1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 07 23 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.3, 3.18, 4 deleted 1992 03 19 DF00E00107002134 Released A. Vallabhanath Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 3 CERAMIC POWDER, ALUMINUM
2、OXIDE, PLASMA SPRAYED ESF-M3L88-A2 1. SCOPE The material defined by this specification is an aluminum oxide ceramic powder (AL2O3). It is also referred to as alumina. 2. APPLICATION This specification was released to define a material to be used in an arc plasma spray application of an alumina coati
3、ng on the aluminum control plate of the 3rdgeneration alternator series. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.4 COMPOSITION (ASTM E 1097
4、) Shall conform to the following weight percents, determined by methods agreed upon by purchaser and supplier. Compound Min Max Al2O393.0 Na2O 0.1 Fe2O31.0 Si21.5 TO21.80-4.20 CaO 0.40 MgO 0.60 3.5 MOISTURE CONTENT, max 0.20% Test Method: A sample of the powder shall be weighed and heated in an oven
5、 for 2 h at 110 C. After heating weigh the sample again. The difference in the weight of the sample before and after heating times 100 shall be the moisture content. 3.6 SPECIFIC GRAVITY 3.70 3.95 (ASTM C 135) ENGINEERING MATERIAL SPECIFICATIONESF-M3L88-A2Printed copies are uncontrolled Copyright 20
6、03, Ford Global Technologies, Inc. Page 2 of 3 3.7 PHASE COMPOSITION OF ALUMINA (AL2O3) DETERMINED BY X-RAY DIFFRACTION Alpha Alumina, approx. 100% Na Beta Alumina Trace 3.8 MICROEXAMINATION At a 20X magnification the particle morphology shall be blocky in nature. 3.9 PARTICLE SIZE DISTRIBUTION (AST
7、M C 690) Powder shall conform to the following particle size requirements, as measured with a coulter multisizer. D3 D50 D94 Ratio Ratio U.S. Sieve Max Min D3/D50 D50/D94 #170 Max Max % Retained 49 28.0 29.0 19 1.7 1.45 0.1 max Explanation: D3 The particle size at the 3% point will be a maximum of 4
8、9 microns. 97% of the material will be smaller than 49 microns. D50 The size at the 50% point will be between 28.0 and 29.0 microns. D94 The size at the 94% point will be a minimum of 19 microns, or 94% of the material will be larger than 19 microns. Ratio Controls the slope of the curve on the fine
9、 side. D50/D94 Ratio Controls the slope of the curve on the coarse side. D3/D50 # 170 Picks up any large particles that the particle sizer cannot. Sieve 3.10 PLASMA SPRAYING Powder shall be capable of producing acceptable plasma spray coatings to standards agreed upon by purchaser and supplier using
10、 the plasma spray parameters defined by purchaser. ENGINEERING MATERIAL SPECIFICATIONESF-M3L88-A2Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 3 3.11 DIELECTRIC BREAKDOWN The powder shall be capable of producing a plasma spray coating able to withstand a di
11、electric breakdown when sprayed to a thickness of 0.165 +/- 0.040 mm and subjected to 500 volts DC. Testing shall be carried out in the following manner: The parts with the coating shall be heated at 100 C for minimum of 10 minutes in a suitable oven. Upon removing from the oven and while still at a
12、n elevated temperature (if the coatings cool to room temperature, they are to be reheated as described above), an uncoated area of the part shall be connected to the negative electrode from the test stand. The positive electrode shall be used to probe the coating surface, subjecting it to an electri
13、cal stress of 500 V DC. The coating is to remain intact and show a maximum leakage current of 60 micro amps through the coating. The specific test stand to be used for this test shall be determined by the purchaser and supplier. 3.12 COATING ADHESION BOND STRENGTH (ASTM C 633) The powder, when sprayed according to the purchasers process parameters, will produce a coating with an adhesion bond strength of 5.6 MPa minimum on an aluminum surface. The test procedure will comply with ASTM C 633 with any necessary modifications to be agreed upon by the purchaser and supplier.
