1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2010 10 07 N-STATUS No replacement named L. Soreide, NA 88 09 30 RD-367000-C12 Revised and Retyped 1963 06 05 AS1-915 Released T for 3.2 mm thick spec (expires01/88) Page 1 of 6 HOSE, MEDIUM PRESSURE - AIR C
2、ONDITIONING UNITS ESA-M4D160-C NYLON CONSTRUCTION ACID RESISTANT SLEEVE HOSE, MEDIUM PRESSURE REFRIGERANT ESH-M4D160-E ACID RESISTANT SLEEVE COVERLESS NOT TO BE USED FOR NEW DESIGN 1. SCOPE: The hoses defined by this specification are constructed from an extruded heat stabilized seamless nylon tube
3、and reinforced with nylon yarn. 2. APPLICATION: This specification was released originally for hoses used for suction and liquid lines in automotive air conditioning systems. 3. REQUIREMENTS: 3.1 NON-PIGMENTED INJECTION MOLDED TEST BARS (Tube only, raw material conforms to ESB-M4D278-A) 3.1.1 Color
4、Natural 3.1.2 Specific Gravity 1.12 - 1.16 (ASTM D 792) 3.1.3 Tensile Strength at Break, min 7000 psi (48.3 MPa) (ASTM D 638, dry as molded) 3.1.4 Elongation at Break, min 250% (ASTM D 638) 3.1.5 Melting Point, min 205 C (FLTM BO 21-2) 3.1.6 Flexural Modulus, max 75 000 psi (517 MPa) (ASTM D 790) 3.
5、2 EXTRUDED TUBE, non-reinforced 3.2.1 Burst Pressure (ASTM D 1680) As extruded See Table 4, Burst Pressure ENGINEERING MATERIAL SPECIFICATION ESA-M4D160-C ESH-M4D160-E Page 2 of 6 Change in burst after heat aging -20% 125 C for 72 h, max 3.3 HOSE, with acid resistant sleeve 3.3.1 Dimensional Toleran
6、ces and Eccentricity Hose I.D. and 0.D. limits shall be as shown in Table 1 of this specification and/or as shown on the engineering released drawing. The outer surface shall be concentric with the inside bore of the hose within the limits shown in Table 2. 3.3.2 Elongation and Contraction Hoses sha
7、ll not exceed +/- 2% change in length when subjected to pressure of 450 psi (3.1 MPa). Collapse of the hose 0.D. shall not exceed 20% of the original 0.D. nor more than 50% of the original I.D. when exposed to vacuum of 25 in Hg (85 kPa). 3.3.3 Heat Aging (Use new hose, destroy after) Coil the hose
8、(uncapped) around a mandrel having a diameter equal to the minimum bend diameter shown in Table 3 and expose to a temperature of 110 C for 72 h. After cool the hose to room temperature, then straighten and rebend 180 deg around the mandrel. Remove and examine for fractures on the outside and inside.
9、 There must be no visual evidence of fracturing on the 0.D. and I.D. 3.3.4 Cold Flexibility (Use new hose, destroy after) Precondition the hose prior to cold soak by exposing to 70 C for 168 h then immersing in 65 C water for 4 h. Immediately following water immersion, cold soak the hose in straight
10、 lengths for 48 h at -40 C. Immediately following, bend the hose 180 deg around a mandrel having a diameter equal to the minimum bend diameter (shown on Table 3), which has also been cold soaked to -40 C. Hose shall not show evidence of fracturing after this test. Check visually for fractures and hy
11、drostatic test at 350 psi (2.4 MPa) for 5 min. (Suffix “C“ test at -29 C instead of -40 C.) ENGINEERING MATERIAL SPECIFICATION ESA-M4D160-C ESH-M4D160-E Page 3 of 6 3.3.5 Refrigerant 12 Effusion (Permeation) (Use new hose) All permeation rates are for assemblies using 1/2 in I.D. hose. Other diamete
12、rs shall have maximum permeation rates proportional to the ratio of the inside diameters (i.e., 1 in I.D. has 2 times the allowable permeation rate as 1/2 in I.D.), unless otherwise specified. Four coupled hose assemblies with 30 in (750 mm) of exposed flexible hose between couplings or metal fittin
13、gs and with both ends adaptable for plugging are to be used for this test. Permeation test is to be conducted as follows: 3.3.5.1 Flush out hose assemblies with commercially acceptable cleaning agents (stanisol or iso-octane) and blow out residue with dry air n Loosely cap both ends of hose and cool
14、 to below -30 C. Tighten both caps on one hose (in each set of 4) which will serve as an “empty“ hose for measuring loss in hose weight. Uncap one end of the remain in hoses and add liquid refrigerant 12, equivalent to 8 +/- 1.0 g/in3 (0.49 +/- 0.06 g/cm3) of internal volume. Recap and tighten both
15、ends. Heat all the assemblies to test temperature for 30 min to drive off surface moisture, then remove from heat and weigh within 1 - 3 min. Record this measurement to the nearest 0.1 g as “original weight“. Check assemblies for leaks to be certain the end caps are sealing properly. 3.3.5.2 The ass
