FORD WSS-M2A177-A6-2014 ALUMINUM ALLOY EXTRUSION HEAT TREATABLE STRUCTURAL HIGH STRENGTH ENERGY ABSORBSION TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M2A177-A1).pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 04 2014 12 17 Released Added A6 and A7 Suffixes C. Mracna, NA 2014 06 20 Revised See Summary of Revisions C. Mracna, NA 2014 03 06 Editorial See Summary of Revisions C. Mracna, NA Controlled document at www.MATS Copyright 2014, Ford Globa

2、l Technologies, LLC Page 1 of 7 ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A1 HIGH STRENGTH ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, SEAMLESS, WSS-M2A177-A2 HIGH STRENGTH, GRAIN SIZE CONTROLLED ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A3 MODERATE STR

3、ENGTH AND FORMABILITY ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, SEAMLESS, WSS-M2A177-A4 MODERATE STRENGTH AND FORMABILITY, GRAIN SIZE CONTROLLED ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A5 ENERGY ABSORBSION ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A

4、6 HIGH STRENGTH, ENERGY ABSORBSION ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A7 HIGH STRENGTH, 6000 SERIES 1. SCOPE The materials defined by these specifications are for 6000 series, heat treatable extruded aluminum tubes and profiles. Ford Motor Company may, at its option an

5、d in agreement with the local or regional supplier, define additional and/or restricted technical delivery requirements such as mechanical properties, forming characteristics, pretreatment, and/or surface texture, for a specific grade and/or part. The defined requirements shall be mandatory and no c

6、haracteristics shall conflict with these engineering specifications. 2. APPLICATION These Global specifications were released originally for extruded aluminum tubes for structural applications. The manufacturing processes used to form these aluminum tubes include but are not limited to rotary bendin

7、g, push roll bending, stretch bending, stamping, hydroforming, piercing, laser trimming, and machine trimming. The alloys defined in this specification are not susceptible to intergranular corrosion or stress corrosion cracking. 2.1 LIMITATIONS The yield strength of the material in the part after th

8、e artificial aging heat treatment and / or paint baking process is a function of the amount of forming deformation and the time-temperature profile during the paint baking process. The mechanical property values shown in Table 2 apply only to the listed condition; individual parts will have differen

9、t properties, depending on specific processing in the vehicle manufacturing plants. 2.2 DEFINITIONS ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page 2 of 9 Variant A1 is a structural, multi-hollow extruded tube alloy typically appl

10、ied to Class 3 non-visible parts where high strength and modest ductility are required. For high strength, these alloys must be artificially aged (e.g. T6) for parts requiring functional performance characterized by controlled in-service deformation. Variant A2 is a seamless extruded tube alloy typi

11、cally applied to Class 3 non-visible parts where high strength and modest ductility are required. For high strength, these alloys must be artificially aged (e.g. T6) for parts requiring functional performance characterized by controlled in-service deformation. Variant A3 is a general structural, mul

12、ti-hollow extruded tube alloy suitable for Class 3 parts where moderate strength and modest formability are required. Variant A4 is a general seamless extruded tube alloy suitable for Class 3 parts where moderate strength and modest formability are required. Variant A5 is a general structural, multi

13、-hollow extruded tube alloy suitable to Class 3 parts where energy absorption and/ or controlled in-service deformation behavior are desired. Variant A6 is a structural, multi-hollow extruded tube alloy typically applied to Class 3 non-visible parts where high strength and energy absorption are requ

14、ired. These alloys must be artificially aged (e.g. T6 or T7) for functional performance characterized by controlled in-service deformation. Variant A7 is a structural, multi-hollow extruded tube alloy typically applied to Class 3 non-visible parts where high strength and modest ductility are require

15、d. These alloys must be artificially aged (e.g. T6 or T7) for functional characterized by controlled in-service deformation. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Mate

16、rials (WSS-M99P1111-A). Material suppliers and part producers must conform to the Companys Quality System Requirements. In order for materials to comply with the requirements of the material specification they shall be sourced from suppliers listed in the Ford Motor Company Approved Source List, ASL

17、 (See also paragraph 4.2). 3.2 CHEMICAL COMPOSITION AND MICROSTRUCTURE (ASTM E34, ASTM E716, ASTM E1251) 3.2.1 Chemical Composition The upper and lower limits of chemical composition of the controlled elements shall be established by the supplier by any of the listed methods and included in the Supp

18、liers Control Plan. In case of dispute, the referee method shall be ASTM E34. The tabulated upper and lower limits of chemical composition for each variant may not agree with those listed in the Aluminum Association “Teal Sheets.“ The values in Table 1 take precedence. Check analyses of extruded tub

