1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2011 01 04 N-STATUS Replaced by WSS-M2D513-A A. Wedepohl, NA 1993 03 15 NC00E10244447006 Released A. Novakovic WP 3948-a Page 1 of 11 HOSE, HIGH PRESSURE, HIGH TEMPERATURE WSA-M96D36-A1 RESISTANT, POWER STEERI
2、NG NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification covers hose fabricated from synthetic rubber and fabric braid for assembly with end fittings to be used in automotive power steering systems. Each suffix corresponds to a different grade of power steering fluid. 2.
3、APPLICATION This specification was originally released for material used for power steering systems requiring long life performance at high temperatures. The hose shall be suitable for pressures up to 11 MPa and service temperatures ranging from - 40 to 150 C. 3. REQUIREMENTS 3.1 STATISTICAL PROCESS
4、 Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to analyze process/product data so that variation in the final product is co
5、ntinuously reduced. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference
6、standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 2 of 11 3.3 DYNAMIC MECHANIC
7、AL ANALYSIS (ASTM D 4065) Ford Motor Company, at its option, may establish shear modulus/damping vs. temperature curves plotted for - 50 to + 150 C temperature range for material/parts supplied to this specification. The shear modulus and damping curves established for initial approval shall constit
8、ute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce shear modulus and damping curves that correspond to the reference standard when tested under the same conditions. 3.4 CONDITIONING AND TEST CONDITIONS All test values indicated herei
9、n are based on material conditioned 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. 3.5 HOSE CONSTRUCTION Hose shall have a smooth bore inner tube of chlorosulfonated po
10、lyethylene (CSM) rubber, two plies of braided polyamide fabric imbedded in and bonded to the inner tube, and an outer cover of chlorinated polyethylene (CM) or chlorosulfonated polyethylene rubber. Braided fabric shall be free from knots, loops, or other harmful imperfections. 3.5.1 Dimensions Insid
11、e diameter 9.5 - 10.2 mm Outside diameter 17.2 - 18.5 mm Inner tube, thickness, min 1.23 mm Outer tube, thickness, min 0.35 mm Concentricity based upon full indicator reading between the inside bore and the outer surface of the hose shall not exceed 0.8 mm. 3.6 TESTING 3.6.1 Original Properties Hard
12、ness, International TBD (ISO 48/ASTM D 1415) Hardness, Durometer “A“ 81 +/- 5 (ISO 868/ASTM D 2240, instantaneous plied-up specimen, hand held durometer shall not be used) ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 3 of 11 Tensile Strength, min Tube 10.4 MPa (ISO 37/ASTM D 412,
13、Die C) Cover 8.3 MPa Elongation, min 70 % (ISO 37/ASTM D 412, Die C) Compression Set, max 80 % (ASTM D 395, 70 h at 150 +/- 3 C) 3.6.2 Heat Aged (ISO 188/ASTM D 573, 150 +/- 50 air changes/h, 70 h at 150 +/- 2 C, tube and cover or slab stock) Hardness Change, Durometer “A“ - 10 to + 10 Tensile Stren
14、gth Change - 30 to + 30 % Elongation Change 0 to - 50 % Visual Evaluation 3.6.3 Heat Aged (ISO 188/ASTM D 573, 150 +/- 50 air changes/h, 1000 h at 125 +/- 2 C, tube and cover or slab stock) Hardness Change, Durometer “A“ 0 to + 15 Tensile Strength Change - 30 to + 30 % Elongation Change 0 to - 70 %
15、Visual Evaluation 3.6.4 Immersion in Oil No. 3 (ISO 1817/ASTM D 471, 70 h at 150 +/- 2 C, tube and cover or slab stock) Hardness Change, Durometer “A“ 0 to - 25 Tensile Strength Change 0 to - 50 % Elongation Change 0 to - 60 % Volume Change 0 to + 60 % Visual Evaluation 3.6.5 Immersion in Currently
16、Released Power Steering Fluid (ISO 1817/ASTM D 471, 70 h at 150 +/- 2 C, tube and cover or slab stock, see section 5 for fluid) ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 4 of 11 Hardness Change, Durometer “A“ - 15 to + 15 Tensile Strength Change 0 to - 60 % Elongation Change 0
17、to - 60 % Volume Change 0 to + 30 % Visual Evaluation 3.6.6 Impulse Test Test Conditions: . Ambient temperature 150 +/- 5 C . Fluid temperature 150 +/- 5 C . Cycle rate 30 - 40 per minute . Cycle data Pressure rise time 0.20 +/- 0.02 s Pressure hold time 0.65 +/- 0.20 s Pressure drop time 0.20 +/- 0
