NAVISTAR MPAPS E-6-2016 Gray Iron Castings (Includes Appendix February 2002).pdf

1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 1 of 13 NAVISTAR, INC. Material, Parts, and Process Specification

2、s (MPAPS) NUMBER: MPAPS E-6 Former Designation: CEMS E-6 TITLE: Gray Iron Castings CURRENT REV No.: 1604 DATE: Apr. 2016 WRITTEN/EDITED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: Rev. 0202 February 2002 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specificati

3、on may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to

4、use. Change Notice: Updated to MPAPS format, combined with appendix, remove all resonant frequency items, remove obsolete chemical composition however, the use of high carbon equivalent 25-S in heavy sections is not recommended. 5.1.1 Alloy Requirements - New Design 5.1.1.1 Specific Alloy Additions:

5、 Castings that require specific alloy additions for heat resistance or other special properties will be designated by the Suffix “A”. Example: Grade 35-SA. The alloy content will be shown on the engineering drawing. 5.1.1.2 Wear Resistance: Castings in which wear resistance is the primary requiremen

6、t will be designated by the Suffix “WR”. Example: Grade 40-WR. 5.1.1.3 Optional Additions: In most cases structural strength is the primary engineering concern. Alloy additions to meet strength requirements are optional with the producer and should not be specified on the drawing. NUMBER: MPAPS E-6

7、TITLE: Gray Iron Castings REVISION: 1604 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 3 of 13 5.1.2 Alloy Requi

8、rements - Existing Design 5.1.2.1 Mandatory Alloy Content: A number of existing drawings specify obsolete grades with mandatory alloy content. For the particular categories of castings listed in Table III, the mandatory requirements will continue to apply until the drawing is reviewed and updated. I

9、t should be emphasized that for new designs involving these categories of castings, the application should be carefully reviewed to determine if the mandatory alloy content is necessary. 5.1.2.2 Non-mandatory Alloy Additions: For casting categories not listed in Table III where structural strength i

10、s the primary engineering concern, mandatory alloy content of the obsolete grade will not apply. A current grade meeting mechanical property requirements may be substituted. Example: Old - Gray Iron No. 61; New - Grade 35-S. 5.1.2.3 Obsolete Grade 65 Hydraulic Castings: Hydraulic castings formerly s

11、pecified as Gray Iron No. 65, require pressure tightness and minimum porosity for surface finish. Mandatory alloy content is no longer required, but initial samples should be inspected to insure that the soundness requirements will be met. TABLE III ALLOY REQUIREMENTS FOR EXISTING CASTINGS Navistar

12、Grade * Obsolete Gray Iron No. Specific Castings Categories Alloy Content, Percent Nickel and/or Copper Chromium Molybdenum 35-SA 61 exhaust manifolds, brake drums, diesel cylinder heads 1.25 0.20 0.65 0.15 - 35-SA 71 manifold heat control valves - 0.75 0.15 - 40-SA 93 exhaust manifolds 0.30 0.10 0.

13、25 0.15 0.60 0.10 *For proper specification of the “A” suffix refer to the preceding paragraphs covering alloy requirements for new and existing designs. 5.2 Mechanical Properties 5.2.1 Castings - As Cast Finished machined castings purchased to this specification will meet the as cast mechanical pro

14、perty requirements shown in Tables IV and IVa, unless otherwise specified. Since foundry hardness measurements are normally made on as-cast surfaces, foundry personnel as well as designers must be alert to the section thickness breakpoints in Tables IV and IVa. 5.2.2 Castings - Critical Sections Whe

15、n sections of a casting are deemed critical for reasons of stress, function or reliability, the controlling engineering department should designate the location of the critical section or sections on the drawing. If widely different solidification and cooling rates are anticipated or experienced in

16、the casting and the foundry anticipates or finds that it cannot meet the hardness or strength requirements throughout the casting, the foundry will request the engineering department concerned to designate the location of a critical section or sections on the drawing. The amount of allowable deviati

17、on from the specified mechanical properties in non-critical areas will be subject to agreement between the foundry and the controlling engineering department. The purpose of these procedures is to clearly establish that the hardness and strength determinations be made in critical areas. NUMBER: MPAP

18、S E-6 TITLE: Gray Iron Castings REVISION: 1604 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 4 of 13 5.2.3 Casti

19、ngs Tension Test Specimens (if required) If test specimens for tension testing are required, conventional machined tension test specimens are preferred and will conform to the dimensions specified for cast iron specimens in ASTM A48. TABLE IV - MECHANICAL PROPERTIES OF FINISHED UN-HEAT TREATED CASTI

20、NGS Navistar Grade Section Thickness, inches * thru 0.25 0.26 thru 0.50 0.51 thru 0.75 0.76 thru 1.00 1.01 thru 1.50 greater than 1.50 (2) tensile strength min hardness BHN tensile strength min hardness BHN tensile strength min hardness BHN tensile strength min hardness BHN tensile strength min hard

21、ness BHN tensile strength min hardness BHN psi min max psi min max psi min max psi min max psi min max psi min max 25-S 32000 197 241 25000 170 229 22000 159 229 not recommended not recommended not recommended 30-S 36000 212 248 30000 192 241 27000 179 229 24000 167 229 20000 149 229 not recommended

22、 32-S* 38000 217 255 32000 197 241 29000 187 235 26000 174 229 22000 159 229 18500 140 229 35-S 41500 229 262 35000 207 248 32000 197 241 29000 187 235 25000 170 229 21500 156 229 40-S 46500 241 277 40000 223 255 37000 217 248 34000 201 248 30000 192 241 27000 179 229 WI - 375 - - 375 - - 352 - - 35

