1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2006 09 20 Revised Inserted 3.0; Deleted 3.1, 3.2, 3.3, 3.9 a single ply of knit or spiral woven aramid reinforcement and a braided cover that is resistant to engine compartment hydrocarbons, water, chlorides, abrasion, heat and ozone. 2. APP
2、LICATION This specification is for fuel supply and return lines with diesel fuel and blends of diesel fuel with RME (such as rapeseed methyl ester) up to 20% by volume. The hose is resistant to sustained exposure of 1000 h in these fluids at 125 C and intermittent exposure to 150 C for 50 h at a max
3、imum pressure of 2.75 MPa. Constructed of a smooth bore, diesel fuel/RME resistant, chlorinated polyethylene (CPE/CM) elastomeric tube, reinforced with a single ply of braided, knit or spiral woven para-aramid fiber and a polyester braided cover which may or may not be resin impregnated. The inner t
4、ube is electrically conductive. This hose is intended to be used in a coupled assembly. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.4 INITIAL Q
5、UALIFICATION Prior to seeking approval to this specification, initial qualification processes including evaluating materials and constructions according to the applicable Fuel System Design Specifications (SDS) and individual Design Verification Methods (DVM) if applicable must be performed. 3.4.1 C
6、ompletion of cover materials evaluation using SAE J2027a/bs procedure in Section 5.2.7 for the following fluids and conditions: Brake Fluid, Diesel fuel (XE-M4CX708-B), current approved Engine Coolant and Service Fluid 105. These fluids are to be tested under the conditions listed in Table 1-7. If n
7、ot listed in Table 1-7 the conditions of 100% concentration for 1 hour at 100 C, with an air dry will apply. There shall be no evidence of softening, blistering or cracking when evaluated in a flexed condition at 7x magnification. The cold temperature testing (impact) is not required. 3.4.2 Establis
8、h the material long term heat aging resistance per SAE J2236. Data to be reviewed by the appropriated materials engineering office of Ford Motor Company and will depend on the anticipated environment in which the material will perform. 3.4.3 Completion of inner tube material compatibility with diese
9、l fuel (XE-M4CX708-B) and an 80/20 diesel-RME blend will be conducted according to the Method B listed in FLTM BZ 105-O3. Test conditions will vary from this procedure in that the test time will be 1000 hours at 125 C. Volume swell percentage, tensile and elongation will be reported after the 1000 h
10、our test time. ENGINEERING MATERIAL SPECIFICATION WSS-M96D46-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 6 3.4.4 The hose must meet the SAE J2260 surface resistivity requirement of 2 minutes 3.03 minutes (5 sample average) ENGINEERING MATERIAL SPECIFICA
11、TION WSS-M96D46-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 6 3.6.4 ADHESION TEST (tube to braid) (ASTM D413, ISO 8033) Tube to reinforcement, min 1.4 kN/M Cover to reinforcement, min Not Applicable 4.6 kN/M (6 sample average) 3.7 PERFORMANCE TESTS ON F
12、INISHED ASSEMBLIES 3.7.1 PROOF PRESSURE TEST No Leakage (All (ISO 1817/ASTM D 380/SAE J 1019) constructions) Test Method: The assembly is proof tested for a period of not less than 30 seconds and not more than 60 seconds at a test pressure of 5.50 MPa. Pass (6 samples) 3.7.2 BURST TEST, min 11 MPa (
13、SAE J343) Test Method: The assembly is subjected to hydrostatic pressure increased at a constant rate so as to attain the specified minimum burst pressure. There shall be no leakage, hose burst or indication of failure below the minimum specified burst pressure. 21 Mpa (6 sample average) 3.7.3 HIGH
14、TEMPERATURE BURST TEST, min 7.7 MPa (SAE J343) Test Method: The assembly is attached by one end to a pressure source and extended straight without restrain. The free end is suitably capped or plugged and pressure is applied until failure. The sample is held at 150 C for 2 h prior to pressurization.
