ASTM D4762-88(1995)e1
(Guide)Standard Guide for Testing Automotive/Industrial Composite Materials
Standard Guide for Testing Automotive/Industrial Composite Materials
SCOPE
1.1 This guide covers the testing of molded automotive/industrial composite materials. It is intended to increase the users awareness of the special considerations necessary for the testing of these materials. In addition, the user is provided with a comparison of some of the more commonly used ASTM International standard test methods that are applicable for evaluating automotive/industrial composites.
1.2 Areas in which current ASTM International standard test methods do not meet the needs for testing of automotive/industrial composites are indicated. This provides direction for future standardization work.
1.3 It is not the intent of this guide to cover all test methods which could possibly be used for automotive/industrial composites. Only the most commonly used and most applicable standards are included.
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
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NOTICE: This standard has either been superseded and replaced by a new version or discontinued.
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e1
Designation: D 4762 – 88 (Reapproved 1995)
Standard Guide for
Testing Automotive/Industrial Composite Materials
This standard is issued under the fixed designation D 4762; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
e NOTE—Section 13 was added editorially in June 1995.
INTRODUCTION
A new class of composite materials has been developed to meet the needs of automotive and
industrial mass production applications. This new class of materials, referred to as automotive/
industrial composites, is comprised of filled and unfilled polymers reinforced with chopped or
continuous high modulus, or both, (greater than 20.7 GPa (3 3 10 psi)) fibers.
Automotive/industrial composites possess some of the same advantages as high-performance
aerospace composites. However, some aspects of performance are traded off for reduced cost, ease of
manufacturing, and high quality appearance. Automotive/industrial composites are also different from
materials classified as plastics. This difference arises from the use of high modulus fiber reinforcement
to provide substantial improvements in structural properties of the base polymer system.
Currently, ASTM standard test methods developed for high performance composites or plastics, or
both, are used for testing of automotive/industrial composites. In many cases, these standards are quite
adequate if proper attention is given to the special testing considerations for automotive/industrial
composites covered in this guide. However, in some cases current standards do not meet the needs for
testing of the required properties. In this case, revised standards or new standards specifically for
automotive/industrial composites may be desirable.
In addition to covering the special considerations required for automotive/industrial composites
testing, this guide points out and compares existing ASTM standards applicable to these materials.
This is done only for some of the more commonly evaluated material properties.
1. Scope responsibility of the user of this standard to establish appro-
priate safety and health practices and determine the applica-
1.1 This guide covers the testing of molded automotive/
bility of regulatory limitations prior to use.
industrial composite materials. It is intended to increase the
users awareness of the special considerations necessary for the
2. Referenced Documents
testing of these materials. In addition, the user is provided with
2.1 ASTM Standards:
a comparison of some of the more commonly used ASTM
C 581 Practice for Determining Chemical Resistance of
standard test methods that are applicable for evaluating
Thermosetting Resins Used in Glass-Fiber-Reinforced
automotive/industrial composites.
Structures Intended for Liquid Service
1.2 Areas where current ASTM standard test methods do
D 256 Test Methods for Impact Resistance of Plastics and
not meet the needs for testing of automotive/industrial com-
Electrical Insulating Materials
posites are indicated. This provides direction for future stan-
D 543 Test Method for Resistance of Plastics to Chemical
dardization work.
Reagents
1.3 It is not the intent of this guide to cover all test methods
D 618 Practice for Conditioning Plastics and Electrical
which could possibly be used for automotive/industrial com-
Insulating Materials for Testing
posites. Only the most commonly used and most applicable
D 638 Test Method for Tensile Properties of Plastics
standards are included.
D 648 Test Method for Deflection Temperature of Plastics
1.4 This standard does not purport to address all of the
Under Flexural Load
safety concerns, if any, associated with its use. It is the
D 671 Test Method for Flexural Fatigue of Plastics by
Constant-Amplitude-of-Force
This guide is under the jurisdiction of ASTM Committee D-30 on High
Modulus Fibers and Their Composites and is the direct responsibility of Subcom-
mittee D30.03 on Automotive/Industrial Composites. Annual Book of ASTM Standards, Vol 08.04.
Current edition approved Jan. 29, 1988. Published June 1988. Annual Book of ASTM Standards, Vol 08.01.
Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.