16、emblies now are ready for testing. Place in the oven at 70 C. Weigh the assemblies after 24 h and record to the nearest 0.1 g. Use this weight as the “first weighing“ and measure loss from this point on to determine loss per ft/year (m/year). Weigh and record at approximately the same time each succ
17、eeding day until test is completed. After soaking the specified number of days at 70 C, increase the temperature to 100 C Again, record the weight after 24 h at 100 C as “first weighing“ and use the weight losses during the remaining test days to calculate permeation rate. Subtract loss in weight of
18、 “empty“ hose assembly from loss in weight of the charged hose assembly. ENGINEERING MATERIAL SPECIFICATION ESA-M4D160-C ESH-M4D160-E Page 4 of 6 3.3.5.3 Maximum permeation rate shall be as follows: Loss of Refrigerant 12, Test Time, lb/ft/year (kg/m/year), Temperature, C days of 1/2 in I.D. hose, m
19、ax 70 8 0.3 (0.45) 100 4 1.0 (1.49) 3.3.6 Impulse Test (Use new hose, destroy after) Hose (with production equivalent couplings on each end) shall withstand 200,000 impulse cycles without leakage or failure when tested as follows: 3.3.6.1 Connect ends of hose assembly to couplings in test fixture so
20、 that hose is in a “U“ shape approximating the minimum bend diameter shown in Table 3 (use heat aging bend diameters). 3.3.6.2 Subject hose assembly to a pulsating pressure from 0 to the recommended working pressure shown in Table 4 at a maximum rate of 70 cycles/min using a good hydraulic oil at 50
21、 C minimum (manifold temperature). 3.3.6.3 Observe for leakage or other failure. After 200,000 cycles, check for leaks with the hose assembly under water and air or nitrogen pressure applied inside the hose equal to the recommended working pressure (Table 4). (Leaks will show up as steady bubbling;
22、wait until any air trapped under the cover has been exhausted through perforations in the cover.) Where test temperatures and pressures are specified without a tolerance being mentioned, it is not necessary to maintain the exact figure, but good laboratory technique should be followed in maintaining
23、 conditions as close as possible to the specifications. 3.3.7 Cleanliness, max 18 mg/ft2 (194 mg/m2) (ASTM D 1680, may be run on uncoupled hose) 3.4 ACID RESISTANT SLEEVE 3.4.1 Acid Resistance Test (Applies to protective sleeve only.) ENGINEERING MATERIAL SPECIFICATION ESA-M4D160-C ESH-M4D160-E Page
24、 5 of 6 Immerse acid resistant hose (suffix C, D and E) in 36% sulfuric acid solution at room temperature for 1 h. Protective acid resistant sleeve must not show signs of cracking or dissolving. 3.5 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct inf
25、rared and/or thermal analysis of material/parts supplied to this specification. The curves established for initial approval shall constitute the reference standard and shall be kept on file at Central Laboratory. All samples shall produce curves that correspond to the reference standard when tested
26、under the same conditions as those specified on the master curve. 3.6 SUPPLIERS RESPONSIBILITY Material supplied to this specification must be equivalent to that originally approved. Changes in formulation or processing shall not be made without prior approval as described in Supplier Procedure I-A.
27、 4. APPROVAL OF SUPPLIERS: Suppliers to this specification must be approved by the affected product engineering office. Procedure for gaining approval of a specific material to a new/existing ES-M specification is contained in Supplier Procedure I-A. Approved new suppliers will be added to the Engin
28、eering Materials Approved Source List. ENGINEERING MATERIAL SPECIFICATION ESA-M4D160-C ESH-M4D160-E Page 6 of 6 TABLE 1 DIMENSIONS, in (mm) I.D. 0.D. Hose Size Suffix C and D Suffix E Suffix C Suffix D Suffix E 5/16 0.300-0.324 0.300-0.324 0.463-0.507 0.480-0.520 (7.62-8.23) (7.62-8.23) (11.76-12.88
29、) (12.19-13.21) 5/8 0.600-0.650 0.610-0.655 0.855-0.905 0.865-0.910 (15.24-16.51) (15.49-16.64) (21.72-22.99) (21.97-23.11) TABLE 2 CONCENTRICITY Hose Max TIR Size in (mm) 5/16 0.015 (0.38) 5/8 0.030 (0.76) TABLE 3 MINIMUM BEND DIAMETERS, in (mm) Hose Heat Aging Cold Flexibility Size Suffix C Suffix D and E All Suffixes 5/16 5.0 (127) 4.5 (114) 7.0 (178) 5/8 10.0 (254) 13.0 (330) TABLE 4 MINIMUM WORKING PRESSURE AND BURST STRENGTH Burst Strength, Tube only Hose Working Pressure (without reinforcement) Size psi (MPa) psi (MPa) 5/16 500 (3.4) 490 (3.4) 5/8 450 (3.1) 270 (1.9)
