NAVISTAR MPAPS C-8-2016 Aluminum Alloy Castings (Includes Appendix).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 11 NAVISTAR, INC. Material, Parts, and Process Specifications

2、 (MPAPS) NUMBER: MPAPS C-8 Former Designation: CEMS C-8 TITLE: Aluminum Alloy Castings CURRENT REV. No: 1604 DATE: APRIL 2016 WRITTEN/REVISED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES : Rev. 1510 Oct. 2015 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification m

3、ay 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 prior to use.

4、 Change Notice: Added 384.0F; Editorial Changes 1.0 SCOPE This specification covers the chemical composition limits and mechanical properties for the most frequently used grades of aluminum alloy castings for engine and truck components. 2.0 INTRODUCTION Aluminum alloy castings are light weight and

5、offer a good combination of strength, corrosion resistance and machinability. They are suitable for many surface treatments like polishing and/or anodizing to provide good cosmetic appearance. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of t

6、his specification must comply with the requirements of the MPAPS B-50 specification. 3.0 CONTENTS PAGE REFERENCE DOCUMENTS 2 CLASSIFICATION 2 GENERAL REQUIREMENTS 3 QUALITY 3 SOURCE APPROVAL AND QUALITY CONTROL 5 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS 5 PACKING AND SHIPPING 5 NUMBER: MPAPS C-8

7、TITLE: Aluminum Alloy Castings 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 11 4.0 REFERENC

8、E DOCUMENTS This standard, unless otherwise specified, shall be used in conjunction with the latest issue of all referenced standards. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 ASTM B85/B85M NAVISTAR Man

9、ufacturing Standard MS-D-13 ASTM B108/B108M NAVISTAR Engineering Procedural Standard EPS-143 ASTM B26/B26M NAVISTAR Engineering Procedural Standard EPS-91 SAE J452 NAVISTAR MPAPS B-50 ASTM B917/B917M CFR Title 29, Part 1910 ASTM E23 ASTM B505 ASTM B769 MIL I 17563C ASTM B557 ASTM E10 5.0 CLASSIFICAT

10、ION Aluminum alloys are classified on the basis of chemical composition. Specification of aluminum alloys further requires the identification of the casting process and post casting heat treatment. Navistar also classifies cast aluminum parts by function: Structural, Fluid Transport, and General Pur

11、pose (non-structural). 5.1 Chemical Composition Proprietary trade names used by specific companies should not be used in a specifying an alloy. Use the designation and defined chemistry as ascribed to each alloy by a national or international standardization organization. Examples of standardization

12、 organizations that may be referenced include The Aluminum Association, ASTM, ISO, DIN and JIS. 5.2. The Casting Process: S, P or D. 5.2.1 The letter S is used mainly for parts made in bonded sand molds. Other casting process that employ sand or plaster as mold medium- Evaporative Pattern Casting (E

13、PC), Shell Mold Casting, Plaster Casting etc, should also use this letter but must also be identified in a separate note on the drawing. 5.2.2 The letter P is used for parts made in metallic permanent molds using gravity or low pressure feed systems (170kPa/ 25psi or less). Semi-permanent mold casti

14、ngs employing the sand cores are included in this process designation. Note that some international standardization organizations use the letter “K” to describe this type of casting process. 5.2.3 The letter D is used for parts made by injecting molten metal into a die- mold under considerable press

15、ure. 5.2.4 When exotic casting/processing methods like centrifugal casting, squeeze casting or semisolid-metal processing are employed, use the letter above that best describes the mold to be used (S or P) and describe the actual casting process in a separate note. 5.3 Post Casting Heat treatment (t

16、emper) Identify along with casting process per The Aluminum Association temper designation system 5.4. Casting Class Indicated for all castings as described in section 7.3. NUMBER: MPAPS C-8 TITLE: Aluminum Alloy Castings REVISION: 1604 This document is restricted and may not be sent outside Navista

