NAVISTAR MPAPS C-14-2015 Zinc Base Alloy Die Casting.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. DECEMBER 2015 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specificati

2、ons (MPAPS) NUMBER: MPAPS C-14 Former Designation: CEMS C-14 TITLE: Zinc Base Alloy Die Casting CURRENT REV No.: 1512 DATE: Dec. 2015 WRITTEN/EDITED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: Rev. December 2001 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This spe

3、cification 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 regulatory limits p

4、rior to use. Change Notice: Editorial changes, combined with CEMS C-14 appendix and updated to MPAPS format. 1.0 APPLICATION Zinc base alloys are highly coatable, easily finished, and generally lower cost than comparable aluminum alloys. They provide good mechanical properties and are used in a wide

5、 range of decorative and light structural applications. 2.0 SCOPE This specification covers zinc base alloy die castings used in the Companys products. Zinc base alloys are classified by chemical composition. The alloy described in this specification, International DZ-96-4-05, UNS Z33525, is a high

6、purity alloy commonly known as Alloy 3. 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 MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue

7、 of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CFR Title 29, Part 1910 NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR Engineering Design Std A-16 NAVISTAR MPAPS B-50 A

8、STM B 86 NUMBER: MPAPS C-14 TITLE: Zinc Base Alloy Die Casting REVISION: 1512 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. DECE

9、MBER 2015 Page 2 of 6 4.0 REQUIREMENTS 4.1 Chemical composition TABLE I - CHEMICAL COMPOSITION OF DIE CASTINGS Percentage International ASTM B86 Elements min max DZ-96-4-05 Alloy 3 Zamak 3 AG40A UNS Z33525 aluminum 3.70 4.30 Copper* 0.10 magnesium 0.02 0.06 iron 0.05 cadmium 0.004 tin 0.002 lead 0.0

10、05 zinc remainder * For the majority of commercial applications, a copper content of up to 0.7 % will not adversely affect the serviceability of die castings and should not serve as a basis for rejection 4.2 Mechanical Properties 4.2.1 In the case of highly stressed parts, minimum requirements for t

11、ensile properties or impact strength, or both, may be specified. 4.2.1.1 Acceptance of castings does not depend on mechanical properties of separately cast test bars samples unless specifically noted on the drawing. 4.2.2 In the event that such requirements are essential, the test bar requirements s

12、hown in Table II will be shown on the drawing. These test bar values do not indicate the actual properties of the castings except in a comparative fashion and should not be used to establish design limits or acceptance criteria. TABLE II - MINIMUM MECHANICAL PROPERTIES OF DIE CAST TEST BARS Tensile

13、Strength min Elongation in 2 in (50 mm) Charpy Impact min psi MPa percent, min ft lbs N m average of specimens tested* 35 000 241 10.0 35.0 47.4 individual specimens 30 000 207 3.0 15.0 20.3 * 5 tension test specimens and 10 impact test specimens (cut from 5 separately cast bars) will be tested from

14、 each shipment when specified. 4.3 Identification Each casting will be marked with the suppliers trademark and the International part number as shown on the drawing. Additional identification requirements may be shown on the drawing. NUMBER: MPAPS C-14 TITLE: Zinc Base Alloy Die Casting REVISION: 15

15、12 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. DECEMBER 2015 Page 3 of 6 5.0 QUALITY Castings will be of uniform quality and f

16、ree from dirt, dross, blowholes, shrink cavities, or other imperfections which affect usability. Some porosity may be present in castings which have large or nonuniform sections. The extent of this porosity, where objectionable, will be mutually agreed upon by the supplier and purchaser for each ind

17、ividual casting. 6.0 METHOD OF TEST 6.1 Test specimens and methods of test will be as shown in ASTM B 86. 7.0 QUALITY CONTROL PLAN A Quality Control Plan for products supplied to the requirements of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless

18、specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control.* * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See

19、NAVISTAR Engineering Design Standard A-16 8.0 SOURCE APPROVAL AND QUALITY CONTROL 8.1 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 fulfill all AI

20、AG 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. 8.2 APPROVAL Parts supplied against contracts or pu

21、rchase 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, construction,

22、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 Material

23、 Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. NUMBER: MPAPS C-14 TITLE: Zinc Base Alloy Die Casting REVISION: 1512 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from C

24、orporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 4 of 6 8.3 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

25、 statistical 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

26、. 9.0 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. 10.0 DESIGNATION ON DRAWINGS Designation on drawings and purchase orde

