SAE J 2435-2015 Welded Flash Controlled SAE 1021 Carbon Steel Tubing Normalized for Cold Forming Welding and Brazing.pdf

1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2435_201508 SURFACE VEHICLE STANDARD J2435 AUG2015 Issued 1999-04 Revised 2015-

5、08 Superseding J2435 FEB2008 Welded Flash Controlled, SAE 1021 Carbon Steel Tubing, Normalized for Cold Forming, Welding and Brazing RATIONALE This five year review of the J2435 standard incorporates revisions requested by producers, fabricators and users of this material type. The updates include t

6、he following: x A revised documents listing, x Verbiage changes to improve the technical meanings of specific terms and expressions x Revised wording of section 5.2 x A recommendation for the use of metric size materials. x Revision of chemical requirements to harmonize with SAE J403 x Added notatio

7、n to clarify test agreement noted on 8.8 Pressure Proof Test x Added notation to clarify test note on 8.9 Nondestructive Electronic Test 1. SCOPE The SAE Standard covers normalized electric resistance welded flash controlled single-wall, carbon steel pressure tubing intended for use as pressure line

8、s and in other applications requiring tubing of a quality suitable for cold forming, welding and brazing. Material produced to this specification should not be used for single flare applications due to the potential leak path that would be caused by the ID weld bead or scarfed region. Assumption of

9、risks when using this material for single flare applications to be defined by agreement between the producer and tube purchaser. The grade of material produced to this specification is higher in carbon and manganese content than the grade of material specified in SAE J356 and is intended to service

10、higher pressure applications than equivalent sizes of SAE J356. Due to the higher carbon and manganese content the forming characteristics of the finished tube are diminished versus the SAE J356 product. Special attention to the overall forming requirements of the finished assembly shall be taken in

11、to consideration when specifying material produced to this specification. SAE INTERNATIONAL J2435 AUG2015 Page 2 of 8 In an effort to standardize within a global marketplace and ensuring that companies can remain competitive in an international market it is the intent to convert to metric tube sizes

12、 which will: x Lead to one global system x Guide users to preferred system x Reduce complexity x Eliminate inventory duplications 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest

13、 issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J356 Welded Flash-Controlled Low-Carbon Steel Tubing Normalize

14、d for Bending, Double Flaring, and Beading SAE J403 Chemical Compositions of SAE Carbon Steels SAE J409 Product Analysis - Permissible Variations from Specified Chemical Analysis of a Heat or Cast of Steel SAE J514 Hydraulic Tube Fittings SAE J533 Flares for Tubing SAE J1677 Tests and Procedures for

15、 Carbon Steel and Low Alloy Steel Tubing 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this document. 2.2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-6

16、06-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J1065 Nominal Reference Working Pressures for Steel Hydraulic Tubing SAE J1453 Fitting - O-Ring Face Seal SAE J2551-1 Recommended Practices for Fluid Conductor Carbon, Alloy and High Strength Low Alloy Steel Tubing Appli

17、cations-Part 1: Design and Fabrication SAE J2551-2 Recommended Practices for Fluid Conductor Carbon, Alloy and High Strength Low Alloy Steel Tubing Applications-Part 2: General Specifications and Performance Requirements SAE J2551-3 Recommended Practices for Fluid Conductor Carbon, Alloy and High St

18、rength Low Alloy Steel Tubing Applications-Part 3: Procurement SAE J2592 Carbon Steel Tubing for General Use - Understanding Nondestructive Testing for Carbon Steel Tubing SAE INTERNATIONAL J2435 AUG2015 Page 3 of 8 2.2.2 ISO Publications Available from American National Standards Institute, 25 West

19、 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org. ISO 3305 Plain end welded precision steel tubes - Technical conditions for delivery ISO 5598 Fluid power systems and components - Vocabulary ISO 8434-2 Metallic tube connections for fluid power and general use - Part 2: 37 flare

20、 fittings ISO 8434-3 Metallic tube connections for fluid power and general use - Part 3: ORFS fittings ISO 10583 Hydraulic fluid power - Test methods for tube connections ISO 10763 Hydraulic fluid power - Plain-end, seamless and welded steel tubes - Dimensions and nominal working pressures ISO 19879

21、 Metallic tube connections for fluid power and general use - Test methods for hydraulic fluid power connections 2.2.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org ASTM A 513 Electric-Resis

