NAVISTAR MPAPS A-45 PART II-2015 Hydraulic Line Tubing and Tubing Assemblies.pdf

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1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. JUNE 2015 Page 1 of 9 NAVISTAR, INC. Material, Parts, and Process Specifications (

2、MPAPS) NUMBER: MPAPS- A-45, PART II Former Designation: CEMS A-45 PART II TITLE: Hydraulic Line Tubing and Tubing Assemblies CURRENT REV No.: 1506 DATE: June 2015 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: April 2011 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REV

3、ISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regul

4、atory limits prior to use. Change Notice: MPAPS Formatting; added references to SAE J356 and SAE J1677; Editorial Changes 1.0 APPLICATION Low carbon steel tubing seamless and normalized, electric-resistance welded, flash controlled single-wall pressure tubing intended for use as pressure lines in ve

5、hicles. MPAPS A-45 is in three parts: Part I Automotive Steel Tubing Part II Hydraulic Line Tubing and Tubing Assemblies Part III - Diesel Injection Tubing 2.0 SCOPE Part II of MPAPS A-45 covers the requirements for tubing and tubing assemblies used in the Companys products for hydraulic lines or ot

6、her applications where fluids are transferred under pressure. It is also suitable for applications requiring flaring and bending. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAP

7、S B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 ASTM A 370 NAVISTAR Manufactu

8、ring Standard MS-K-5 NAVISTAR MPAPS G-1 NAVISTAR Manufacturing Standard MS-D-13 SAE J524 CFR Title 29, Part 1910 SAE J525 NAVISTAR MPAPS G-5 Pt. II SAE J1677 SAE J356 4.0 REQUIREMENTS 4.1 Grade Classification Hydraulic line tubing is produced in three grades which are classified as shown in Table I.

9、 NUMBER: MPAPS A-45, PART II TITLE Hydraulic Line Tubing and Tubing Assemblies CURRENT ISSUE DATE: June 2015 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liabili

10、ty. 2015 by Navistar, Inc. JUNE 2015 Page 2 of 9 TABLE I GRADE CLASSIFICATION NAVISTAR Grade Approximate SAE Equivalent Description Permissible Alternates NF S F J525 J524 J356 No Inside Flash, Drawn Over Mandrel, Electric Resistance Welded, Single Wall Seamless Flash Controlled, Electric Resistance

11、 Welded, Single Wall None Grade NF Grade NF 4.2 Chemical Composition Tubing purchased to this specification will be made from steel conforming to the chemical composition shown in Table II. TABLE II CHEMICAL COMPOSITION Element Ladle (Heat) Analysis, % Check (Product) Analysis, % Carbon Manganese 0.

12、18 max 0.60 max 0.21 max 0.63 max Phosphorus Sulfur 0.04 max 0.05 max 0.05 max 0.06 max 4.3 Mechanical Properties Tubing furnished to this specification will conform to the mechanical property requirements shown in Table III, unless otherwise specified. See “Methods of Test,” Section 5.4. TABLE III

13、MECHANICAL PROPERTIES Yield Strength 0.2% Offset, min Tensile Strength, Min % Elongation in 2 Inches (50 mm), min Hardness* Rockwell B, max ksi MPa Ksi MPa 25 170 45 310 35* 65 * * Elongation for tubing with nominal outside diameters up to 9.52 mm (0.375 inch) inclusive and/or nominal wall thickness

14、es of 0.89 mm (0.035 inch) or less is 25%, minimum. * Not required on tubing with nominal wall thicknesses less than 1.65 mm (0.065 inch) or with inside diameters less than 6.4 mm (0.25 inch). 4.4 Performance Requirements The finished tubing will meet the following requirements when inspected with a

15、n unaided eye. See “Methods of Test,” Section 5.4. 4.4.1 Flattening The tested sample will have no cracks or other flaws. Superficial ruptures resulting from minor surface imperfections will not be cause for rejection. See Section 5.2 for definition of minor surface imperfections. 4.4.2 Reverse Flat

