1、 FORD LABORATORY TEST METHOD BJ 110-04 Date Action Revisions 2001 07 24 Revised Editorial no technical change A. Cockman 1992 06 23 Printed copies are uncontrolled Page 1 of 14 Copyright 2001, Ford Global Technologies, Inc. ALUMINUM BEAKER OXIDATION TEST PART I - APPARATUS AND PROCEDURES Application
2、 This procedure is used to determine the oxidation stability of automatic transmission fluids (ATFs) in the presence of some of the materials used in construction of automatic transmissions. It may also be applicable to other fluids whose degradation in service is controlled by time, temperature, an
3、d the availability of air. Summary of the Method A clean, freshly-etched aluminum beaker is used as the oxidation vessel. This beaker is equipped with a cover from which test strips of various metals can be suspended into the fluid and then withdrawn after different lengths of exposure. Air is intro
4、duced at a prescribed flow rate into the test fluid held at the specified test temperature for the specified time. To assure intimate mixing of air and fluid, the air is introduced directly into a rotating gear pump immersed in the oil; this gear pump also serves to circulate the oil approximately f
5、our times per minute and to subject the fluid to a shearing action. Deterioration of the fluid during the test is determined by analysis of aliquot samples withdrawn periodically and by examination of the test strips at specified times in the test cycle. A copper and an aluminum strip are rated for
6、corrosion and varnish deposits at the end of the test. Also at the end of the test, the beaker is disassembled and the top surface of the pump housing and inside walls of the beaker are rated for sludge deposits. Apparatus Required Aluminum Beaker The aluminum beaker (alloy 6061-T6) and associated c
7、omponents may be fabricated from detail drawings available from: Scientific Research Lab or Standards Operations 21500 Oakwood Blvd. (313) 323-2161 Dearborn, MI 48121 FORD LABORATORY TEST METHOD BJ 110-04 Page 2 of 14 Copyright 2001, Ford Global Technologies, Inc. The assembly is shown in Figure 1.
8、The inside surfaces of the beaker and pump housing are machined to a 30 40 microinch finish. Bushings An upper and a lower PTFE (Teflon) bushing are used to align the pump shaft with the stirring mechanism and to serve as bearing. Gear Pump Steel Gerotor Gear Pumps, Type 10010 Source: W. H. Nichols
9、Co. 2400 Congress Street Portland, ME 04102 The gears of these pumps are 25.4 mm O.D. and 7.938 mm thick and have a 9.25 mm diameter bore. A stainless steel shaft of appropriate length is fabricated with a pressed-in key to accommodate the pump rotor. The shaft should slide in and out of the rotor s
10、o that the rotor does not fall from the shaft easily. Gear Pump Base Plates The pump base plates are fabricated from materials used as thrust washers in automatic transmissions. Two pump plates (B-19319, Bronze Coated) and (B-19318, Lead Coated) are used. B-19319 is SAE 1010 low carbon steel with a
11、0.25 - 0.41 mm plating of SAE 799 Bronze; total thickness = 1.52 - 1.57 mm. B-19318 is the B-19319 part with an 0.0025 - 0.0102 mm overplate of SAE 190 lead-tin alloy. Source: Federal Mogul Sealing Research and Development 3874 Research Park Drive Ann Arbor, MI 48108 Holes are drilled to attach the
12、pump plates to the bottom of the gear pump. Check base plates for flatness after drilling. New pump base plates are used for each test. Gear Pump Base Plates Spacers Stainless steel or aluminum washers 19.1 mm O.D., 7.94 mm I.D. and 3.18 mm thickness. FORD LABORATORY TEST METHOD BJ 110-04 Page 3 of
13、14 Copyright 2001, Ford Global Technologies, Inc. Air Flow Control System Air flow into the assembled beaker must be carefully controlled. The following combination has been used satisfactorily: (a) Flowmeters (1) Hastings Mass Flow Meter, Model NALL-10, with transducer, Model HS-105 Source: Teledyn
14、e-Hastings Raydist P.O. Box 1275 Hampton, VA 23661 (2) Fisher-Porter Precision Flowrater Tube No. 80F-1/16 SA 19808 Source: Fisher-Porter Co. 51 Warminster Road Warminster, PA 18974 (b) Control Valves (1) Hoke Metering Valves #2RB280 with Hoke 280-25 vernier handles Source: Hoke, Inc. 10 Tenakill Pa
15、rk Cresskill, NJ 07626 (c) Capillary A capillary tube located between the air supply and the flowmeters can help stabilize air flow by maintaining a more nearly constant back pressure. Also, if the pressure drop across the capillary is much greater than the pressure drop across the mass flowmeter, t
16、he measured flow rate will accurately reflect the actual flow rate when the mass flowmeter is removed. Glass capillary tubes, 0.099 mm I.D. and 76.2 mm long have been successfully employed. Source: Labcrest Scientific Glass Company County Line Road Warminster, PA 18974 (d) Air Inlet Tube The air inl
17、et tube is made from 4.8 mm outside diameter aluminum or stainless steel and is inserted into the top of the aluminum pump housing. A 2.4 mm hole, 25 +/- 2 mm above the entry to the housing allows oil to enter the air inlet tube for recirculation through the pump. A new air inlet tube is used in eac
18、h test. FORD LABORATORY TEST METHOD BJ 110-04 Page 4 of 14 Copyright 2001, Ford Global Technologies, Inc. The Mass Flow Meter is used as the primary flow standard to establish the position of the ball in the flowrater tube for the prescribed flow rate. The Mass Flow Meter is used at least once each
