1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2013 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside U
4、SA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AMS4778K AEROSPACE MATERIAL SPECIFICATION AMS4778 REV. K Issued 1955-08 Revised 2013-03 Super
5、seding AMS4778J Nickel Alloy, Brazing Filler Metal 92Ni - 4.5Si - 3.1B 1800 to 1900 F Solidus-Liquidus Range (Composition similar to UNS N99630) RATIONALE AMS4778K results from a limited scope ballot to revise tolerances for sheet, strip and foil (3.5.2). 1. SCOPE 1.1 Form This specification covers
6、a nickel alloy in the form of wire, rod, strip, foil, tape, and powder and a viscous mixture (paste) of the powder in a suitable binder and procured in inch/pound units. 1.2 Application This filler metal has been used typically for joining corrosion and heat-resistant steels and alloys requiring cor
7、rosion and oxidation-resistant joints with good strength at elevated temperatures, but usage is not limited to such applications. Also may be used as a corrosion and oxidation-resistant hard coating. 2. APPLICABLE DOCUMENTS The issue of the following documents in effect on the date of the purchase o
8、rder forms a part of this specification to the extent specified herein. The supplier may work to a subsequent revision of a document unless a specific document issue is specified. When the referenced document has been cancelled and no superseding document has been specified, the last published issue
9、 of that document shall apply. 2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. AMS2222 Tolerances, Copper and Copper Alloy Sheet, Strip, and Plate AMS2224 T
10、olerances, Copper and Copper Alloy Wire SAE AMS4778K Page 2 of 9 2.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM B 214 Sieve Analysis of Metal Powders ASTM D 638 Tensile Properties
11、of Plastics ASTM E 18 Rockwell Hardness of Metallic Materials ASTM E 354 Chemical Analysis of HighTemperature, Electrical, Magnetic, and Other Similar Iron, Nickel, and Cobalt Alloys 3. TECHNICAL REQUIREMENTS 3.1 Composition Shall conform to the percentages by weight shown in Table 1, determined by
12、wet chemical methods in accordance with ASTM E 354, by spectrochemical methods, or by other analytical methods acceptable to purchaser. TABLE 1 - COMPOSITION Element min max Carbon Silicon Phosphorus Sulfur Boron Cobalt (3.1.1) Titanium Aluminum Iron (3.1.2) Zirconium Selenium (3.1.1) Nickel - 4.00
13、- - 2.75 - - - - - - remainder 0.06 5.00 0.02 0.02 3.50 0.10 0.05 0.05 0.50 0.05 0.005 (50 ppm) 3.1.1 Determination not required for routine acceptance. 3.1.2 Iron to 1.50% by weight maximum is permissible in strip and foil products (tape form). 3.2 Condition The product shall be supplied in the fol
14、lowing condition: 3.2.1 Wire, Tape and Strip Powder bonded in a suitable plastic. 3.2.2 Rod As cast, with fins and projections removed. SAE AMS4778K Page 3 of 9 3.2.3 Foil and Powder As fabricated. 3.2.4 Paste Shall consist of 84 to 90% by weight powder in a suitable binder and, unless otherwise ord
15、ered, shall not contain flux. 3.3 Properties Filler metal shall conform to the following requirements: 3.3.1 Wire and Strip 3.3.1.1 Burn-Off of Plastic The plastic used for bonding powder to form wire and strip shall burn off, leaving no adherent residue, when the product is heated to a temperature
16、not higher than 1800 F. 3.3.1.2 Tensile Strength Shall be not lower than 360 psi, determined in accordance with ASTM D 638, Speed B. 3.3.1.3 Metallic Content The ratio of volume of powder to volume of plastic binder shall be the largest possible consistent with the requirements of 3.3.1.1 and 3.3.1.
17、2. 3.3.2 Rod, Foil, Tape and Powder When specified, properties shall be as agreed upon by purchaser and vendor. 3.3.3 Paste 3.3.3.1 Paste shall have a shelf life of not less than 6 months; not more than thorough mixing shall be required to restore paste for use during that time. 3.3.3.2 Paste, witho
18、ut flux, shall leave no adherent residue when heated in a protective atmosphere to a temperature higher than 1000 F (538 C). 3.3.4 When used as a hard coating, alloy shall melt quickly and shall flow freely under neutral oxy-acetylene flame, without bubbling or boiling, to produce an adherent deposi
19、t free from porosity due to blowholes, gas cavities, or slag inclusions. 3.3.4.1 Alloy, deposited as in 3.3.4, shall have hardness not lower than 25 HRC, or equivalent (See 8.3), determined in accordance with ASTM E 18. 3.4 Quality The product, as received by purchaser, shall be uniform in color, qu
20、ality, and condition and free from foreign materials and from imperfections detrimental to its working qualities. Rod and powder shall have a metallic luster. Wire, strip, tape, and foil shall be clean, sound, smooth, and free from ragged edges, splitting, damaged ends, and other imperfections detri
21、mental to usage of the product. SAE AMS4778K Page 4 of 9 3.5 Sizes and Tolerances The product shall be supplied in the following standard sizes and to the tolerances shown: 3.5.1 Wire and Rod TABLE 2 - STANDARD DIAMETER SIZES Inch Millimeters 0.005 0.13 0.007 0.18 0.010 0.25 0.015 0.38 0.025 0.64 0.