16、tening (Grades NF and F Only) The tested sample will not reveal evidence of cracks, metal flaking, lack of weld penetration or overlaps resulting from flash control or flash removal in the weld. NUMBER: MPAPS A-45, PART II TITLE Hydraulic Line Tubing and Tubing Assemblies CURRENT ISSUE DATE: June 20

17、15 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. JUNE 2015 Page 3 of 9 4.4.3 Expansion The tested sample will show no evidence o

18、f splitting or other flaws 4.4.4 Hydrostatic Proof Pressure All tubing supplied to this specification will be hydrostatically tested without showing defects at a pressure equivalent to a fiber stress of 138 MPa (20 ksi). A nondestructive test, such as eddy current, may be substituted for hydrostatic

19、 test by agreement between purchaser and supplier. 4.5 Dimensional Tolerances of Tubing Tubing purchased to this specification will conform to the following requirements for dimensional tolerances. Grades NF and S tubing will be subject to any two of the following dimensional requirements: outside d

20、iameter (OD), inside diameter (ID) and wall thickness. Grade F tubing will be specified to only outside diameter and wall thickness. TABLE IV DIAMETER TOLERANCES, PLUS OR MINUS Nominal Outside Diameter, Inches, Incl Outside and Inside Diameters Tolerances, Inch Nominal Outside Diameter, mm, Incl Out

21、side and Inside Diameters Tolerances, mm Grade NF Grade S Grade F* Grade NF Grade S Grade F* Thru 0.375 OD:0.002 ID: 0.005 0.004 0.0025 Thru 9.52 OD: 0.05 ID: 0.013 0.010 0.06 Over 0.375 to 0.625 Over 0.625 to 1.000 Over 1.000 to 1.125 Over 1.125 to 1.500 0.0025 0.003 0.003 0.003 0.004 0.004 0.006 0

22、.006 0.003 0.0035 0.0035 0.005 Over 9.52 to 15.88 Over 15.88 to 25.4 Over 25.4 to 28.6 Over 28.6 to 38.1 0.06 0.08 0.08 0.08 0.10 0.10 0.15 0.15 0.06 0.09 0.09 0.13 Over 1.500 to 2.000 Over 2.000 to 2.500 Over 2.500 to 3.000 Over 3.000 to 3.500 Over 3.500 to 4.000 0.003 0.004 0.005 0.006 0.006 0.008

23、 0.010 0.010 0.010 - 0.005 0.006 0.008 0.009 0.010 Over 38.1 to 50.8 Over 50.8 to 63.5 Over 63.5 to 76.2 Over 76.2 to 88.9 Over 88.9 to 101.6 0.08 0.10 0.13 0.15 0.15 0.20 0.25 0.25 0.25 - 0.13 0.15 0.20 0.23 0.25 * Inside diameter tolerances not applicable to Grade F tubing. 4.5.1 Flash Height Grad

24、e NF: There will be no dimensional indications of the presence of the weld. Grade F: The outside flash will be removed to provide a smooth surface. The inside flash will conform to the following. Nominal OD Nominal Wall Thickness, incl Height of Flash, Maximum Inch mm Inch mm Inch mm Thru 1.000 Over

25、 1.000 Thru 25.4 Over 25.4 Up to 0.035 Over 0.035 to 0.065 Over 0.065 Up to 0.89 Over 0.8 to 1.65 Over 1.65 All 0.005 0.008 0.010 0.010 0.13 0.20 0.25 0.25 NUMBER: MPAPS A-45, PART II TITLE Hydraulic Line Tubing and Tubing Assemblies CURRENT ISSUE DATE: June 2015 This document is restricted and may

26、not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. JUNE 2015 Page 4 of 9 4.5.2 Wall Thickness Grade NF 15% for tubing with nominal OD 9.52 mm (0.375 inch) and under 10%

