FORD WSS-M1A176-E4-2017 GRAY IRON BRAKE COMPONENTS DRUMS AND ROTORS HIGH PERFORMANCE APPLICATIONS TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M1A176-E1).pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 03 17 Released R. Tillenbureg EU Controlled document at www.MATS.com Copyright 2017, Ford Global Technologies, LLC Page 1 of 6 GRAY IRON, BRAKE COMPONENTS, DRUMS AND ROTORS WSS-M1A176-E1 GRAY IRON, BRAKE COMPONENTS, DRUMS AND ROT

2、ORS, IMPROVED DAMPING PROPERTIES WSS-M1A176-E2 GRAY IRON, BRAKE COMPONENTS, DRUMS AND ROTORS, IMPROVED TEMPERATURE PROPERTIES WSS-M1A176-E3 GRAY IRON, BRAKE COMPONENTS, DRUMS AND ROTORS, HIGH PERFORMANCE APPLICATIONS WSS-M1A176-E4 1. SCOPE The materials defined in these specifications are low to med

3、ium strength structural gray cast iron. 2. APPLICATION This specification was released originally for gray iron used for all brake rotor and brake drum applications. Specification E2, E3 and E4 are a lower strength, high carbon equivalent grade and shall not be used for unicast rotor applications. E

4、3 and E4 materials are low silicon cast irons which in combination with performance friction materials may result in increased wear and cracking resistance, where the B5 material should be used in high performance applications for HP1 and HP2 vehicles. E1 is low carbon material with higher tensile s

5、trength. Any deviation to the material specification should be included on the print adjacent to the specification number. The material selection is done by Foundation Brake Core Engineering in agreement with Brake System Lay Out Team. Table Material specification application guide Material specific

6、ation Material application guide E1 For brake discs with threaded holes for connection to hub; brakes for value vehicles; brakes for nonperformance vehicles E2 Front brakes; brakes facing issues with thermal cracking and NVH (material with better damping than E1) E3 Alternative to E2 for better heat

7、 conductivity, wear performance and cracking resistance E4 Alternative to E2 and E3 for better heat conductivity, wear performance and cracking resistance in high temperatures 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification does not use approved sources. Any reliable supplier meeting these r

8、equirements may be used. ENGINEERING MATERIAL SPECIFICATION WSS-M1A176-E1/E2/E3/E4 Copyright 2017, Ford Global Technologies, LLC Page 2 of 6 3.2 PART SAMPLING LOCATIONS Cast or finished components must be used to determine conformance to this specification unless otherwise indicated on Engineering D

9、rawing. Table Part Sampling Locations * Fig. 1 Tensile Test Bar Hardness Microstructure Full-cast (or loose) Brake Rotor * Center of brake plate Hardness measured on center of brake plate (2 sides) every 90 (8 measurements). Center of brake plate; swan neck (connection of friction ring to hat) Unica

10、st Brake Rotor* Wheel mounting flange Hardness measured on center of brake plate (2 sides) every 90 (8 measurements). Cross-section of cup seat swan neck (connection of friction ring to hat) Brake Drum Side wall Inboard rim edge every 90 (4 measurements). On braking surface * Where callouts of this

11、table are not suitable due to part geometry or section size, the sampling locations will be as specified in supplier control plan. * Full-cast (or loose) Brake Rotor A rotor that is cast separately from the hub. It consists of the brake plate (or plates) and a “hat“ used to mount onto the hub. * Uni

12、cast Brake Rotor A casting that includes the brake rotor, hub and wheel bearing. 3.3 TENSILE STRENGTH E1: 207 MPa, min (ASTM A48/ASTM E8M/ISO 6892) E2, E3, E4: 150 MPa, min Mechanical properties of finished components may differ from separately cast test bars due to section size and foundry practice

13、. Preferred sampling method is from component casting. Component castings or separately cast tensile test bars may be used in accordance with the above standard. Separately cast test bars shall be processed and cooled from the same mold shakeout temperature and cooling rate as the castings they repr

14、esent. If tensile strength is determined from separately cast bars or other Materials Engineering-approved method, a correlation study must be conducted to determine relationship with component castings. Frequency of test bar sampling shall be as specified in the supplier control plan. 3.4 HARDNESS

