GMW GMW16037-2012 Test Method to Quantify Cleanliness of Powertrain Components Issue 2 English.pdf

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1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW16037 Test Method to Quantify Cleanliness of Powertrain Components Copyright 2012 General Motors Company All Rights Reserved November 2012 Originating Department: North American Engineering Standards Page 1 of 7 1 Scope Note: Nothing in this standar

2、d supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. This document outlines a method for determining the weight (and size or size distribution, if specified) of foreign materia

3、l (e.g., sand, machining chips, blasting media, etc.) retained in or on any component after the final washing operation in the partial and/or finish machining process. 1.2 Foreword. This method involves washing components with a fluid, collecting the fluid, filtering the solid materials from it, and

4、 determining the weight (and size or size distribution, if specified) of the solids present. 1.3 Applicability. This method may be used to quantify foreign material present in or on engine and transmission components, including sub-assemblies and assemblies. 2 References Note: Only the latest approv

5、ed standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. None 3 Resources 3.1 Facilities. It is preferred that the test procedure be carried out in an enclosed room or laboratory separate from the plant environment. This wil

6、l minimize the possibility of introducing extraneous foreign material to the components. 3.1.1 Compressed air capable of 210 kPa (30 psi) gauge pressure and a nozzle with an orifice size of 2.0 mm (0.080 in) nominal is required. The air must be filtered to be free of any debris that may contaminate

7、the part being tested. 3.2 Equipment. A list of additional equipment and materials which may be necessary and useful in evaluating components for sediment levels is shown in Appendix A, required equipment and materials are listed below. An example of the equipment setup is shown in Figure A2. 3.2.1

8、Drying oven with a thermometer (Figure 1). Figure 1: Drying Oven with a Thermometer Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16037

9、 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 2 of 7 3.2.2 Desiccator. 3.2.3 Analytical balance with an accuracy of at least 0.1 mg. A more accurate balance may be necessary depending on the level of debris being analyzed for. 3.2.4 Vacuum pump manifold and trap. 3.2.

10、5 Squeegee. 3.2.6 Drum pump or wash solution reservoir. 3.2.7 Stainless steel rinse collection sink which is washable and/or drainable. Figure 2: Stainless Steel Rinse Collection Sink 3.2.8 Sidearm flask, filter funnel, beakers, and wash bottles. 3.2.9 Nylon filter membranes, 10 micron, shall be use

11、d except where local test procedures require the use of 44 micron and 10 micron nylon filters in series. Finer filters may be required for components with tighter cleanliness requirements. Alternative filter media (type and size) must be agreed upon and documented (see 4.2.2). 3.2.9.1 Paper filter e

12、lements may also be used at those locations where this procedure is used to monitor grease content of the plant wash system coolant. 3.2.9.2 A 5 micron filter shall be used for filtering wash fluid that is re-used. Finer filters may be required for components with tighter cleanliness requirements. 3

13、.2.10 Wash Fluids. See Appendix A for a list of fluids that have been used previously. The wash fluid is to be matched to the application. Alternative fluids can be agreed upon and documented (reference 4.2.2). The wash fluid should be a sediment free, non-polar organic liquid with a flash point 40

14、C which dries with close to zero residue. 3.2.11 Rinse device should be a handheld spray gun with 70 kPa (10 psi) minimum nozzle pressure. Pressures higher than this may require an alternative collection sink and safety pre-cautions. 3.3 Test Vehicle/Test Piece. Partial and finish machined component

15、s shall be obtained from the production process at the final washer exit location. Assemblies and sub-assemblies shall be obtained from the point of their introduction into the engine or transmission assembly. 3.4 Test Time. Not applicable. 3.5 Test Required Information. Not applicable. 3.6 Personne

16、l/Skills. Per local requirements. 4 Procedure 4.1 Preparation. 4.1.1 Test Equipment and Materials. Oven dry the required number of filters for 30 to 35 minutes at 50 C to 55 C. Allow filters to cool for 15 minutes to 20 minutes in a desiccator prior to use. Collect test samples per 3.3 prior to sedi