27、for tubing with nominal OD over 9.52 thru 101.6 mm (0.375 thru 4 inches) Grade S 15% for tubing with nominal ID under 12.7 mm (0.500 inch). 10% for tubing with nominal ID 12.7 thru 88.9 mm (0.500 thru 3.500 inches). TABLE V WALL THICKNESS TOLERANCES GRADE F Nominal Wall Thick- ness, * Inch Nominal T

28、ubing Outside Diameter, Inches Nominal Wall Thick- ness, * mm Nominal Tubing Outside Diameter, mm Thru 1.000 Over 1.000 thru 2.000 Over 2.000 thru 4.000 Thru 25.4 Over 25.4 thru 50.8 Over 50.8 thru 101.6 Tolerances, Inches * Tolerances, mm * Plus Minus Plus Minus Plus Minus Plus Minus Plus Min,us Pl

29、us Minus 0.028 0.035 0.049 0.065 0.002 0.002 0.002 0.004 0.003 0.004 0.005 0.006 0.003 0.003 0.003 0.005 0.003 0.004 0.005 0.008 0.004 0.004 0.004 0.006 0.003 0.004 0.005 0.008 0.71 0.89 1.24 1.65 0.05 0.05 0.05 0.10 0.08 0.10 0.13 0.15 0.08 0.08 0.08 0.13 0.08 0.10 0.13 0.20 0.10 0.10 0.10 0.15 0.0

30、8 0.10 0.13 0.20 0.083 0.095 0.109 0.120 0.004 0.004 0.004 0.004 0.006 0.006 0.006 0.008 0.006 0.006 0.008 0.008 0.008 0.010 0.010 0.010 0.007 0.008 0.009 0.009 0.008 0.010 0.010 0.010 2.11 2.41 2.77 3.05 0.10 0.10 0.10 0.10 0.15 0.15 0.15 0.20 0.15 0.15 0.20 0.20 0.20 0.25 0.25 0.25 0.18 0.20 0.23

31、0.23 0.20 0.25 0.25 0.25 0.134 0.148 0.165 0.180 0.004 - - - 0.008 - - - 0.008 0.008 0.008 0.008 0.010 0.011 0.011 0.011 0.009 0.009 0.009 0.009 0.010 0.011 0.011 0.011 3.40 3.76 4.19 4.57 0.10 - - - 0.20 - - - 0.20 0.20 0.20 0.20 0.25 0.28 0.28 0.28 0.23 0.23 0.23 0.23 0.25 0.28 0.28 0.28 0.203 0.2

32、20 0.238 0.259 - - - - - - - - 0.008 0.008 0.013 0.013 0.012 0.012 0.018 0.020 0.009 0.009 0.014 0.014 0.012 0.012 0.018 0.020 5.16 5.59 6.05 6.58 - - - - - - - - 0.20 0.20 0.33 0.33 0.30 0.30 0.46 0.51 0.23 0.23 0.36 0.36 0.30 0.30 0.46 0.51 * For an intermediate wall thickness, the tolerance for t

33、he next thicker wall thickness will apply. * Plus tolerances include allowance for crown on flat rolled steel. 4.6 Formed Tubing Out of roundness will not exceed 10% of the tubing outside diameter in the area of bending. 4.6.1 Brazed Joints All brazed joints will be smooth and have complete penetrat

34、ion of the brazing alloy (i.e., a complete ring of brazing alloy at the top and bottom of the joint). No evidence of pin holes, voids, etc., regardless of size, will be permitted. Prior to brazing, phosphate coating must be removed in area to be brazed. When brazing with a silver base filler metal,

35、procedures will be in accordance with Manufacturing Standard MS-K-5. For furnace atmosphere brazing with a copper base filler metal, recommended joint clearances are from 0.025 mm (0.001 inch) interference to 0.050 mm (0.002 inch) loose on a diameter. 4.6.2 Flares Flares will be 37 degrees in accord

36、ance with Engineering Standard Parts MPAPS-S, Section L. Grades NF and S tubing will be single flared and Grade F tubing will be double flared. NUMBER: MPAPS A-45, PART II TITLE Hydraulic Line Tubing and Tubing Assemblies CURRENT ISSUE DATE: June 2015 This document is restricted and may not be sent

