers to prevent wicking and
APPENDIX Appendix
subsequent leakage, loss of strength, or both. A gel coat or other means of providing a resin-rich surface
is commonly used.
A.4.6 Abrasion Resistance

FRP materials are not as suitable as some other plastics for applications involving severe wear or
abrasion. Where moderate conditions are expected, special compounding can provide some benefits.
Compounding with solid lubricants can also be utilized to provide parts suitable for light bearing
applications.
A.4.7 Joining and Assembly
FRP parts are commonly joined by adhesive bonding, riveting, or bolting. Sufficient sized washers
should be used in bolted assemblies to distribute the load and avoid cutting the FRP with the bolt head.
A number of plastic fasteners are also available which may be assembled simply and inexpensively from
one side. Hollow rivets may be used for simple permanent joining where appearance and other factors
permit. For permanently sealed joints and joints where visible fasteners are undesirable, adhesive
bonding may be used. Bonded joints should be loaded in shear rather than in peel or cleavage. Rivets are
occasionally used to reinforce joint ends in cases where peel or cleavage may tend to initiate failure. Any
mold release agents used in the manufacture of parts to be bonded must be of a type which will not
interfere with adhesion. Joint areas should be sanded to obtain proper adhesion.
A.4.8 Flame Resistance
The FMVSS test described for Suffix M1 may not completely describe requirements in critical
applications. In such cases, requirements, as agreed upon by NAVISTAR and the vendor, will be placed
on the part drawing.
A.4.9 Resin Control
Applications requiring heat or chemical resistance may involve the use of special resins in part
manufacture. In such cases, it may be desirable, from a quality control standpoint, to “fingerprint” those
resins which have proven satisfactory on engineering evaluation. This “fingerprint” may be obtained by
gas chromatography, infrared or other suitable analytical techniques.
A.4.10 Electrical Properties
FRP materials share with most other plastics the characteristic of having good electrical insulating
properties. This combination of insulating ability and mechanical strength rigidity, and heat resistance
makes FRP materials particularly useful for replacing complicated assemblies, involving both structural
metal components and insulating materials, with a single molded part. Type I materials are most
commonly used in such applications. These materials have the additional advantage of high resistance to
arcing and tracking across electrical contacts under adverse conditions.
A.5 DESIGN
Table A.5 includes general rules that provide guidance in the design of FRP parts. A notation of
“possible” indicates a less common and, in some cases, less desirable feature.
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APPENDIX Appendix
Table A.5 Design Guidance
TYPE I TYPE II TYPE III TYPE IV

Minimum Inside Radius, inches 0.030 (0.76 mm) 0.030 (0.76 mm) 0.25 (6.35 mm) 0.25 (6.35 mm)
Molded-in Holes Yes Yes Large No
Trimming Required After Molding No No Yes Yes
Undercuts Yes No Possible Possible
recommended 2° + 3° + 2° + 3° +
Draft
minimum 1° 1° 0 -possible 1°
Thickness, minimum 0.060 (1.52 mm) 0.050 (1.3 mm) 0.060 (1.52 mm) (a) 0.100 (2.5 mm)
inches maximum 1.0 (25.4 mm) 1.0 (25.4 mm) No Limit 0.50 (12.7 mm)
+ 0.002 to + 0.005 + 0.006 to + 0.010 + 0.020 to + 0.060 + 0.010 to + 0.030
Thickness Tolerance, inches (b) (+ 0.05 to (+ 0.15 to (+ 0.51 to (+ 0.25 to
+ 0.13 mm) + 0.25 mm) + 1.5 mm) + 0.76 mm)
Wall Section Change Any 2:1 Any 2:1
Metal Inserts Yes Yes Yes Yes
Surfacing Veil No No Yes Yes
Bosses Yes Yes Possible Possible
Ribs Yes Yes Possible Possible
Gel Coat No No Yes Yes
Shape Limitations Moldable Moldable Almost Any Moldable
Molded Surfaces All All One All
(a) Not including gel coat

(b) Dependent on nominal wall thickness
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NAVISTAR, INC.

WRITTEN/EDITED BY: APPROVED BY: SUPERSEDES:

3.0 RESTRICTED CHEMICAL SUBSTANCES

4.0 REFERENCE DOCUMENTS

NAVISTAR CEMS G-5 ASTM D 495 ASTM D 570

5.0 CLASSIFICATION OF COMPOUNDS

February 2014 Page 2 of 12

5.3.14 S - Electrical Properties

TABLE 1 CROSS REFERENCE TO OBSOLETE CLASSIFICATIONS

6.0 PROPERTY REQUIREMENTS

TABLE 2 – BASIC PROPERTY REQUIREMENTS

TABLE 2 – BASIC PROPERTY REQUIREMENTS (Continued)

TABLE 3 – SUFFIX REQUIREMENTS

TABLE 3 – SUFFIX REQUIREMENTS (continued)

Property Suffix Requirements

TABLE 3 – SUFFIX REQUIREMENTS (continued)

Property Suffix Requirements

TABLE 3 – SUFFIX REQUIREMENTS (continued)

6.1 Part Marking Requirements

8.0 METHODS OF TEST

TABLE 4 - METHODS OF TEST

February 2014 Page 10 of 12

9.0 SOURCE APPROVAL AND QUALITY CONTROL

10.0 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS

10.2 Purchase Orders

11.0 PACKING AND SHIPPING

12.0 TECHNICAL INFORMATION

WRITTEN/EDITED BY: APPROVED BY: SUPERSEDES:

PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION

A.2 TYPES OF FRP

RELATIVE COSTS FOR AS-MOLDED PARTS

Type II 100 100

Type III 200 10

Type IV 150 - 200 20 - 60

A.4.6 Abrasion Resistance

February 2014 Page 5 of 6

Table A.5 Design Guidance

TYPE I TYPE II TYPE III TYPE IV

(a) Not including gel coat

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