NAVISTAR MPAPS C-1059-2016 Aluminum Tubing For Engine Air Fluid Systems.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. 2016 by Navistar, Inc. APRIL 2016 Page 1 of 14 NAVISTAR, INC. Material, Parts, and Process Specification

2、s (MPAPS) NUMBER: MPAPS C-1059 Former Designation: TMS-1059 TITLE: Aluminum Tubing For Engine Air/Fluid Systems CURRENT REV No.: 1604 DATE: April 2016 WRITTEN/EDITED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: Rev. 1204 April 2004 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURREN

3、T REVISION 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

4、regulatory limits prior to use. Change Notice: Updated to MPAPS format, editorial corrections 1.0 APPLICATION This specification covers aluminum tubing used in coolant, engine air intake, and charge air cooler systems (CAC), with formed, beaded, or straight ends. 2.0 SCOPE This specification covers

5、construction, material, welding, dimensional tolerances, KCC, workmanship standards, source approval and quality control, and shipping requirements. NOTE: Existing drawings for product covered by this specification may refer to Engineering Drawing AM-74447 or to MPAPS F-1058 for workmanship standard

6、s; such references on existing drawings are superseded by this specification. NOTE: Coolant hose end form designs are covered by MPAPS F-1. Any releases after April 2012 shall use that standard. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of

7、 this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality

8、System Standard ISO 9001 or TS-16949 NAVISTAR Engineering Design Std A-16 MPAPS F-2 CFR Title 29, Part 1910 NAVISTAR MPAPS B-50 AWS A2.4 CFR Title 40, Section 205 NAVISTAR MPAPS F-1 ANSI H35.2 NAVISTAR Manufacturing Std. MS-D-13 MPAPS C-10 AWS D1.2 NUMBER: MPAPS C-1059 TITLE: Aluminum Tubing For Eng

9、ine Air/Fluid Systems REVISION: 1604 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. 2016 by Navistar, Inc. APRIL 2016 Page 2 of 14 4.0 REQUIREMENTS 4.1

10、Construction 4.1.1 Engineering design (RPO) is generally based upon single piece construction, rather than cut and weld construction. The welding process adds extra cost and introduces distortion, which reduces the consistency and accuracy of alignment at the tube ends. Unless otherwise specified on

11、 the engineering drawing or purchase order, the use of cut and weld construction shall require engineering approval. 4.1.2 In many cases, tubing used in the air intake and/or charge air systems are parts of the truck system which are required to meet Federal Noise Regulations (CFR Title 40, Section

12、205). All such applications shall be so indicated on the engineering drawing, and in these applications no deviations in construction and/or material shall be permitted without prior Engineering approval. 4.2 Material Requirements Unless otherwise specified on the engineering drawing, tubing supplie

13、d will meet the following requirements: 4.2.1 Tubing Material: Shall be 3003, 6061, or 6063 aluminum per MPAPS C-10. 4.2.2 Temper: Unless engineering drawing specifies a particular temper, the tubing fabricator is responsible to select a temper suitable for fabrication which will allow the part(s) t

14、o meet the requirements of this specification. 4.2.3 Tubing: Shall be seamless drawn, extruded, or welded tube at the option of the tubing fabricator. Tubing shall meet dimensional requirements of ANSI H35.2. 4.3 Dimensional Tolerances Unless otherwise specified, the dimensional tolerances shown in

15、Figs. 2 thru 10 of this specification shall apply to fabricated tube and tube assemblies, and the standard dimensional tolerances shown in the title block of the Navistar Engineering drawing are not applicable. 4.3.1 Tubing Wall Thickness Tubing wall thickness shall be specified on the engineering d

16、rawing. On existing drawings where thickness is not specified, wall thickness shall be 0.083 inch. 4.4 Welding Required welding will be specified on the engineering drawing, and will comply with the American Welding Society standard AWS D1.2, Structural Welding Code for aluminum. Weld symbols shown

17、on engineering drawings shall be in accordance with AWS A2.4. Sizes of fillet/groove welds shown on the engineering drawing are minimum values. 4.4.1 Welds on Fabricated Tubing All welds on fabricated tube shall be neat and continuous with a minimum of flash and/or weld spatter. No weld spatter is p

18、ermitted on flange sealing surfaces. 4.4.2 Leakage Welded pipes/tubing shall show no leakage when pressure-tested at 25 psi (min) pressure. NUMBER: MPAPS C-1059 TITLE: Aluminum Tubing For Engine Air/Fluid Systems REVISION: 1604 This document is restricted and may not be sent outside Navistar, Inc. o

19、r reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 3 of 14 4.5 Workmanship 4.5.1 Unless otherwise specified, contour of the pipes/tube is to be maintained to provide 0.25 inch location of t

20、he end points with the layout. Intermediate points shall be located within 0.25 inch. Bend radii to be within 0.25 inch. See Figures 2 and 3. 4.5.2 Wrinkles in or adjacent to bends shall not exceed 0.030 inch depth on pipes/tubes up to 3.0 inch OD (inch) and shall not exceed 0.040 inch depth on larg

21、er OD pipes/tubes. 4.5.3 Reduction of the OD in bend areas shall conform to limits shown in chart #1 and Fig. 3. 4.5.4 There shall be no severe scratches or tool marks on the pipe/tube. All product supplied to the requirements of this specification shall be free of oxidation, stains, oil, dirt, meta