19、es shall be provided as part of the initial material source approval process in a format suitable for upload into the Ford Material Database. ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page 3 of 9 Table 1: Chemical Composition (we

20、ight percent maximum, unless shown as a range or a minimum; balance Al) A1 A2 A3/A4 A5 A6 A7 Si 0.70 - 1.30 0.70 - 1.30 0.40 - 0.80 0.20 - 0.60 0.30 1.5 0.90 1.2 Fe 0.5 0.5 0.70 0.35 0.50 0.50 Cu 0.10 0.10 0.40 0.10 0.50 0.05 0.30 Mn 0.40 1.00 0.10 0.60 0.15 0.10 0.60 0.75 Mg 0.60 - 1.20 0.60 - 1.20

21、 0.80 - 1.20 0.45 - 0.90 0.30 1.50 0.70 1.0 Cr 0.25 0.25 0.35 0.10 0.35 0.25 Zn 0.20 0.20 0.25 0.10 0.20 0.05 Ti 0.10 0.10 0.15 0.10 0.20 0.10 V - - - - 0.30 - Others (each) 0.05 0.05 0.05 0.05 0.10 0.05 Others (total) 0.15 0.15 0.15 0.15 0.20 0.15 3.2.2 Average Grain Size, (ASTM E112, Comparison Pr

22、ocedure) WSS-M2A177-A2 Report Only WSS-M2A177-A4 Report Only 3.3 MECHANICAL PROPERTIES (ASTM B557M, 50 mm gauge length; ASTM E517) Mechanical properties are valid in the longitudinal direction parallel to extrusion direction, except as noted. Certification of ongoing production material shall be in

23、accordance with regional and/or local requirements. In cases of dispute, test data obtained from supplier retained samples that have been stored under environmentally controlled conditions will serve as the arbitrator. The samples shall be tested at a third party laboratory. Mechanical properties sh

24、all be valid for a period of between seven (7) and sixty seven (67) days following solution heat treatment unless otherwise noted. For the determination of mechanical properties, the material cross sectional area shall be defined as that of the aluminium alloy; contribution of any surface treatments

25、 to the calculated cross-sectional area used for stress calculations is neglected. The test specimen geometry is to be established locally to certify ongoing production material. Yield Strength is defined as 0.2% proof stress. Yield Strength (T81 therefore, the billet change scrap (start/change/end)

26、 is not useable. Start and end scrap length to be developed based on the installed equipment. Guidelines for usable material and scrap subject to control plan. ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page 6 of 9 3.6.1.2 Longitu

27、dinal Welds Longitudinal weld-line integrity shall be assessed per FLTM BB 116-01. Samples are to be taken from the front of beam after the prescribed scrap is removed. Actual sampling plan shall be established with Ford materials engineering and based on PFMEA and control plan. 3.7 SURFACE APPEARAN

28、CE, CONDITION, AND SURFACE ROUGHNESS 3.7.1 Surface Classification All variants of this specification are suitable for Class 3 applications as defined in ESF75B-11007-(*). (*) latest level 3.7.2 Incoming Lubricant Products coated with a lubricant shall comply with regional requirements and the region

29、al approved lubricant list. 3.7.3 Pretreatments Batch-applied pretreatments shall comply with performance specification WSS-M10P12-B2. 3.7.4 Surface Roughness The surface roughness and associated parameters for a given component are to be defined and recorded, if necessary, by the regional manufactu

30、ring activity. 3.7.5 Final Product Identification WSS-M2A177-A2/A4 - Unless an alternate method is agreed upon by the aluminum alloy supplier and the manufacturing activity, the final extruded tube product shall be identified per ESDU5A-1B328-(*) (*) latest level WSS-M2A177-A1/A3/A5/A6/A7 - Unless a

31、n alternate method is agreed upon by the aluminum alloy supplier and the manufacturing activity, the final extruded tube product shall be identified as follows. This information shall be marked by ink-jet or similar printer, at one meter intervals, in a color as specified by the regional Purchasing

32、activity and shall consist of human readable information in which each piece of information is separated by “ “. The final product should have traceable material identification information including: Part Number Global Product Grade Name Heat Treat Date (yyyy-mm-dd) Extruded Tube Supplier Name Globa

33、l Supplier Data Base (GSDB) Code Lot Number Stencil Example: 16107K40-A 6XHS yyyy-mm-dd Supplier GSDB A1234567-1 ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page 7 of 9 3.8 PAINTABILITY In conjunction with the material supplier and