22、tance-Welded Carbon and Alloy Steel Tubing ASTM A 450/A 450M Standard Specifications for General Requirements for Carbon, Ferritic Alloy and Austenitic Alloy Steel Tubing 3. MANUFACTURE The tubing shall be made from a single strip of steel shaped into a tubular form, the edges of which are joined an

23、d fused by electric resistance welding. After forming and welding, the outside flash shall be removed to provide a smooth surface. The inside flash shall be of uniform contour, free from saw-tooth peaks and controlled in height by seam-welding techniques or by cutting, but not by hammering or rollin

24、g. The inside flash height shall conform to the dimensional characteristics listed in Table 1. Particular attention shall be given to the weld to minimize strip edge mismatch that can result in a sharp step or edge, which can create localized stresses and eventual fatigue fracture. The tubing shall

25、be normalized using an atmospherically controlled method to produce a finished product, which will meet all requirements of this document. SAE INTERNATIONAL J2435 AUG2015 Page 4 of 8 Table 1 - Inside flash height Nominal Wall Thickness mm Maximum Flash Height(1)(2)Through 25.4 mm OD mm Maximum Flash

26、 Height Over 25.4 mm OD mm Less than 0.90 0.13 0.25 0.90 through 1.65 0.20 0.25 Greater than 1.65 0.25 0.25 1. For tubes having an ID greater than 8 mm, the height of the inside weld flash shall be measured with a ball micrometer having a 3.96 mm 0.41 mm radius on the anvil or ballpoint. For tubes h

27、aving an ID 8 mm or less, screw thread micrometers shall be used. The height of the flash shall be the difference between the thickness of the tubing wall at the point of maximum height of the flash and the average of the wall thickness. 2. Tubing with an ID that is smaller than the producers capabi

28、lity to scarf the ID weld bead shall be produced as a “flash in“ tube. Seam welding techniques may be applied in order to control the ID flash height. The maximum ID flash height, however, will be determined by agreement between the producer and the purchaser. 4. DIMENSIONS AND TOLERANCES The tolera

29、nces applicable to tubing outside diameter are shown in Table 2. The tolerances applicable to tubing wall thickness are shown in Table 3. Table 2 - Tubing outside diameter tolerance Nominal Tubing OD(1)(2)mm Tube OD Tolerance mm Up to 15.88 0. 08 Over 15.88 to 28.57 0.09 Over 28.57 to 50.80 0.13 Ove

30、r 50.80 to 63.50 0.15 Over 63.50 to 76.20 0.20 Over 76.20 to 88.90 0.23 Over 88.90 to 101.60 0.25 1. OD measurements shall be taken at least 50 mm from the end of the tubing. 2. Refer to SAE J514 for nominal tubing OD to be used in conjunction with standard hydraulic tube fittings and SAE J533 for r

31、ecommended maximum nominal wall thickness for double flaring. SAE INTERNATIONAL J2435 AUG2015 Page 5 of 8 Table 3 - Tubing wall thickness tolerances Nominal Wall Thickness(1)mm Nominal Tubing Outside Diameter Through 25 mm (2)mm Nominal Tubing Outside Diameter Through 50 mm (2)mm Nominal Tubing Outs

32、ide Diameter Over 50 mm Through 100 mm (2)mm 0.71 0.05/0.08 0.08/0.08 0.08/0.080.89 0.05/0.10 0.05/0.10 0.05/0.10 1.00 0.05/0.10 0.05/0.10 0.05/0.101.25 0.10/0.13 0.08/0.13 0.10/0.20 1.50 0.15/0.15 0.10/0.20 0.10/0.20 1.65 0.15/0.15 0.10/0.20 0.10/0.202.00 0.15/0.25 0.15/0.25 0.15/0.25 2.11 0.15/0.2

33、5 0.15/0.25 0.15/0.252.41 0.15/0.25 0.15/0.25 0.15/0.25 2.50 0.15/0.25 0.15/0.25 0.15/0.252.77 0.15/0.25 0.15/0.25 0.15/0.25 3.00 0.15/0.25 0.15/0.25 0.15/0.253.05 0.15/0.25 0.15/0.25 0.15/0.25 3.40 0.15/0.25 0.15/0.25 0.15/0.25 3.75 0.18/0.28 0.18/0.284.00 0.18/0.28 0.18/0.284.19 0.18/0.28 0.18/0.2

34、8 4.57 0.18/0.28 0.18/0.285.00 0.20/0.30 0.20/0.30 5.16 0.20/0.30 0.20/0.305.59 0.20/0.30 0.20/0.306.00 0.36/0.46 0.36/0.46 6.05 0.36/0.46 0.36/0.466.58 0.36/0.51 0.36/0.51 1. For intermediate wall thickness, the tolerance for the next heavier wall thickness shall apply. 2. Plus tolerances include a

35、llowance for crown on flat-rolled steel. 5. MANUFACTURING STANDARDS 5.1 Straightness Tubing shall be straightened to a tolerance of 1 mm over a 1000 mm length. SAE INTERNATIONAL J2435 AUG2015 Page 6 of 8 5.2 Tubing End Condition The tubing shall be produced using normal mill cut-off practices, e.g.