27、rs will show alloy designation. When minimum mechanical properties or special physical tests are required, they will also be shown. Example: DZ-96-4-05, MPAPS C-14 11.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purcha

28、se controlled copies of this specification 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:

29、/ NUMBER: MPAPS C-14 TITLE: Zinc Base Alloy Die Casting REVISION: 1512 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. DECEMBER 20

30、15 Page 5 of 6 A.0 GENERAL INFORMATION A.1 CHARACTERISTICS A.1.1 This alloy is subject to some aging changes, one of which is a dimensional change. It is possible to accelerate this shrinkage by a stabilizing anneal, after which no further changes occur. The recommended stabilizing anneal is 3 to 6

31、hours at 212F (100C). Stabilizing results in a decrease in dimensions of about 0.0005 in/in (0.5 mm/m) from the original size of the casting. Stabilizing is, of course, unnecessary if the machine or fitting operations can be delayed until the castings have aged five weeks at room temperature. A.1.2

32、A nonuniform type of corrosion may occur on zinc die castings, which often results in the formation of a bulky film of white corrosion products. This may hinder the operation of some parts. Various types of chromate films are available to alleviate this condition. A.1.3 Organic finishes are quite va

33、riable in their ability to adhere well to zinc surfaces. The phosphate type of chemical pretreatment has received widest commercial utilization, and most zinc die castings which are to be finished with lacquers or enamels are phosphate pretreated. In general, a much wider selection of finishes can b

34、e used on pretreated die castings. A.1.4 Zinc base alloys have a relatively high coefficient of thermal expansion, which is sometimes an important factor in determining whether this material may be used in the same assembly with other materials. The coefficients of expansion for the alloy covered by

35、 this specification and for those of other commonly used metals and alloys are shown in Table I. A.1.5 Die casting cost comparisons between aluminum and zinc cannot be covered here but will be appreciably affected by such factors as quantity, weight and the type of finish required. TABLE I - COEFFIC

36、IENTS OF THERMAL EXPANSION Material Temperature Range Coeff of Linear Expansion x 106 F C per F per C pure zinc 50-212 10-100 14.6 26.3 zinc base alloy DZ-96-4-05 68-212 20-100 15.2 27.4 aluminum silicon die cast alloy C413.0 68-212 20-100 12.2 22.0 aluminum silicon die cast A413.0 68-212 20-100 11.

37、1 20.0 aluminum copper die cast alloys B380.0 68-212 20-100 11.6 20.9 aluminum alloys 1100, 20124, 5052, 6061, 319.0, 355.0 68-212 20-100 12.0-13.2 21.6-23.8 brass 68-212 20-100 9.7-10.7 17.5-19.3 cast iron 68-212 20-100 5.9 10.6 copper 68-212 20-100 9.3 16.7 lead 68-212 20-100 16.3 29.3 steel 68-21

38、2 20-100 6.0-7.0 10.8-12.6 NUMBER: MPAPS C-14 TITLE: Zinc Base Alloy Die Casting REVISION: 1512 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 N

39、avistar, Inc. DECEMBER 2015 Page 6 of 6 A.2 TYPICAL PROPERTIES OF CASTINGS AND TEST BARS The mechanical properties of castings covered by this specification will differ from those of the test bars and there will be variation in different locations in the casting. Variation in properties within the c

40、asting will depend on design and casting practice. Uniformity in shape and wall thickness is desirable. When variation in wall thickness is necessary, transition from heavy to light sections should be gradual. Light sections will be proportionately higher in strength than heavy sections. Physical co

41、nstants and typical mechanical properties are shown in Table II. TABLE II - TYPICAL MECHANICAL AND PHYSICAL PROPERTIES OF TEST BARS tensile strength, as cast 41 000 psi 283 MPa tensile strength after 7 years indoor aging 33 800 psi 233 MPa tensile elongation % in 2 in. (50 mm), as cast 10 10 tensile

42、 elongation % in 2 in. (50 mm), after 7 years indoor aging 16 16 impact strength (Charpy), as cast 43 ft lbs 58 Nm impact strength (Charpy), after 7 years indoor aging 41 ft lbs 56 Nm Brinell hardness (500 kg Load) 82 82 melting point 728 F 387 C modulus of rupture 95 000 psi 655 MPa specific gravity 6.6 6.6 thermal conductivity (cal/sec/sq cm/cm C at 18 C 0.27 113 watts/m C thermal expansion, in/in/F (m/m/C) 15.2/ F 27.4/ C