17、ment evaluation, test samples must not be rinsed, wiped, or cleaned in any way other than what is typical for the production process. Lot numbers or other pertinent shipment information should be Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for Resale

18、No reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16037 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 3 of 7 recorded for samples to be tested. Protect samples from airborne debris during transport to the sedimen

19、t test equipment. Avoid handling samples in a manner that could loosen or remove debris from the samples. 4.2 Conditions. 4.2.1 Environmental Conditions. Not applicable. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be s

20、pecified on component drawings, test certificates, reports, etc. Deviations for a given part number should be identical site-to-site. 4.2.2.1 When evaluating transmission assemblies, exterior surfaces shall not be rinsed as part of the procedure. Torque converters shall be checked separately. Local

21、procedures shall dictate whether or not to remove valves from valve body bores. 4.2.2.2 Sample size must be sufficient to allow for statistical control of production processes and establishment of control limits. 4.3 Instructions. 4.3.1 Ascertain the individual weight(s) of the required number of fi

22、lters in milligrams (mg) to one significant digit beyond the specification by means of an analytical balance and record the value(s). 4.3.2 Rinse collection sink/tray before and after each test with a sufficient quantity of wash fluid to purge the system of any foreign material. Collect the fluid in

23、 a beaker and visually examine the sediment for unusual particles or amounts. Equipment and materials must be protected from environmental contamination when not in use. 4.3.2.1 Monthly Wash Fluid Cleanliness Check (for Sites that Recycle Fluid). Collect at least 1.0 L of wash fluid in a clean beake

24、r and note the volume used. Filter the fluid with vacuum assist through a pre-dried and pre-weighed 10 micron filter. Remove filter from the funnel and expose to drying cycle (reference 4.1). Determine amount of residue collected by subtracting original filter weight from weight of filter plus (+) r

25、esidue. If the amount of residue exceeds the lesser of 0.50 mg/L or the product specification, wash fluid must be replaced with new wash fluid. 4.3.3 Place component to be evaluated in the clean collection sink/tray and rinse all surfaces (unless otherwise specified) with wash fluid. When the compon

26、ent being tested has internal passages, the rinse nozzle shall be directed into the passageway openings to ensure proper rinsing of the passageways. Ensure that all foreign material and loose debris is removed from the component and the collection sink/tray by flushing the tray with excess fluid and

27、 wiping it with a non-metallic squeegee. Collect all sediment from the tray in a beaker and mark the beaker for identification. 4.3.3.1 Appendix A lists equipment part numbers currently in use at some plants. Other equipment may be acceptable as long as a minimum nozzle pressure of 70 kPa (10 psi) i

28、s maintained throughout the rinsing operation. 4.3.3.2 Engine components with internal oil and/or coolant passages (e.g., engine blocks) shall be rinsed according to work instructions such that sediment levels are established for each type of passage, when specified. 4.3.3.2.1 To ensure all sediment

29、 is removed from internal passageways of components such as cylinder blocks and heads, pressurized air shall be directed into the passageways of interest after the part has been rinsed. Gauge pressure shall be 210 kPa (30 psi) and orifice size shall be 2.0 mm (0.080 in). 4.3.4 Examine the components

30、 for burrs and loose chips resulting from machining operations, casting processes, etc. 4.3.4.1 Burrs which are not removed after rinsing and air blowout shall be noted but shall not be included in the total sediment weight. 4.3.4.2 Appropriate equipment (mirrors, lights, bore scopes, etc.) shall be

31、 used to inspect internal passageways for unattached foreign debris (e.g., chips, sand, blast media, etc.) not removed by the rinse or air blowout. Unattached foreign debris that can be removed shall be included in the total sediment weight (reference 5.1). 4.3.5 Place dried and weighed filters in t

32、he filtration funnel. 4.3.6 Pour the collected wash fluid through the filter plus (+) funnel using a vacuum assist. Rinse the collection chamber/beaker thoroughly and transfer the wash fluid to the funnel for filtering. Copyright General Motors Company Provided by IHS under license with General Moto