19、day but is disconnected during interim periods; the flowraters are connected throughout the test to provide an instantaneous indication of flow rate. The air from the laboratory compressed air supply or bottled compressed air is dried by passage through a tower of fresh anhydrous calcium sulfate. Dr
20、y compressed air does not require a drying tower. Constant Temperature Block An aluminum block with built-in heaters and with wells to accommodate the aluminum beakers has proved satisfactory. Any block can be used that is capable of continuous operation at the test temperatures. Liquid baths are no
21、t recommended at high temperatures for reasons of safety. Temperature Control A stainless steel sheathed thermocouple immersed in the oil is used to sense the temperature. The heat input into the constant temperature block may be controlled using the output from this thermocouple. In that case, it m
22、ay be connected at a temperature controller to maintain temperatures at the required +/- 1 C. Love Model 149 controllers have been found to be adequate. Source: Love Controls Corporation 1475 S. Wheeling Road Wheeling, IL 60090 Temperature Recorder A temperature recorder capable of continuous record
23、ing of the fluid temperature within +/- 1 C throughout the test cycle is used. A multi-channel recorder such as YEW Model 4156, 6-Point Model 100 mm Micro Recorder was found to be satisfactory. Source: Great Lakes Controls, Inc. 23373 Commerce Drive, Suite A5 Farmington Hills, MI 48024 Metal Strips
24、Metal strips are suspended into the fluid from the aluminum strip holders. These strips are used to examine interactions between fluid and different metals and to collect deposits such as varnish which can then be rated by standard techniques. One aluminum and one copper strip are suspended into the
25、 fluid. The aluminum strip is fabricated from No. 1100 alloy and the copper strip from CA 110 alloy; both are manually wet polished with No. 000 steel wool before use. Note: Stoddard solvent is used in wetting the strips for polishing. FORD LABORATORY TEST METHOD BJ 110-04 Page 5 of 14 Copyright 200
26、1, Ford Global Technologies, Inc. Conax Fittings No. MPG-125-A-T and 187-A-T stainless steel or equivalent. Source: Conax Corp. 2300 Walden Avenue Buffalo, NY 14225 Millipore Filter 0.45 micron filter with 47 mm diameter. Source: Millipore Corp. Bedford, MA 01730 Drive Mechanism Any suitable mechani
27、sm capable of driving the gear pump at 1100 +/- 100 RPM may be used provided it is designed to prevent axial loading which could cause wear of the gear pump base plate. Materials Required Sodium Hydroxide 2 - 4 wt % NaOH (Reagent grade) in water. Caution: Corrosive. Nitric Acid 50 vol % nitric acid
28、(Reagent grade) in water. Caution: Corrosive. Trichloroethane Caution: TLV = 350 PPM. N-Pentane Caution: - 50.6 C flash point. Also avoid inhalation. Acetone Caution: - 9 C flash point. Also avoid inhalation. Conditioning and Test Conditions All test values indicated herein are based on material con
29、ditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. FORD LABORATORY TEST METHOD BJ 110-04 Page 6 of 14 Copyright 2001, Ford Global Technologies, Inc. Preparation of
30、 Beakers for Test 1. The aluminum parts, including the beaker, beaker cover, strip holders, air inlet tube and pump housing are cleaned as thoroughly as possible with a solvent such as trichloroethane. Except for the air inlet tube, these parts are then subjected to a liquid honing process or glass
31、bead blasting to remove all remaining deposits. We have found that Ballotini impact beads, type AG (53 - 105 micron), give good results with our equipment when used with a nozzle size of 7.94 mm and an air pressure of 200 kPa. The air pressure used should be the minimum pressure consistent with effe
32、ctive cleaning in order to minimize erosion of the aluminum. Source for impact beads: Johnston Sales Corporation 9185 General Court Plymouth, MI 48170 The parts should be thoroughly rinsed to remove all residual beads. Subsequently, the aluminum parts are etched as follows: (a) Dip part in an aqueou
33、s solution of sodium hydroxide (2 - 4 wt % of NaOH in water) at 70 - 80 C for approximately one minute. Soot-like deposits may form. Note: It has been found advisable to use a fresh solution of sodium hydroxide for each etching procedure. (b) Rinse sodium hydroxide off part by dipping in water for 3
34、0 seconds. (c) Dip part for approximately 30 seconds in 50 volume % of nitric acid in water. (d) Rinse part under running water. Brush, if necessary, to remove any soot-like deposits. (e) Dip part in acetone and dry thoroughly in air. (f) If parts appear to have surface contamination or to have etch
35、ed poorly, repeat steps 1-a - 1-e. 2. The steel components, including shaft and gear pump, and the cast iron pump sleeves, are cleaned by liquid honing or impact beads blasting. They are rinsed in acetone, dried thoroughly, and immediately coated with test fluid to prevent rust. Assembly of Beakers
36、1. Attach the pump gear to the pump shaft and insert into the pump housing, using the lower bushing. 2. Attach the two pump plates to the underside of the pump housing. The bronze coated plate is mounted against the pump housing with the bronze coating facing the pump. The lead coated plate is space
37、d 3.2 mm from the other plate using stainless steel washers; the lead coated surface faces the pump. The plates are attached to the pump housing with two 12.7 mm long, 1/4 - 20 Allen head, steel bolts. FORD LABORATORY TEST METHOD BJ 110-04 Page 7 of 14 Copyright 2001, Ford Global Technologies, Inc.
