FORD FLTM BB 116-01-2013 PROCEDURE FOR TESTING THE INTEGRITY OF WELD-LINES IN EXTRUDED STRUCTURAL ALUMINUM TUBES USING TUBE FLARE TEST METHOD.pdf

1、 FORD LABORATORY TEST METHOD FLTM BB 116-01 Date Action Revisions Rev. 0 2013 11 20 Released C. Mracna, NA Controlled document at www.MATS Copyright 2013, Ford Global Technologies, LLC Page 1 of 3 PROCEDURE FOR TESTING THE INTEGRITY OF WELD-LINES IN EXTRUDED STRUCTURAL ALUMINUM TUBES USING TUBE FLAR

2、E TEST METHOD Application Scope This procedure is used to determine the integrity of longitudinal extrusion weld-lines on aluminum extrusion structural / porthole tubes. Significance and Use This procedure describes the method for flare testing extruded structural/porthole aluminum tubes using a tes

3、t fixture and the analysis of test results. A standard specified conical mandrel is forced into the test specimen using a hydraulic press until failure or calculated minimum expanded diameter is reached (per ISO 8493). Any resulting split propagation pattern and edge appearance are used to pass or s

4、crap the tubes based on the criteria defined in this document. The rating standard assigns an acceptable or not acceptable split condition for assessing the integrity of the weld-line in a structural / porthole tube. Applicable Materials This test applies to the flare testing (drift testing) of extr

5、uded structural aluminum tubes for automotive body-in-white applications. Applicable Documents Standard ISO 8493 for metallic materials Tube Conflicts In the event of a conflict between the text of this procedure and the references cited herein, the text of this procedure shall take precedence. Defi

6、nitions Quality Assurance Requirements Unless otherwise specified, the users of this procedure are responsible for all inspection and the test requirements specified herein, and may use internal testing facilities as long as they meet the requirements of this procedure and any other test agencies ac

7、ceptable to Ford Motor Company. Sampling Samples from a single production lot of extruded tubes shall be used for the flare test evaluation. Data Reporting Flare test acceptance shall be recorded on production documents with inspection sign-off indicating that all tubes on the order passed the flare

8、 test. FORD LABORATORY TEST METHOD FLTM BB 116-01 Copyright 2013, Ford Global Technologies, LLC Page 2 of 3 Apparatus Required Test Equipment 1. Variable speed hydraulic press or universal testing machine with sufficient capacity. 2. Polished conical hardened steel mandrel, with a specified angle an

9、d sufficient hardness. Preferred angles for the conical mandrel are 300, 450, and 600. 3. Lubricant for the conical mandrel surface. The lubricant shall be a light machining oil, WD-40, or equivalent. Maintenance The conical mandrels should be cleaned periodically to remove any dirt / dust and resid

10、ue from flare test samples. The mandrel must be kept clean, free of solid residue, and only aluminum is to be tested with the apparatus. Each mandrel must be inspected periodically to confirm the dimensions remain within both equipment and testing tolerances. Test Specimen Dimensions The round / cir

11、cular extruded aluminum tube test specimens are to have length between 125 - 400 mm (5 - 16 inches). Both ends of the test specimen should be in plane perpendicular to the axis of the tube. The edges of the end to be tested may be rounded by filing or chamfered by other methods. Prior to testing the

12、 samples should be cleaned to remove dirt/dust built up on the tube surfaces during the extrusion process. Test Specimen Preparation Test specimens are to be fabricated using in-line production cutting equipment. Both ends of the test specimen should be plane perpendicular to the axis of the tube. N

13、umber of Test Specimens It is recommended that each billet, but no fewer than four (4) non-consecutive billets, be tested for each extruded tube lot. Procedure 1. Align the vertical axis of the conical mandrel in the hydraulic press with the vertical axis of the test specimen. 2. Apply load using th

14、e hydraulic press until test specimen failure or mandrel has moved to the end of its travel. 3. Stop the hydraulic press and retract the conical mandrel to its initial position. 4. Remove the test specimen and record the results. 5. When finished with the apparatus, retract the conical mandrel fully

15、 back to its initial position to avoid any accidents. Analysis Flare Test Rating Standard By assessing the cracking edge location and edge pattern of the flare test specimen a pass or fail rating is assigned. The limits of acceptably are to be established in raw material supplier PFMEA, documented i

16、n the process control plan and visually posted at the location of flair testing within the extruder facility. Examples are provided below: Acceptable: Tear out with jagged or rough edge surface, possibly a spiral shaped tear of the test specimen. This is considered a pass condition. Not acceptable: Split with a straight, semi-smooth, clean break along the weld-line of the test specimen. This is considered a fail condition as the welds fail before the parent metal. FORD LABORATORY TEST METHOD FLTM BB 116-01 Copyright 2013, Ford Global Technologies, LLC Page 3 of 3