33、rs CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16037 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 4 of 7 4.3.7 Carefully remove the filter from funnel and expose to the drying cycle in

34、 Section 4.1. Debris samples must be identified for traceability. 4.3.8 Weigh dried filter plus (+) sediment plus (+) collected foreign debris from 4.3.4.2 and record weight to four decimal places. 4.3.9 Tested parts may be returned to the production process unless the surface condition has been deg

35、raded or the component has been disassembled during sediment testing. Re-introduction of test samples into the production process must occur before the final wash. Transmission seals and clutch plates must be scrapped. 5 Data 5.1 Calculations. Determine total sediment weight by subtracting filter we

36、ight (reference 4.3.1) from weight of filter plus (+) sediment (reference 4.3.8). When two filters are used (reference 3.2.9), weights should be reported for each filter size. 5.2 Interpretation of Results. If something unusual is observed on the contaminated filters (high weights, large particles,

37、etc.) examination of the filters under a light microscope is recommended. Should part specifications include a maximum allowable particle size or size distribution, measure the sediment particles using a calibrated grid, image analyzer, or particle size analyzer. Note the size (longest dimension in

38、microns) of the largest particle and record on datasheet. Additional identification of particles (e.g. chemistry, etc.) via specific analytical techniques may be required. These techniques must be agreed upon (reference 4.2.2). 5.3 Test Documentation. 5.3.1 Transfer data to Statistical Process Contr

39、ol (SPC) charts and plot the data. 5.3.2 Notify the production department Supervisor and the Quality Department of any out-of-specification points. Proper action(s) shall be taken to improve the cleanliness condition of these parts. 6 Safety This standard may involve hazardous materials, operations,

40、 and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 7 Notes 7.1 Gl

41、ossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. DRE Design Responsible Engineer PVDF Polyvinylidene fluoride SPC Statistical Process Control 8 Coding System This standard shall be referenced in other documents, drawings, etc., as follows: Measure debris per GMW16037 Example: In no

42、case shall debris exceed _ mg when measured per test method GMW16037 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16037 Copyright 2012

43、 General Motors Company All Rights Reserved November 2012 Page 5 of 7 9 Release and Revisions This standard was originated in August 2008. It was first approved by GM Powertrain in June 2009. It was first published in July 2009. Issue Publication Date Description (Organization) 1 JUL 2009 Initial pu

44、blication. 2 NOV 2012 For clarification, images of required equipment added to sections; 3.2.1, 3.2.7, A1.2 and Figure A2. (Non-ferrous Metallic Materials) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted

45、without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16037 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 6 of 7 Appendix A A1 Laboratory Equipment Some specific equipment that has proven useful in testing is listed below. Other fluids and other brands/mod

46、els of equipment may be used as long as the test procedure is not compromised. A1.1 Magnet. A1.2 Brushes. (See Figure A1.) Figure A1: Brushes A1.3 Sediment wash cart. A1.4 Nalgene vacuum manifold Catalog No. DS0345-0001. A1.5 Jabsco drum pump Model No. 16520-3350 (to be used with air pressure of 350

47、0 kPa (50 psi). A1.6 Spraying Systems Co. GunJet Model No. 31-39430 (source: Industrial Hose and Hydraulics, Ltd.) A1.7 Vacuum pump Gast 0211 Series, oiless (pump to be set at 381 mm (15 in) of Hg); or Piab, Inc. A1.8 Glass pan. A1.9 Tweezers. A1.10 Stereomicroscope, light microscope, flow-through p

48、article counter, or automatic particle counter. A1.11 Calibrated grid. A1.12 Wash Fluids: TechSolv 331, 334, or 336; Chemcentral SC142; Betz Permatreat 435 (4% solution); Citrikleen 3SR166 (1:10 in water); Odorless mineral spirits; Naptha; Orange Sol Inc./Mykal Industries DE-SOLV-IT 1000; Henkel Neu

49、trasel 5225 (2% solution); Houghton International HOCUT 4149-D; Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16037 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 7 of 7 Qua