34、 Ford Materials Engineering, the affected local manufacturing activity shall, as part of the initial material source approval process, approve the paintability (e.g., compatibility, appearance, performance) of this material by means of laboratory test(s), manufacturing trial(s), and/or another mutua

35、lly acceptable alternative, using the equipment and methods that are proposed for production. If needed to enable the fabrication of a specific component, restricted tolerances and/or additional material property requirements (i.e., the “quality level“ of the aluminum alloy) shall be developed by th

36、e affected manufacturing activity and the aluminum supplier. Examples include, but are not limited to: restricted dross content and specified surface condition. The “quality level“ of the aluminum alloy for a specific component: shall not conflict with specified requirements in paragraph 3 of this E

37、ngineering Material Specification shall be described in detail by the local manufacturing activity shall be a mandatory extension of these Engineering Material Specifications Acceptance of subsequent orders by the aluminum alloy supplier for a given component at the agreed upon quality level implies

38、 that all aluminum alloy supplied will be of a comparable quality level and can be painted satisfactorily as defined and recorded by the manufacturing activity. 3.9 METHOD OF SPECIFYING The specification on the Engineering Drawing, CAD file, or related documents shall include the base aluminum alloy

39、 and, as applicable, the pretreatment. e.g. An Aluminum Alloy, Extrusion, Heat Treatable, Structural, High Strength, pretreated for an unexposed upperbody rail would be defined thus: Aluminum to WSS-M2A177-A1, pretreated to WSS-M10P12-B2. 4. GENERAL INFORMATION The information given below is provide

40、d for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 REFERENCE DOCUMENTS The reference documents are: External Standards: ANSI H35.2 Dimensional Tolerances for Aluminum Mill Products ASTM E8M

41、Test Methods for Tension Testing of Metallic Materials ASTM E34 Standard Test Methods for Chemical Analysis of Aluminum and Aluminum-Base Alloys ASTM E112 Standard Test Method for Determining Average Grain Size ASTM E517 Test Method for Plastic Strain Ratio r for Sheet Metal ASTM B557M Standard Test

42、 Methods for Tension Testing Wrought and Cast Aluminum- and Magnesium-Alloy Products ASTM E716 Standard Practices for Sampling and Sample Preparation of Aluminum and Aluminum Alloys for Determination of Chemical Composition by Spectrochemical Analysis ASTM E1251 Standard Test Method for Analysis of

43、Aluminum and Aluminum Alloys by Atomic Emission Spectrometry ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5/A6/A7 Copyright 2014, Ford Global Technologies, LLC Page 8 of 9 ASTM B221 Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes AS

44、TM B429 Standard Specification for Aluminum-Alloy Extruded Structural Pipe and Tube ASTM B918 Standard Practice for Heat Treatment of Wrought Aluminum Alloys ISO 4587 Adhesives Determination of Tensile Lap-Shear Strength of Rigid-to-Rigid Bonded Assemblies SAE J1523 Metal to Metal Overlap Shear Stre

45、ngth for Automotive Type Adhesives Ford Material / Engineering Standards: ESBAU5-1A275-(*) Specification for Aluminum Extruded Hydroformed Tubes ESDU5A-1B328-(*) Aluminum Material Traceability ESF75B-110007-(*) Specification for Sheet Metal Surfaces and Edges FLTM BB 113-07 Welding Acceptance Test f

46、or Aluminum FLTM BV 101-07 Stress Durability Test for Adhesive Lap-Shear Bonds FLTM AB 108-01 Mechanical Properties Measurement After Thermal Processing of Aluminum Alloy Extrusions FLTM BB 116-01 Procedure for Testing the Integrity of Weld-Lines in Extruded Structural Aluminum Tubes Using Tube Flar

47、e Test Method WSS-M99P1111-A Standard Requirements for Production Materials WSS-M10P12-B2 Pretreatment, Aluminum, Batch Applied (*) latest level 4.2 INITIAL MECHANICAL MECHANICAL PROPERTY TESTING For initial approval, the supplier should contact Ford Materials Engineering to obtain the latest revisi

48、on of the Global Extruded Aluminum Material Development Form. Upon initial technical approval and completion of a functional prove-out (line trial), the material will be added to the Approved Source List (ASL). 4.3 COMMON DESIGNATION The requirements of these specifications take precedence over thos

49、e in the Aluminum Association International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys (or “Teal Sheets“), or any other industry standard. Variant A1 6XHS Variant A2 6XHSG Variant A3 6XST Variant A4 6XSTG Variant A5 6XEA Variant A6 6XEA2 Variant A7 6XHS2 4.4 MECHANICAL PROPERTIES, AFTER THERMAL TREA