FORD W-HTX-2006 CONTROL OF HEAT TREATING PROCESSES AND AUXILIARY EQUIPMENT《热处理过程的控制和辅助设备》.pdf

1、 Printed Copies are Uncontrolled Page 1 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision Date: 08/25/2006 FORD MANUFACTURING STANDARD “CONTROL OF HEAT TREATING PROCESSES AND AUXILIARY EQUIPMENT” W-HTX FORD MANUFACTURING STANDARDS Printed Copies are Uncontrol

2、led Page 2 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision Date: 08/25/2006 W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIARY EQUIPMENT Page 1 _ INDEX Item No. Subject Page 1. DESCRIPTION AND REQUIREMENTS 6 1.1 Scope 6 1.2 Specification

3、of Requirements 7 1.3 Process Specification 7 1.4 Process and Quality Controls 8 1.5 Control Plan 8 1.6 Statistical Methods 8 1.7 Cleanliness of Parts Prior to Heat treat 8 2. FURNACE PROCESSES 9 2.1 Process Monitoring 9 2.1.1 Indicated Temperature 9 2.1.2 Standardize Temperature Controller 10 2.1.3

4、 Temperature Measurement Devices and Protection Tubes 10 2.1.4 Monitor of the Furnace/Generator of Carbon Bearing Atmosphere 10-11 2.1.5 Atmosphere Flow Rate 12 2.1.6 Atmosphere Purging 12 2.1.7 Monitor of an Ammonia Enriched Atmosphere 12 2.1.8 Monitor of the Salt Bath 12 2.2 Condition of Quench 13

5、 2.2.1 Water-Soluble Polymer Quench 13 2.2.2 Water Quench 13 2.2.3 Soluble Oil 13 2.2.4 Oil 13 2.2.5 Salt Bath 13 2.2.6 Brine and Caustic 13 2.2.7 High Pressure Gas Quench 13 2.3 Loading Rate and Cycle Time 14 2.4 Material Control 14 2.5 Laboratory Controls 15 2.5.1 Concentration of Water-Soluble Po

6、lymer Quenchants 15 2.5.2 Cleanliness of Water Quench Systems 15 2.5.3 Soluble Oil Quenchants 15 2.5.4 Condition of Quench Oil 16 2.5.5 Salt Bath Analysis and Contaminants 16 2.5.6 Brine and Caustic Quench Solutions 16 2.6 In-Process Tests 16 2.6.1 Microstructure 16 2.6.2 Hardness 17 2.6.3 Case Dept

7、h 17 Printed Copies are Uncontrolled Page 3 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision Date: 08/25/2006 FORD MANUFACTURING STANDARDS W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIARY EQUIPMENT Page 2 _ INDEX Item No. Subject Page 3.

8、 INDUCTION AND FLAME PROCESSES 18 3.1 Process Monitoring 18 3.1.1 Heating Parameters 18 3.1.2 Atmosphere Flow Rate 18 3.2 Condition of Quench 18 3.2.1 Water-Soluble Polymer Quench 18 3.2.2 Water Quench 18 3.2.3 Soluble Oil 19 3.2.4 Oil 19 3.3 Loading Rate and Cycle Parameters 19 3.4 Material Control

9、 20 3.5 Laboratory Controls 20 3.5.1 Concentration of Water-Soluble Polymer Quenchants 20 3.5.2 Cleanliness of Water Quench Systems 21 3.5.3 Soluble Oil Quenchants 21 3.5.4 Condition of Quench Oil 21 3.6 In-Process Tests 21 3.6.1 Microstructure 21 3.6.2 Hardness 22 3.6.3 Case Depth 22 3.6.4 Inductio

10、n/Flame Pattern 22 Printed Copies are Uncontrolled Page 4 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision Date: 08/25/2006 FORD MANUFACTURING STANDARDS W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIARY EQUIPMENT Page 3 _ Item No. Subject

11、 Page 4. FREQUENCIES FOR PROCESS MONITORS, LABORATORY CONTROLS AND IN-PROCESS TESTS FOR FURNACE PROCESSES Gas Carburizing/Carbonitriding/Carbon Correction 23 Process Monitor Test Frequencies 23 Laboratory Control Test Frequencies 23 In-Process Test Frequencies 23 Vacuum Carburizing/Carbonitriding Ge