38、3. Insert the air inlet tube into the pump housing. 4. Place the pump assembly in the beaker so that the heads of the two Allen head bolts holding the pump plates rest in the recessed holes in the beaker bottom. 5. Fasten the pump assembly to the bottom of the beaker using two 38 mm long, 1/4 - 20 A
39、llen head, steel bolts. Insert the air inlet tube into the pump housing. 6. Place the beaker cover on the beaker; secure the cover in place with four 19.1 mm long, 1/4 - 20 Allen head, steel bolts. Align the shaft using the upper bushing. 7. Fasten air inlet tube in place using a stainless steel fit
40、ting, Conax MPG-187-A-T or equivalent. 8. Mount the specified strips in the strip holders using a 3.2 mm diameter set screw. Screw these strip holders into the beaker cover. 9. Mount the beaker in the constant temperature block and connect the pump shaft to the drive mechanism. Insert the thermocoup
41、le into the beaker reaching within 3.2 mm from the upper surface of the pump housing; it is fastened in place with a Conax stainless steel fitting number MPG-125-A-T or equivalent. 10. Introduce 250 mL of test fluid into the beaker through one of the strip holder openings. Tighten remaining strip ho
42、lders into the beaker cover. 11. Make connections to air supply and to temperature controlling and indicating equipment. Test Procedure 1. Start the drive mechanism and maintain the pump at 1100 +/- 100 rpm throughout the test. 2. Raise to the test temperature as rapidly as feasible. Approximately 2
43、 h are normally required. Maintain the temperature within +/- 1 C. 3. On reaching the desired test temperature introduce air into the gear pump at the specified rate, i.e. 5 mL/minute. This is recorded as the starting time of the test. 4. Remove 10 mL samples through the sampling port at the specifi
44、ed times using a pipette or hypodermic syringe. 5. Remove the copper strip for rating at the specified times. After a pentane rinse, rate the copper strip for corrosion by the copper strip tarnish test, ISO 2160/ASTM D 130, and reinsert. 6. At test completion, terminate the test by shutting off the
45、pump, air flow, and heaters. Allow the beaker to cool before disassembly. FORD LABORATORY TEST METHOD BJ 110-04 Page 8 of 14 Copyright 2001, Ford Global Technologies, Inc. 7. Examine the aluminum strip for varnish deposits at the end of the test by comparison with a fresh strip. Report as “Varnish P
46、resent“ or “No Varnish“. Note: If comparison with a fresh strip is ambiguous, the following additional steps should be taken. Place the strip on a clean, flat surface and wipe the lower half with a cotton knit cloth or equivalent material dipped in sludge and varnish remover. No brownish deposit sho
47、uld appear on the material used for wiping. A slight light to dark gray deposit, which may be due to aluminum dispersed in the oil, should not be confused with varnish. 8. Remove the shaft and pump housing assembly from the beaker after removing the appropriate bolts. Be careful that sludge deposits
48、 on top of pump housing are not disturbed. Tilt the housing to 45 from horizontal and clamp in this position for a minimum of 4 h to allow the fluid to drain off the pump housing. Examine the top of the pump housing for sludge deposits. 9. Examine the beaker for varnish and sludge. Report observatio
49、ns under comments in Test Report. 10. Analyze the fluid. Analysis of Samples 1. Upon withdrawal of each of the samples, the following tests shall be run: (a) Pentane Insolubles Weigh 1 +/- 0.1 g sample to the nearest 0.1 mg in a 150 mL beaker. Add 120 mL of n-pentane and mix thoroughly with a stirring rod. Filter through a preweighed 0.45 micron millipore filter with a 47 mm diameter. If plugging occurs, discard and repeat with a smaller sample. It is recommended that in the event of plugging the sample size should be decreased in the following sequence: 1 g, 0.5
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