18、.10 s Maximum pressure 10.1 - 10.5 MPa Minimum pressure 0.0 - 0.7 MPa Test Cycle (Repeat for duration of test) Hot cycle 25 000 cycles Cool down Shut off machine and cool to reservoir temperature of 82 C After initial cool down, resume cycling and repeat the cool down at 50 000 cycle intervals for t
19、he remainder of the test. Hose assemblies shall be inspected for leakage within the first five minutes of machine start-up following cool down. Any fluid observed dripping from the hose during test constitutes failure. Test Duration, min Lot approval 150 000 cycles Performance validation 400 000 cyc
20、les 3.6.7 Tensile Test with Fittings, min 6670 N (ASTM D 622) Hose assemblies shall withstand minimum tensile load without fittings pulling off or rupture of the hose. ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 5 of 11 3.6.8 Cold Flexibility at - 40 C No cracks or (FLTM BN 102-0
21、1, Procedure B) breaks At the end of the aging period, neither the tube nor cover shall show signs of cracking or disintegration when examined under 7X power glass. 3.6.9 Adhesion (ASTM D 413, strip method, type A) Tube to Cover 2 kN/m 3.6.10 Burst Pressure, min 44.2 MPa (ASTM D 380) 3.6.11 Ozone Re
22、sistance, max Rating 0 (FLTM BP 101-01, Procedure B) 3.6.12 Volumetric Expansion Samples shall be installed on the test fixture in a manner that allows the hose to lie straight, but not under tension when test pressure is applied. The test pressure, 10.4 +/- 0.2 MPa, shall be applied and held for 2
23、minutes +/- 5 s. At the end of this period the inlet valve shall be closed and the test fluid allowed to rise in the burette for a period of 1 minute +/- 5 s. The outlet valve shall be closed and the reading taken. This test shall be run at 23 +/- 2 C, 93 C and 150 C. Test must be completed within t
24、wo minutes at each temperature. The values obtained must fall within the limits specified on the chart below: ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 6 of 11 3.6.13 100 % Proof Test All hose shall be proof pressure tested using air, oil, or water as the pressure medium. CARE
25、SHOULD BE TAKEN WHEN TESTING WITH AIR DUE TO ITS EXPLOSIVE NATURE AT HIGH PRESSURES. Test pressure shall be no less than 10.4 MPa when tested with air or no less than 13.8 MPa when tested with oil or water. Test pressure shall be held for not less than 30 seconds and not more than 60 seconds. Any le
26、akage or rupture through the hose while test pressure is applied constitutes failure. Hose assemblies may also be proof pressure tested as described above. Any leakage or rupture through the assembly while test pressure is applied constitutes failure. Hose assemblies may be pneumatic pressure decay
27、tested using air or other suitable gases as the pressure medium. Hose assemblies are to be tested by pressurizing to 551 +/- 14 kPa, allowing pressure stabilization to occur, and then monitoring pressure for at least five seconds to ensure that hose assembly leak rate does not exceed 3.00 cc/min (me
28、asurements corrected to standard conditions, 20 C at one atmosphere). Assemblies must be automatically accepted or rejected at test completion. Each hose assembly must be either proof pressure tested or pneumatic pressure decay tested. In addition to testing for leakage on all parts of the hose asse
29、mbly, testing (if applicable) must be capable of detecting flare seats with longitudinal score or flare T.I.R. greater than maximum tolerances specified in ES-D9AC-3F536-AB. All rejected hose assemblies must be destroyed. 3.6.14 Low Temperature Cycling Performance Cold start durability of coupled ho
30、se assemblies shall be tested using a production power steering pump 9.7 - 10.0 MPa relief pressure with a production power steering gear and pitman arm. TEST APPARATUS SCHEMATIC ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 7 of 11 Test fluid shall be currently released power stee
31、ring fluid. (See Section 5 for fluid). Procedure: . Mount hose sample, without movement restrictions, with a 51 mm bend radius. . Soak system at - 40 C for at least 12 h. . Start pump drive motor and allow pump to run for 15 s prior to start of test cycle. . Rotate the steering gear input shaft at a
