FORD WSS-M2A180-A1-2017 ALUMINUM ALLOY EXTRUSION HEAT TREATABLE STRUCTURAL HIGH STRENGTH 7000 SERIES TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 02 16 Released K. Morgan, NA Controlled document at www.MATS Copyright 2017, Ford Global Technologies, LLC Page 1 of 7 ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A180-A1 HIGH STRENGTH, 7000 SERIES 1. SCOPE The m

2、aterial defined by these specifications is for 7000 series, heat treatable extruded aluminum profiles. Ford Motor Company may, at its option and in agreement with the local or regional supplier, define additional and/or restricted technical delivery requirements such as mechanical properties, formin

3、g characteristics, pretreatment, and/or surface texture, for a specific grade and/or part. The defined requirements shall be mandatory and no characteristics shall conflict with these engineering specifications. 2. APPLICATION This specification was released originally for extruded aluminum profiles

4、 for bumper applications. The manufacturing processes used to form these profiles includes but are not limited to rotary bending, push roll bending, stretch bending, stamping, piercing, laser trimming, and machine trimming. 2.1 LIMITATIONS The alloy defined in this specification may be susceptible t

5、o intergranular corrosion or stress corrosion cracking. The yield strength of the material in the part after the artificial aging heat treatment and/or paint baking process is a function of the thermo-mechanical history. The mechanical property values shown in Table 2 apply only to the listed condit

6、ion; individual parts will have different properties, depending on specific processing in the vehicle manufacturing plants. 2.2 DEFINITIONS Variant A1 is a 7000 series structural alloy with gage thicknesses 1.8mm to 5.0mm, typically applied to non-visible structural parts (Class 3) where high streng

7、th and good ductility are required. This alloy will be used for high volume extrusions, which will then be subjected to a prescribed artificial aging heat treatment such that the material achieves desired minimum mechanical properties. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires

8、 the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at or available externally through a Ford Materials Engine

9、er. 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 Suppliers Control Plan. In

10、case of dispute, the referee method shall be ASTM E34. ENGINEERING MATERIAL SPECIFICATION WSS-M2A180-A1 Copyright 2017, Ford Global Technologies, LLC Page 2 of 7 The tabulated upper and lower limits of chemical composition for each variant may not agree with those listed in the Aluminum Association

11、“Teal Sheets.“ The values in Table 1 take precedence. Check analyses of cast billets shall be provided as part of the initial material source approval process in a format suitable for upload into the Ford Material Database. Table 1: Chemical Composition (weight percent maximum, unless shown as a ran

12、ge or a minimum; balance Al) A1 Si 0.20 Fe 0.30 Cu 0.05 Mn 0.05 Mg 0.7 1.5 Cr 0.04 Zn 4.8 5.8 Ti 0.03 Zr 0.10 0.25 Other Elements 0.05 Others (total) 0.15 3.3 MECHANICAL PROPERTIES (ASTM B557M, 50 mm gauge length; ISO 6892-1) Mechanical properties are valid in the longitudinal direction parallel to

13、extrusion direction, except as noted. Certification of ongoing production material shall be in accordance with regional and/or local requirements. For the determination of mechanical properties, the material cross sectional area shall be defined as that of the aluminium alloy; contribution of any su

14、rface treatments 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 (s

15、tart/change/end) is not useable. Start and end scrap length are to be developed during process development for a new product. Guidelines for usable material and scrap subject to control plan. 3.6.1.2 Longitudinal Welds Longitudinal weld-line integrity shall be assessed per FLTM BB 116-01. Samples ar

16、e to be taken from the front of the extrusion coming from one billet 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 APPEARANCE, CONDITION, AND SURFACE ROUGHNESS 3.7.1 Surface Classifica

17、tion All variants of this specification are suitable for Class 3 applications as defined in ESF75B-11007-(*). (*) latest level 3.7.2 Surface Roughness The surface roughness and associated parameters for a given component are to be defined and recorded, if necessary, by the regional manufacturing act

