1、 ENG INEERING MATERIAL SP ECIFICATION Material Name Specification Number Date Action Revisions 2000 04 25 Revised Revised para 3.5.4 L. Rumao 1998 04 23 Revised Revised para 2 N. Kurtycz 1991 07 02 CE00E10109215009 Released C. C. Gray Page 1 of 10 HOSE, AIR CONDITIONING REFRIGERANT WSH - M96D25 - A2
2、 (NYLON BARRIER) RESISTANT, MEDIUM PRESSURE 1. SCOPE The materials defined by this specification is a polychloroprene (Neoprene) rubber/nylon/elastomeric layer (nitrile, neoprene), high tensile polyest er reinforcement, butyl covered medium pressure refrigerant hose. 2. APPLICATION This specificatio
3、n was originally released for hoses designed for use with refrigerant R -134a and refrigerant oils that must be serviceable over an ambient temperature range of - 40 C to 125 C, and that must exhibit good long term transport/minimal fluid change properties at an operating temperature of - 40 C to 12
4、5 C and a maximum operating pressure of 3.4 MPa. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Materia l suppliers and part producers must conform to Quality System Requirements, QS - 9000. Material specification requirements are to be used for initial qualification of materials. A Control Plan fo
5、r ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to analyze process/product data and assure c
6、onsistent proce ssing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page
7、2 of 10 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 st andard an
8、d 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. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned
9、 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. 3.4 CONSTRUCTION The hose shall consist of a seamless smooth bore inner tube of a layered polychloroprene rubber/nylon
10、/elastomeric layer (nitrile, neoprene), reinforced with a high tensile ply or plies of polyester fabric bonded to the inner tube, and a butyl rubber weather resistant outer cover. The outer cover shall be perforated (pin pricked). 3.5 MOLDED TEST SPECIMEN/TEST SLABS 3.5.1 Preparation of Test Specime
11、ns - Nylon Core Unless otherwise specified all tests shall be carried out on extrusion molded specimens. The specimens shall be prepared according to ASTM D 1879. The test specimens have the following dimensions: 150 x 12.7 mm x 3.2 +/0 0.2 mm (tensile bar) and 120 x 12.7 x 3.2 +/ - 0.2 mm (flex bar
12、). No annealing allowed. 3.5.2 Preparation of Test Specimens - Butyl and Nitrile Rubber Whenever possible, all test specimens shall be die - cut from the finished parts. When not feasible, specimens cut from molded test slabs manufactured from the same material and with equivalent cure to molde d pa
13、rts are recommended. The test slabs shall have the following dimensions: 150 x 150 mm, min x 2.0 +/ - 0.2 mm. ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page 3 of 10 Nylon Core Polychloroprene Butyl Barrier Inner Core Cover 3.5.3 Density, g/cm 3 1.09 - 1.19 1.40 - 1.55 1.05 - 1.30 (ISO 11
14、83, Method A/ ASTM D 297) 3.5.4 Hardness, 80 - 90 60 - 70 Durometer A (ISO 868/ASTM D 2240, Instantaneous plied - up specimen. Hand held durometers shall not be used) 3.5.5 Tensile Strength, 17.2 9.0 6.2 MPa, min (ISO 37/ASTM D 412, Die C) Nylon Core Polychloroprene Butyl Barrier Inner Core Cover 3.
15、5.6 Elongation, % 200 150 125 (ISO 37/ASTM D 412, Die C) 3.5.7 Melt Temperature, 200 N/A N/A C, min (ASTM D 789) 3.5.8 Flexural Modulus, 517 N/A N/A MPa, max (ASTM D 790, Method I, Procedure A) 3.5.9 Moisture Content, 0.3 N/A N/A %, max 3.5.10 Ozone Resistance, - - Rating 0 max (ASTM D 1171, Method
16、A, 70 h at 50 pphm) 3.6 DIMENSIONS The hose shall conform to the dimensions and tolerances specified in Table 1. Measurement shall be made in accordance with ASTM D 380. ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page 4 of 10 TABLE 1 BARRIER HOSE MATERIAL _ Hose Inside Outside Concentrici
