NAVISTAR MPAPS F-6034-2017 Charge Air Cooler (CAC) Turbo Hose.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. 2017 by Navistar, Inc. February 2017 Page 1 of 14 NAVISTAR, INC. Material, Parts, and Process Specificati

2、ons (MPAPS) NUMBER: MPAPS F-6034 Former Designation: TMS-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose CURRENT REV No.: 1702 DATE: Feb. 2017 WRITTEN/EDITED BY: M. Ghaddar APPROVED BY: R. Goluch SUPERSEDES: 1510 Oct 2015 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This spec

3、ification 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 pr

4、ior to use. 1.0 APPLICATION This specification covers different types of hoses used in engine turbo CAC systems. The hoses are used as connectors between the turbocharger, the charge air cooler, and the engine. Selection of the type shall be made by Materials Engineering. 2.0 SCOPE This specificatio

5、n covers construction, property requirements, dimensional tolerances, identification, source approval and quality control for the several types of hose connectors used in the CAC system. NOTE: Successful design of the connections between the turbocharger, charge-air-cooler and the engine, requires c

6、areful consideration of the length, alignment, rigidity, and spacing of the elements that comprise the joint. Straight turbo hoses should be used for connectors. Curves and elbows should be designed into the metal pipes or other components whenever possible. See Section A.0 on DESIGN GUIDANCE. 2.1 R

7、estricted 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 specified* the latest issue of all referenced standards shall apply. The

8、 following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 MPAPS DT-15 ASTM D 1418 NAVISTAR Supplier Packing and Shipping Std. D-13 MPAPS P-9543 ASTM D 2240 NAVISTAR Eng. Design Std. A-16 MPAPS F-2 ASTM D 865 NAVISTAR Eng.

9、 Dwg. PT12-16751 CFR Title 29, Section 1910 ASTM D 395 NAVISTAR MPAPS A-37 ASME Y14.5M-1994* ASTM D 1171 NAVISTAR MPAPS D-28 ASTM D 380 ASTM D 2137 NAVISTAR MPAPS F-1058 ASTM D 412 ASTM D 2000 NAVISTAR MPAPS C-1059 ASTM D 413 SAE J20 NAVISTAR MPAPS F-1 ASTM D 471 SAE J30 NAVISTAR MPAPS GT-31 ASTM D

10、624 *Conformance to the 1994 version of ASME Y14.5M is required NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose REVISION: 1702 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are requ

11、ired to assume all patent liability. 2017 by Navistar, Inc. February 2017 Page 2 of 14 4.0 GENERAL REQUIREMENTS Unless otherwise specified all tests will be performed per SAE J20 and indicated ASTM Test Methods. 4.1 Classification and Construction Grade designations are used to specify the applicati

12、on in the system and the allowed materials that can be used to meet those requirements. Suffix designations are used to specify the manufacturing method used to make the hose; the reinforcement fibers allowed; additional oil resistance required and higher heat or pressure requirements beyond the bas

13、ic levels. 4.1.1 Grades 4.1.1.1 Grade C This grade of hose is used after the air cooler and in the part of the system considered the “cold” side of the charge-air-cooler system. The tube and cover stocks should typically be made to conform to Suffix R and should be made from chlorinated polyethylene

14、 (CPE), chlorosulfonated polyethylene (CSM,) or epichlorohydrin (ECO). If oil resistance is not required, then the tube and cover stocks shall be made from ethylene-propylene-diene (EPDM), similar to SAE J20 20R4 Class D-1. The cover shall be non-blooming. Polysiloxane elastomers may be used in plac

15、e of EPDM if necessary. Polysiloxanes are acceptable for use on systems that are designed to recirculate oil and fuel vapors. Unless modified by other suffix call-outs, this grade of hose shall be rated to 125C (257F) and 345 kPa gauge (50 psig), suffix N. Polysiloxane elastomers with fluoro elastom

16、er barriers may be used if other materials and manufacturing methods cannot meet the performance requirements of this specification. 4.1.1.2 Grade H This grade covers hose used after the turbo charger and before the air-to-air cooler in the section of the system considered as the “hot” side of the c

17、harge air cooler. The tube and cover stocks should typically be made to conform to Suffix R which will usually require the use of fluoro elastomer barriers or other compound variations to meet both the temperature and the oil resistance required. If oil resistance is not required the tube and cover

18、shall be made from polysiloxane elastomers. This grade of hose shall be rated to a minimum of 249C (480F), (260C (500F) suffix Y is encouraged), and 345 kPa gauge (50 psig), suffix N. 4.1.2 Suffix Letters 4.1.2.1 Suffix A Straight or formed hose reinforced with wrapped plies of woven cord nylon (Gra

19、de C only), polyester (Grade C only) or aramid fabric. 4.1.2.2 Suffix B Preformed hose with ply or plies of lockstitch knitted aramid (blend of para and meta aramids for high fatigue performance) yarn. Design and application should be thoroughly tested to ensure a durable assembly. 4.1.2.3 Suffix M

20、(Obsolete) Mid high pressure rating to 210 kPa gauge (30 psig). (Not for use in future designs) 4.1.2.4 Suffix N (Must be selected for all hoses) - High pressure rating to 345 kPa gauge (50 psig). 4.1.2.5 Suffix R Required for systems utilizing a closed breather system or any other method of introdu

21、cing oil to the air stream. Must use oil resistant unless test data shows that negligible oil will be introduced by the turbocharger under all expected operating profiles. 4.1.2.6 Suffix X (Obsolete) Temperature rating to 249oC (480oF). (Not for future use since suffix H already meets 480oF.) 4.1.2.