D 4762
D 695 Test Method for Compressive Properties of Rigid 4. Significance and Use
Plastics
4.1 This guide is intended to serve as a reference for the
D 696 Test Method for Coefficient of Linear Thermal Ex-
testing of automotive/industrial composite materials.
pansion of Plastics Between − 30°C and 30°C
4.2 The use of this guide assures that proper consideration is
D 756 Practice for Determination of Weight and Shape
given to the unique characteristics of these materials in testing.
Changes of Plastics Under Accelerated Service Condi-
In addition, this guide also assists the user in selecting the best
tions
currently available ASTM test method for measurement of
D 790 Test Methods for Flexural Properties of Unreinforced
commonly evaluated material properties.
and Reinforced Plastics and Electrical Insulating Materi-
5. Summary of Guide
als
D 792 Test Methods for Density and Specific Gravity (Rela-
5.1 Special testing considerations unique to automotive/
tive Density) of Plastics by Displacement
industrial composites are identified and discussed. Recommen-
D 1822 Test Method for Tensile-Impact Energy to Break
dations for handling these considerations are provided. Special
Plastics and Electrical Insulating Materials
considerations covered are included in Section 7 on Material
D 2289 Test Method for Tensile Properties of Plastics at
Definition, Section 8 on Sampling Techniques, Section 9 on
High Speeds
Test Specimen Preparation, Section 10 on Test Specimen
D 2344 Test Method for Apparent Interlaminar Shear
Conditioning, and Section 11 on Reporting of Results.
Strength of Parallel Fiber Composites by Short Beam
5.2 Current ASTM standard test methods applicable to
Method
automotive/industrial composites are compared for commonly
D 2584 Test Method for Ignition Loss of Cured Reinforced
evaluated material properties. Areas where revised or new
Resins
standards are needed are identified. Test methods for com-
D 2734 Test Method for Void Content of Reinforced Plas-
monly evaluated properties in the following test method groups
tics
are compared:
D 2990 Test Methods for Tensile, Compressive, and Flex-
Test Methods Sections
ural Creep and Creep Rupture of Plastics
Mechanical Properties 12.4
D 3039 Test Method for Tensile Properties of Polymer
Fatigue Properties 12.5
Matrix Composite Materials
Environmental Resistance 12.6
Creep Properties 12.7
D 3410 Test Method for Compressive Properties of Unidi-
4 Thermal Properties 12.8
rectional or Crossply Fiber-Resin Composites
Physical Properties 12.9
D 3418 Test Method for Transition Temperatures of Poly-
Impact Properties 12.10
mers by Thermal Analysis
6. Procedure for Use
D 3479 Test Methods for Tension-Tension Fatigue of Ori-
ented Fiber, Resin Matrix Composites 6.1 Review Sections 7-11 to become familiar with the
special testing considerations for automotive/industrial com-
D 3846 Test Method for In-Plane Shear Strength of Rein-
forced Plastics posites.
6.2 Locate the table for the property that you would like to
D 4065 Practice for Determining and Reporting Dynamic
Mechanical Properties of Plastics determine in Section 12. Use the table to help in selecting the
best ASTM standard test method for determining that property.
D 4255 Guide for Testing In-Plane Shear Properties of
6.3 Follow the selected ASTM standard but refer back to the
Composites Laminates
E 228 Test Method for Linear Thermal Expansion of Solid guide for recommendations on material definition, sampling
procedures, test specimen preparation, test specimen condition-
Materials With a Vitreous Silica Dilatometer
ing, and reporting of results.
3. Terminology
7. Material Definition
3.1 Definitions:
7.1 Constituent Definition—Variations in the type and con-
3.1.1 automotive/industrial composite—any filled or un-
tent of fiber, filler, and resin can have a significant influence on
filled polymer reinforced with chopped or continuous high
material property test results. Each constituent material should
modulus, or both, (greater than 20.7 GPa (3 3 10 psi)) fibers
be carefully defined and documented prior to testing to avoid
whose properties are dependent on the process parameters used
misinterpretation of test results.
in mass production manufacturing.
7.1.1 Fiber, filler, and resin content should be measured and
3.1.2 Plaque—A flate plate of molded material for evalua-
recorded at least one location in each part or plaque from which
tion of material properties.
test specimens are machined. Section 12.9 covers techniques
3.1.3 Part—A component of a manufactured assembly.
for measuring these values.
