NAVISTAR MPAPS-A-45 PART I-2015 Automotive Steel Tubing.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. 2015 by Navistar, Inc. JUNE 2015 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specifications (

2、MPAPS) NUMBER: MPAPS- A-45 PART I Former Designation: CEMS A-45 Part I TITLE: Automotive Steel Tubing CURRENT REV No.: 1506 DATE: June 2015 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: April 2011 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specificatio

3、n 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 u

4、se. Change Notice: MPAPS Formatting. Editorial Changes, 1.0 APPLICATION Single-wall automotive steel tubing is designed for low-pressure fluid applications, while double-wall Automotive steel tubing is designed for high-pressure applications (see Table I for grade classifications). MPAPS A-45 consis

5、ts of three parts: Part I Automotive Steel Tubing Part II Hydraulic Line Tubing and Tubing Assemblies Part III Diesel Injection Tubing 2.0 SCOPE Part I of MPAPS A-45 covers the requirements for tubing used in Navistar products for general automotive applications such as hydraulic brake, oil, gas, ai

6、r and vacuum lines. 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 specified, the latest issue of all referenced s

7、tandards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001or TS-16949 CFR Title 29, Part 1910 NAVISTAR Mfg Standard MS-D-13 NAVISTAR MPAPS B-50 ASTM A 309 ASTM A 370 ASTM B 487 SAE J533 SAE J527 SAE J525 SAE J5

8、26 SAE J356 NUMBER: MPAPS A-45, PART I TITLE Automotive Steel Tubing CURRENT ISSUE DATE: JUNE 2015 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. 2015 b

9、y Navistar, Inc. JUNE 2015 Page 2 of 7 4.0 GENERAL REQUIREMENTS 4.1 Grade Classification Automotive tubing grades supplied to MPAPS A-45 Part I are described in Table I below. NOTE: Terne coating previously specified for Grades 1 and 5 tubing is no longer used. TABLE I GRADE CLASSIFICATION Designati

10、on Construction Surface Coating Requirements NAVISTAR Grade Obsolete IH Grade Approx. SAE 1 3 J527 Double Wall Tubing, Brazed Zinc-Aluminum* None (or specified) 5 6 2, 4 J525/ J526 * Single Wall, Electric Resistance Welded Zinc-Aluminum* None Unless other coating specified on engineering drawing, pu

11、rchase order, or referenced in CEMS or TMS specification. * *Hot dipped zinc-aluminum coating with 5% aluminum and trace elements, balance zinc (also known as GALFAN tubing). Minimum coating weight is 0.13 oz/ft2 (39.9 g/m2). Must provide ASTM B117 salt spray performance of 360 hr with no more than

12、1% red rust per ASTM D610, Plate #6. For better corrosion protection, an aluminum-rich epoxy paint layer may be applied (also known as ALGAL tubing). *SAE J356 Type A tubing may be used when needed. 4.2 Chemical Composition Tubing purchased to this specification will be made from steel conforming to

13、 the chemical composition shown in Table II. TABLE II CHEMICAL COMPOSITION Element Ladle (Heat) Analysis, % Check (Product) Analysis, % Carbon Manganese 0.18 max 0.60 max 0.21 max 0.63 max Phosphorus Sulfur 0.04 max 0.05 max 0.05 max 0.06 max 4.3 Mechanical Properties Tubing furnished to this specif

14、ication will conform to the mechanical property requirements shown in Table III, unless otherwise specified. See Section 5.4, Methods of Test. NUMBER: MPAPS A-45, PART I TITLE Automotive Steel Tubing CURRENT ISSUE DATE: JUNE 2015 This document is restricted and may not be sent outside Navistar, Inc.

