NAVISTAR TMS 3102-2006 Cast Aluminum Wheels (Revision A).pdf

1、 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation APRIL 2006 Page 1 of 5 INTER

2、NATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-3102 TITLE: Cast Aluminum WheelsREVISION: A WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: APRIL 2006 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION T

3、his specification 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 l

4、imits prior to use. Change Notice: Added Section 2.1; changes to Sections 4.5 and 6.0; changed leak testing parameters in Section 4.5.3. Reference: File 17; 30-2B Keywords: Wheels, aluminum casting, cast wheels, A356 aluminum 1.0 APPLICATION This specification covers cast aluminum alloy wheels used

5、for commercial trucks. 2.0 SCOPE This specification covers the requirements for material, mechanical properties, fatigue performance, cosmetic appearance, quality, and qualification. 2.1 Restricted Chemical SubstancesEffective January 1, 2007, all product supplied to the requirements of this specifi

6、cation must comply with the requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard

7、 QS-9000 (ISO 9000 or TS-16949) ASTM E155 INTERNATIONAL IQR Quality Standard INTERNATIONAL Manufacturing Standard D-13 CFR Title 29, Part 1910 INTERNATIONAL CEMS B-50 4.0 REQUIREMENTS 4.1 Material 4.1.1 Chemical Composition The alloy used to produce cast wheels will be A356 aluminum and meet the fol

8、lowing chemical composition requirements: Silicon 6.5-7.5% Magnesium 0.25-0.4% Copper 0.05% max Manganese 0.05% maIron 0.18% max Zinc 0.10% maTitanium 0.2% max NUMBER: TITLE: REVISION: TMS-3102 Cast Aluminum Wheels A This document is restricted and may not be sent outside International Truck and Eng

9、ine Corporation or reproduced without permission from Sodium* None Strontium* 0.008-0.030% Other elements 0.05% max Others total 0.15% max Aluminum Remainder *May be used to achieve silicon modification. 4.1.2 Heat Treatment The wheel casting shall be solution heat treated and artificially aged to p

10、rovide the specified microstructure and mechanical properties. 4.1.3 Microstructure The microstructure will exhibit a modified, finely dispersed, aluminum-silicon eutectic. Figure 1 shows the minimum acceptable microstructure for the hub Fig. 1(b), and the minimum acceptable for the rim Fig. 1(d). 4

11、.2 Mechanical Properties The properties shall be measured by standard tensile specimens taken from the flange region of the wheel. The testing must be performed after heat treatment to ensure properties are representative of the finished part. Yield strength 189 MPa (27 ksi) min Ultimate tensile str

12、ength 259 MPa (37 ksi) min Elongation (in./in.) 7.0% min in outboard flange Hardness* 60-90 HBW*Brinell HBW 500 kg 10 mm ball; measured in hub area only 4.3 Fatigue Performance The wheels will meet the following fatigue life requirements. For the new wheel designs, six samples for both radial and co

13、rnering fatigue shall be tested for initial qualification. For periodic quality audit or if any material or process changes are made, the following tests will be performed: 4.3.1. Radial Fatigue: run at 2.8 load factor minimum is 700,000 cycles 4.3.2. Radial Fatigue: run at 2.0 load factor minimum i

14、s 3,500,000 cycles 4.3.3. Cornering Fatigue: run at 1.35 load factor minimum is 500,000 cycles The supplier can select the accelerated load factor as required, however any load factor not specified above requires the written approval of International Truck Wheel Systems Engineering. At least one sam

15、ple of each test will be run until failure, preferably two samples. If only one is run to failure, then at least two others shall be run to 120% of the minimum requirement. 4.4 Cosmetic Appearance The surface finish and cosmetic appearance of the wheels will conform to the quality initially approved

16、 by International Industrial Design department and the receiving Plant Quality Control department. Master samples shall be retained by the supplier and the using plant for reference. Wheels reworked for cosmetic repair shall be identified for traceability. Corporate Technical Standards. Suppliers ar

17、e required to assume all patent liability. 2006 International Truck and Engine Corporation APRIL 2006 Page 2 of 5 NUMBER: TITLE: REVISION: TMS-3102 Cast Aluminum Wheels A This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permissi

18、on from 4.5 Quality Castings shall be sound and free from burrs, sharp edges, corrosion, cracks, parting line flash, laps, cold shuts, shrinkage, porosity, hard spots, and non-metallic inclusions. 4.5.1 Fluoroscope All wheels must be inspected by fluoroscope to a 4% resolution, with maximum allowabl

19、e defects not exceeding level 4, unless otherwise noted on print. 4.5.2 X-ray Radiographs X-ray radiographs of the initial production mold shall be submitted to International Materials Engineering for part approval. Supplier shall conduct periodic quality audit by X-ray radiography to ensure integri

20、ty of the castings. ASTM E155 shall be used to determine the maximum acceptable levels of porosity, shrinkage, gas holes, and foreign material. X-rays must be conducted at a 2% resolution. Porosity levels greater than 3 may be unacceptable for wheels based on fatigue test requirements. The X-rays sh

21、all assure the complete coverage of the wheel. 4.5.3 Leak Detection All wheels must be leak tested by visual inspection of bubbles at a minimum pressure of 689 kPa (100 psi) for a duration of 60 seconds minimum when fully immersed in water. Wheels failing the leak detection test shall be scrapped. N

22、o repair is allowed unless approved by International Quality Control and Materials Engineering. 4.5.4 Dimensional 100% dimensional layout is required on one piece per mold for initial validation. Inspection for safety and critical dimensions and uniformity must be verified to be within specification

23、 based on in-process capability studies. 5.0 SOURCE APPROVAL AND QUALITY CONTROL5.1 Supplier RequirementsAll suppliers to International Truck and Engine are required to be registered to QS-9000 Quality System Requirements. International will also accept ISO 9000 or TS-16949 registration as long as t

24、he 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 International Corporate Buyer upon request. 5.

25、2 ApprovalParts 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 event that changes in material,

26、properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Truck Development and Technology Center and International Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of t

27、his 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. Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Tru

28、ck and Engine Corporation APRIL 2006 Page 3 of 5 NUMBER: TITLE: REVISION: TMS-3102 Cast Aluminum Wheels A This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from 5.3 Process ControlThe supplier shall either perform and

29、report results of tests on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the plant metallurgist and/or the quality control manage

30、r of the using International plant may determine testing and reporting requirements on specific products. 6.0 SHIPPING, PACKING, AND IDENTIFICATIONShipping and identification shall be in accordance with Manufacturing Standard D-13. All wheels shall have date identification for traceability. 7.0 DESI

31、GNATION ON DRAWINGS Drawings shall reference this specification in the material block: TMS-3102 8.0 APPROVED SOURCES Hayes Lemmerz International 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Materials Engineering and Technology Dep

32、t. Truck Development and Technology Center (TDTC) 2911 Meyer Road Fort Wayne, IN 46803 E-mail: MaterialsEngineeringNav-I Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation APRIL 2006 Page 4 of 5 NUMBER: TITLE: REVISIO

33、N: TMS-3102 Cast Aluminum Wheels A This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from FIGURE 1 Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation APRIL 2006 Page 5 of 5