17、r, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 3 of 11 6.0 GENERAL REQUIREMENTS 6.1 Chemical Composition Requirements Alloy designations and chemical composition limits are sho

18、wn in Table I (refer to the applicable ASTM standard - ASTM B85/B85M for die castings, ASTM B26/B26M for sand castings, and ASTM B108/B108M for permanent or semi-permanent mold castings). Alloy designations and compositions compiled by other standardization bodies which are not listed in Table 1, ma

19、y be specified in the callout in conjunction with the governing standard as indicated in section 10.0. 6.2 Mechanical Properties Heat treatment of sand and permanent mold castings shall be specified by the addition of a suffix to the alloy designation as shown in Table II. The letter “F” indicates t

20、hat castings are to be supplied “as cast” without any heat treatment. Die castings are not heat treated. 6.2.1 Mechanical properties of separately cast test bars representing sand and permanent mold castings shall conform to the requirements listed in Table III. Property requirements of test bars ma

21、chined from castings shall be not less than 75% of the tensile and yield strength values shown and not less than 25% of the elongation values specified, except for permanent mold castings of alloys 354.0, C355.0, A356.0, A357.0, and 359.0 for which the tensile strength and elongation of test specime

22、ns cut from castings shall be in accordance with the values listed in Table III. When the strength of particular areas of the casting is critical, the locations where test bars may be obtained will be shown on the drawing and test bars machined from these locations can be used to verify that require

23、ments are met. 6.2.2 Die castings purchased to this specification will not depend on mechanical properties unless specified on the engineering drawing and guaranteed by the manufacturer. For typical properties of die castings, see Table II in MPAPS C-8 Appendix. 6.3 Identification Where space permit

24、s, the NAVISTAR part number and vendors identification will be shown When a date code is required by the controlling engineering department on castings, it will be specified on the engineering drawing. Engineering Procedural Standard EPS-91* covers requirements for date codes. The company trademark

25、per Engineering Procedural Standard EPS-143* may also be cast or stamped on each casting at a location shown on the engineering drawing Packaging and identification for shipment to Navistar facilities will be in accordance with Manufacturing Standard MS-D-13*. *Navistar EPS-143, EPS-91, and can be o

26、btained from Corporate Technical Standards, 2601 Navistar Dr., Lisle IL 60532. MS-D-13, Supplier Packing and Shipping Standard, can be obtained at 7.0 QUALITY 7.1 Casting Soundness Castings must be clean, sound and free from harmful porosity and segregation or other injurious defects. Unless otherw

27、ise specified on the drawing, sand and permanent mold castings shall meet the discontinuity requirements for a Grade C casting in ASTM B26 and B108 respectively. Die castings shall have no worse than a Level 2 discontinuity in any category per ASTM E505 except by agreement between the producer and N

28、avistar Engineering. When the soundness of particular areas of the casting is critical, the locations will be shown on the drawing with specific discontinuity type and level requirements. Sand and permanent NUMBER: MPAPS C-8 TITLE: Aluminum Alloy Castings REVISION: 1604 This document is restricted a

29、nd 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 4 of 11 mold castings may be required to meet the discontinuity requirements for a Grade B cast

30、ing on the print. When a non-critical area of a component cannot realistically meet the Grade C general requirement, it shall be documented on the print, annotating the location and the discontinuity types and achievable severity levels to be allowed. The specification of a maximum pore/ hole/ defec

31、t size may also be indicated on a drawing by agreement. 7.2 Repair The only repair allowed to castings without written approval from engineering is impregnation. All other repair procedures (welding, sealing, straightening, heat treatment, etc.) require written approval from the responsible design e

32、ngineer and materials engineering. Impregnation of castings to seal voids which cause leaking is allowed per MIL-I-17563C, unless otherwise stated on the print. The impregnant shall be Class 1 (suitable for service temperatures up to 300F). Higher temperature applications will call out the requireme