15、 or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. JUNE 2015 Page 3 of 7 TABLE III MECHANICAL PROPERTIES Yield Strength 0.2% Offset, min Tensile Strength, Min % Elongation in 2 Inches (50 mm), min Rockwe

16、ll Hardness HR30T, max * ksi MPa Ksi MPa 25 172 42 290 25* 65 * Elongation for tubing with nominal outside diameters over 0.375 inch (9.52 mm) is 35% minimum * Not required provided that the tubing meets all other properties specified herein. 4.4 Performance Requirements The finished tubing will sat

17、isfactorily meet the following performance requirements. Tests will be conducted as described in Section 5.4, Methods of Test. 4.4.1 Bending The tested sample will not have undue reduction of area, cracking, flattening, or kinking. 4.4.2 Expansion The tested sample will show no evidence of cracks or

18、 other flaws. 4.4.3 Hydrostatic Proof Pressure All tubing supplied to this specification will be hydrostatically tested without showing defects at a pressure equivalent to a fiber stress of 20 ksi (130 MPa). Unless otherwise specified, no tube needs to be tested with a hydrostatic pressure greater t

19、han 5 ksi (43.5 MPa). However, these tubes must be capable of being tested at a pressure equivalent to a fiber stress of 20 ksi (138 MPa). A nondestructive test may be substituted for the hydrostatic test by agreement between purchaser and supplier. 4.5 Surface Coatings Surface coating requirements

20、for the tubing are shown in Table I. No loss of adhesion will be evident after testing. 4.6 Dimensional Tolerances Tubing purchased to this specification will conform to the tolerance requirements shown in Table IV. NUMBER: MPAPS A-45, PART I TITLE Automotive Steel Tubing CURRENT ISSUE DATE: JUNE 20

21、15 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. 2015 by Navistar, Inc. JUNE 2015 Page 4 of 7 TABLE IV OUTSIDE DIAMETER AND WALL THICKNESS TOLERANCES,

22、+/- Navistar Grade Nominal* Outside Diameter, Inch Nominal Wall Thickness, Inch Tolerances,* Inch Nominal* Outside Diameter, mm Nominal Wall Thickness, mm Tolerances,* mm Outside* Diameter Wall* Thickness Outside* Diameter Wall * Thickness 5, 6 All 5, 6 5, 6 1, 3 5, 6 All All All All 5, 6 All 5,6 1,

23、 3 All 5, 6 0.125 0.125 0.125 0.188 0.188 0.188 0.250 0.312 0.375 0.438 0.500 0.500 0.562 0.562 0.625 0.750 0.020 0.025 0.028 0.020 0.028 0.028 0.028 0.028 0.028 0.030 0.030 0.035 0.030 0.035 0.035 0.035 0.002 0.002 0.002 0.003 0.003 0.003 0.003 0.003 0.003 0.004 0.004 0.004 0.004 0.004 0.004 0.005

24、0.005 0.005 0.005 0.005 0.003 0.005 0.003 0.003 0.003 0.003 0.003 0.0035 0.003 0.0035 0.0035 0.0035 3.18 3.18 3.18 4.78 4.78 4.78 6.35 7.95 9.52 11.13 12.70 12.70 14.27 14.27 15.88 19.05 0.51 0.64 0.71 0.51 0.71 0.71 0.71 0.71 0.71 0.76 0.76 0.89 0.76 0.89 0.89 0.89 0.05 0.05 0.05 0.08 0.08 0.08 0.0

25、8 0.08 0.08 0.10 0.10 0.10 0.10 0.10 0.10 0.13 0.13 0.13 0.13 0.13 0.08 0.13 0.08 0.08 0.08 0.08 0.08 0.09 0.08 0.09 0.09 0.09 5, 6 5, 6 1.000 1.000 0.049 0.065 0.005 0.005 0.004 0.0059 25.4 25.4 1.24 1.65 0.13 0.13 0.11 0.15 * These tolerances will be measured at a minimum distance of one inch (25m

26、m) from the cut end. * The actual OD is the average of the maximum and minimum diameters as determined at any one cross section of the tubing. * The tolerances listed represent the maximum permissible deviation at any point. 5.0 QUALITY 5.1 Manufacture 5.1.1 Grades 1 and 3, double wall tubing, will

27、be brazed in a controlled atmosphere. The braze will be uniform with no evidence of bead on either the inside or outside of the tubing. 5.1.2 Grades 5 and 6 single wall tubing will be welded from cold rolled strip and the outside bead will be removed to provide a smooth round surface. A slight weld

28、bead and spatter on the inside surface will be permissible but must be held to the minimum consistent with good welding practice. 5.1.3 After brazing or welding, all grades will be annealed or normalized to produce a finished product which will meet all requirements of this specification. 5.2 Workma