22、l chips, grease, etc., and shall be clean and dry to the touch. When specified on the engineering drawing, the pipe shall meet cleanliness requirements of MPAPS F-2 and, when so specified, the ends of the pipe shall be capped or otherwise protected to prevent contamination in shipment and/or storage

23、. 5.0 QUALIFICATION Engineering qualification of sources is required in advance of production shipments. Samples shall be accompanied by test data certifying that all requirements of the specification have been met. 5.1 Quality Control Plan A Quality Control Plan for products supplied to the require

24、ments of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control.* * Other characteristi

25、cs for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Design Standard A-16 5.2 KCC Requirements Applicable To CAC Pipes Specific dimensions have been designated by Engineering as KCC features for all charge air cooler (CAC)

26、 pipes. Unless specific exception is noted on the engineering drawing and/or purchase order, the following characteristics are designated as KCC features: 1. OD of the pipe within 1.5 inches of the pipe ends. 2. Height of the sealing bead. 5.3 KCC Requirements Applicable to Air Cleaner Pipes Specifi

27、c dimensions have been designated by Engineering as KCC features for air cleaner pipes. Unless specific exception is noted on the engineering drawing and/or purchase order, the following characteristics are designated as KCC features: 1. OD of the pipe within 1.8 inches of the pipe ends. 2. Height o

28、f the sealing bead. NUMBER: MPAPS C-1059 TITLE: Aluminum Tubing For Engine Air/Fluid Systems REVISION: 1604 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 liabilit

29、y. 2016 by Navistar, Inc. APRIL 2016 Page 4 of 14 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfil

30、l all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 6.2 Approval Parts supplied against contrac

31、ts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, constr

32、uction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated

33、Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide stat

34、istical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. 7.0

35、 SHIPPING AND HANDLING Shipping and identification shall be in accordance with NAVISTAR Manufacturing Standard MS-D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. 8.0 DESIGNATION ON DRAWINGS The drawing must indicate material and workmans

36、hip as per MPAPS C-1059. Standard drafting stamps/notes are included in the UG library. Example of note to use on drawings: 1. For pipe material, material specification, and workmanship, see MPAPS C-1059. 2. Bead design per MPAPS C-1059, Fig. 5 or Fig. 7 3. Optional Engagement Dimple per MPAPS C-105

37、9, Fig. 9 4. Cleanliness per MPAPS F-2; ends to be capped. See requirements per MPAPS C-1059 NUMBER: MPAPS C-1059 TITLE: Aluminum Tubing For Engine Air/Fluid Systems REVISION: 1604 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate

38、Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 5 of 14 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification

39、 by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ NUMBER: MPAPS C-1059 TITLE: Aluminum Tub

40、ing For Engine Air/Fluid Systems REVISION: 1604 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. 2016 by Navistar, Inc. APRIL 2016 Page 6 of 14 A.0 GENERA

41、L INFORMATION (not a requirement) In order to obtain maximum life for pipe/tubing systems, to standardize designs and minimize costs, procedures described herein should be followed. This is particularly important with regard to bend radii and bend locations relative to each other. A.1 Design Procedu

42、re for Engineering Reference A more effective and efficient method for the design of tubular products used in engine air/fluid systems has been developed. This method involves the simple use of a line drawing (center line) and XYZ coordinate table. An example of this method is shown in Figure 10. Al

43、l radii are specified to the center line of the pipe and all dimensions are given from the centerline and intersecting points. Provision of coordinates is via the XYZ-Tubing program available within the UNIGRAPHIC GRIP Program system. A.1.1 The use of this design method facilitates transfer of data

44、from the engineering drawing to manufacturing operations because the data can be transferred directly into CNC controlled tube benders and/or coordinate measuring systems to permit manufacturing/inspection without the need for intermediate manufacturing drawings and/or checking/testing templates fix

45、tures. The elimination of these steps improves efficiency/economy of operations. A.2 Manufacturing Methods and Design Procedure “Press“ (compression) bends generally have higher production rates and hence lower costs than “Mandrel“ bends and should be used whenever space permits their larger radii a

46、nd lesser degree of bend. The supplier should be consulted for the preferred bend radius and availability of tooling before release of the drawing. A.2.1 Avoid bends which are too close together and the use of “bends-within-bends.“ They are difficult to fabricate, require non-standard tooling, and a

47、dd significantly to the cost of the product. In many cases, rotating the bends (as shown in Fig. 6) will achieve the same result while permitting the use of standard tooling and reducing the costs. Use Chart #1, if necessary, to maintain adequate distance between bends as shown in Fig. 8. A.2.2 All

48、radii on each pipe/tube should be the same in order to minimize tool changes and set-up time. The exception to this rule is the special case where bends smaller than those shown in Chart #1 are necessary at one or two points and space permits the use of larger bend radii (as shown in Chart #1) at ot

49、her points. The tubing fabricator/supplier should be consulted for guidance in these cases. A.2.3 Pipes used in pressurized fluid systems (coolant, charge air coolers, and air cleaners) are often connected to elastomeric hose(s) or use elastomeric connectors to reduce vibration. Beading at the end of the tube is used to provide adequate sealing and pull-off resistance. To reduce the transmission of vibrations and stress