17、ty Burst Operating Bend Size Diameter Diameter Tir min Pressure, Radius, min mm mm mm mm MPa max, MPa mm min max min max _ _ 8.0 7.84 8.61 14.22 15.24 .76 17.2 3.4 38 10.0 10.16 11.17 16.76 17.78 .76 17.2 3.4 50.8 13.0 12.44 13.46 18.92 19.94 .76 17.2 3.4 63.5 16.0 15.62 16.63 23.11 24.13 .76 17.2 3
18、.4 90 19.0 18.92 19.93 26.92 27.94 .76 12.1 2.4 152.4 _ Acceptable hose must meet the following min performance requirements. Tests shall be conducted in accordance with ASTM D 1680 unless otherwise specified. 3.7 AEROSTATIC LEAK TEST There shall be no evidence of leakage (bubbles) through the hose
19、or at the couplings after a 30 minute hold period. Test Method: Pressurize the hose assembly at the test pressure with dry air for 30 minutes to permit purging of any entrapped gasses. The hose assembly may be submerged during this time. Disperse any bubbles that remain on the sur face of the hose,
20、couplings, or tubing. 3.7.1 Hose I.D. Test Pressure For 8 mm, 10 mm, 13 mm 3.4 MPa For 16 mm, 19 mm 2.4 MPa 3.8 CLEANLINESS (ASTM D 1680/SAE J51, Method 4.14.1) The hose shall meet the following requirements. The test fluid shall be collected in a clean beaker and poured through a 60 mesh screen and
21、 into the filter holder assembly. a) There shall be no evidence of water in the test fluid. b) There shall be no foreign material collected on a 60 mesh screen. c) The total weight of all contaminants shall not exceed 194 mg/m 2 of internal surface. d) No particle size shall be greater than .25 mm l
22、ineal dimension of any non - friable material. ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page 5 of 10 3.9 EXTRACTABLES, max 500 mg/cm 2 (SAE J51, Procedure 4.10) The extractables from the inside of the hose surface, and all extractables shall be oily or soft and greasy in nature and not
23、harmful to the refrigerant system. 3.10 HEAT AGING RESISTANCE After heat aging for 240 h at 125 +/ - 2 C the hose shall not show any evidence of charring, cracking, leaking or disintegration. Capped hose assemblies may be charged with ESA - M17B2 - A or WSH -M17B19 - B refrigerant, or nitrogen, befo
24、re being subjected to heat age. Aerostatic leak test per para 3.7 and check inner tube visually for fracture after leak test. 3.11 WEIGHT LOSS, max 0.5 % (After 8 h at 70 +/ - 2 C) 3.12 R - 12 OR R - 134a PERMEATION Coupled hose assemblies must be tested with both R - 12 and R - 134a refrigerants an
25、d appropriate, compatible lubricants. 3.12.1 Test Specimens 4 test specimens each having 107 +/ - 1.2 cm of exposed hose between hose couplings are required. Three of the assemblies are to determine the refrigerant loss and the fourth is a control sample. The hose assemblies are to be connected to c
26、anisters each having an internal volume of 510 cm 3 +/ - 25 cm 3 and a minimum burst strength of 8.6 MPa. Each test assembly will have a capped charge fitting. The assemblies will be subjected to the leak test in para 3.7 before and after the p ermeation test. 3.12.2 Charging Procedure and Initial W
27、eights The coupled hose assemblies are to be weighed and recorded to 0.01 g to establish an initial weight prior to charging. The test samples are to be loaded to 0.61 g/cm 3 . Evacuation and cooling of samples is recommended for ease of charging. ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A
28、2 Page 6 of 10 3.12.3 Temperature Exposure The test temperature is 100 +/ - 2 C. 3.12.4 Establish Constant Loss Rate (Saturate Test Specimens) Weigh the samples after 24 h of temperature exposure. Con tinue to weigh the samples every 24 h until steady state weight loss is reached. Steady state is re
29、ached when the last four weighings are with 10 % of the lowest reading or after 25 d, whichever comes first. Net weight loss should be used for all calculations and charting. Net weight loss equals the weight loss (grams) of a charged sample minus the weight loss (grams) of the control sample. 3.12.
