NAVISTAR MPAPS E-9-2016 Compacted Graphite Iron Castings.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. JUNE 2016 Page 1 of 5 NAVISTAR, INC. Material, Parts, and Process Specifications

2、(MPAPS) NUMBER: MPAPS E-9 Former Designation: CEMS E-9 TITLE: Compacted Graphite Iron Castings CURRENT REV No.: 1606 DATE: June 2016 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: Rev. April 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification

3、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 use

4、. 1.0 APPLICATION Compacted graphite iron is a cast iron with the graphite in compacted (vermicular or worm-like) shapes and essentially free of flake graphite. It is similar to ductile (nodular) iron in chemistry except for a lower magnesium or cerium content. Mechanical properties are intermediate

5、 to gray iron and ductile iron. CGI has better strength and stiffness than gray iron, and better castability, machinability, and thermal conductivity than ductile iron. 2.0 SCOPE This specification describes the chemistry, microstructure and mechanical property requirements for castings made of comp

6、acted graphite iron (CGI) used in the Corporations products. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specif

7、ied, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CFR Title 29, Part 1910 ASTM E 10 NAVISTAR Manufacturing Standard MS-D-13 ASTM A 48 ASTM E 18 NAVI

8、STAR Eng. Proc. Std EPS-91 ASTM A 247 MPAPS B-50 NAVISTAR Eng. Proc. Std EPS-143 ASTM A 842 ASTM E 8 4.0 REQUIREMENTS 4.1 CLASSIFICATION This specification covers five grades of CGI, meeting the requirements as designated in Table I below. NUMBER: MPAPS E-9 TITLE: Compacted Graphite Iron Castings CU

9、RRENT ISSUE DATE: June 2016 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. JUNE 2016 Page 2 of 5 TABLE I MECHANICAL PROPERTIES AN

10、D MICROSTRUCTURE REQUIREMENTS (1) Navistar Grade (2) Tensile Strength (min.) MPa ksi Yield Strength (min.) MPa ksi Elongation % (min.) Typical Matrix Microstructure (4) Brinell Hardness HBW BID (3) 250 250 36.3 175 25.4 3.0 Ferritic 121-179 4.5 min 300 300 43.5 210 30.5 1.5 Ferritic/Pearlitic 143-20

11、7 5.0-4.2 350 350 50.8 245 35.5 1.0 Ferritic/Pearlitic 163-229 4.7-4.0 400 400 58.0 280 40.6 1.0 Pearlitic/Ferritic 207-255 4.2-3.8 450 450 65.3 315 45.7 1.0 Pearlitic 217-269 4.1-3.7 ( 1) Refer to Section 6.4 for designation of critical sections of castings. (2) Grade designations are approximately

12、 equivalent to ASTM A 842 grade designations. (3) BID (Brinell impression diameter) is the diameter (mm) of the impression of a 10-mm ball at a 3000-kg load. (4) Refer to Section 6.2 for specific requirements. 4.2 Chemical Composition The chemical composition of CGI castings will be selected to prod

13、uce the desired mechanical properties, but may be specified by agreement between the supplier and the controlling Engineering Dept. CGI can be alloyed with various elements to optimize properties.* Table II gives a typical composition for CGI castings. TABLE II TYPICAL CHEMICAL COMPOSITION (%) * Car

14、bon Equivalent* Carbon Silicon Sulfur Manganese Phosphorus 4.20-4.60 3.5-3.8 2.0-2.6 0.025 0.20-0.50 0.050 *Carbon equivalent is defined as: % total C+% Si + % P3 *NOTE: Casting composition will be limited to a maximum of 0.015% Ti and 0.10% Cr for maximum machinability. 4.3 Microstructure Requireme

15、nts 4.3.1 Metallographic examination of graphite morphology will be performed on a casting, on a test lug from the casting, or on a separately cast test coupon or test bar (see ASTM A 842, Fig. 1), as specified on the engineering drawing or per agreement between supplier and controlling Engineering

16、Dept. Test bars or coupons will be representative of the cast metal. 4.3.2 Graphite morphology will be evaluated per ASTM A 247. The microstructure of all grades will contain 80% minimum Type IV graphite (CGI shape) per Plate 1, ASTM A 247, with the remaining graphite being of Types I or II (nodules

17、). Flake graphite (Type VII) is not permitted. 4.3.3 The matrix microstructure will consist of ferrite or pearlite, or a combination of these depending on the required mechanical properties, and will be substantially free of primary cementite. For areas designated as critical sections of the casting

18、, the matrix microstructure for Grade 400 must consist of 80% minimum pearlite, and 90% minimum pearlite for Grade 450 (assumes pearlite + ferrite = 100%). NUMBER: MPAPS E-9 TITLE: Compacted Graphite Iron Castings CURRENT ISSUE DATE: June 2016 This document is restricted and may not be sent outside

