VW 54045 PP - Material Requirements for Finished Parts in Chassis and Powertrain Areas

The “VW 54045 PP - Material requirements for finished parts in chassis and powertrain areas” standard, developed by the Volkswagen automotive company, describes the material requirements for unfilled, glass fiber reinforced or mineral reinforced polypropylene (PP) in powertrain, engine, chassis, transmission and body sections (unpainted). The VW 44045 standard should be used for interior and exterior parts.

As a rule, the basic conditions regarding the maximum part temperature must be met to allow the use of PP. Long-term operating temperatures of approximately 110 degrees are considered the critical limit. The maximum short-term temperature (a total of 300 hours during the service life) should not exceed 130 degrees. Short-term peak temperatures above approximately 140 degrees prevent the use of this material.

The general requirements in this standard are determined as follows:

• Initial supply and modification approval must comply with VW 01155 standard.
• For thermoplastic parts, the granular material must conform to the VW 50026 standard.
• Outdoor durability must comply with VW 50185 standard.
• Environmental requirements must comply with the VW 91100 standard.
• Material suitability must be in accordance with the VW 91101 standard.

Tests should be performed on samples taken from finished parts. If the part geometry makes on-part testing impossible, data sheets or measurements from standard injection-molded specimens or test plates may be used. Measured characteristic values ​​on finished parts may differ from standard specifications. Deviations should be agreed upon with the buyer and indicated in the drawing if necessary.

The surface of finished parts must be free from irregularities (voids, cracks, cold closures) resulting from the manufacturing process. For parts subjected to high loads or those of particularly critical function, porosity and properties must be examined according to the VW 50093 standard. After obtaining satisfactory test results, the measured characteristic values ​​must be recorded in the drawing. The buyer decides whether a porosity specification is necessary. Parts must allow for proper assembly. There should be no functional risk or risk of injury to assembly workers due to loosening of burrs, chips, or particulate matter.

The materials are designed for injection molding. The materials can also be processed using the blow molding method. If switching to this particular method results in a deviation from the properties listed below, this must be taken into account and indicated in the drawing. Re-grinding of materials obtained from the same process and consisting of a single material type from the first processing step is possible unless it is impact-modified PP. The amount of added re-grinding must be agreed upon with the buyer and indicated in the drawing. Parts must be verified with the expected maximum recycling percentage. The use of recycled materials (i.e., raw materials from non-process sources) is only permitted after consultation with the buyer and must be clearly indicated in the drawing. The VW 50026 standard applies to the classification of granular material.

If there is contact between PP and metallic substrates (e.g., threaded connection or encapsulation of a contact ring), especially copper, it must be ensured that the PP is adequately stabilized with respect to copper ions, for example, during material selection at the part concept stage. Insufficient stabilization can lead to premature thermooxidative aging.

The color must be black or according to the drawing specification.

Thermally unstable fillers (e.g., carbon fibers, chalk) must be specified. Tests to determine the filler content should be determined accordingly. If the material contains unspecified fillers such as mixed mineral powders (such as talc, chalk, and lime powders), the mixture compositions must be specified. Particular attention should be paid to this when dealing with recycled materials.

Aging resistance testing allows for accelerated (extreme temperature) testing of machining quality. It has no relation to actual application temperatures. Different temperatures and aging times must be agreed upon with the customer and specified in the drawing.

Prior to testing, the samples required for each test must be conditioned for at least 48 hours in a standard atmosphere according to the VW 50554 standard.

The required numerical values ​​apply to each measurement.

For material requirements, the tables given in the standard should be taken into account. Specific requirements for the material (e.g., light fastness, flammability, emissions) should be derived from the drawing. If materials from the list of released materials in the annex to this standard are used, only a narrowed scope of testing needs to be carried out.

In the high-risk world of automotive manufacturing, where every component must withstand extreme conditions (from scorching engine compartments to corrosive fuels), the VW 54045 standard is a cornerstone for the use of advanced polymers in vehicle production. This standard outlines stringent requirements for polypropylene-based materials, guaranteeing durability, safety, and performance in critical vehicle systems.

The VW 54045 standard essentially requires polypropylene compounds to meet or exceed specific mechanical and thermal criteria. For example,

• Tensile strength and elongation: Reinforced variants should exhibit a minimum tensile strength of 40-60 MPa depending on the filler content, and elongation at break should be tested after exposure to fuels or lubricants. This ensures that the parts do not fracture brittlely during use.
• Impact resistance: Charpy or Izod impact tests simulate real-world impacts and require notched impact resistances above 5 kJ/m2 for glass-filled grades.
• Thermal stability: Thermal deflection temperatures are limited to 100-120 degrees under load, which prevents bending in hot environments.

A key feature is the emphasis placed on aging and compatibility. For example, this standard simulates decades of exposure to the engine compartment by evaluating tensile strength, breaking stress, and elongation after being immersed in fuel. Suppliers must also verify weld line strength and scratch resistance, especially for visible internal parts, to prevent aesthetic defects.

The tests under VW 54045 are application-oriented. For powertrain components, additional examination of creep resistance and fatigue guarantees long service life under vibration. Full verification requires samples of up to 150 parts per batch.

For many years, our organization, with its competent and experienced staff, has been understanding the needs of its customers, providing the advanced testing services they require, and assisting them in the establishment, implementation, and improvement of management systems. Within this framework, we also provide testing services to businesses in accordance with the "VW 54045 PP - Material requirements for finished parts in chassis and powertrain areas" standard.