NAVISTAR MPAPS F-6034-2015 Charge Air Cooler (CAC) Turbo Hose.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. OCTOBER 2015 Page 1 of 14 NAVISTAR, INC. Material, Parts, and Process Specificatio

2、ns (MPAPS) NUMBER: MPAPS F-6034 Former Designation: TMS-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose CURRENT REV No.: 1510 DATE: OCT. 2015 WRITTEN/EDITED BY: M. Ghaddar APPROVED BY: R. Goluch SUPERSEDES: 1406 June 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This spec

3、ification 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 pr

4、ior to use. Change Notice: Updated Table 1b, heat aged Tensile % change to -35 and the % Elongation change to -45% 1.0 APPLICATION This specification covers different types of hoses used in engine turbo CAC systems. The hoses are used as connectors between the turbocharger, the charge air cooler, an

5、d the engine. Selection of the type shall be made by Materials Engineering. 2.0 SCOPE This specification covers construction, property requirements, dimensional tolerances, identification, source approval and quality control for the several types of hose connectors used in the CAC system. NOTE: Succ

6、essful design of the connections between the turbocharger, charge-air-cooler and the engine, requires careful consideration of the length, alignment, rigidity, and spacing of the elements that comprise the joint. Straight turbo hoses should be used for connectors. Curves and elbows should be designe

7、d into the metal pipes or other components whenever possible. See Section A.0 on DESIGN GUIDANCE. 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 REFERE

8、NCE 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 System Standard ISO 9001 or TS-16949 NAVISTAR TMS-6033 ASTM D 1418 NAVISTAR Manufacturing Std. MS

9、-D-13 NAVISTAR MPAPS P-9543 ASTM D 2240 NAVISTAR Eng. Design Std. A-16 NAVISTAR MPAPS F-2 ASTM D 865 NAVISTAR Eng. Dwg. PT12-16751 CFR Title 29, Section 1910 ASTM D 395 NAVISTAR MPAPS A-37 ASME Y14.5M-1994* ASTM D 1171 NAVISTAR MPAPS D-28 ASTM D 380 ASTM D 2137 NAVISTAR MPAPS F-1058 ASTM D 412 ASTM

10、D 2000 NAVISTAR TMS-1059 ASTM D 413 SAE J20 NAVISTAR MPAPS F-1 ASTM D 471 SAE J30 NAVISTAR MPAPS GT-31 ASTM D 624 *Conformance to the 1994 version of ASME Y14.5M is required NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose REVISION: 1510 This document is restricted and may not be sent

11、outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 2 of 14 4.0 GENERAL REQUIREMENTS Unless otherwise specified all tests will be performed per SAE J20 and indicate

12、d ASTM Test Methods. 4.1 Classification and Construction Grade designations are used to specify the application in the system and the allowed materials that can be used to meet those requirements. Suffix designations are used to specify the manufacturing method used to make the hose; the reinforceme

13、nt fibers allowed; additional oil resistance required and higher heat or pressure requirements beyond the basic levels. 4.1.1 Grades 4.1.1.1 Grade C This grade of hose is used after the air cooler and in the part of the system considered the “cold” side of the charge-air-cooler system. The tube and

14、cover stocks should typically be made to conform to Suffix R and should be made from chlorinated polyethylene (CPE), chlorosulfonated polyethylene (CSM,) or epichlorohydrin (ECO). If oil resistance is not required, then the tube and cover stocks shall be made from ethylene-propylene-diene (EPDM), si

15、milar to SAE J20 20R4 Class D-1. The cover shall be non-blooming. Polysiloxane elastomers may be used in place of EPDM if necessary. Polysiloxanes are acceptable for use on systems that are designed to recirculate oil and fuel vapors. Unless modified by other suffix call-outs, this grade of hose sha

16、ll be rated to 125C (257F) and 345 kPa gauge (50 psig), suffix N. Polysiloxane elastomers with fluoro elastomer barriers may be used if other materials and manufacturing methods cannot meet the performance requirements of this specification. 4.1.1.2 Grade H This grade covers hose used after the turb

17、o charger and before the air-to-air cooler in the section of the system considered as the “hot” side of the charge air cooler. The tube and cover stocks should typically be made to conform to Suffix R which will usually require the use of fluoro elastomer barriers or other compound variations to mee

18、t both the temperature and the oil resistance required. If oil resistance is not required the tube and cover shall be made from polysiloxane elastomers. This grade of hose shall be rated to a minimum of 249C (480F), suffix X (260C (500F) suffix Y is encouraged), and 345 kPa gauge (50 psig), suffix N

19、. 4.1.2 Suffix Letters 4.1.2.1 Suffix A Straight or formed hose reinforced with wrapped plies of woven cord nylon (Grade C only), polyester (Grade C only) or aramid fabric. 4.1.2.2 Suffix B Preformed hose with ply or plies of lockstitch knitted aramid (blend of para and meta aramids for high fatigue