30、5 Loss Rate Determination The permeation for each specimen may be determined as follows: Plot net w eight loss versus time. Establish the slope of steady state net weight loss in grams per day for the 107 cm length specimen and multiply by the conversion factor (.341) to obtain the permeation rate i
31、n kg/m/yr. Hose I.D. 24 h Total Loss Loss Rate at 100 C mm g kg/m/yr 8.0 20 0.982 10.0 26 1.340 13.0 32 1.562 16.0 40 1.935 3.13 COLD FLEXIBILITY AT - 40 C No leaks or fractures Precondition the hose prior to cold soak by filling to approximately 70 % of capacity at 23 +/ - 2 C with refrigerant (for
32、 both R - 12 and R - 134a), sealing the ends and heating to 70 +/ - 1 C for 48 h. After preconditioning, expose the hose to - 40 C for 48 h in a straight position. Then remove and immediately bend 180 around a mandrel having a diameter equal to the min bend diameter for the appropriate hose construc
33、tion and size (as shown in Table 1, 19 mm hose will be bent around mandrel with a 330 mm diameter), which has been chilled to - 40 C. Aerostatic leak test per para 3.7. Check inner tube visually for fractures after leak test. ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page 7 of 10 3.14 BU
34、RST PRESSURE (ASTM D 380) The hose shall not rupture or separate from the fittings at a pressure less than the minimum shown in Table 1, when tested in accordance with ASTM D 380. 3.15 VACUUM COLLAPSE, max 20 % The hose shall be subjected to a vacuum of 85 kPa for 5 minutes while bent in a “U“ shape
35、 to a radius five times the nominal hose O.D. (six times the O.D. for 19 mm hose). 3.16 LENGTH CHANGE, max + 2 to - 4 % (Pressurized to 3.4 MPa ) 3.17 ADHESION, min (ASTM D 413, ring specimen, Type A) 3.17.1 Second Rubber Layer to Reinforcement 31 N 3.17.2 Reinforcement to Cover 22 N 3.18 TENSILE FO
36、RCE There shall be no separation of the hose from the fittings or rupture of the hose structure at a load less than the following: Hose Size Tensile Force, min mm N 8.0 1557 10.0 2220 13.0 2220 16.0 2446 19.0 TBD 3.19 KINK RESISTANCE Hold one end of the hose stationary and bend hose to form a 360 de
37、gree loop. Pull the free end of hose in a direction 180 away from fixed end, thus reducing the diameter of the loop. Continue to decrease the diameter of the loop until the outside diameter of the hose is reduced by 20 % of its original outer diameter. At this point, the inside diameter of the loop
38、must be less than or equal to the bend diameter listed below. Hose Size Bend Diameter mm mm 8.0 TBD 10.0 77.0 16.0 127.0 19.0 229.0 ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page 8 of 10 3.20 COUPLING INTEGRITY Coupling integrity test to be conducted with FLTM BP 118 - 02. Acceptable det
39、ermination: a) Applies to six canister assemblies (12 couplings). b) Maximum weight loss per canister (two couplings) per exposure interval shall not exceed 7 g. c) All eight post interval flexing evaluations shall not produce hissing visible oil loss or a refrigerant leak rate in excess of 5.9 g/ye
40、ar at any location in the coupling assembly. d) At completion of test, hose shall be depressurized and couplings shall be cut from hose. Cut hose open longitudinally and note any cracking, blistering or separation of the core tube. Any such core tube damage will result in failure of the test. 3.21 I
41、MPULSE TEST (Pressure Cycling) Assemblies shall withstand 200 000 cycles of hydrostatic pressure from 0 to 3.4 MPa at a cycle rate of 30 +/ - 5 cycles/minute. Test fluid shall be ESH - M2C31 - A2 or WSH - M1C231 - B refrigerant oil, ESW - M2C33 -F transmission fluid or equivalent hydraulic fluid mai
42、ntained at 125 +/ - 2 C. Test assemblies shall be installed in a 180 arc to the min bend radius specified in Table 1. There shall be no leakage when assemblies are subjected to the aerostatic leak test of para 3.7 at the conclusion of the impulse test. 3.22 VIBRATION RESISTANCE There shall be no lea
43、kage when subjected to the leak test of para 3.7 after the vibration test. Hose assemblies shall be leak tested per para 3.7 and then charged with Refrigerant R -12 or Refrigerant R -134a to 0.61 g/cm 3 of internal volu me. One end of the hose fitting shall be attached to a fixture to be vibrated. E
44、NGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page 9 of 10 The hose shall be bent horizontally to form a 90 bend with the axis of the hose couplings in the same plane, and the opposite fitting attached to a rigid (fixed) support. Vibration shall be conducted for 100 h in the vertical directio
45、n with an amplitude of 3.2 mm at a cycle rate of 30 Hz. The ambient temperature shall be maintained at 77 C to maintain a refrigerant pressure of 1.9 MPa. 3.23 MOISTURE INGRESSION, max 3 50 g/m 2 /year (FLTM BP 118 - 01) 3.24 IDENTIFICATION The hose shall be identified as follows: a) Hose supplier i
46、dentification code. b) Hose I.D./in millimeters. c) Four - digit date code. d) Color of lettering - Yellow. The following code format is recommended, but not mandatory: G 2 01 Where G = Plant Designation 2 = Year (single digit) 01 = Week (two digit number) These markings shall appear at intervals no
47、t greater than 305 mm. The markings shall not be soluble in water or automatic transmission fluid, and shall withstand normal handling without smearing. 3.25 ADDITIONAL REQUIREMENTS Specific requirements for material and/or manufactured parts shall be specified on the Engineering drawing, Engineerin
48、g parts specification and/or performance specification. All critical areas with respect to these properties shall be clearly designated on the engineering drawing. 3.26 SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all char acteristics to the material upon which approval was originally granted. ENGINEERING MATERIAL SPECIFICATION WSH - M 96D25 - A2 Page 10 of 10 Prior to making any change in the properties, composition, cons
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