33、nts for the impregnant on the drawing. A casting is allowed to be impregnated up to two times to meet leaking requirements. 7.3 Casting Class: All castings shall be placed into one of the classes below and the class denoted on the drawing. Castings which have a critical dFMEA failure mode severity o

34、f 9 or 10, and/or any component identified on “Critical Cast Component List” provided in Section A0 at the end of this specification, shall be reviewed by the responsible design SMT and Materials Engineering and assigned a Class of F, S, or M. and shall be identified as a “Critical Casting” by notat

35、ion on the drawing. All other castings shall be placed into Class G. Class F: components which require a validation and verification plan for fluid transport properties Class S: components which require a validation and verification plan for structural support properties Class M: components which re

36、quire a validation and verification plan for a mix of fluid transport and structural support properties Class G: components which have general validation and verification plan requirements A validation and verification plan shall be executed during the total product lifecycle of all castings per the

37、ir classification as indicated in Section A1 below. Evaluation of castings against criteria listed here and to other specified requirements shall be conducted during initial part development (DVP Boron, 0.005 max. (3) Beryllium, 0.04-0.07 (4) Per JIS H5302 * D = die; P = permanent mold; S = sand * P

38、iston alloys; 32M is a Navistar designation. NUMBER: MPAPS C-8 TITLE: Aluminum Alloy Castings 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 liabili

39、ty. 2016 by Navistar, Inc. APRIL 2016 Page 7 of 11 TABLE II HEAT TREATMENT SUFFICES Temper designation Type of heat treatment F As cast O Annealed T1 Controlled cooling from casting and naturally aged T4 Solution heat treated and naturally aged T5 Controlled cooling from casting and artificially age

40、d or over-aged T6 Solution treated and fully artificially aged T61 Solution Treated, held at room temperature for at least 8 hours and artificially aged T64 Solution treated and artificially under-aged T7 Solution heat treated and artificially over-aged (stabilized) NUMBER: MPAPS C-8 TITLE: Aluminum

41、 Alloy Castings 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 8 of 11 TABLE III - MECHANICAL PROP

42、ERTY REQUIREMENTS, SAND AND PERMANENT MOLD CASTINGS Designation /Temper Casting Process Tensile Strength, min(1) Yield Strength (0.2% offset), min(1) Elongation in 2 inches (50 mm), % min(1) Typical Brinell Hardness (500 kg)(2) ksi Ksi % HBW 32MT5-F P - 90-125 A332.0-T551 P 31 90-120 A332.0-T65 P 40

43、 125 F332.0-T5 P 31 90-120 Z332.0-T5 P 31 70 201.0-T7 S 60 50 3.0 - 204.0-T4 S 45 28 6.0 - 206.0-F S measured by the distance a molten alloy will flow at a given pouring temperature before freezing. Resistance to hot cracking the property of an alloy to withstand stresses from contraction while cool

44、ing through the final (“hot short”) stage of solidification. Pressure tightness the degree of soundness attainable in a casting as indicated by the absence of leakage, through the walls or sections, of air or other media under pressure. Response to heat treatment - a characteristic dependent upon co

45、mposition. Some of the alloys listed as “not normally heat treated” may show some improvement of properties when heat treated. Moreover, alloys listed as normally heat treated are frequently used without heat treatment if their as-cast properties are adequate for a specific application. Corrosion re

46、sistance the resistance of alloys to loss of sectional strength and surface appearance upon exposure to various environments. The comparative ratings given in Table I are based, in general, upon performance in various industrial or seacoast atmospheres. Exposures to specific corroding conditions sho

47、uld be investigated in further detail. Strength at elevated temperatures rating based upon tests made at temperatures up to 260C (500F) after prolonged exposure at such temperatures. NUMBER: MPAPS C-8, APPX TITLE Aluminum Alloy Castings - APPENDIX REVISION: 1604 This document is restricted and may n

48、ot 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 9 Machinability based upon ease of cutting, chip characteristics, quality of finish and tool life. For the heat-treated alloys, the ratings are based upon the T6 temper