22、031 0.79 0.040 1.02 0.047 1.19 0.062 1.57 0.094 2.39 0.125 3.18 0.175 4.44 0.188 4.78 0.225 5.72 0.250 6.35 3.5.1.1 Diameter Tolerances for Drawn Wire and Rod Shall be in accordance with AMS2224 as applicable to refractory alloys. 3.5.1.2 Diameter Tolerances for Rolled or Extruded Wire and Rod Shall
23、 be as shown in Table 3. TABLE 3A - DIAMETER TOLERANCES, INCH/POUND UNITS Nominal Diameter or Distance Between Parallel Sides Inch Tolerances, Inch Plus and Minus Rounds Tolerances, Inch Plus and Minus Squares 0.031 to 0.062, incl 0.005 0.008 Over 0.062 to 0.125, incl 0.006 0.009 Over 0.125 to 0.188
24、, incl 0.007 0.009 Over 0.188 to 0.250, incl 0.008 0.010 TABLE 3B - DIAMETER TOLERANCES, SI UNITS Nominal Diameter or Distance Between Parallel Sides Millimeters Tolerances, Millimeter Plus and Minus Rounds Tolerances, Millimeter Plus and Minus Squares 0.79 to 1.57, incl 0.13 0.20 Over 1.57 to 3.18,
25、 incl 0.15 0.23 Over 3.18 to 4.78, incl 0.18 0.23 Over 4.78 to 6.35, incl 0.20 0.25 SAE AMS4778K Page 5 of 9 3.5.1.3 Concentricity When long lengths are supplied as welded composites of cast lengths, diameters of adjacent sections shall be concentric within 0.031 inch (0.79 mm). 3.5.2 Sheet, Strip,
26、and Foil 3.5.2.1 Nominal Thicknesses Shall be as shown in Table 4. TABLE 4 - STANDARD THICKNESSES Inch Millimeter 0.001 0.025 0.0015 0.038 0.002 0.05 0.003 0.08 0.004 0.10 0.005 0.13 0.006 0.15 0.008 0.20 0.010 0.25 0.014 0.36 0.020 0.51 0.030 0.76 3.5.2.2 Tolerances, Thickness When specified, toler
27、ances shall be as agreed upon by purchaser and vendor. 3.5.2.3 Tape When specified, sizes and tolerances shall be as agreed upon by purchaser and vendor. 3.5.3 Powder 3.5.3.1 Mesh Designations Shall be 60 (250 m), 100 (150 m), 140 C or F (106 m C or F), 200 (75 m), and 325 (45 m). 3.5.3.2 When a mes
28、h designation is not specified, 140F (106 m F) mesh shall be supplied. 3.5.3.3 Powder shall be supplied in accordance with the limits on particle size distribution shown in Table 5, unless some other distribution is specified. Tests shall be in accordance with ASTM B 214. SAE AMS4778K Page 6 of 9 TA
29、BLE 5A - PARTICLE SIZE DISTRIBUTION U.S.Mesh Designation U.S. Standard Sieve No. Distribution % 60 Through a 40 Through a 60 Through a 325 100 95 min. 10 max. 100 Through a 60 Through a 100 Through a 325 100 95 min. 15 max. 140C On a 100 On a 140 Through a 325 0.5 max. 10 max. 20 max. 140F On a 100
30、On a 140 Through a 325 0.5 max. 10 max. 55 max. 200 On a 140 On a 200 Through a 325 0.5 max. 10 max. 65 max. 325 On a 200 On a 325 Through a 325 0.5 max. 10 max. 90 min. TABLE 5B - PARTICLE SIZE DISTRIBUTION (METRIC) m Mesh Designation Sieve Opening m Distribution % 250 Through a 425 Through a 250 T
31、hrough a 45 100 95 min. 10 max. 150 Through a 250 Through a 150 Through a 45 100 95 min. 15 max. 106C On a 150 On a 106 Through a 45 0.5 max. 10 max. 20 max. 106F On a 150 On a 106 Through a 45 0.5 max. 10 max. 55 max. 75 On a 106 On a 75 Through a 45 0.5 max. 10 max. 65 max. 45 On a 75 On a 45 Thro
32、ugh a 45 0.5 max. 10 max 90 min SAE AMS4778K Page 7 of 9 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for Inspection The vendor of the product shall supply all samples for vendors tests and shall be responsible for the performance of all required tests. Purchaser reserves the right to sample a
33、nd to perform any confirmatory testing deemed necessary to ensure that the product conforms to specified requirements. 4.2 Classification of Tests 4.2.1 Acceptance Tests All technical requirements, other than shelf life of paste (3.3.3.1), are acceptance tests and shall be performed on each lot. 4.2
34、.2 Periodic Tests Shelf life of paste (3.3.3.1) is a periodic tests and shall be performed at a frequency selected by the vendor unless frequency of testing is specified by purchaser. 4.3 Sampling and Testing Shall be in accordance with the following: 4.3.1 Composition One sample shall be taken from