19、Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 3 of 5 4.4 Mechanical Properties 4.4.1 Tensile Properties The minimum tensile properties for the applicable CGI grade are s

20、hown in Table I and will be verified on separately cast test bars poured from the same iron as the castings they represent. Requirements for cast test bars are described in ASTM A 842. Tests will be performed in accordance with ASTM E 8. 4.4.2 Hardness Hardness will be checked on areas of the castin

21、g established by agreement between the purchaser and the supplier. Brinell hardness will be determined per ASTM E 10. 4.5 Critical Sections of Castings When sections of a casting are deemed critical for reasons of stress, function or reliability, the controlling Engineering Department should designa

22、te the location of the critical section or sections on the drawing. If widely different solidification and cooling rates are anticipated or experienced in the casting and the foundry anticipates or finds that it cannot meet the hardness or strength requirements throughout the casting, the foundry sh

23、ould request the engineering department concerned to designate the location of a critical section or sections on the drawing. The amount of allowable deviation from the specified mechanical properties in non-critical areas will be subject to agreement between the foundry and the controlling Engineer

24、ing Department. The purpose of these procedures is to clearly establish that the hardness and strength determinations be made in critical areas. 4.6 Heat Treatment Heat treatment such as to obtain minimum mechanical properties, to remove residual stresses, or to improve machinability, may only be pe

25、rformed by agreement between the supplier and the controlling Engineering Department. 4.7 Pressure Tests Certain castings such as engine cylinder heads, engine blocks (crankcases) and castings for hydraulic systems may be required to pass pressure tests as indicated on the engineering drawings. 4.8

26、Welding Salvage or repair welding of CGI castings may only be performed upon prior approval by the controlling Engineering Department. 4.9 Certification Producers of castings will, upon request, provide certification that castings furnished comply with the requirements of this specification. 5.0 QUA

27、LITY 5.1 Castings supplied to the requirements of this specification will be representative of good foundry practice and conform to the dimensions and tolerances specified on the casting drawing. 5.2 Castings may be rejected for injurious defects (such as cracks, sand and slag inclusions, massive ca

28、rbides, porosity, etc.) as detected by visual inspection of the as-cast or the machined surfaces. 5.3 Castings will be satisfactorily cleaned for their intended use when offered for inspection. They will NUMBER: MPAPS E-9 TITLE: Compacted Graphite Iron Castings CURRENT ISSUE DATE: June 2016 This doc

29、ument 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. JUNE 2016 Page 4 of 5 not be rusted or covered with any substance which would hide defects

30、, nor will they be painted unless designated or authorized by the purchaser. 6.0 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. 6.1 Quali

31、ty Control Plan A Quality Control Plan for products supplied to the requirements of this specification will be 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 fea

32、tures for management by statistical process control.* * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Design Standard A-16 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requirements All sup

33、pliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also 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 c

34、ertification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 7.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by

35、 the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purcha

36、sing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements 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 ch

37、ange. 7.3 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 control and with a process capable of providing

38、 all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. NUMBER: MPAPS E-9 TITLE: Compacted Graphite Iron Castings CURRENT ISSUE DATE: June 2016 This document is restricted and may n

39、ot 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. JUNE 2016 Page 5 of 5 8.0 SHIPPING AND HANDLING Shipping and identification shall be in accordance with NAVISTAR Manufa

40、cturing Standard MS-D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. 9.0 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS Material designation on drawings and purchase orders will reference this specification and indicate the Navistar Grade as

41、 well as other special requirements, if necessary. Example: Compacted Graphite Iron, Grade 300, MPAPS E-9 9.1 Identification of Castings When specified on the engineering drawing and/or purchase order, castings of sufficient size and shape will be identified with the following information: 9.1.1 Nav

42、istar part number 9.1.2 Navistar trademark shown in Engineering Procedural Standard EPS-143 9.1.3 Identification mark of the producing foundry. 9.1.4 A casting date code may also be required on certain castings as identified by the controlling engineering department and specified on the drawing or p

43、urchase order. Engineering Procedural Standard EPS-91 covers requirements for this code. 9.1.5 An additional foundry identification for the heat or ladle number may be required as described on the purchase order. 9.1.6 The location of the identification may be shown on the drawing, but if not specif

44、ied, will be selected so that the markings will not interfere with machining, service use or appearance. The markings will preferably be placed near each other. If the casting is too small for the identification to be legible after cleaning, the engineering department concerned may waive these requi

45、rements. 10.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ REVISION HISTORY Revision Level Change Approved by Date Approved 1606 Converted to MPAPS, Reformatted, editorial Changes, R. Goluch 5/24/2016