15、12.5 Mpa (6 sample average) 3.7.4 HIGH TEMPERATURE IMPULSE TEST No leaks at (SAE J343) fittings through 500,000 cycles, followed by Burst, para 3.7.2 Test Method: The assemblies are attached to a rigid impulse manifold and subjected to dynamic impulse from 0 MPa to the required percentage of working
16、 pressure of the hose. ENGINEERING MATERIAL SPECIFICATION WSS-M96D46-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 6 Impulse Test Conditions: Position 180 Test Pressure 2.75 MPa Cycles Required 500,000 Test Fluid Mil-L-2104 or Synthetic oil, RN 3576 or eq
17、uivalent Fluid Temperature 150 C Ambient Temperature Approximately 100 C Bend Radius 7.62 cm Wave Pattern Square Pressure Rise Rate 26.1 MPa/second Cycle Rate 70 cycles/minute Leakage: Pass (6 samples) Burst: 14.6 Mpa (6 sample average) 3.7.5 FITTING PULL TEST Pass (All (SAE J1019, ASTM D 380) const
18、ructions) After Impulse Test, N 250 N Test Method: The assemblies are installed in a tensile testing machine so the hose and fittings have a straight center line corresponding to the direction of machine pull. An increasing tensile load is applied at a rate of 25.4 mm per minute until failure. 924 N
19、 (6 sample average) 3.7.6 COLD FLEXIBILITY TEST No Cracks and/ (SAE J 343, ASTM D 380) or malfunctions Test Method: The assembly is placed in a cold chamber for conditioning. At the end of the conditioning period and while still at the test temperature, each assembly is bent around a mandrel until t
20、he full length of the hose is in contact with the mandrel circumference. After flexing, the samples are removed from the chamber, allowed to warm to room temperature and examined for cover cracks or other malfunctions and proof tested. Conditions: Conditioning period 24 h Test Temperature -40 C Flex
21、ing Time 12 +/-3 second Bend Radius 76.2 mm Proof Test Pressure 5.5 MPa Min Pass (6 samples) ENGINEERING MATERIAL SPECIFICATION WSS-M96D46-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 6 3.7.7 VACUUM TEST Pass (All (ISO 7233/ASTM D 622/SAE J 343) construc
22、tions) Test Method: The hose shall be bent 180 to the specified minimum bend radius, and the outside diameter may deform or flatten up to a max of 10% of the original outside diameter. Flattening or deformation greater than 10% shall be cause for rejection. With the assemblies in the bent configurat
23、ion, a vacuum of 28 in Hg shall be applied. While under vacuum, the hose will be checked for additional flattening or deformation. Reduction of the outside diameter due to the applied vacuum shall not exceed 10% of the original outside diameter. Any evidence of ply separation after testing shall be
24、cause for rejection. Pass (6 samples) 3.7.8 CYCLE CORROSION TEST (FLTM BI 123-01) Test Method: 10 Hose assemblies are exposed to salt spray according to FLTM BI 123-01. The samples are oriented in a horizontal position on plastic bars. One sample is removed from the spray every 10 cycles. Every hose
25、 is then rinsed with cool water to cool to room temperature and dried with air prior to proof, leakage and burst testing. Proof Test No Leakage Burst Test, min 11 MPa Proof: Pass (10 samples) Burst: 23.8 Mpa (10 sample average) 3.7.9 HOT FUEL CIRCULATION No leakage (SAE J 1019) at 1008 h Burst 7.7 M
26、Pa Fitting Pull 250 N Test Method: Reference diesel fuel (XE-M4CX708-B, U.S. Development) is circulated through two assemblies at a rate to maintain the bore temperature of 125 C. The internal pressure is to be maintained in the range of 0.52-0.69 Mpa for the duration of the test. The ambient temper
27、ature will be 100 C minimum. After the test time of 1008 hours, both assemblies are to be subjected to the kink test in 3.6.2 with acceptable results. The hose cover is to be examined and shall show no evidence of cracks or other deterioration. Following the kink test, one assembly is to be subjecte
28、d to the burst test in 3.6.6, while the other is subjected to the fitting pull test as in 3.6.9. No leakage at 1008 hrs - Pass (6 samples) Kink - Pass (6 samples) Burst 7.7 Mpa - 23.2 (3 sample average) Fitting Pull 250N 1058 (3 sample average) ENGINEERING MATERIAL SPECIFICATION WSS-M96D46-A1 Printe
29、d copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 6 3.8 HOSE IDENTIFICATION The words ”Diesel fuel“ and the coding described below shall appear on the outer cover of the hose in contrasting color and repeated at intervals of 60 mm or less. The following format is reco
30、mmended: a) Supplier identification code. b) Time of manufacture (week, year) and plant designation if supplier has more than one plant producing hoses to this specification. No space between letters. Mandatory on hoses longer than 80 mm only. c) Ford Trademark on hoses longer than 150 mm. d) Recycl
31、ing codes for constituent polymers, in order starting with the I.D. (See paragraph 5). Letters 2-4 mm height may be used. e) All of the above printing shall be clearly and legibly printed in letters of 4.5-12.5 mm in height and width. When hose is less than 80 mm long, width of letters may be reduce
32、d to 3 mm. Note: For braided exterior constructions where effective printed identification is not feasible, printed plastic bands of resistant material (per SAE J2027b) affixed at one coupling end may be substituted. 5. GENERAL INFORMATION The information given below is provided for clarification an
33、d assistance in meeting the requirements of this specification. 5.1 RECYCLING CODES 5.2 Note: Before proceeding with tests involving fuels at elevated temperatures, consult your building coordinator for compliance to required safety procedures and refer to fluids documentation provided by Specified Fuels and Chemicals, Inc. 5.3 Test fuel and RME fluids available from: Specified Fuels and Chemicals, Inc. 1201 South Sheldon Road Channelview, TX 77530-0425 5.4 Service Fluid 105 available from: ASTM Test Monitoring Center 6555 Penn Avenue Pittsburgh, PA 15026-4489 (412) 365-1000
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