1、I INTERNATIONAL TRUCK and ENGINE CORPORATION I CEMS (CORPORATE ENGINEERING MATERIAL SPECIFICATION) TITLE: Malleable Iron Castinps WHTTENREVIE WED BY: PPROVED Bi? Materials Enpineerinp Materials Enpineerinp NUMBER: CEMS E-7 CURRENT ISSUE DATE: February 2002 July 1999 SUPERSEDES ISSUE OF: 1.0 SCOPE Th
2、is specification covers the Corporations requirements for malleable iron castings. Quality System Standard QS-9000 (IS0 9001) INTERNATIONAL IQR Quality Standard INTERNATIONAL Manufacturing Standard D- 13 2.0 INTRODUCTION Malleable iron castings provide good ductility and machinability. They are simi
3、lar to nodular iron castings except that the graphite in malleable castings is present as temper carbon nodules. CFR Title 29, Part 1910 ASTM A247 SAE 5158 ASTM A602 ASTM E10 3.0 CONTENTS REFERENCE DOCUMENTS GRADES AND REQUIRMENTS QUALITY METHODS OF TEST SOURCE APPROVAL AND QUA ITJ CO TRO PAGE 1 1 3
4、 3 3 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS 4 PACKING AND SHIPPING 4 APPENDIX - GENERAL INFORMATION Green Sheets 4.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced i
5、n this specification. 5.0 CLASSIFICATION Malleable iron grades are classified on the basis of strength and hardness. 6.0 GRADES AND REQUIREMENTS Requirements for the grades defined in this specification cover castings of ferritic, pearlitic and tempered martensitic malleable iron. These requirements
6、 as shown in Table I are in close agreement with such National standards as SAE 5158 and ASTM A602. Additional casting requirements or limitations such as chemical composition and tensile properties may be agreed upon by the purchaser and supplier. Typical properties are shown in the “Appendix - Gen
7、eral Information“ section. Any additional product requirements must appear on the casting drawing. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume
8、all patent liability. 02002 International Truck and Engine Corporation FEBRUARY 2002 Page i of4 NUMBER: CEMS E-7 TABLE I - CASTING REQUIREMENTS pearlitic-ferritic or tempered *See ”Appendix - General Information” for recommended ranges. 6.1 Property Requirements Castings regarded as critical by engi
9、neering should be noted as such on the part drawing with the critical sections and required minimum properties clearly indicated. When specific tensile properties are required, they will be applicable to a standard test specimen machined from the casting at the section indicated. For hardness requir
10、ements at critical sections, alternate locations may be checked provided adequate correlation with the required areas has been established. It is the foundrys responsibility to meet all requirements on part drawings or to initiate negotiations with the purchasing plant and the controlling design eng
11、ineering department to amend the requirements. 6.2 Microstructure All Grades The graphite present will be in the form of nodules of temper carbon. The structure will be free from massive primary cementite and primary flake graphite. A total decarburized zone at the surface will not exceed 0.050 inch
12、 (1.27 mm). Oxidation and scale will be 0.002 inch (0.05 mm) maximum. No intergranular-oxidation is permitted. 6.3 Grade M3210 The matrix will be primarily ferrite with traces of pearlite allowed. A surface layer or rim containing some coarse pearlite may be present due to a reaction with the anneal
13、ing furnace atmosphere. This rim or surface layer will not exceed 0.050 inch (1.27 mm). 6.4 Grades M4504 And M5003 For normalized castings or annealed alloy iron, the matrix will be primarily lamellar pearlite with small amounts of ferrite allowed. For liquid quenched and tempered castings, the matr
14、ix will be primarily tempered martensite. Surface decarburized layer (total + partial) max depth, is 0.045 inch (1.15 mm). 6.5 Grades M6003 And Q Engineering Data on Malleable Cast Irons, BCIRA (British Cast Iron Research Association), 1976 * Data Sources: This document is restricted and may not be
15、sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 02002 International Truck and Engine Corporation FEBRUARY 2002 Page 3 of 7 NMBER: CEMS E-7, APPX A.5 Design Information
16、(Continued) TITLE: CURRENT ISSUE DATE: Malleable Iron Castings February 2002 8 E 130 120 110 100 90 80 70 60 50 40 15 10 5 160 180 200 220 240 260 280 300 320 Brinell Hardness Number Figure Al Typical Tensile Properties Pearlitic/Martensitic Malleable Iron 900 825 760 690 620 550 485 4 15 345 275 Th
17、is document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 02002 International Truck and Engine Corporation FEBRUARY 2002 Page 4 of 7 . .