12、ars and Shafts 24 Process Monitor Test Frequencies 24 Laboratory Control Test Frequencies 24 In-Process Test Frequencies 24 Neutral Hardening-Atmosphere 25 Process Monitor Test Frequencies 25 Laboratory Control Test Frequencies 25 In-Process Test Frequencies 25 Tempering & Stress Relieving 26 Proces

13、s Monitor Test Frequencies 26 Laboratory Control Test Frequencies 26 In-Process Test Frequencies 26 Nitriding/NitroCarburizing 27 Process Monitor Test Frequencies 27 Laboratory Control Test Frequencies 27 In-Process Test Frequencies 27 Annealing/Normalizing 28 Process Monitor Test Frequencies 28 Lab

14、oratory Control Test Frequencies 28 In-Process Test Frequencies 28 Aluminum Solution Heat treating/Age Hardening 29 Process Monitor Test Frequencies 29 Laboratory Control Test Frequencies 29 In-Process Test Frequencies 29 Brazing/Sintering 30 Process Monitor Test Frequencies 30 Laboratory Control Te

15、st Frequencies 30 In-Process Test Frequencies 30 Salt Bath Heat treating 31 Process Monitor Test Frequencies 31 Laboratory Control Test Frequencies 31 In-Process Test Frequencies 31 Printed Copies are Uncontrolled Page 5 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standar

16、ds Revision Date: 08/25/2006 FORD MANUFACTURING STANDARDS W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIARY EQUIPMENT Page 4 _ Item No. Subject Page 5. FREQUENCIES FOR PROCESS MONITORS, LABORATORY CONTROLS, AND IN-PROCESS TESTS FOR INDUCTION AND FLAME PROCESSES Induction Hardenin

17、g/Flame Hardening/Annealing of Gears, Shafts and Crankshafts 32 Process Monitor Test Frequencies 32 Laboratory Control Test Frequencies 32 In-Process Test Frequencies 32 Printed Copies are Uncontrolled Page 6 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision

18、Date: 08/25/2006 FORD MANUFACTURING STANDARDS W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIARY EQUIPMENT Page 5 _ Item No. Subject Page 6. THERMOCOUPLE, TEMPERATURE INSTRUMENTATION, AND PROTECTION TUBE CHECKING AND REPLACEMENT PROCEDURE 6.1 General 33 6.2 Scope 33 6.3 Equipment

19、for Checking Service Thermocouples 33 6.3.1 Verification Instrument 33 6.3.2 Primary Standard Thermocouples 33 6.3.3 Test Thermocouples 33 6.3.3.1 Sources for Test Thermocouples 34 6.4 Rules of Procedure in Checking Service Thermocouples and Temperature Instrumentation 34 6.4.1 Independent portable

20、verification 34 6.4.2 Placement of calibrated test thermocouple 34 6.4.3 Checking of Service Thermocouples 34 6.5 Allowable Temperature Deviation 34 6.6 Frequency of Checking and the Replacement of Thermocouple and Protection Tubes in Furnaces, Salt Baths and Related Equipment 34 6.6.1 Calibrate 34

21、6.6.2 General Rules/Notes 34 6.6.3 General Rules/Notes 35 6.7 Recording of Test Results and Replacement Dates 6.7.1 Test Results 35 6.7.2 Replacement Dates 35 Printed Copies are Uncontrolled Page 7 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision Date: 08/25

22、/2006 FORD MANUFACTURING STANDARDS W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIARY EQUIPMENT Page 6 _ 1. DESCRIPTION AND REQUIREMENTS: 1.1 SCOPE: This Standard defines the requirements for the type and frequency of process monitors, laboratory controls, and in-process inspectio

23、ns and tests to be performed as part of the ongoing operation of production heat treating equipment and the maintenance of related records. This Standard is applicable to the following Heat treat Processes: . Carburizing/Carbonitriding/Carbon Correction . Vacuum Carburizing/Carbonitriding Gears and

24、Shafts . Neutral Hardening - Atmosphere . Tempering and Stress Relieving . Nitriding/NitroCarburizing . Annealing/Normalizing . Aluminum Solution Heat treating/Age Hardening . Brazing/Sintering . Salt Bath Heat treating . Induction Hardening, Flame Hardening, Tempering and Annealing of Gears, Shafts

25、 and Crankshafts This Standard applies to all production and service parts. For parts whose heat treat characteristics are not identified by any of the above criteria, the minimum requirements for a specific type and frequency of process monitor, laboratory control, or in-process inspection or test