36、punch-cut ends, double cut ends or rotary-cut ends. Tube end distortion must be minimized; end condition shall not affect normal re-cut processes performed by the end user. Extraordinary end cut processing requirements shall be defined by agreement between the producer and purchaser. 5.3 Surface Con

37、dition The outside surface condition of the tube is critical in order to prevent possible leak paths on double flare fittings, mechanical form fittings, or other applications where the outside surface of the tube becomes the sealing surface. The outside surface of the tube shall be free of excessive

38、 roll marks, score marks, chatter marks, or other surface imperfections that are considered detrimental to the function of the tubing. 5.4 Thermal Treatment The tubing is to be heated to a temperature above the upper transformation point in an atmospherically controlled furnace, and then cooled in a

39、 protective atmosphere. 6. MATERIAL Tubing shall be made from low-carbon, hot- or cold-rolled steel conforming to the chemical composition in Table 4.The steel shall be made by the basic oxygen or electric furnace process. A ladle analysis of each heat shall be made to determine the percentages of t

40、he elements specified. The chemical composition thus determined shall be reported to the purchaser, or his representative, if requested, and shall conform to the requirements specified. If a check analysis is required, the tolerances shall be as specified in SAE J409, Table 3. Table 4 - Chemical req

41、uirements Element Cast or Heat Analysis, Weight % Carbon 0.18 min/0.23 max Manganese 0.60 through 0.90 Phosphorus 0.030 max Sulfur 0.035 ma7. MECHANICAL PROPERTIES The finished tubing shall have mechanical properties as tabulated in Table 5. Table 5 - Mechanical properties Properties Values Yield St

42、rength, min 275 MPa Ultimate Strength, min 415 MPa Elongation in 50 mm, min 25% Hardness(Rockwell B), max 78(1)1. The hardness test shall not be required on tubing with a nominal wall thickness of less than 1.65 mm. Such tubing shall meet all other mechanical properties and performance requirements.

43、 SAE INTERNATIONAL J2435 AUG2015 Page 7 of 8 8. PERFORMANCE REQUIREMENTS The finished tubing shall satisfactorily meet the following performance tests. All tests shall be conducted in accordance with the procedures in SAE J1677. 8.1 Flattening Test 8.2 Flaring Test 8.3 Reverse Flattening Test 8.4 Ex

44、pansion Test 8.5 Hardness Test 8.6 Tensile Test 8.7 Elongation Test 8.8 Pressure Proof Test NOTE: Pressure Proof Test performed when agreed upon between the purchaser and the producer (where allowable unit stress of material(s) = 220 MPa (80% of min yield strength). 8.9 Nondestructive Electronic Tes

45、t NOTE: Nondestructive Electronic Test is to be conducted after all cold-working tube manufacturing operations are performed on the tubing. 9. TEST CERTIFICATES A certificate of compliance to the performance requirements shall be furnished to the purchaser by the producer if requested in the purchas

46、e agreement. The tube producer shall be able to certify that each heat lot used to produce the tubing complies with the performance requirement. 10. CLEANLINESS The inside and outside surfaces of the finished tubing shall be commercially bright, clean, and free from grease, oxide scale, carbon depos

47、its, and any other contamination that cannot readily be removed by cleaning agents normally used in manufacturing plants. 11. CORROSION PROTECTION The inside and outside surfaces of the finished tubing shall be protected against corrosion during shipment and normal storage. If a corrosion preventive

48、 compound is applied, it shall be such that after normal storage periods it can readily be removed by cleaning agents normally used in manufacturing. A specific corrosion resistant coating may be specified by the purchaser. 12. PACKAGING The tubing shall be packaged in such a way to allow it to be t

49、ransported and stored, with normal care, without being damaged. Any special packaging shall be by agreement between the producer and purchaser. SAE INTERNATIONAL J2435 AUG2015 Page 8 of 8 13. NOTES 13.1 Marginal Indicia A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have been made to the previous issue of th