1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 02 20 N-STATUS Replaced by WSS-M96D4-B A. Wedepohl 2004 06 04 Revised Para 3.0 inserted; para 3.1, 3.2, 3.6 and 4 deleted 1984 10 22 Released CDP2-1R006207-CD Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC P
2、age 1 of 4 HOSE, HYDRAULIC BRAKE ESA-M96D4-A NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines a hose fabricated from textile braid and synthetic rubber, assembled with steel or brass end fittings. 2. APPLICATION This specification was released originally for a hose used on automotiv
3、e hydraulic brake equipment. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.3 HOSE CONSTRUCTION The hose shall consist of an ethylene propylene te
4、rpolymer (EPDM) rubber inner tube and outer cover, reinforced with twenty-four carrier polyvinyl alcohol braids and assembled with steel or brass end fittings. The material must conform to all the requirements of FMVSS 106 brake hoses and the following requirements. 3.4 INITIAL QUALIFICATION These t
5、ests are to be conducted by all material suppliers prior to source approval and at least once every 6 months. 3.4.1 Constriction The constriction shall be measured by dropping a gage plug a distance of 76 mm through the inside diameter of the brake hose. The hose is to be held vertically and the gau
6、ge plug must drop the required distance with in a maximum time of 5 seconds. Both ends of the hose assembly must be checked. When the hose in one fitting is blind or at an angle to the center line of the hose, it is permissible to check entire hose length from one end. The gauging portion of the plu
7、g shall have a diameter of 2.040 +/- 0.010 mm and shall be 11.4/14 mm long. The leading edge of the plug shall have a corner radius of 0.64/0.89 mm. The total weight of the gage shall be 57 +/- 3 g. ENGINEERING MATERIAL SPECIFICATION ESA-M96D4-A Printed copies are uncontrolled Copyright 2007, Ford G
8、lobal Technologies, LLC Page 2 of 4 3.4.2 Expansion and Burst Strength All 3.175 (+0.381 - 0.000 mm I.D.) brake hoses must have a maximum expansion rate of 0.72 cm3/m at 6.9 MPa and 1.08 cm3/m at 10.3 MPa. Test Method: FMVSS 106, Section S6.1. 30 min after the expansion test, the hose assembly shall
9、 be burst tested. When tested under hydraulic pressure, each sample hose assembly must withstand a maintained pressure of 41.4 +/- 0.7 MPa for 2 min. The pressure shall then be increased at the rate of 172 +/- 69 MPa/min until burst occurs. The minimum burst pressure is to be 62 MPa. No seepage or b
10、raid wicking is permitted during the 2 min hold period. 3.4.3 Adhesion, min 36 N (FLTM BP 8-3, cover to braid, 25.4 mm wide longitudinal specimen) 3.4.4 Whip Life, min Free Hose Length: Up to 300 mm 50 h 300 - 450 mm 35 h No leakage or deterioration of the outer cover, braid or inner tube is permiss
11、ible. Test Method: FMVSS 106, Section S6.3. Test samples to be air aged for 30 min at 146 +/- 3 C prior to testing. The hose is to contain current production Ford Motor Company brake fluid during aging. The hose assembly may be tested without mounting brackets. 3.4.5 Tensile Strength, min (FMVSS 106
12、, Section S6.4) . 24 h after crimping 1.76 kN . Within 12 h after crimping 1.54 kN All hose assemblies must withstand a minimum tensile load without separation of the hose from its end fittings. 3.4.6 Water Absorption The hose assemblies must pass all burst, whip and tensile tests after a 72 h soak
13、in water, with the outer cover partially removed. The cover is to be removed 13 - 16 mm on either side of the center of the hose (28.6 to 31 mm total). The outer braid must not be damaged and no elongation of the hose is permissible. 3.4.6.1 Burst Test per para 3.4.2 within 10 min of removal from wa
