NAVISTAR TMS 7101-2010 Thermoplastic Engine Air Intake System Components.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. 2010 by Navistar, Inc. OCTOBER 2010 Page 1 of 11 NAVISTAR, INC. PORATION TMS (TRUCK MATERIAL SPECIFICATIO

2、N) NUMBER: TMS-7101 srr TITLE: Thermoplastic Engine Air Intake System Components CURRENT REV. Nb.: 1010 DATE: October 2010 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev 0906 June 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION

3、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 of regulatory

4、limits prior to use. Change Notice: Corrected Type 8 F testing requirements by moving to the same testing requirements as Type 8. Reference: File: 30-14E Keywords: Plastic tube, air pipes, air intake pipes/tubes, thermoplastic pipe. 1.0 APPLICATION This specification covers plastic parts and compone

5、nts used in engine air intake systems. Materials shown are approved for use in filtered and unfiltered air systems. Materials Engineering should be consulted prior to the selection of a material for any application. 2.0 SCOPE This specification covers Material, Part, and Assembly Performance Require

6、ments for eight types of material. Quality, Source Approval and Quality Control, Shipping and Identification, Designation on Drawings, Approved Materials, and Engineering Design Guidance are included. NAVISTAR Type Description and Application * Types 1, 3, and 4 These are elastomeric compounds used

7、in applications where vibration or relative movement are anticipated. Type 2 Not assigned at this time. Types 5 and 6 These are rigid compounds for use in applications with minimum structural loading. Type 7 This is a high rigidity type compound for use in applications with higher structural loading

8、 or with metal inserts or threaded connectors. Type 8 These are elastomeric dual durometer compounds co-extruded into a single part and used in applications where vibration or relative movements are anticipated. The soft component is available in 3 different hardnesses, designated as D, E, and F. *

9、See Engineering Design Guidance, Section A.0. NOTE: Existing drawings referencing obsolete versions of this specification may indicate obsolete material types/grade classification. These are replaced by new Navistar types as shown below: OBSOLETE DESIGNATION REPLACED BY NAVISTAR TYPE Type I, Grade a

10、 Type 3 Type I, Grade b Obsolete * Type I, Grade c Type 4 Type II, Grade a Obsolete * Type II, Grade b Type 4 *Contact Materials Engineering for selection of replacement material. NUMBER: TMS-7101 TITLE: Thermoplastic Engine Air Intake System Components REVISION: 1010 This document is restricted and

11、 may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2010 by Navistar, Inc. OCTOBER 2010 Page 2 of 11 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to t

12、he requirements of this specification 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 Specifications, Standards, and Regulations are referenced in this specifi

13、cation. Quality Standard ISO 9001 or TS-16949 TMS-1059 ASTM D 709 NAVISTAR Mfg. Standard MS-D-13 TMS-6907 ASTM D 746 NAVISTAR Design Std A-16 TMS-9543 ASTM D 792 NAVISTAR Eng. Std Parts (ESP), Book II, Sect. K CFR Title 29, Part 1910 ASTM D 955 CEMS DT-4 ASTM D 624 SAE J1344 TMS-1058 ASTM D 638 ASTM

14、 D 648 CEMS B-50 TMS-9543 4.0 MATERIAL REQUIREMENTS All material types shall meet the minimum property requirements shown in Table 1 and Graph 1. 4.1 Color Material shall be pigmented black unless otherwise specified on the engineering drawing. 4.2 Part Marking Parts supplied to the requirements of

15、this specification shall be marked to identify the specific polymeric material that the part is made from. The identification marking shall be in accordance with SAE J1344. Marking is an aid to field repair and aids in the recovery/recycling of the part at its eventual end-of-life. 4.2.1 Additional

16、Marking: When specified on the Engineering drawing, purchase order, or other controlling specification, the part shall also be identified so as to provide traceability to the resin lot/batch, mold and cavity number, manufacturing date, and operator, or other identification as specified. 4.3 Performa

17、nce Requirements Duct only 4.3.1 Vacuum Collapse The vacuum collapse requirement must be met for each part number and shall be requalified for any design change which affects the part number. 4.3.1.1 Method 1: For all material types except Types 8D and 8E, measure the outside dimensions of the part

18、at one or more points and mark the measured points. Install the part onto a test fixture, simulating the installed condition. Both ends of the test part shall be held rigidly with the end-plugs or hose inserted to their design depth. Place the fixture and test part into a forced convection oven and

