FORD WSE-M1A320-A5-2017 GRAY CAST IRON CYLINDER LINERS ROUGH CAST OUTSIDE DIAMETER TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSE-M1A320-A3).pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 07 2017 01 13 Revised A5 Added, See Summary of Revisions T. Covert, NA 2016 07 25 Inactive A1 and A2 A. Wedepohl, NA 1991 05 08 Released Released A1 J. Webster Controlled document at www.MATS Copyright 2017, Ford Global Technologies, Inc

2、 Page 1 of 3 GRAY CAST IRON, CYLINDER LINERS WSE-M1A320-A3 GRAY CAST IRON, CYLINDER LINERS, HIGH DURABILITY WSE-M1A320-A4 GRAY CAST IRON, CYLINDER LINERS, ROUGH CAST OUTSIDE DIAMETER WSE-M1A320-A5 1. SCOPE The materials defined by these specifications are gray cast iron with controlled hardness and

3、microstructure to achieve optimum cylinder bore functional characteristics. 2. APPLICATION These specifications were released originally for materials used as cylinder liners in aluminum blocks. The A4 material was added for long-term durability and improved oil consumption. The A5 material was adde

4、d for un-machined OD liners, directly cast in the block. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification does not use approved sources. Any reliable supplier meeting these requirements may be used. 3.2 CHEMICAL COMPOSITION (Weight Percent) A3 A4 A5 Carbon (total) 3.00 - 3.50 3.00 - 3.50 3.00

5、 3.70 Carbon Equivalent 4.40 max 4.40 max 4.00 4.40 Silicon 2.00 - 2.80 2.00 - 2.80 2.00 2.80 Manganese 0.50 - 1.00 0.50 - 1.00 0.50 1.00 Phosphorus 0.10 - 0.40 0.10 - 0.40 0.25 max Sulfur 0.12 max 0.12 max 0.12 max Chromium 0.10 - 0.40 0.10 - 0.40 0.05 0.40 Copper + Nickel* - 0.20 - 1.50 0.10 1.00

6、Tin 0.15 max 0.15 max 0.15 max Vanadium 0.03 max 0.03 max 0.03 max Titanium 0.04 max 0.04 max 0.04 max Tungsten 0.02 max 0.02 max 0.02 max Molybdenum - 0.20 - 0.50 - Carbon Equivalent = Total Carbon + 1/3 Silicon * Nickel may be substituted for copper or visa versa to the extent that the total nicke

7、l plus copper equals specified amount. Specific composition limits and foundry practice to meet performance and manufacturing requirements will form part of an agreed Control Plan for individual components. ENGINEERING MATERIAL SPECIFICATION WSE-M1A320-A3/A4/A5 Copyright 2017, Ford Global Technologi

8、es, Inc. Page 2 of 4 3.3 HARDNESS (ASTM E10 / ISO 6506, P/D2 Ratio = 30:1; ASTM E18 / ISO 6507) Rough cast liner Brinell hardness test location is on a ground flat area on the OD at least 25 mm from the skirt end of the casting. Finished liner hardness and location shall be taken as shown on Enginee

9、ring Drawing or Control Plan. A3 / A4 / A5 Rough cast 205-273 HB 10mm Rough cast 205-273 HB 10mm & Finished* 94-106 HRB *Average of three readings. Method for hardness measurement of thin wall cylinder liners Cut section of liner along the length of the liner resulting in a long section Machine or g

10、rind the OD surface until texture is removed and flat Machine or grind the ID surface only until parallel and flat with the OD surface (do not remove any more than the minimum amount of material than needed to achieve a flat sample) The width of the cut section of the liner will be dependent on the

11、diameter and thickness of the liner. Care must be taken to ensure the thickness of the liner and the measurement surface area meets the requirements for the measurement method. 3.4 MICROSTRUCTURE (Average over a minimum of 10 adjacent fields at 100X magnification) (ASTM A247 / ASTM E562) A3/A4: Eval

12、uate microstructure at any position greater than 2 mm from finished outer diameter. The graphite structure at the wear surface of a finished liner at a point approximately 25 mm from the flange end shall consist as defined in the following. A5: Evaluate microstructure in a zone 12 mm from cast OD su

13、rface (OD surface as defined on the liner engineering drawing). Also see Figure 1 below. Form VII flake graphite as follows: A3 A4 A5 Type A, % (size) Permissible 50% min (4-7) 50% min (4-8) Type B, % (size) 75% max (6-8) - - Type D&E, % (size) 75% max (6-8) 25% max (4-8) 25% max (4-8) The graphite

14、morphology, size and matrix microstructure content may be measured by comparison to available industry charts, or by quantitative methods (ASTM E562 or approved image analysis techniques). In case of dispute, the quantitative metallurgical method will be the umpire method. ENGINEERING MATERIAL SPECI

15、FICATION WSE-M1A320-A3/A4/A5 Copyright 2017, Ford Global Technologies, Inc. Page 3 of 4 The matrix microstructure at the wear surface shall consist of fine lamellar pearlite with a maximum of 5% free ferrite and a maximum of 5% free carbides. No carbide network is permitted. If present, iron phosphi

16、de eutectic (steadite) must be fine, evenly distributed in a random pattern with no continuous network and shall not exceed 8% for A3/A4/A5. A3/A4/A5 must meet Liner Machinability ES Specification ESHL3E-6055-AA for all new and resourcing actions post sign-off. Fig. 1 4. GENERAL INFORMATION The info

17、rmation given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 REFERENCE DOCUMENTS The following documents are referenced in this specification: ASTM A247 ASTM E10 ASTM E18

18、 ASTM E562 ISO 6506 ISO 6507 WSS-M99P9999-A1 4.2 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory

19、 test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supp

20、lier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.3 SUPPLIERS ONGOING RESPONSIBILITY Ma 1 mm Overall Liner Wall Thickness Zone for Microstructure Analysis 1 mm OD is defined by the liner drawing: I

21、n this example OD is the top of the peaks. ENGINEERING MATERIAL SPECIFICATION WSE-M1A320-A3/A4/A5 Copyright 2017, Ford Global Technologies, Inc. Page 4 of 4 All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes

22、 to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) b

23、y submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign

24、off must be kept until Job 1. 4.4 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is

25、updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2017 01 13 Removed WSS-M99P1111-A and added those requirements into this specification. Removed A1 and A2 (inactive). Released A5 suffix A

26、dded method of hardness measurements for thin walled cylinders Added V, Ti, W, and Mo elements to elemental composition. 2016 07 25 A1 and A2 Inactive status 2011 12 15 N Status A1/A2 - No Usage 2002 07 23 Updated and renumbered 2002 01 31 Released A4 and updated and renumbered 1995 03 01 Released A3 1992 06 16 Released A2 1991 05 08 Released A1 NE01E1012707601027076010