22、7 Suffix Y Temperature rating to 260C (500F) NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose REVISION: 1702 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

23、patent liability. 2017 by Navistar, Inc. February 2017 Page 3 of 14 4.2 Stainless Steel Spring Insert or Construction Rings 4.2.1 Unless otherwise specified on the engineering drawing, a steel spring insert or rings may be used to insure compliance with the “Vacuum Collapse“ or “Hot Swell“ requireme

24、nt of this specification. Under certain circumstances, a thermoplastic (glass filled nylon) may be appropriate for this application. Use of the insert, rings, or thermoplastic shall be approved by Materials Engineering. 4.2.2 Unless otherwise specified, the steel spring insert shall be formed from a

25、 wire having a minimum diameter of 1.57 mm (a larger diameter wire may be used at the suppliers discretion). The spring shall exhibit a 25 mm pitch (a pitch of up to 35 mm is acceptable with larger diameter wire) and an OD approximately 3.0 mm less than the nominal ID of the hose. The wire shall be

26、300 series stainless steel, full hard, as per MPAPS A-37. The length of the spring shall be such that a minimum of 60 mm of free hose length remains on each end of the hose for ease of assembly and clamping. 4.3 Property and Performance Requirements - Elastomer Elastomer designation is as per ASTM D

27、 1418 except where otherwise indicated. See Tables 1a and 1b for material property requirements. 4.3.1 Hardness Durometer Measure hardness per ASTM D 2240, Type A. Initial and nominal hardness values shall be stated on qualification report. Material shall be controlled to within 5 points of nominal

28、while the material is in production unless it is re-qualified to another value. Aging test values shall be measured as change from initial as listed in Tables 1a and 1b. NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose REVISION: 1702 This document is restricted and may not be sent outs

29、ide Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2017 by Navistar, Inc. February 2017 Page 4 of 14 TABLE 1a PROPERTIES OF TUBE AND COVER Grade C PROPERTIES OF TUBE AND COVER TEST METHOD (ASTM) TUBE AND COVE

30、R Grade C TUBE AND COVER Grade C TUBE AND COVER Grade C-R TUBE AND COVER Grade C-R TUBE BARRIER Grade C-R POLYMER D1418 EPDM VMQ CM (CPE) VMQ FVMQ ORIGINAL PROPERTIES: TENSILE STRENGTH, MPA (PSI) D412, DIE C 7.0(1015) 6.0(870) 11(1595) 6.0(870) 6.0(870) ELONGATION, PERCENT MIN D412, DIE C 250 250 18

31、0 250 250 25% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* Report* 100% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* Report* TEAR RESISTANCE, kN/m (LBF/in), MIN D624, DIE B 17.5(100) 12 (68) 15.7(90) 12 (68) 15 (85) HEAT AGING CONDITIONS AND CHANGE LIMIT

32、S HOURS EXPOSURE D573 168 168 168 168 168 TEMPERATURE, C (F) D573 135(275) 135(275) 120(248) 135(275) 120(248) HARDNESS, DUROMETER, SHORE A D2240 0 to 18 0 to 10 0 to 20 0 to 10 0 to 10 TENSILE STRENGTH, % MAX D412, DIE C -35 -35 -20 -35 -35 ELONGATION, % MAX D412, DIE C -65 -65 -60 -65 -65 25% MODU

33、LUS, % MAX D412, DIE C Report* Report* Report* Report* Report* 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B Report Report Report Report Report HEAT AGING, 1000 HOURS TEMPERATURE, C (F) D573 100(212) 100(212) 100(212) 100(212) 100(212) ELO

34、NGATION, % MIN D412, DIE C 120 120 120 120 120 HARDNESS, MAX D2240 90 90 90 90 90 PROPERTIES AFTER IMMERSION IN CEMS B-21 15W-40 Engine oil (P/N 2643576R1, Shell Rimula Premium IFF, 54267) HOURS D471 N/A N/A 70 70 70 TEMPERATURE, C (F) D471 N/A N/A 120(248) 120(248) 120(248) HARDNESS, DUROMETER, SHO

35、RE A D2240 N/A N/A 25 25 25 TENSILE STENGTH, % MAX D412, DIE C N/A N/A -50 -50 -50 ELONGATION, % MAX D412, DIE C N/A N/A -60 -60 -60 25% MODULUS, % MAX D412, DIE C N/A N/A Report* Report* Report* 100% MODULUS, % MAX D412, DIE C N/A N/A Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B N/A N