19、heat soak at 100C (212F)* for a minimum of 2 hours. Apply a vacuum of 10kPa (40 inches of water) to the test part for 5 minutes. Measure the outside dimensions at the indicated test points while under vacuum. 4.3.1.2. Method 2: For Type 8D and 8E, measure the outside dimensions of the part at one or

20、 more points and mark the measured points. Install the part onto a test fixture, simulating the installed condition. Both ends of the test part shall be held rigidly with the end-plugs or hose inserted to their design depth. Place the fixture and test part into a forced convection oven and heat soak

21、 at 100C (212F) for a minimum of 2 hours. Apply a vacuum of 10kPa (40 inches of water) to the test part for 5 minutes. Measure the outside dimensions at the indicated test points while under vacuum. After successfully completing vacuum collapse evaluation at given temperature, successive collapse ev

22、aluations are to be taken at 10C increments with 2 hour soak times until part failure. Record temperature at which collapse exceeded requirement. Type 8D and 8E materials shall qualify to 200C soak temperature. NUMBER: TMS-7101 TITLE: Thermoplastic Engine Air Intake System Components REVISION: 1010

23、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. 2010 by Navistar, Inc. OCTOBER 2010 Page 3 of 11 4.3.1.3 Required: 20% maximum collapse. *Note: All parts

24、 qualified under this specification prior to Rev.E and previous revisions shall meet an 82C (180F) temperature exposure requirement. 4.3.2 Elevated Temperature Performance 4.3.2.1 Heat Resistance Type 4 materials are limited to 70C maximum constant service temperatures. Other types will pass the ind

25、icated test requirement. 4.3.2.1.1 Method: Parts are mounted on a fixture simulating vehicle installation and exposed as follows: 4.3.2.1.1.1 Short term: 1 hour at 120 C (100 C for Type 4 materials), (180C for Type 8D and 8E materials). 4.3.2.1.1.2 Long Term: 336 hours at 150 C (100 C for Type 4 mat

26、erials); Type 8 and 8F materials shall pass 336 hours at 135 C (except 110 C with an insert molded compressor tap in Type 8 and 8F material), (195C for Types 8D and 8E material except 170C with an insert molded compressor tap in Types 8D and 8E material). 4.3.2.1.2 Required 4.3.2.1.2.1 Short Term: P

27、arts shall not deform beyond the part tolerance. 4.3.2.1.2.2 Long Term: Parts shall exhibit no evidence of degradation; some deformation is allowed. 4.3.3 Low Temperature Resistance 4.3.3.1 Bending Flexible, convoluted ducts shall not crack or break when flexed through full range design flex immedia

28、tely after exposure to -34 C for four hours. 4.3.4 Cyclic Fatigue Convoluted, Type 8 ducts only. 4.3.4.1 Method: A block cycle fatigue test shall be performed on a finished assembly in the axial direction of the convolutes at 20 C. The cycle shall consist of two blocks. The first block cycle consist

29、s of 120 cycles with 35 mm total displacement. The second block consists of 12,000 cycles with 2.5 mm displacement. A total of 1000 block cycles are to be performed. 4.3.4.2 Required: The duct shall not exhibit any cracks. Duct ends shall remain firmly secured. The finished assembly shall meet the v

30、acuum collapse requirements detailed in Section 4.3.1. 4.3.5 Duct Flexibility Convoluted, Type 8 ducts only 4.3.5.1 Method: Fixture both ends of the part, attaching one side to an actuator with a load cell and measuring applied load. Position the part in a manner so the bellows section longitudinal

31、axis is in the same orientation as the actuator displacement. The part shall be compressed through a displacement range starting from 0 to + 12.5mm and 12.5mm at a temperature of 70F. Cycle the part six times before taking a reading. 4.3.5.2 Required: The duct bellow shall not exceed 75 lbs of force

32、. 4.4 Property and Performance Requirements Duct and Fitting Assembly Test assemblies shall be made with production materials whenever possible. See TMS-1058 or 1059 for guidance on end/bead configurations. Contact TDTC Chassis Design Engineering for assistance in identifying production parts to be

33、used in the test assembly. Inspect, measure and report the relevant dimensions of the parts used in the test. The test assembly should represent manufacturing assembly NUMBER: TMS-7101 TITLE: Thermoplastic Engine Air Intake System Components REVISION: 1010 This document is restricted and may not be