14、ter soak. ENGINEERING MATERIAL SPECIFICATION ESA-M96D4-A Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 4 3.4.6.2 Tensile Strength Test per para 3.4.5 within 30 min of removal from water soak. 3.4.6.3 Whip Resistance Test per para 3.4.4 within 30 min of remov
15、al from water soak. 3.4.7 Low Temperature Flexibility No cracking or breaking After cold soaking 2 assemblies at - 54 C to - 57 C for 72 h, they shall be bent around a 76 mm diameter mandrel within 5 seconds. Care must be taken during the bending so that no part of the hose assembly has less than an
16、 equivalent of 76 mm diameter bend. Hose assemblies may be cold bend tested without grommets. 3.4.8 Brake Fluid Compatibility, Constriction, and Burst Strength The hose assemblies shall meet the constriction (para 3.4.1) and burst (para 3.4.2) requirements after having been subjected to a temperatur
17、e of 93 C for 70 h while filled with SAE RM-1 compatibility brake fluid per FMVSS 106, S6.7. 3.4.9 Ozone Resistance (FMVSS 106, Section S6.8) No cracks visible under 7-power magnification after exposure to ozone for 70 h at 40 C. 3.4.10 Dynamic Ozone No cracks visible under 7-power magnification aft
18、er exposure to 80 pphm ozone at 40 C for 1 x 106cycles at 20 cpm. Test Method: Mount samples (190 mm free hose length) on the test fixture and condition hoses (80 pphm, 40 C, & 20 cpm). Inspect for cracks after 1 x 106cycles. 3.4.11 Heat Aging and Cold Bend Resistance After 10 days of heat aging at
19、120 +/- 3 C, followed by a cold soak at - 46 to - 48 C, the brake hose cover must not crack when bent around a 76 mm diameter mandrel. Abrasion grommets are to be removed from all hose assemblies so equipped prior to testing. Test Method: Heat age at 120 +/- 3 C (ASTM D 573) for 10 days (240 h). Rem
20、ove from the oven and allow to stabilize to room temperature for 6 - 12 h. Condition hoses and a 76 mm diameter mandrel for 48 h in a cold chamber maintained at -46 to -48 C. Without removing from chamber, bend the hose 180 around the mandrel within 5 seconds. Remove the hose from the cold chamber a
21、nd allow to stabilize to room temperature for 1 - 6 h. Wrap the hose around a 76 mm diameter mandrel and inspect, without magnification, for cracks in the outer cover. A crack is defined as a discontinuity in the outer cover extending through to the outer braid. ENGINEERING MATERIAL SPECIFICATION ES
22、A-M96D4-A Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 4 3.4.12 End Fitting Corrosion Resistance (FMVSS 106, Section S6.9) After 24 h of exposure to salt spray, a hydraulic brake hose end fitting shall show no base metal corrosion on the end fitting surface
23、. 3.4.13 Impulse, min 150 cycles The hose assemblies must show no sign of fluid seepage, rubber blistering, cracking or separation and must be tested under hydraulic pressure. The assemblies must withstand a maintained pressure of 13.8 +/- 0.07 MPa for 2 min and a minimum burst pressure of 34.5 MPa.
24、 Test Method: The hose assemblies are to be cycled a minimum of 150 times with the fluid and ambient temperature of 146 +/- 3 C. A cycle consists of 1 min at 11.0 MPa and 1 min at 0 MPa. The current production Ford Motor Company hydraulic brake fluid will be the pressure medium. After the impulse te
25、st, the hose assemblies shall be conditioned at ambient temperature for 45 min minimum and be burst tested (reference para 3.4.2) 3.4.14 Immersion in ASTM #3 Oil (ASTM D 471, 48 h at 70 +/- 2 C, using 76.2 mm hose specimen) Outside Diameter Change 0 to 15% 3.5 ACCEPTANCE (IN-PROCESS) TESTING The tes
26、ts and frequencies shall be specified in the applicable Engineering Specification noted on the engineering drawing. Tests must be completed with production parts on a continuing basis. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. The combination of elastomers and reinforcing fibers also provides compatibility with DOT 4 brake fluids.