20、 performance) yarn. Design and application should be thoroughly tested to ensure a durable assembly. 4.1.2.3 Suffix M (Obsolete) Mid high pressure rating to 210 kPa gauge (30 psig). (Not for use in future designs) 4.1.2.4 Suffix N (Must be selected for all hoses) - High pressure rating to 345 kPa ga

21、uge (50 psig). 4.1.2.5 Suffix R Required for systems utilizing a closed breather system or any other method of introducing oil to the air stream. Must use oil resistant unless test data shows that negligible oil will be introduced by the turbocharger under all expected operating profiles. 4.1.2.6 Su

22、ffix X Temperature rating to 249oC (480oF). 4.1.2.7 Suffix Y Temperature rating to 260C (500F) 4.1.2.8 Grade C Without Any Suffix (Obsolete) Minimum pressure rating of 120 kPa and a minimum temperature rating of 125o C. 4.1.2.9 Grade H Without Any Suffix (Obsolete) Minimum pressure rating of 120 kPa

23、 and a minimum temperature rating of 210o C. NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose REVISION: 1510 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

24、patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 3 of 14 4.2 Stainless Steel Spring Insert or Construction Rings 4.2.1 Unless otherwise specified on the engineering drawing, a steel spring insert or rings may be used to insure compliance with the “Vacuum Collapse“ or “Hot Swell“ requiremen

25、t of this specification. Under certain circumstances, a thermoplastic (glass filled nylon) may be appropriate for this application. Use of the insert, rings, or thermoplastic shall be approved by Materials Engineering. 4.2.2 Unless otherwise specified, the steel spring insert shall be formed from a

26、wire having a minimum diameter of 1.57 mm (a larger diameter wire may be used at the suppliers discretion). The spring shall exhibit a 25 mm pitch (a pitch of up to 35 mm is acceptable with larger diameter wire) and an OD approximately 3.0 mm less than the nominal ID of the hose. The wire shall be 3

27、00 series stainless steel, full hard, as per MPAPS A-37. The length of the spring shall be such that a minimum of 50 mm of free hose length remains on each end of the hose for ease of assembly and clamping. 4.3 Property and Performance Requirements - Elastomer Elastomer designation is as per ASTM D

28、1418 except where otherwise indicated. See Tables 1a and 1b for material property requirements. 4.3.1 Hardness Durometer Measure hardness per ASTM D 2240, Type A. Initial and nominal hardness values shall be stated on qualification report. Material shall be controlled to within 5 points of nominal w

29、hile the material is in production unless it is re-qualified to another value. Aging test values shall be measured as change from initial as listed in Tables 1a and 1b. NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose REVISION: 1510 This document is restricted and may not be sent outsi

30、de Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 4 of 14 TABLE 1a PROPERTIES OF TUBE AND COVER Grade C PROPERTIES OF TUBE AND COVER TEST METHOD (ASTM) TUBE AND COVER

31、Grade C TUBE AND COVER Grade C TUBE AND COVER Grade C-R TUBE AND COVER Grade C-R TUBE BARRIER Grade C-R POLYMER D1418 EPDM VMQ CM (CPE) VMQ FVMQ ORIGINAL PROPERTIES: TENSILE STRENGTH, MPA (PSI) D412, DIE C 7.0(1015) 6.0(870) 11(1595) 6.0(870) 6.0(870) ELONGATION, PERCENT MIN D412, DIE C 250 250 180

32、250 250 25% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* Report* 100% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* Report* TEAR RESISTANCE, kN/m (LBF/in), MIN D624, DIE B 17.5(100) 12 (68) 15.7(90) 12 (68) 15 (85) HEAT AGING CONDITIONS AND CHANGE LIMITS

33、HOURS EXPOSURE D573 168 168 168 168 168 TEMPERATURE, C (F) D573 135(275) 135(275) 120(248) 135(275) 120(248) HARDNESS, DUROMETER, SHORE A D2240 0 to 18 0 to 10 0 to 20 0 to 10 0 to 10 TENSILE STRENGTH, % MAX D412, DIE C -35 -35 -20 -35 -35 ELONGATION, % MAX D412, DIE C -65 -65 -60 -65 -65 25% MODULU

34、S, % MAX D412, DIE C Report* Report* Report* Report* Report* 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B Report Report Report Report Report HEAT AGING, 1000 HOURS TEMPERATURE, C (F) D573 100(212) 100(212) 100(212) 100(212) 100(212) ELONG

35、ATION, % MIN D412, DIE C 120 120 120 120 120 HARDNESS, MAX D2240 90 90 90 90 90 PROPERTIES AFTER IMMERSION IN CEMS B-21 15W-40 Engine oil (P/N 2643576R1, Shell Rimula Premium IFF, 54267) HOURS D471 N/A N/A 70 70 70 TEMPERATURE, C (F) D471 N/A N/A 120(248) 120(248) 120(248) HARDNESS, DUROMETER, SHORE