3.2 Abbreviations:Abbreviations:
7.1.2 The following items should be documented each time
3.2.1 A/I Composite, automotive/industrial composite.
a material is tested: fiber type, dimensions, and surface
treatment; filler type, dimensions, and surface treatment; and
resin type and component breakdown.
Annual Book of ASTM Standards, Vol 15.03.
5 7.2 Process Definition—Processing techniques can affect
Annual Book of ASTM Standards, Vol 08.02.
Annual Book of ASTM Standards, Vol 14.02. fiber orientation, void content, and state of polymerization.
D 4762
These factors can in turn influence material property test results from which it was cut can be identified.
significantly. Each of these items should be defined and 8.3 Test Specimen Orientation—Overall and local fiber
documented prior to testing to avoid misinterpretation of test orientation effects can have a significant influence on material
results. property test results.
7.2.1 Fiber orientation should be quantitatively measured 8.3.1 Test specimen orientation should be mixed to deter-
and documented for each part or plaque from which test mine average properties of a nominally planar isotropic mate-
specimens are machined. Both overall and local variations in rial. A minimum of two perpendicular directions should be
fiber orientation should be documented. Unfortunately, a prac- selected for test specimens within each part (or plaque). These
tical test method for measuring and quantifying local fiber orientations should be selected to produce the maximum and
orientation has not yet been developed and standardized. minimum material property test results if possible.
7.2.2 Void content should be measured for each material 8.3.2 Maximum and minimum properties should be mea-
tested in at least three different parts or plaques from which test sured independently for materials with oriented fiber reinforce-
specimens are taken. Methods for measuring void content are ment. Test results for minimum and maximum properties
reviewed in 12.9. should not be averaged.
7.2.3 State of polymerization should be measured quantita- 8.3.3 Each test specimen should be marked so that its
tively and documented for at least three different parts or orientation within the original part can be identified.
plaques from which test specimens are machined. Although a 8.4 Test Specimen Location—The location of test specimens
specific test is not standardized for measuring state of poly- within a part (or plaque) can influence material property test
merization, other auxilliary tests are often used. One such results.
measurement is determination of glass transition temperature 8.4.1 Areas near the edges of parts should be avoided for
by Test Method D 3418. test specimen location unless the properties in these areas are
7.2.4 As a minimum, the following process conditions specifically desired.
should be documented for each material tested: compound 8.4.2 Areas near or over local geometric conditions such as
preparation, charge preparation, molding technique, molding ribs, bosses, molded holes, corners, and flanges should be
temperature, molding pressure, molding time, and part or avoided for routine material property testing. Test specimens
plaque dimensions. may be taken from these areas when properties are needed for
7.3 History Definition—Load and environmental history the analysis of these specific geometric conditions.
after molding and prior to testing can have a significant 8.4.3 Test specimen location within each part should be
influence on A/I composite materials property test results. documented with a drawing or photograph. Each test specimen
These history factors should be fully defined prior to testing to should be identified so that its location within the original part
avoid misinterpretation of test results. can be traced. Special identification should be used for test
7.3.1 Load history, if any, should be documented for each specimens taken from part edges or from an area near or over
test specimen. Information on the loading mode, magnitude, any local geometric variation.
rate, and number of times that the load was applied should be 8.5 Number of Test Specimens—the more test specimens
included. that are used to determine each material property, the less local
7.3.2 Environmental history should be documented for each and part to part variations in properties will affect average test
test specimen. Time, temperature, and humidity conditions results.
from molding to testing should be fully documented. 8.5.1 A minimum of six test specimens for each material
property to be measured is suggested for a nominally planar
8. Sampling Techniques
isotropic material. These six should be from three separate
8.1 Test Plaques and Parts—Either parts or test plaques
parts with two from each part. Each two should be perpendicu-
may be used as a source of test specimens. Flat plaques tend to
larly oriented so that fiber orientation effects are averaged in
produce optimum and more uniform material property results
each part. More test specimens may be required depending on
than complex parts if the plaques are molded under carefully
the variability of test data and the desired confidence level in
controlled conditions. If complex parts are used, the effects of
the value of the property being measured.
local flow and molding conditions are much more likely to
8.5.2 When testing oriented fiber reinforced materials, at
affect test results. The objectives of the testing to be done
least six test specimens should be used for evaluating both
dictate the choice of parts or flat plaques for sampling.
minimum and maximum property values. These six should be
8.1.1 A complete description of the part or plaque dimen-
fr
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