37、outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. JUNE 2015 Page 5 of 9 4.6.3 Flared Tube Nuts And Sleeves 37 degree flared hydraulic tube sleeves and Style B nuts will be provided

38、. They will conform to the requirements shown in MPAPS-S- L, for zinc plated steel. For convenience, the part number combinations to be used are listed in Table VI below. TABLE VI 37 DEGREE FLARED HYDRAULIC TUBE NUTS AND SLEEVES Nominal Tube Outside Diameter Straight Thread Size Part Number Inches m

39、m Nut Sleeve 0.188 0.250 0.312 0.375 4.78 6.35 7.92 9.52 3/8-24 7/16-20 -20 9/16-18 9403524 9403525 9403526 9403527 9403446 9403447 9403448 9403449 0.500 0.625 0.750 0.875 12.70 15.88 19.05 22.22 -16 7/8-14 1-1/16-12 1-3/16-12 9403528 9403529 9403530 9403531 9403450 9403451 9403452 9403453 1.000 1.2

40、50 1.500 25.40 31.75 38.10 1-5/16-12 1-5/8-12 1-7/8-12 9403532 9403533 9403534 9403454 9403455 9403456 4.6.4 Hydrostatic Proof Pressure All tubing assemblies will be capable of withstanding the hydrostatic proof pressure for the size tubing used without showing defects. See Section 3.6.4 for require

41、ments, except that the maximum hydrostatic pressure limitation of 43.5 MPa (5 ksi) does not apply to tubing assemblies. Tubing assemblies will conform to drawing configuration after testing. 4.6.4.1 Perform the test per Section 8.6 with the following modifications: 4.6.4.1.1 Fill assembly with fluid

42、 before applying pressure 4.6.4.1.2 Use a maximum increase in pressure rate of 103 MPa/minute (15 ksi/minute) 4.6.4.1.3 Maintain the test procedure for 30 second minimum. 4.6.5 Phosphate Coating The outside and inside diameters of the tubes will be phosphate coated in accordance with Class B-1 per M

43、PAPS G-1. A protective phosphate coating is required on all tubing used in any assembly regardless of type of connection (hose or metal fitting). The phosphate coating may be applied to either the individual tubing piece part or the tubing assembly. When the tubing is phosphate coated as an assembly

44、, uncoated areas may occur on the OD where sleeves and/or nuts have been positioned. These uncoated areas must be satisfactorily protected from corrosion prior to painting or other surface finishing. 4.6.6 Capping And Sealing Of Finished Tubes The inside of the tubes will be clean and free of foreig

45、n particles. The tubes will be capped and sealed as outlined below. Deviation from this procedure, such as for the use of aluminum caps, non-threaded caps for male threaded ends, etc., will be permitted only by authority of the controlling engineering department. 4.6.6.1 Procedure for Production Tub

46、es Installed at Navistar Plants NUMBER: MPAPS A-45, PART II TITLE Hydraulic Line Tubing and Tubing Assemblies CURRENT ISSUE DATE: June 2015 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are requir

47、ed to assume all patent liability. 2015 by Navistar, Inc. JUNE 2015 Page 6 of 9 4.6.6.1.1 Plain Non-threaded Ends Caps with Caplug(1) Series SC of Clover Industries(2) Series LT non-threaded plastic sleeve caps which have a minimum length of 19 mm (0.75 inch). They will be installed in such a manner

48、 that the tube end contacts the bottom of the cap and the snug friction grip exists between the tube and cap. 4.6.6.1.2 Female Straight Threaded Ends Flared ends with nuts and sleeves will be capped with Caplug(1) Series PD caps. Install the caps in such a manner that the nut is drawn tightly on the flare and the nut is completely covered by the cap. 4.6.6.1.3 Male Straight Threaded ends Caplug(1) Series CD threaded caps will be used