26、will be specified. CAUTION: APPROPRIATE PRECAUTIONS MUST BE TAKEN RELATIVE TO HEALTH AND SAFETY AND ENVIRONMENTAL HAZARDS. FORD FACILITIES SHALL CONTACT THE APPROPRIATE FORD MOTOR COMPANY HEALTH AND SAFETY AND ENVIRONMENTAL ACTIVITIES FOR SPECIFIC INFORMATION REGARDING SUCH PRECAUTIONS. These monito

27、ring and control tests are required to keep heat treating processes and processing equipment under control to produce parts that will meet Product Engineering requirements and functional tests. Regularly scheduled maintenance as well as equipment operating responsibilities of the production operator

28、 are not included. The emphasis on process control is to provide indications that the process is stable or is drifting out of control or actually is out of control before part quality is adversely affected. It is expected that such process monitoring will be of value in maintaining process stability

29、 and in bringing a process back into control. The responsible outside supplier or Company plant or division shall consider requirements for each individual part and decide whether the minimum requirements of this general Standard is adequate or whether they should prepare a more specific or detailed

30、 local process control standard for the individual part. Printed Copies are Uncontrolled Page 8 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision Date: 08/25/2006 FORD MANUFACTURING STANDARDS W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIA

31、RY EQUIPMENT Page 7 _ Exceptions to this Standard and alternative plans for control of heat treating processes may be used provided they afford adequate protection of a process currently proven to be stable and capable, and have the concurrence of the affected Ford Supplier Technical Assistant (STA)

32、 and/or Quality Planning Team and are documented in a control plan. Reduced sampling strategies for control of heat treating processes may be used provided they afford adequate protection of a process currently proven to be stable and capable, and have the concurrence of the affected Ford Supplier T

33、echnical Assistant (STA), Ford Heat Treat Assessor(s) and/or Quality Planning Team and are documented in a control plan. The objective of this Standard is to define the requirements and to encourage Best Practices which will assure a quality part as well as promoting continuous improvement relative

34、to quality and productivity. The principal concerns which are addressed by this Standard include: . The heat treater must know the specification(s) to which the parts are to be heat treated. . The processes used to heat treat the parts must be clearly defined. . All parts must be heat treated to the

35、 defined process and specification. . Monitoring of the process through the use of an approved control plan must be such to assure that the process is in control and is being improved in order to minimize variability as well as minimize the risk of out of specification parts. . Incoming materials sh

36、all be specified and controlled in such a manner to assure a product which can be heat treated with minimum part variability. 1.2 SPECIFICATION OF REQUIREMENTS: The heat treater shall have an Engineering Drawing or a written specification listing the engineering requirements (e.g., incoming material

37、, case depth, surface hardness, core hardness, etc.) of Ford parts processed. 1.3 PROCESS SPECIFICATION: The supplier shall establish a written process specification (complete with a control plan) for all processes used to heat treat parts supplied directly or indirectly to the Ford Motor Company. T

38、he specification shall completely describe the process and the pertinent variables and specify the principal operating parameters (e.g., temperature, cycle time, Carbon potential, etc.) and their acceptable ranges as part of the program to assure that the parts meet the requirements of the Engineeri

39、ng Drawing. Printed Copies are Uncontrolled Page 9 of 46 Standard Number w-HTX Issue Date: 03/01/1996 Global Manufacturing Standards Revision Date: 08/25/2006 FORD MANUFACTURING STANDARDS W-HTX CONTROL OF HEAT TREATING PROCESSES W-HTX MAY 2006 AND AUXILIARY EQUIPMENT Page 8 _ 1.4 PROCESS AND QUALITY

40、 CONTROLS: Included in this Standard are the required checks, observations, and tests (including frequencies) to be performed to assure that the product is in conformance with the in-process and Engineering Drawing requirements. . Section 2 describes those requirements relative to Furnace Processes

41、and Section 3 describes the same requirements for both Induction and Flame Processes. . Sections 2.1 and 3.1 include detailed descriptions of the process monitors which are normally done by production and/or maintenance personnel, usually requiring minimal testing apparatus, and often involving visu

42、al observations of monitoring equipment. . Sections 2.5 and 3.5 cover the laboratory controls which normally require skilled operators and involve checks and tests of a more exact nature than those controls which are considered to be process monitors. . Sections 2.6 and 3.6 cover the tests and inspections to be performed on heat treated parts or test samples. An operations manual including emergency, start-up, shutdown, and general operating procedures should be readily available to the production supervisors and operators. It should