FORD WSS-M2A177-A5-2014 ALUMINUM ALLOY EXTRUSION HEAT TREATABLE STRUCTURAL ENERGY ABSORBSION TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M2A177-A1).pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 04 2014 06 20 Revised See Summary of Revisions C. Mracna, NA 2014 03 06 Editorial See Summary of Revisions C. Mracna, NA 2013 11 06 Released C. Mracna, NA Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page

2、1 of 7 ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A1 HIGH STRENGTH ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, SEAMLESS, WSS-M2A177-A2 HIGH STRENGTH, GRAIN SIZE CONTROLLED ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A3 MODERATE STRENGTH AND FORMABILITY ALU

3、MINUM ALLOY, EXTRUSION, HEAT TREATABLE, SEAMLESS, WSS-M2A177-A4 MODERATE STRENGTH AND FORMABILITY, GRAIN SIZE CONTROLLED ALUMINUM ALLOY, EXTRUSION, HEAT TREATABLE, STRUCTURAL, WSS-M2A177-A5 ENERGY ABSORBSION 1. SCOPE The materials defined by these specifications are for 6000 series, heat treatable e

4、xtruded aluminum tubes and profiles. Ford Motor Company may, at its option and in agreement with the local or regional supplier, define additional and/or restricted technical delivery requirements such as mechanical properties, forming characteristics, pretreatment, and/or surface texture, for a spe

5、cific grade and/or part. The defined requirements shall be mandatory and no characteristics shall conflict with these engineering specifications. 2. APPLICATION These Global specifications were released originally for extruded aluminum tubes for structural applications. The manufacturing processes u

6、sed to form these aluminum tubes include but are not limited to rotary bending, push roll bending, stretch bending, stamping, hydroforming, piercing, laser trimming, and machine trimming. The alloys defined in this specification are not susceptible to intergranular corrosion or stress corrosion crac

7、king. 2.1 LIMITATIONS The yield strength of the material in the part after the artificial aging heat treatment and / or paint baking process is a function of the amount of forming deformation and the time-temperature profile during the paint baking process. The mechanical property values shown in Ta

8、ble 2 apply only to the listed condition; individual parts will have different properties, depending on specific processing in the vehicle manufacturing plants. 2.2 DEFINITIONS Variant A1 is a structural, multi-hollow extruded tube alloy typically applied to Class 3 non-visible parts where high stre

9、ngth and modest ductility are required. For high strength, these alloys must be artificially aged (e.g. T6) for parts requiring functional performance characterized by controlled in-service deformation. ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5 Copyright 2014, Ford Global Technolo

10、gies, LLC Page 2 of 9 Variant A2 is a seamless extruded tube alloy typically applied to Class 3 non-visible parts where high strength and modest ductility are required. For high strength, these alloys must be artificially aged (e.g. T6) for parts requiring functional performance characterized by con

11、trolled in-service deformation. Variant A3 is a general structural, multi-hollow extruded tube alloy suitable for Class 3 parts where moderate strength and modest formability are required. Variant A4 is a general seamless extruded tube alloy suitable for Class 3 parts where moderate strength and mod

12、est formability are required. Variant A5 is a general structural, multi-hollow extruded tube alloy suitable to Class 3 parts where energy absorption and/ or controlled in-service deformation behavior are desired. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers a

13、nd part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). Material suppliers and part producers must conform to the Companys Quality System Requirements. In order for materials to comply with the requirements of the material specification they sh

14、all be sourced from suppliers listed in the Ford Motor Company Approved Source List, ASL (See also paragraph 4.2). 3.2 CHEMICAL COMPOSITION AND MICROSTRUCTURE (ASTM E34, ASTM E716, ASTM E1251) 3.2.1 Chemical Composition The upper and lower limits of chemical composition of the controlled elements sh

15、all be established by the supplier by any of the listed methods and included in the Suppliers Control Plan. In case of dispute, the referee method shall be ASTM E34. The tabulated upper and lower limits of chemical composition for each variant may not agree with those listed in the Aluminum Associat

16、ion “Teal Sheets.“ The values in Table 1 take precedence. Check analyses of extruded tubes shall be provided as part of the initial material source approval process in a format suitable for upload into the Ford Material Database. Table 1: Chemical Composition (weight percent maximum, unless shown as

17、 a range or a minimum; balance Al) A1 A2 A3/A4 A5 Si 0.70 - 1.30 0.70 - 1.30 0.40 - 0.80 0.20 - 0.60 Fe 0.5 0.5 0.70 0.35 Cu 0.10 0.10 0.40 0.10 Mn 0.40 1.00 0.10 0.60 0.15 0.10 Mg 0.60 - 1.20 0.60 - 1.20 0.80 - 1.20 0.45 - 0.90 Cr 0.25 0.25 0.35 0.10 Zn 0.20 0.20 0.25 0.10 Ti 0.10 0.10 0.15 0.10 Ot

18、hers (each) 0.05 0.05 0.05 0.05 Others (total) 0.15 0.15 0.15 0.15 ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5 Copyright 2014, Ford Global Technologies, LLC Page 3 of 9 3.2.2 Average Grain Size, (ASTM E112, Comparison Procedure) WSS-M2A177-A2 Report Only WSS-M2A177-A4 Report Only 3.