36、/A Report* Report* Report* VOLUME CHANGE, shrink/swell, % D471 N/A N/A -10 TO +70 -10 TO +70 -3 TO +10 OTHER PROPERTIES COMPRESSION SET HOURS 70 70 70 70 70 TEMPERATURE C (F) 100(212) 100(212) 100(212) 100(212) 100(212) PERCENT MAX, PLIED D395 25 25 90 25 25 OZONE RESISTANCE (COVER ONLY) 100MPa part

37、ial pressure, RATING % D1149 Method A 100 100 100 100 N/A LOW-TEMPERATURE RESISTANCE, NONBRITTLE AFTER 3 MINUTES AT: C D2137 METHOD A -40 -40 -40 -40 -40 * Report value determined in qualification and validation testing. N/A not applicable NUMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Ho

38、se REVISION: 1702 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. 2017 by Navistar, Inc. February 2017 Page 5 of 14 TABLE 1b PROPERTIES OF TUBE AND COVER

39、 Grade H PROPERTIES OF TUBE AND COVER TEST METHOD (ASTM) TUBE AND COVER Grade H (H-X) TUBE BARRIER Grade H-R (H-RX) TUBE AND COVER Grade H-Y* TUBE BARRIER Grade H-RY* POLYMER D1418 VMQ FKM VMQ FKM ORIGINAL PROPERTIES: TENSILE STRENGTH, MPA (PSI) D412, DIE C 6.0(870) 7.0(1015) 6.0(870) 7.0(1015) ELON

40、GATION, PERCENT MIN D412, DIE C 250 175 250 175 25% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* 100% MODULUS, MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* TEAR RESISTANCE, kN/m (LBF/in), MIN D624, DIE B 12 (68) 15 (85) 12 (68) 15 (85) HEAT AGING CONDITIONS AND C

41、HANGE LIMITS HOURS EXPOSURE D573 168 168 168 168 TEMPERATURE, C (F) D573 249(480) 249(480) 260(500) 260(500) HARDNESS, DUROMETER, SHORE A D2240 0 to 15 0 to 15 0 to 15 0 to 15 TENSILE STRENGTH, % MAX D412, DIE C -35 Report* Report* Report* ELONGATION, % MAX D412, DIE C -45 Report* Report* Report* 25

42、% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B Report Report Report Report HEAT AGING, 1000 HOURS TEMPERATURE, C (F) D573 249(480) 249(480) 260(500) 260(500) ELONGATION, % MIN D412, DIE C

43、 120 120 Report* Report* HARDNESS, MAX D2240 90 90 Report* Report* PROPERTIES AFTER IMMERSION IN CEMS B-21 15W-40 Engine oil (P/N 2643576R1, Shell Rimula Premium IFF, 54267) HOURS D471 70 500 70 500 TEMPERATURE, C (F) D471 150 (302) 150 (302) 150 (302) 150 (302) HARDNESS, DUROMETER, SHORE A D2240 -3

44、0 Report* -30 Report* TENSILE STENGTH, % MAX D412, DIE C -40 Report* -40 Report* ELONGATION, % MAX D412, DIE C -30 Report* -30 Report* 25% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* TEAR RESISTANCE, % MAX D624, DIE B Rep

45、ort* Report* Report* Report* VOLUME CHANGE, shrink/swell, % D471 +40% -3 TO +10 +40% -3 TO +10 OTHER PROPERTIES COMPRESSION SET HOURS 70 70 70 70 TEMPERATURE C (F) 150(302) 150(302) 150(302) 150(302) PERCENT MAX, PLIED D395 50 50 50 50 OZONE RESISTANCE (COVER ONLY) 100MPa partial pressure, RATING %

46、D1149 Method A 100 N/A N/A N/A LOW-TEMPERATURE RESISTANCE, NONBRITTLE AFTER 3 MINUTES AT: C D2137 METHOD A -55 -25 -25 -25 * Report value determined in qualification and validation testing. *Suffix Y requirement is currently being developed. Suffix X is obsolete for new Drawings N/A not applicable N

47、UMBER: MPAPS F-6034 TITLE: Charge Air Cooler (CAC)/Turbo Hose REVISION: 1702 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. 2017 by Navistar, Inc. Febru

48、ary 2017 Page 6 of 14 4.4 Property and Performance Requirements - Hose 4.4.1 Adhesion Strength 4.4.1.1 Suffix A - Strip or Ring Specimen method using an average of the adhesion peaks to determine strength. Tube to Ply, kN/m width, minimum, 2.1 Ply to Ply, kN/m width, minimum, 2.1 Ply to Cover, kN/m width, minimum, 2.1 4.4.1.2 Suffix B - Tube to cover adhesion to be 1.75 kN/m minimum. 4.4.2 Burst Strength See Table 2