32、 30 rpm wheel rate to the right to the end of travel, against the stop, then back through center to the left stop. . Repeat for a total of 4 cycles. . After cycling, run the pump for 10 - 50 minutes to purge air from the system. . Repeat the soak cycle at - 40 C for a minimum of 4 h and repeat the 4
33、 cycle test. . Run entire sequence above for a total of 20 cycles or until failure. Soak time may be lengthened to accommodate lab test work schedule. For acceptance, both samples must complete or exceed 20 cold start cycles without failure. Any fluid observed dripping from the hose during test cons
34、titutes failure. 3.6.15 Hose Identification Unless otherwise specified on engineering drawing Hose shall be identified as follows: . Supplier identification code. . Date of manufacture (week, year) and plant designation if supplier has more than one plant producing hoses to this specification. No sp
35、ace between letters. . All of the above printing shall be clearly and legibly printed letters of 3 mm minimum in height and proportional width. ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 8 of 11 The following code format is recommended, but not mandatory: G 2 01 Where: G = Plant
36、 designation 2 = Year (single digit) 01 = Week (two digit number) 3.7 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engineering parts specification and/or performance specifications. All critical areas with respect
37、 to these properties shall be clearly designated on the engineering drawing. 3.8 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, c
38、omposition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineeri
39、ng activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this
40、document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain
41、 an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the tes
42、t facility, demonstrating full compliance with all the requirements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specificat
43、ion and on an assessment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List. ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 9 of 11 5. GENERAL INFORMATION The information below is prov
44、ided for clarification and assistance in meeting the requirements of this specification. 5.1 For information on currently approved power steering fluids for use in this specification contact: Materials Laboratory 13/100 Materials & Corrosion Research and Engineering Centre Protection Department Ford
45、 Motor Company Ltd. Chassis Engineering Laindon, Basildon Car Product Development Essex SS15 6EE, England 20000 Rotunda Dr., Bldg. No. 5 P.O. Box 2053, Room 2024 Dearborn, MI 48121-2053 Materials Engineering Product Engineering Office Ford Motor Co. of Australia Ltd. Princes Highway, Norlane Victori
46、a 3214, Australia 5.2 CERTIFICATION 5.2.1 Initial Qualification Tests To qualify hose or hose assemblies under this specification, all requirements shown in para 3.6 (TESTING) must be met. Slab stock and/or samples from one lot of manufactured hose must be tested as indicated in Sections 3.6.1 (orig
47、inal properties), 3.6.2 (heat aged), 3.6.3 (oil immersion) and 3.6.4 (fluid immersion). Samples from three lots of manufactured hose (in coupled assemblies, where required) must be tested as indicated in Table 1. Tests requiring currently released power steering fluid must use fluid as specified in
48、Section 5. ENGINEERING MATERIAL SPECIFICATION WSA-M96D36-A1 WP 3948-b Page 10 of 11 Table 1 Manufactured Coupled Section Description Hose Assemblies 3.6.2 Dry Heat Test 3 per lot or 3 per lot 3.6.6 Impulse Test - 5 per lot 3.6.7 Tensile Test - 6 per lot 3.6.8 Cold Flexability 3 per lot or 3 per lot
49、3.6.9 Adhesion Test 3 per lot or 3 per lot 3.6.10 Burst Test 3 per lot or 3 per lot 3.6.11 Ozone Resistance 3 per lot or 3 per lot 3.6.12 Volumetric Expansion 3 per lot or 3 per lot 3.6.13 100 % Proof Test - All samples 3.6.14 Low Temp Cycling - 2 per lot 3.6.15 Identification All samples All samples 5.2.2 Periodic Qualification Tests Every 6 months each hose manufacturer and coupler is required to perform complete qualification testing as listed in para 3.3. The testing shall be performed in February and August
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