18、ivity. ENGINEERING MATERIAL SPECIFICATION WSS-M2A180-A1 Copyright 2017, Ford Global Technologies, LLC Page 5 of 7 3.7.3 Final Product Identification Unless an alternate method is agreed upon by the aluminum alloy supplier and the manufacturing activity, the final extruded product shall be identified

19、 as follows per ESDU5A-1B328-(*). This information shall be marked by ink-jet or similar printer, at one meter intervals, in a color as specified by the regional Purchasing activity and shall consist of human readable information in which each piece of information is separated by “ “. The final prod

20、uct should have traceable material identification information including: Part Number Global Product Grade Name Heat Treat Date (yyyy-mm-dd) Extruded Tube Supplier Name Global Supplier Data Base (GSDB) Code Lot Number Stencil Example: 16107K40-A 6XHS yyyy-mm-dd Supplier GSDB A1234567-1 3.8 PAINTABILI

21、TY In conjunction with the material supplier and 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(

22、s), manufacturing trial(s), and/or another mutually 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“

23、 of the aluminum alloy) shall be developed by the 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

24、 specified requirements in Section 3 of this Engineering 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 comp

25、onent at the agreed upon quality level implies 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 Ford Engineering Drawing, CAD file, or rela

26、ted documents shall include the base aluminum alloy and, as applicable, the pretreatment. Extrusions heat treated to T7 shall call out mechanical properties on the Ford component drawings. e.g. An Aluminum Alloy, Extrusion, Heat Treatable, Structural, High Strength, for an unexposed bumper beam woul

27、d be defined thus: Aluminum Extrusion to WSS-M2A180-A1 ENGINEERING MATERIAL SPECIFICATION WSS-M2A180-A1 Copyright 2017, Ford Global Technologies, LLC Page 6 of 7 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specif

28、ication. Contact for questions concerning Engineering Material Specifications. 4.1 REFERENCE DOCUMENTS The reference documents are: External Standards: ASTM E8M Test Methods for Tension Testing of Metallic Materials ASTM E34 Standard Test Methods for Chemical Analysis of Aluminum and Aluminum-Base

29、Alloys ASTM B557M Standard Test 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 Standa

30、rd Test Method for Analysis of Aluminum and Aluminum Alloys by Atomic Emission Spectrometry ISO 4587 Adhesives Determination of Tensile Lap-Shear Strength of Rigid-to-Rigid Bonded Assemblies ISO 6892-1 Metallic materials - Tensile testing - Part 1: Method of test at room temperature SAE J1523 Metal

31、to Metal Overlap Shear Strength for Automotive Type Adhesives Ford Material / Engineering Standards: ESDU5A-1B328-(*) Aluminum Material Traceability FLTM BB 113-07 Welding Acceptance Test for Aluminum FLTM BV 101-07 Stress Durability Test for Adhesive Lap-Shear Bonds FLTM AB 108-01 Mechanical Proper

32、ties 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 Flare Test Method WSS-M99P1111-A Standard Requirements for Production Materials (*) latest level 4.2 INITIAL MECHAN

33、ICAL PROPERTY TESTING For initial approval, the supplier should contact Ford Materials Engineering to obtain the latest revision of the Global Extruded Aluminum Material Checklist. 4.3 COMMON DESIGNATION The requirements of these specifications take precedence over those in the Aluminum Association

34、International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys (or “Teal Sheets“), or any other industry standard. Variant A1 - 7XHS 4.4 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interes

35、t from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized ENGINEERING MATERIAL SPECIFICATION WSS-M2A180-A1 Copyright 2017, Ford Global Technologies, LLC Page 7 of 7 re

36、presentative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control docume

37、nts (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.5 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material origin

38、ally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a compl

39、eted Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until

40、Job 1. 4.6 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS