NAVISTAR TMS 6815-2006 Sheet Metal Processing Lubricants (Revision D).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 4 INTER

2、NATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-6815 TITLE: Sheet Metal Processing Lubricants REVISION: D WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: April 2006 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURR

3、ENT REVISION This 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 o

4、f regulatory limits prior to use. Change Notice: Added Sections 2.1 and 8.0; revised Section 4.1; editorial changes. Reference: File 30-8 Keywords: Drawing Lubricants, Processing Lubricants, Mill Oils, Sheet Metal 1.0 APPLICATION This specification covers mill oils and drawing lubricants used in pro

5、cessing of sheet aluminum, galvanized steel, hot and cold rolled steel, and pre-painted sheet steel. 2.0 SCOPE This specification covers requirements for corrosion protection, formability, compatibility with subsequent operations and qualification of materials. It is not the intent to dictate the lu

6、bricant composition; however, changes in composition from initially qualified samples are not permitted. 2.1 Restricted Chemical SubstancesEffective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 3.0 R

7、EFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard QS-9000 (ISO 9000 or TS-16949) INTERNATIONAL TMS-4110 AISI SG-81-5INTERNATION

8、AL IQR Quality Standard INTERNATIONAL TMS-6915 ASTM D 4173 INTERNATIONAL Manufacturing Std. D-13 INTERNATIONAL TMS-6916 INTERNATIONAL CEMS G-5, Parts I, II, V INTERNATIONAL TMS-6917 INTERNATIONAL CEMS GT-24 INTERNATIONAL CEMS B-50 CFR Title 29, Part 1910 4.0 REQUIREMENTS 4.1 Corrosion Protection Dur

9、ing shipping and handling or for 90 days after coating, production sheet metal coated with these lubricants shall not exhibit any corrosion or staining which could impair subsequent processing or part appearance. When service parts are stored unheated indoors for one year, any sheet metal coated wit

10、h these lubricants shall not exhibit any corrosion or staining which could impair subsequent processing or part appearance. NUMBER: TITLE: REVISION: TMS-6815 Sheet Metal Processing LubricantsD This document is restricted and may not be sent outside International Truck and Engine Corporation or repro

11、duced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation. 4.1.1 Prepared Panels: Test panels, prepared as per Section 5.1-Test Panel Preparation, shall not exhibit more corrosion or staining th

12、an the control panels (see Section 5.1) after 1, 5 and 10 cycles of 16 hours at 100F/100% RH and 8 hours at room temperature. 4.2 Formability (Drawing Lubricants Only) Lubricants shall be qualified by plant trial for ability to perform in the required metal forming operations. Lubricant concentratio

13、ns and coating thicknesses required for difficult draws, and metals tested and approved with each lubricant, will be documented as part of the qualification procedure. 4.2.1 Formability Test: Prepared panels* shall provide results equal or superior to the control panels* when tested by the round bot

14、tom cup test and the flat die strip draw test per ASTM D-4173. (*See Section 5.1 on Test Panel Preparation.) 4.3 Compatibility With Zinc Rich, Weld Through Primer Prepared panels* shall meet the dry film and weldability requirements specified when evaluated with TMS-4110 zinc rich, weld-through prim

15、er. (*See Section 5.1 on Test Panel Preparation.) 4.4 Weldability Lubricants shall be qualified by plant trial to perform satisfactorily in all welding methods used by the plant for the type of sheet metal for which the lubricant is approved. 4.4.1 Panel Weld Tests: Weldability shall be equal or sup

16、erior to that of the control panels* when tested in accordance with the weldability test section of TMS-4110 and the pertinent sections of Aluminum Association Specification T-10 and AISI SG 81-5. (*See Section 5.1 on Test Panel Preparation.) 4.5 Compatibility With Sealers And Adhesives Prepared pan

17、els* shall meet the adhesive strength requirements specified when evaluated with TMS-6915, Type III; TMS-6916, Type II; and TMS-6917, Types II and I body sealers and adhesives. (*See Section 5.1 on Test Panel Preparation.) 4.6 Compatibility With Wash/Phosphate The supplier of the test lubricant will

18、 have an approved wash/phosphate system supplier perform the tests shown in GT-24. Test results will be submitted in writing to Materials Engineering at TDTC, Fort Wayne, Indiana. International will be solely responsible for determining pass or fail in accordance with the tests described in this sec

19、tion. 4.6.1 Water Break Free 4.6.2 Foaming 4.6.3 Emulsification 4.6.4 Phosphate: Shall provide complete coverage at a coating weight of zinc phosphate of 150 mg/ft minimum for cold rolled and galvanized steel, and 50 mg/ft minimum for aluminum. Panels shall not be streaked or blushed. 4.6.5 Painting

20、: Phosphated panels that have been finished with current production materials shall meet the adhesion, salt spray and humidity requirements of Grade 18 and/or Grade 56 per CEMS G-5, Parts II and V. 4.7 General Requirements No silicone or lanolin compound of any kind is allowed as a component in a lu

21、bricant covered by this specification. APRIL 2006 Page 2 of 4 NUMBER: TITLE: REVISION: TMS-6815 Sheet Metal Processing LubricantsD This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. S

22、uppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation. 4.7.1 International will conduct an infrared spectral analysis and a chemical analysis on the initial qualified samples for each approved material. This information will become part of the master c

23、ontrol file, and will be used to detect any subsequent changes in composition (See Qualification). 4.7.2 The material must be formulated such that dilution does not require special mixing equipment and that no more than moderate agitation is required to achieve a uniform and stable mixture. Cleaning

24、 of dies and application equipment shall not require excessive effort. Material shall not become separated, rancid or otherwise unusable or objectionable after 30 days storage either neat or as diluted for use. 4.7.3 All materials furnished under this specification shall be formulated and manufactur

25、ed using good commercial practice and comply with all applicable OSHA, FDA and EPA regulations concerning use, handling and disposal. 5.0 QUALIFICATION Production material can be furnished under this specification only after formal qualification, which will include approvals from Materials Engineeri

26、ng at TDTC in Fort Wayne and from the using plant(s). All material submitted for qualification shall be accompanied by certification and by complete test data showing conformance to this specification, and by Materials Safety Data Sheets. The data will be submitted to Materials Engineering at TDTC,

27、Fort Wayne, Indiana, which will verify test results and arrange for additional testing and trials, as required. 5.1 Test Panel Preparation Panels for corrosion protection and forming tests shall have a 0.54 mil (oil based lubricants) or 0.75 mil (water diluted lubricants) film of the test material a

28、pplied to both sides of clean, cold rolled steel, G-60 galvanized and 5052-H32 aluminum panels. Panels shall be held horizontally for 45 minutes, and in a near vertical position for an additional 72 hours prior to testing. 5.1.1 Panels for welding, zinc rich weld through primer, adhesives compatibil

29、ity and wash/phosphate testing shall have the same film thickness of test lubricants (as in above) applied over 0.54 mil (drained for 16 hours in vertical position) of a standard mill oil. Cold rolled steel, G-60 galvanized and 5052-H32 aluminum panels will be tested. Dry and drain times will be as

30、in above. 5.1.2 Control panels will be prepared in the same manner as above, using standard control materials for all tests. Unless otherwise specified, the standard control oils used will be as follows: 5.1.2.1 Mill Oil: Exxon 4063 Rust Preventative or Quaker 61 AUS 5.1.2.1 Drawing Lubricant: Pills

31、bury FB27M and/or Nalco 6299 and/or Quaker 66 AUS 6.0 SOURCE APPROVAL AND QUALITY CONTROL6.1 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

32、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 the INTERNATIONAL Corporate Buyer upon requ

33、est. APRIL 2006 Page 3 of 4 NUMBER: TITLE: REVISION: TMS-6815 Sheet Metal Processing LubricantsD 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 al

34、l patent liability. 2006 International Truck and Engine Corporation. 6.2 ApprovalParts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or processing practices a

35、re 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 Materials Engineering at TDTC and International Purchasing & Logistics of the proposed change(s). Test data

36、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. 6.3 Process ControlThe supplier shall either perform and repo

37、rt 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 manager of

38、 the using International plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATIONShipping, packing and identification shall be in accordance with Manufacturing Std. D-13. 8.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Materials Engineering and Technology Dept. Technical Development and Technology Center (TDTC) 2911 Meyer Road Fort Wayne, IN 46803 E-mail: MaterialsEngineeringNav-I APRIL 2006 Page 4 of 4