1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 02 20 N-STATUS No replacement named A. Wedepohl 2006 08 11 Revised Inserted 3.0; Deleted 3.1, 3.2, 3.6 & 4 1986 08 27 Released CDQ2-624798 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 4 HOSE, HYD
2、RAULIC BRAKE ESA-M96D4-A2 NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines a reinforced rubber hose assembly. 2. APPLICATION This specification was released originally for a hose used on automotive hydraulic brake equipment. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION M
3、ATERIALS 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 a styrene butadiene (SBR) rubber inner tube and a chloroprene (CR) or chloroprene blend rubber cover, reinforce
4、d with polyvinyl alcohol and/or rayon braids, 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 tests are to be conducted by all material suppliers prior to source app
5、roval and at least once every 6 months. 3.4.1 Constriction The constriction shall be measured by dropping a gauge plug a distance of 76 mm through the inside diameter of the brake hose. The hose is to be held vertically and the gauge plug must drop the required distance within a maximum time of 5 se
6、conds. Both ends of the hose assembly must be checked. When the hose in one fitting is blind or at an angle to the centerline of the hose, it is permissible to check entire hose length from one end. The gauging portion of the plug shall have a diameter of 2.040 +/- 0.010 mm and shall be 11.4/14 mm l
7、ong. The leading edge of the plug shall have a corner radius of 0.64/0.89 mm. The total weight of the gauge shall be 57 +/- 3 g. ENGINEERING MATERIAL SPECIFICATIONESA-M96D4-A2Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 4 3.4.2 Expansion and Burst Strength
8、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 be burst tested. When tested under hydraulic pressure, each sample hose
9、 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 braid wicking is permitted during the 2 min hold period. 3.4.3 Adhesion,
10、min 1.42 N/m (FLTM BP 008-03, cover to braid) 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 permissible. Test Method: FMVSS 106, Section S6.3. Test samples to be air aged for 30 min at 146 +/- 3 C pri
11、or 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, Section S6.4) . 24 h after crimping 1.76 kN . Within 12 h after crimping 1.54 kN All hose assemblie
12、s 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 in water, with the outer cover partially removed. The cover is to be removed 13 - 16 mm on either sid
13、e 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 water soak. ENGINEERING MATERIAL SPECIFICATIONESA-M96D4-A2Printed copies are uncontrolled Copyright 200
14、7, 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 removal from water soak. 3.4.7 Low Temperature Flexibility No cracking or breaking After cold soaking 2 ass
15、emblies 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 equivalent of 76 mm diameter bend. Hose assemblies may be cold bend tested without grommets. 3.4.8 Brak
16、e 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 temperature of 93 C for 70 h while filled with SAE RM-1 compatibility brake fluid per FMVSS 106, S6.7. 3.4.9 Ozone
17、 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 after exposure to 80 pphm ozone at 40 C for 2.25 x 105cycles at 20 cpm. Test Method: Mount samples (190 mm
18、free hose length) on the test fixture and condition hoses (80 pphm, 40 C, & 20 cpm). Inspect for cracks after 2.25 x 105cycles. 3.4.11 Heat Aging and Cold Bend Resistance After 8 days of heat aging at 120 +/- 3 C, followed by a cold soak at -46 to -48 C, the brake hose cover must not crack when bent
19、 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 8 days (192 h). Remove from the oven and allow to stabilize to room temperature for 6 - 12 h. Condition hoses and a 76 mm
20、 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 and allow to stabilize to room temperature for 1 - 6 h. Wrap the hose around a 76 mm diameter mandrel an
21、d 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 SPECIFICATIONESA-M96D4-A2Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 4 3.4.
22、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. 3.4.13 Impulse, min 150 cycles The hose assemblies must show no sign of fluid seepage, rubber blisteri
23、ng, 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. Test Method: The hose assemblies are to be cycled a minimum of 150 times with the fluid and ambient tem
24、perature 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 test, the hose assemblies shall be conditioned at ambient temperature for 45 min minimum and be burst test
25、ed (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 10% 3.5 ACCEPTANCE (IN-PROCESS) TESTING The tests 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.