34、sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2010 by Navistar, Inc. OCTOBER 2010 Page 4 of 11 conditions, lubricants and torque rates as closely as possible. Clamp duct using production clamps

35、and torque values with one test set to the minimum and one test set to maximum of torque. When appropriate, measure and report the residual torque of each fastener. When crimp assembly techniques are used, crimp separate sets of test samples to minimum and maximum crimp diameters. 4.4.1 Air Leakage

36、4.4.1.1 Method: Use the same procedure as for vacuum collapse as shown in Section 4.3.1, except that the assembly shall replicate production fittings and clamps as closely as possible. Measure leak rate under vacuum. 4.4.1.2 Required: No more than 4.25 ml/sec air loss through the sidewalls and fitti

37、ngs. 4.4.2 Coupling Integrity 4.4.2.1 Method: Subject each assembly to a vacuum of 10 kPa throughout the test cycle indicated below. Coupling Integrity Test Cycle Step Duration hours Condition 1 .5 to 1.0 Ramp from 20 C to 80 C 2 96.0 4 Hold at 80 C 3 1.0 to 2.0 Ramp from 80 C to 40 C 4 4.0 1.0 Hold

38、 at 40 C 5 .5 to 1.0 Ramp from -40 C to 80 C 6 4.0 1.0 Hold at 80 C 7 Minor Cycle Repeat back to step 3 for four iterations. 8 Flex Flex the assembly 15, making ten full flexes in approximately 10 seconds each. Repeat flexes in a perpendicular plane. Evaluate each joint for leakage. 9 Major Cycle Re

39、peat back to step 1 for two iterations 4.4.2.2 Required: The duct shall not exhibit any cracking anywhere in the assembly. Hose ends shall remain firmly secured. Air leakage shall not exceed 8.5 ml/sec. 4.4.3 Pull Out Strength 4.4.3.1 Method: Hard Plastic Ports (Male type) 4.4.3.1.1 Axial: Mount duc

40、t in fixed position. Attach port to actuated load cell and subject to 150 pounds of force along the axis of the port for at least 2 seconds 4.4.3.1.2 Radial: Mount duct in fixed position. At a point (no less than half the length of the port) away from the body of the duct, attach port to actuated lo

41、ad cell. Subject port to 150 pounds of force radially outward from the axis of the port for at least 2 seconds. 4.4.3.2 Method: Soft Plastic Ports (Female type) 4.4.3.2.1 Mount duct in fixed position with production fittings assembled in the port. Attach the mating component to actuated load cell an

42、d subject to 50 pounds of force along the axis of the port for at least 2 seconds. 4.4.3.3 Required: The port (both hard and soft) shall remain firmly secured in the duct. Leak rate not to exceed that of coupling integrity. NUMBER: TMS-7101 TITLE: Thermoplastic Engine Air Intake System Components RE

43、VISION: 1010 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. 2010 by Navistar, Inc. OCTOBER 2010 Page 5 of 11 4.4.4 Air Port Test (Hard Plastic Ports, ma

44、le type only) 4.4.4.1 Method: Assemble production equivalent hose to port and secure with SAE type F worm clamp. Torque clamp to 60 in-lbs. 4.4.4.2 Required: No cracks or visible deformation allowed. 4.5 Special Requirements Other properties of molded parts shall be specified on the individual part

45、drawings, using Z suffixes. 4.6 Auxiliary Sealing (Specific Suffix Requirement) In certain instances, molded features at the parting line of complex air ducts may affect the ability to establish and maintain an airtight seal. For filtered air components, this results in the need to apply a sealer or

46、 caulk material under the rubber connector at the clamp location. Satisfactory performance has been achieved by brushing a butyl sealer (per TMS-6907) on the plastic duct prior to assembly of the rubber connector. Materials Engineering should be contacted for assistance. Note: When Auxiliary Sealing

47、 is required, it should be so indicated on the engineering drawing using the “Z“ suffix. However, to effectively communicate this requirement to the assembly plant, it must also be so indicated on the engineering assembly drawing(s). 5.0 QUALITY Parts supplied to this specification shall be free fro

48、m parting line flash, wrinkles, voids, and other processing defects affecting performance in the application. All parts produced to this specification shall be clean and free of dirt, grease, and contamination. All debris from cutting and processing shall be removed. Any internal release agents shall be flushed from the inside of the part. There shall be no flash exposed on the ID of the part. P