18、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUMBER: CEMS E-7, APPX TITLE:
20、CURRENT ISSUE DATE: Malleable Iron Castings February 2002 A.5.1.2 Compressive Properties Ferritic Malleable Pearlitic and Martensitic Yield Strength = Y.S. (Tension) + 1100 psi (8 MPa) Yield Strength = T.S. (Tension) + 1300 to 2200 psi (9 to 16 ma) A.5.1.3 Modulus of Elasticity: Ferritic Malleable P
21、earlitic and Martensitic Compression Shear E = 24 to 25 x lo6 psi (165 to 172 GPa) E = 25 to 28 x lo6 psi (172 to 193 GPa) E = 22 to 25 x lo6 psi (152 to 172 GPa) G = 9.5 to 11 x lo6 psi (66 to 76 GPa) A.5.1.4 Shear Properties: Ration of shear strength to tensile strength = 0.90 A.5.1.5 Torsional Pr
22、operties: Ratio of torsional strength to tensile strength = 0.90 Ratio of torsional yield strength to tensile yield strength = 0.70 to 0.77 A.5.1.6 Fatime Characteristics (based on Wohler rotating bending fatigue data): Smooth (unnotched) Ferritic Malleable Pearlitic and Martensitic FL, = 0.45 x Ten
23、sile Strength FL, = 0.40 to 0.45 x Tensile Strength Notched: (all grades) FL, =0.60xFL, A.5.1.7 Impact Properties: (Ferritic malleable) Transition Temperature (notched) TTn = - 10C to +30“C Transition Temperature (unnotched) TT, = 50C lower than TTn Notched impact value = 10 to 13 fi lbsf (13.6 to 1
24、7.6J) Unnotched impact value = 80 to 100 fi lbsf (108 to 136J) (Pearlitic malleable) Notched impact value = 3 to 9 fi lbsf (4.1 to 12.2J) NDT = 50C A.5.1.8 Damping Capacity (energy lost in one vibration cycle): Ferritic = 6.30% at 30 O00 psi (207 MPa); 4.20% at 15 O00 psi (103 MPa) Pearlitic = 4.55%
25、 at 30 O00 psi (207 MPa); 3.30% at 15 O00 psi (103 ma) A.5.1.9 Poissons Ratio: p = 0.26 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent
26、liability. 02002 International Truck and Engine Corporation FEBRUARY 2002 Page 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28、. . . . . . . . . . . . . . . . . . . . NUMBER: CEMS E-7, APPX TITLE: CURRENT ISSUE DATE: Malleable Iron Castings February 2002 A.5.1.10 Wear Properties A.5.1.10.1 Ferritic malleable iron (Grade M3210) is satisfactory in very moderate wear applications. Use should be limited to low bearing pressures
29、 and low speeds to avoid galling. A.5.1.10.2 For improved wear resistance, the pearlitic and martensitic grades are recommended. These grades provide satisfactory performance in lubricated bearing and dry bearing applications such as gears, camshafts, etc. They have nongalling properties in metal-to
30、-metal contact similar to gray iron. Wear resistance may be further improved by flame or induction surface hardening techniques. This improvement in wear resistance is generally in proportion to the hardness developed. General surface hardnesses in the range Rockwell C55 to 60 are obtainable. (Note:
31、 Conventional measurements reflect the influence of both the graphite and matrix structure. The matrix microhardness may be some 5 to 7 points higher.) Response to induction or flame hardening is dependent upon a prior microstructure having a high percentage of combined carbon. The recommended grade
32、s for this processing are: M5003, M6003 and Q&T. A.5.2 Physical Properties A.5.2.1 Density: 7.20 to 7.45 gm/cm3 A.5.2.2 Coefficient of Thermal Expansion (u m/m/“C: -100“ c to +20“ c = 10.0 x iod +20“ c to +200“ c = 1 1 .o x iod +20“ C to +400“ C = 12.5 x lod A.5.2.3 Thermal Conductivity (wm OC): 100
33、“ c 200“ c (Ferritic malleable) 49.0 48.1 (Pearlitic/Martensitic)* 45.2138.9 44.4138.1 * Values decrease with higher strength grades. A.5.2.4 Specific Heat (JIkglC: +20“ C to +200“ C = 520 +20“ C to +300“ C = 535 +20“ C to +400“ C = 555 +20“ C to +500“ C = 580 +20“ C to +600“ C = 6 1 O +20“ C to +70
34、0“ C = 665 300“ C 400“ C 500“ C 47.3 46.5 45.6 43.5137.2 42.7136.4 41.9135.6 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability.
35、02002 International Truck and Engine Corporation FEBRUARY 2002 Page 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUMBER: CEMS E-7,
39、 APPX TITLE: CURRENT ISSUE DATE: Malleable Iron Castings February 2002 A.6 Recommended O&T Ranges The mechanical properties for Grade Q&T vary with hardness as shown in Figure Al. For optimum mechanical properties in the quench and tempered condition, the section size of malleable iron castings shou
40、ld be limited to 0.75 inches (19 mm) to ensure a uniform structure. When Grade Q&T is selected, the following quenched and tempered hardness ranges are suggested: BHN 229-269 BHN 241-285 BHN 269-321 A.7 Casting Tolerances Thickness: f 10% Fillet Radii: f 10% Core, Cope or Drag Shift: 0.04 inch (1 mm
41、) max Other Dimensions: to 200 mm (7.87 inch) = f 1 mm 0.04 ich over 200 mm (7.87 inch) to 600 mm (23.6 inch) = f 2 mm (0.08 inch) over 600 mm (23.6 inch) = f 3 mm (0.12 inch) Shrinkage Allowance: % to % incldfoot (1 O to 20 mm/m) Draft: Sand castings = 2“ Maximum Section Thickness: Normally 1% inch
42、es (38 mm), specials to 4 inches (100 mm) This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 02002 International Truck and Engin
43、e Corporation FEBRUARY 2002 Page 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