19、3 MECHANICAL PROPERTIES (ASTM B557M, 50 mm gauge length; ASTM E517) Mechanical properties are valid in the longitudinal direction parallel to extrusion direction, except as noted. Certification of ongoing production material shall be in accordance with regional and/or local requirements. In cases of

20、 dispute, test data obtained from supplier retained samples that have been stored under environmentally controlled conditions will serve as the arbitrator. The samples shall be tested at a third party laboratory. Mechanical properties shall be valid for a period of between seven (7) and sixty seven

21、(67) days following solution heat treatment unless otherwise noted. For the determination of mechanical properties, the material cross sectional area shall be defined as that of the aluminium alloy; contribution of any surface treatments to the calculated cross-sectional area used for stress calcula

22、tions is neglected. The test specimen geometry is to be established locally to certify ongoing production material. Yield Strength is defined as 0.2% proof stress. Yield Strength (T81 therefore, the billet change scrap (start/change/end) is not useable. Start and end scrap length to be developed bas

23、ed on the installed equipment. Guidelines for usable material and scrap subject to control plan. ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5 Copyright 2014, Ford Global Technologies, LLC Page 6 of 9 3.6.1.2 Longitudinal Welds Longitudinal weld-line integrity shall be assessed per FL

24、TM BB 116-01. Samples are to be taken from the front of beam after the prescribed scrap is removed. Actual sampling plan shall be established with Ford materials engineering and based on PFMEA and control plan. 3.7 SURFACE APPEARANCE, CONDITION, AND SURFACE ROUGHNESS 3.7.1 Surface Classification All

25、 variants of this specification are suitable for Class 3 applications as defined in ESF75B-11007-(*). (*) latest level 3.7.2 Incoming Lubricant Products coated with a lubricant shall comply with regional requirements and the regional approved lubricant list. 3.7.3 Pretreatments Batch-applied pretrea

26、tments shall comply with performance specification WSS-M10P12-B2. 3.7.4 Surface Roughness The surface roughness and associated parameters for a given component are to be defined and recorded, if necessary, by the regional manufacturing activity. 3.7.5 Final Product Identification WSS-M2A177-A2/A4 -

27、Unless an alternate method is agreed upon by the aluminum alloy supplier and the manufacturing activity, the final extruded tube product shall be identified per ESDU5A-1B328-(*) (*) latest level WSS-M2A177-A1/A3/A5 - Unless an alternate method is agreed upon by the aluminum alloy supplier and the ma

28、nufacturing activity, the final extruded tube product shall be identified as follows. This information shall be marked by ink-jet or similar printer, at one meter intervals, in a color as specified by the regional Purchasing activity and shall consist of human readable information in which each piec

29、e of information is separated by “ “. The final product should have traceable material identification information including: square4 Part Number square4 Global Product Grade Name square4 Heat Treat Date (yyyy-mm-dd) square4 Extruded Tube Supplier Name square4 Global Supplier Data Base (GSDB) Code sq

30、uare4 Lot Number Stencil Example: 16107K40-A 6XHS yyyy-mm-dd Supplier GSDB A1234567-1 ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5 Copyright 2014, Ford Global Technologies, LLC Page 7 of 9 3.8 PAINTABILITY In conjunction with the material supplier and Ford Materials Engineering, the

31、affected local manufacturing activity shall, as part of the initial material source approval process, approve the paintability (e.g., compatibility, appearance, performance) of this material by means of laboratory test(s), manufacturing trial(s), and/or another mutually acceptable alternative, using

32、 the equipment and methods that are proposed for production. If needed to enable the fabrication of a specific component, restricted tolerances and/or additional material property requirements (i.e., the “quality level“ of the aluminum alloy) shall be developed by the affected manufacturing activity

33、 and the aluminum supplier. Examples include, but are not limited to: restricted dross content and specified surface condition. The “quality level“ of the aluminum alloy for a specific component: shall not conflict with specified requirements in paragraph 3 of this Engineering Material Specification

34、 shall be described in detail by the local manufacturing activity shall be a mandatory extension of these Engineering Material Specifications Acceptance of subsequent orders by the aluminum alloy supplier for a given component at the agreed upon quality level implies that all aluminum alloy supplied