23、2 - - 352 - - 352(1) - TABLE IVa - METRIC EQUIVALENT OF TABLE IV Navistar Grade Section Thickness, millimeters thru 6.47 6.48 thru 12.82 12.83 thru 19.17 19.8 thru 25.52 25.53 thru 38.22 greater than 38.22 (2) tensile strength min hardness BHN tensile strength min Hardness BHN tensile strength min h

24、ardness BHN tensile strength min hardness BHN tensile strength min hardness BHN tensile strength min hardness BHN MPa min max MPa min max MPa min max MPa min max MPa min max MPa min max 25-S 221 197 241 172 170 229 152 159 229 not recommended not recommended not recommended 30-S 248 212 248 207 192

25、241 186 179 229 165 167 229 138 149 229 not recommended 32-S* 262 217 255 221 197 241 200 187 235 179 174 229 152 159 229 128 140 229 35-S 286 229 262 241 207 248 221 197 241 200 187 235 172 170 229 148 156 229 40-S 321 241 277 276 223 255 255 217 248 234 201 248 207 192 241 186 179 229 WI - 375 - -

26、 375 - - 352 - - 352 - - 352 - - 352(1) - * Properties are based upon the thickest section of each classification. * Grade 32-S: Not to be used for new design. (1) Applicable to 2 inch (50 mm) thickness. (2) Based on 2.50 inch (63.50 mm) section thickness. 5.3 Metallurgical Requirements An essential

27、ly pearlitic matrix is desired in all as cast gray iron castings. This requires a combined carbon content between approximately 0.50 and 0.80 percent. If part sampling is required, the microstructure location will be agreed upon by the controlling design engineering department and the foundry and wi

28、ll be clearly identified on the drawing. All castings purchased to this specification will conform to the following requirements for microstructure: 5.3.1 In castings whose primary requirement is resistance to wear (WR Grades), the matrix may contain small, well distributed free cementite islands in

29、 an amount not to exceed 10 percent of the area of the specimen examined. Exceptions to the above are: 5.3.1.1 Alloyed irons which have over 0.60 percent chromium content are permitted to have higher than 10 percent free cementite. NUMBER: MPAPS E-6 TITLE: Gray Iron Castings REVISION: 1604 This docu

30、ment is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 5 of 13 5.3.1.2 Chromium-molybdenum alloyed iron with 0.40 percent minimum

31、molybdenum content may have fine pearlitic matrices with fine, small cementite particles interspersed through the matrices and outlining the grain boundaries. 5.3.2 Free ferrite is not desirable in the matrix of WR Grades. Under certain conditions it is not practical to entirely eliminate its occurr

32、ence in the microstructure of gray irons. However, WR Grades will contain no more than 5 percent free ferrite in the specific wear areas of the castings. 5.3.3 In all grades of gray iron, uniformly distributed graphite flakes with random orientation is preferred (Type A - ASTM A247, Plate II) partic

33、ularly in the harder, higher strength irons. A minimum of seventy percent of Types A plus B graphite is required in all WR Grade castings. 6.0 QUALITY 6.1 Castings will be sound and free from harmful porosity, segregation of impurities or other injurious defects. Castings may be rejected for injurio

34、us defects as detected by visual inspection of the as cast or the machined surfaces. 6.2 Gates, runners, risers, fins and other extraneous cast on parts will be removed. The surface will be free from burned on sand and will be reasonably smooth. Castings will be satisfactorily cleaned for their inte

35、nded use when offered for inspection. They will not be rusted or covered with any substance which would hide defects, nor will they be painted unless authorized by the purchaser. 6.3 Additional Requirements 6.3.1 Pressure Tests: Certain castings such as engine cylinder heads, engine blocks (crankcas

36、es) and castings for hydraulic systems may be required to pass pressure tests as indicated on the drawings. 6.3.2 Salvage Welding: Salvage welding of gray iron castings may be performed in accordance with AWS D11.2, except where restricted by the engineering department involved. 6.3.3 Certification:

37、 Producers of castings will, upon request, provide certification that castings furnished comply with these specifications. NUMBER: MPAPS E-6 TITLE: Gray Iron Castings REVISION: 1604 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate

38、 Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 6 of 13 7.0 METHODS OF TEST 7.1 Tensile Strength of Casting The tensile properties will be determined as described in ASTM E8. 7.1.1 Standard Cast Test Bars Pour separately cast test b

39、ars as described in ASTM A48. These test bars will be poured from the same iron as the castings they represent. Machine the samples as described in ASTM A48. 7.1.2 Test Bars Machined from the Casting Test bars that are machined from the casting will have the location clearly identified on the drawin

40、g. 7.2 Hardness Test for Castings The Brinell hardness test (3000 kilogram - force load) in accordance with ASTM E10, will be the standard hardness test unless otherwise agreed upon. The area or areas on the casting to be checked will be agreed upon by the controlling design engineering department a

41、nd the foundry and will be clearly identified on the drawing. 8.0 QUALIFICATION Engineering qualification of sources is required in advance of production shipments. Samples shall be accompanied by test data certifying that all requirements of the specification have been met. Upon approval, styling m

42、aster samples denoting the minimum level of acceptable appearance quality shall be developed and retained by the supplier and the quality department of each using NAVISTAR facility. 8.1 Quality Control Plan A Quality Control Plan for products supplied to the requirements of this specification will b

43、e established by mutual agreement between NAVISTAR and the supplier. Unless specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control. * * Other characteristics for inclusion in the control p

44、lan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Design Standard A-16 9.0 SOURCE APPROVAL AND QUALITY CONTROL 9.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also

45、 accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corp

46、orate Buyer upon request. NUMBER: MPAPS E-6 TITLE: Gray Iron Castings REVISION: 1604 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, In

47、c. APRIL 2016 Page 7 of 13 9.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the ev

48、ent that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requiremen

49、ts of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 9.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical contr