15、(As Cast or Finished Components) E1: 187 241 HBW (ISO 6506/ASTM E10) E2, E3, E4: 149 229 HBW Hardness measured on one part can vary maximum 20 HB. Hardness to be measured on both machined friction surfaces, 4 times every 90 in the middle between inner and outer friction ring diameter 3.5 MICROSTRUCT

16、URE (ASTM A247) The microstructure shall consist of types “A” graphite of size 3 5 predominantly (shares of 2 and 6 are allowed, to be quantified on drawing), in a pearlitic matrix, with a maximum of 5% free ferrite. A region next to cast surfaces and outer diameter containing type “D” graphite is p

17、ermissible. This region to extend no further than 2 mm into the part from the casting surface. ENGINEERING MATERIAL SPECIFICATION WSS-M1A176-E1/E2/E3/E4 Copyright 2017, Ford Global Technologies, LLC Page 3 of 6 Graphite Distribution Type A Predominant Type B 10% Max. Type C 2% Max. Types D and E 5%

18、Max. Graphite flake size: 3 - 5 Matrix: Fine to medium lamellar pearlite with maximum of 5% ferrite. Primary carbides and phosphid eutectic are undesirable, but, if present should be evenly distributed and at a level less than 1%. 3.6 HEAT TREATMENT No post casting heat treatment permitted. If heat

19、treatment of the part is desired, it must be approved by Ford engineering, called out on the engineering drawing and controlled with an appropriate heat treatment specification 3.7 REPAIRS No welding, heat treatment or other repairs permitted. 3.8 HEAT CONDUCTIVITY Laser Flash Analysis (LFA) accordi

20、ng to ASTM E-1461 Heat conductivity at 100C E1: 48 W/mK min. E2, E3, E4: 55 W/mK min. The measurements for 50C and 200C-900C (every 100C) are to be reported. FIGURE 1. ENGINEERING MATERIAL SPECIFICATION WSS-M1A176-E1/E2/E3/E4 Copyright 2017, Ford Global Technologies, LLC Page 4 of 6 4. GENERAL INFOR

21、MATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. ENGINEERING MATERIAL SPECIFICATION WSS-M1A176-E1/E2/E3/E4 Copyright 2017, Ford Global Technologies

22、, LLC Page 5 of 6 4.1 FOUNDRY PRACTICE 4.1.1 Shakeout Practice Recommended shakeout time depends on practice used by each casting source. It is strongly recommended that castings be shaken out from the molds below the lower critical temperature for these alloys; otherwise there will be a bimodal dis

23、tribution for tensile strength and hardness with unacceptable microstructural variation affecting machining and customer. Casting source should use a process with the minimal alloy content necessary to meet requirements and reduce material property variation. 4.1.2 Control of Microstructure Ferrosil

24、icon inoculants and/or graphitizing agents should be added to the molten iron or in the mold to reduce chilling tendency and reduce variation in the resultant microstructure. Use of thermal analysis is strongly recommended. 4.1.3 Chemical Composition, (wt. Percent) (ASTM E415) E1 E2 E3 E4 Carbon 3.4

25、0 - 3.65 3.60 - 3.90 3.7-3.9 Silicon 1.60 - 2.40 2.10 - 2.90 1.1 - 1.6 Manganese 0.50 - 0.70 0.50 - 0.70 0.4-0.8 Chromium 0.4 Max Copper - 0.3 Max Boron 0.01 Max Phosphorous 0.12 Max Sulfur 0.15 Max Molybdenum - - - 0.25 - 0.45 Carbon Equivenent 4.30 Max 4.30 - 4.80 4 4.43 Carbon Equivalent = % Tota

26、l Carbon + 1/3 % Silicon - 1/3 (% Chromium - 0.10). 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 lab

27、oratory 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, t

28、he supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.3 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originall

29、y granted. Prior to making any changes 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

30、 the ENGINEERING MATERIAL SPECIFICATION WSS-M1A176-E1/E2/E3/E4 Copyright 2017, Ford Global Technologies, LLC Page 6 of 6 proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specificati

31、ons, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.4 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction appl

32、ies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is 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