35、 will be of a comparable quality level and can be painted satisfactorily as defined and recorded by the manufacturing activity. 3.9 METHOD OF SPECIFYING The specification on the Engineering Drawing, CAD file, or related documents shall include the base aluminum alloy and, as applicable, the pretreat

36、ment. e.g. An Aluminum Alloy, Extrusion, Heat Treatable, Structural, High Strength, pretreated for an unexposed upperbody rail would be defined thus: Aluminum to WSS-M2A177-A1, pretreated to WSS-M10P12-B2. 4. GENERAL INFORMATION The information given below is provided for clarification and assistanc

37、e in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 REFERENCE DOCUMENTS The reference documents are: External Standards: ANSI H35.2 Dimensional Tolerances for Aluminum Mill Products ASTM E8M Test Methods for Tension Testing

38、of Metallic Materials ASTM E34 Standard Test Methods for Chemical Analysis of Aluminum and Aluminum-Base Alloys ASTM E112 Standard Test Method for Determining Average Grain Size ASTM E517 Test Method for Plastic Strain Ratio r for Sheet Metal ASTM B557M Standard Test Methods for Tension Testing Wrou

39、ght and Cast Aluminum- and Magnesium-Alloy Products ASTM E716 Standard Practices for Sampling and Sample Preparation of Aluminum and Aluminum Alloys for Determination of Chemical Composition by Spectrochemical Analysis ASTM E1251 Standard Test Method for Analysis of Aluminum and Aluminum Alloys by A

40、tomic Emission Spectrometry ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A4/A5 Copyright 2014, Ford Global Technologies, LLC Page 8 of 9 ASTM B221 Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes ASTM B429 Standard Specification for Alum

41、inum-Alloy Extruded Structural Pipe and Tube ASTM B918 Standard Practice for Heat Treatment of Wrought Aluminum Alloys ISO 4587 Adhesives Determination of Tensile Lap-Shear Strength of Rigid-to-Rigid Bonded Assemblies SAE J1523 Metal to Metal Overlap Shear Strength for Automotive Type Adhesives Ford

42、 Material / Engineering Standards: ESBAU5-1A275-(*) Specification for Aluminum Extruded Hydroformed Tubes ESDU5A-1B328-(*) Aluminum Material Traceability ESF75B-110007-(*) Specification for Sheet Metal Surfaces and Edges FLTM BB 113-07 Welding Acceptance Test for Aluminum FLTM BV 101-07 Stress Durab

43、ility Test for Adhesive Lap-Shear Bonds FLTM AB 108-01 Mechanical Properties Measurement After Thermal Processing of Aluminum Alloy Extrusions FLTM BB 116-01 Procedure for Testing the Integrity of Weld-Lines in Extruded Structural Aluminum Tubes Using Tube Flare Test Method WSS-M99P1111-A Standard R

44、equirements for Production Materials WSS-M10P12-B2 Pretreatment, Aluminum, Batch Applied (*) latest level 4.2 INITIAL MECHANICAL MECHANICAL PROPERTY TESTING For initial approval, the supplier should contact Ford Materials Engineering to obtain the latest revision of the Global Extruded Aluminum Mate

45、rial Development Form. Upon initial technical approval and completion of a functional prove-out (line trial), the material will be added to the Approved Source List (ASL). 4.3 COMMON DESIGNATION The requirements of these specifications take precedence over those in the Aluminum Association Internati

46、onal Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys (or “Teal Sheets“), or any other industry standard. Variant A1 6XHS Variant A2 6XHSG Variant A3 6XST Variant A4 6XSTG Variant A5 6XEA 4.4 MECHANICAL PROPERTIES, AFTER THERMAL TREATMENTS, 0% STRAI

47、N, TYPICAL VALUES Table 2: Typical Mechanical Properties A1 A2 A3 A4 A5 Yield Strength, T6, MPa (0.2% offset) 310 305 260 260 200 Yield Strength, T81, MPa (0.2% offset) N/A N/A 150 130 N/A Ultimate Tensile Strength, T6, MPa 340 320 310 TBD 250 ENGINEERING MATERIAL SPECIFICATION WSS-M2A177-A1/A2/A3/A

48、4/A5 Copyright 2014, Ford Global Technologies, LLC Page 9 of 9 5. SUMMARY OF REVISIONS 2014 06 20 Section 3.3 Table 2 Changed MRD for 6XHSG from 10 to 9. 2014 03 06 Section 3.7.5 and 4.1 updated to include Aluminum Material Traceability spec 2014 01 29 Section 3.9 corrected specification typo from B1 to B2 Section 4.1 corrected specification typo from B1 to B2 2014 01 24 Section 3.7.3 corrected specification typo from B1 to B2.