35、 each furnace charge except that powder produced from consecutive furnace charges and collected together, without teardown of the atomizing equipment, shall constitute a batch, from which one sample shall be taken. 4.3.2 Properties Except Shelf Life of Paste One sample from each lot. 4.3.2.1 A lot s
36、hall be all product, other than powder, tape or paste, which has been tested and found to conform to Table 1, in the same temper and size, and presented for vendors inspection at one time. 4.3.2.2 A lot of powder shall be a uniform blend of powder produced from one or more furnace charges, each meet
37、ing the requirements of Table 1, as modified by 4.3.1, and presented for vendors inspection at one time. 4.3.2.3 A lot of paste or tape shall be that paste produced from a single lot of powder, combined with binder from the same manufacturing batch, and presented for vendors inspection at one time.
38、4.4 Reports The vendor of the product shall furnish with each shipment a report showing the results of tests on each lot or batch to determine conformance to the composition requirements, and stating that the product conforms to the other technical requirements. This report shall include the purchas
39、e order number, lot number or numbers, AMS4778K, form, size, and quantity. 4.5 Resampling and Retesting Not applicable. SAE AMS4778K Page 8 of 9 5. PREPARATION FOR DELIVERY 5.1 Identification 5.1.1 Shall be as agreed upon by purchaser and vendor. 5.1.2 Each exterior container or package shall be per
40、manently and legibly marked with not less than the following information: NICKEL ALLOY, BRAZING FILLER METAL AMS4778K LOT NUMBER _ MANUFACTURERS IDENTIFICATION _ NOMINAL DIMENSIONS _ WEIGHT _ 5.1.2.1 Each container and package of paste shall also be marked with the date of manufacture. 5.2 Packaging
41、 5.2.1 The product shall be suitably wrapped, sealed, and boxed or otherwise packaged for protection against injury and contamination during shipment and under normal dry storage conditions. 5.2.2 Packages of filler metal shall be prepared for shipment in accordance with commercial practice and in c
42、ompliance with applicable rules and regulations pertaining to the handling, packaging, and transportation of the filler metal to ensure carrier acceptance and safe delivery. 6. ACKNOWLEDGMENT A vendor shall mention this specification number and its revision letter in all quotations and when acknowle
43、dging purchase orders. 7. REJECTIONS Filler metal not conforming to this specification, or to modifications authorized by purchaser, will be subject to rejection. 8. NOTES 8.1 A change bar (|) located in the left margin is for the convenience of the user in locating areas where technical revisions,
44、not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editori
45、al changes only. 8.2 This filler metal has an approximate solidus temperature of 1800 F and an approximate liquidus temperature of 1900 F. 8.3 Hardness conversion tables for metals are presented in ASTM E 140. 8.4 Terms used in AMS are clarified in ARP1917. 8.5 Dimensions and properties in inch/poun
46、d units and the Fahrenheit temperatures are primary; dimensions and properties in SI units and the Celsius temperatures are shown as the approximate equivalents of the primary units and are presented only for information. SAE AMS4778K Page 9 of 9 8.6 Purchase documents should specify not less than t
47、he following: AMS4778K Form and size of filler metal desired Quantity of filler metal desired. 8.7 Similar Specifications AWS A5.8, Class BNi3, is listed for information only and shall not be construed as an acceptable alternate unless all requirements of this AMS are met. PREPARED BY AMS COMMITTEE “F“