29、nship And Cleanliness 5.2.1 Lengths of finished tubing will be reasonably straight and will have smooth ends free from burrs. The finished tubing will be free from scale, rust and injurious imperfections. Outside surface imperfections such as handling marks, straightening marks, light die marks or s

30、hallow pits are not considered injurious imperfections if they are not detrimental to the function or life of the tubing. The NUMBER: MPAPS A-45, PART I TITLE Automotive Steel Tubing CURRENT ISSUE DATE: JUNE 2015 This document is restricted and may not be sent outside Navistar, Inc. or reproduced wi

31、thout permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. JUNE 2015 Page 5 of 7 removal of such minor surface imperfections is not required. Coated tubing will have the outside bead removed prior to dipping. 5.2.2 The inside of

32、 the tubing will be commercially bright, clean, and free from grease, drawing compounds, oxide scale, rust, carbon deposits or any other substance which will impair the processing or serviceability of the tubing and that cannot be readily removed by cleaning with alkaline cleaners or any other commo

33、nly used cleaning solvent. 5.3 Flaring Ability All grades will be capable of being flared as per SAE J533 without evidence of cracking or flaws. 5.4 Methods of Test 5.4.1 Tensile Test Perform this test in accordance with the applicable portions of ASTM A370. Determine the yield strength by the 0.2%

34、offset method. 5.4.2 Hardness Test Perform the test on the inside surface of a specimen cut longitudinally from the tubing. Make the impressions away from the seams. Avoid cold working of tubing before testing. 5.4.3 Flaring Ability All grades will be capable of being flared as per SAE J533 without

35、evidence of cracking or flaws. 5.4.4 Bending Test Bend the tube in a proper bending fixture around a cylindrical mandrel, with a diameter equal to 3 times tubing OD, through 360 degrees. Examine for cracking, flattening, kinking or undue reduction of area. 5.4.5 Expansion Expand a sample with a leng

36、th equal to 2 times tubing OD or 2.00 in. (50mm), whichever is greater, over a hardened and polished tapered plug having a slope of 1.00 inch in 10.00 inches (25 mm in 250 mm) until the outside diameter has been expanded 20%. The axes of the plug and tubing will be kept parallel during the flaring p

37、rocess and the test may be made in a die to restrict the expansion to 20% of the OD. 5.4.6 Hydrostatic Proof Pressure Determine the test pressure needed to produce the required fiber stress by use of Barlows formula as follows: P = 2 T S D Where: P = hydrostatic pressure, psi (MPa) T = minimum wall

38、thickness, inch (mm) S = allowable fiber stress, 20,000 psi (138 MPa) D= outside diameter of tube, inches (mm) 5.4.7 Nondestructive Electric Test Use a nondestructive electric tester which is capable of detecting any defect that would prevent the tubing from passing the hydrostatic pressure proof te

39、st. 5.4.8 Coating Thickness 5.4.8.1 Determine the thickness of coating by the microscopic method as specified in ASTM B 487. When examined metallographically, the zinc-aluminum coating and the aluminum-rich epoxy paint dry film will each exhibit a minimum thickness of 3m at any point on the circumfe

40、rence of the tube. A process control feature representative of coating thickness will be included in the quality control plan for this product. 5.4.8.2 An optional test method is the weight-area (chemical) method described in ASTM A309. For referee purpose, the microscopic method per ASTM B 487 will

41、 be used. NUMBER: MPAPS A-45, PART I TITLE Automotive Steel Tubing CURRENT ISSUE DATE: JUNE 2015 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. 2015 by

42、Navistar, Inc. JUNE 2015 Page 6 of 7 5.4.9 Corrosion Testing Salt spray tests will be conducted per ASTM B 117. 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 spe

43、cification have been met. 6.1 Quality 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*, s

44、hall be included in the plan as features 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 CONTRO

45、L 7.1 Supplier Requirements All suppliers 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 requiremen

46、ts. Suppliers must maintain their certification 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 t

47、hose samples which were approved by 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 NAVIST

48、AR Materials Engineering and Purchasing 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 change. 7.3 Process Control The supplier shall either perform a