36、 A D2240 N/A N/A 25 25 25 TENSILE STENGTH, % MAX D412, DIE C N/A N/A -50 -50 -50 ELONGATION, % MAX D412, DIE C N/A N/A -60 -60 -60 25% MODULUS, % MAX D412, DIE C N/A N/A Report* Report* Report* 100% MODULUS, % MAX D412, DIE C N/A N/A Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B N/A N/A

37、 Report* Report* Report* VOLUME CHANGE, shrink/swell, % D471 N/A N/A -10 TO +70 -10 TO +70 -3 TO +10 OTHER PROPERTIES COMPRESSION SET HOURS 70 70 70 70 70 TEMPERATURE C (F) 100(212) 100(212) 100(212) 100(212) 100(212) PERCENT MAX, PLIED D395 25 25 90 25 25 OZONE RESISTANCE (COVER ONLY) 100MPa partia

38、l pressure, RATING % D1149 Method A 100 100 100 100 N/A LOW-TEMPERATURE RESISTANCE, NONBRITTLE AFTER 3 MINUTES AT: C D2137 METHOD A -40 -40 -40 -40 -40 * Report value determined in qualification and validation testing. N/A not applicable NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose

39、 REVISION: 1510 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. OCTOBER 2015 Page 5 of 14 TABLE 1b PROPERTIES OF TUBE AND COVER Gr

40、ade H PROPERTIES OF TUBE AND COVER TEST METHOD (ASTM) TUBE AND COVER Grade H-X TUBE BARRIER Grade H-RX TUBE AND COVER Grade H-Y* TUBE BARRIER Grade H-RY* POLYMER D1418 VMQ FKM VMQ FKM ORIGINAL PROPERTIES: TENSILE STRENGTH, MPA (PSI) D412, DIE C 6.0(870) 7.0(1015) 6.0(870) 7.0(1015) ELONGATION, PERCE

41、NT MIN D412, DIE C 250 175 250 175 25% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* 100% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* TEAR RESISTANCE, kN/m (LBF/in), MIN D624, DIE B 12 (68) 15 (85) 12 (68) 15 (85) HEAT AGING CONDITIONS AND CHANGE LIMITS

42、HOURS EXPOSURE D573 168 168 168 168 TEMPERATURE, C (F) D573 249(480) 249(480) 260(500) 260(500) HARDNESS, DUROMETER, SHORE A D2240 0 to 15 0 to 15 0 to 15 0 to 15 TENSILE STRENGTH, % MAX D412, DIE C -35 Report* Report* Report* ELONGATION, % MAX D412, DIE C -45 Report* Report* Report* 25% MODULUS, %

43、MAX D412, DIE C Report* Report* Report* Report* 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B Report Report Report Report HEAT AGING, 1000 HOURS TEMPERATURE, C (F) D573 249(480) 249(480) 260(500) 260(500) ELONGATION, % MIN D412, DIE C 120 120 Repo

44、rt* Report* HARDNESS, MAX D2240 90 90 Report* Report* PROPERTIES AFTER IMMERSION IN CEMS B-21 15W-40 Engine oil (P/N 2643576R1, Shell Rimula Premium IFF, 54267) HOURS D471 70 500 70 500 TEMPERATURE, C (F) D471 150 (302) 150 (302) 150 (302) 150 (302) HARDNESS, DUROMETER, SHORE A D2240 -30 Report* -30

45、 Report* TENSILE STENGTH, % MAX D412, DIE C -40 Report* -40 Report* ELONGATION, % MAX D412, DIE C -30 Report* -30 Report* 25% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B Report* Report*

46、Report* Report* VOLUME CHANGE, shrink/swell, % D471 +40% -3 TO +10 +40% -3 TO +10 OTHER PROPERTIES COMPRESSION SET HOURS 70 70 70 70 TEMPERATURE C (F) 150(302) 150(302) 150(302) 150(302) PERCENT MAX, PLIED D395 50 50 50 50 OZONE RESISTANCE (COVER ONLY) 100MPa partial pressure, RATING % D1149 Method

47、A 100 N/A N/A N/A LOW-TEMPERATURE RESISTANCE, NONBRITTLE AFTER 3 MINUTES AT: C D2137 METHOD A -55 -25 -25 -25 * Report value determined in qualification and validation testing. *Suffix Y requirement is currently being developed. N/A not applicable NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/

48、Turbo Hose REVISION: 1510 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. OCTOBER 2015 Page 6 of 14 4.4 Property and Performance Requirements - Hose 4.4.1 Adhesion Strength 4.4.1.1 Suffix A - Strip or Ring Specimen method using an average of the adhesi