1、 FORD LABORATORY TEST METHOD BV 131-01 Date Action Revisions 2000 12 11 Revised Editorial no technical change A. Cockman 1999 06 04 Printed copies are uncontrolled Page 1 of 8 Copyright 2000, Ford Global Technologies, Inc. METHOD OF TESTING IMPREGNATION MATERIALS FOR CAST AND POWDER METAL COMPONENTS
2、 Application The intent of this test method is to determine the sealing ability, solvent resistance, and general integrity of impregnation materials as applied to actual impregnated components. There shall be two classes of impregnation materials included under this test method: anaerobic, and therm
3、oset resins. Scope The procedure contains two Impregnation Methods for preparing samples - 2a and 2b. Method 2a consists of impregnating specimens in a laboratory autoclave so that comparisons can be made of the integrity of different impregnation materials under controlled conditions. Method 2b use
4、s the same environmental and solvent resistance test schedules, but is performed on specimens which have been impregnated in actual production impregnation processes to ensure that the production parts will have acceptable pressure tightness. Reference Specifications Used in This Document ASTM B 328
5、 ASTM D 1888 FLTM AZ 105-02 WSE-M97B44-B WSE-M2C903-A2 NOTE: Use latest revision level, or replacement document indicated Apparatus Required Pressure Testing Equipment A schematic of the pressure testing apparatus is shown in Figure 1. The system shall be configured such that leak-down can be calcul
6、ated from a measurement of pressure decay of the system over time, via a direct milliliter displacement reading. The test specimens shall be held in a fixture, shown in Figure 2, such that “O“ rings seal the part at top and bottom surfaces after the part is impregnated, and shall be submerged into t
7、he pressure testing apparatus as shown. Approved Laboratories for all Testing: 1. The Ford Central Laboratory, 15000 Century Drive, Dearborn, MI, 2. National Technical Systems, 12601 Southfield Road, Detroit MI. FORD LABORATORY TEST METHOD BV 131-01 Page 2 of 8 Copyright 2000, Ford Global Technologi
8、es, Inc. Pressure Testing Equipment (cont.) Figure 1 Figure 2 FORD LABORATORY TEST METHOD BV 131-01 Page 3 of 8 Copyright 2000, Ford Global Technologies, Inc. Fuel Immersion Testing Equipment Figure 3 FORD LABORATORY TEST METHOD BV 131-01 Page 4 of 8 Copyright 2000, Ford Global Technologies, Inc. Co
9、olant and Oil Immersion Testing Equipment Any Laboratory approved pressure vessel is acceptable for this testing, such as Par Bombs, etc. Test Specimens The test specimens used for this test method shall consist of a sintered powder metal cylinder, with nominal dimension 25.4 mm long with a 19.2 mm
10、inner diameter and 25.4 mm outer diameter, as shown in Figure 4. These test specimens can be obtained from the designated source which has been approved by an appropriate Ford Materials Engineering authority. The specimens must conform to the chemistry requirements outlined in Table I. Figure 4 TABL
11、E I Nominal Composition of 201 AB Aluminum Blend Element Weight % Copper 4.4 Silicon 0.8 Magnesium 0.5 Lubricant 1.5 Aluminum Grade 1202 With the exception of the top and bottom flat sealing surfaces, specimens shall not have any surfaces altered by operations such as burnishing, coining, sizing, or
12、 machining. However, each test specimen shall have an identification number scribed onto the OD of the part prior to testing, as described in the Procedure section. FORD LABORATORY TEST METHOD BV 131-01 Page 5 of 8 Copyright 2000, Ford Global Technologies, Inc. The interconnected porosity, by volume
13、 shall be 15 - 20%, as determined by he method specified in ASTM B 328. The specimen lot shall be certified by the following source such that only one test to verify density need be run per 1000 pieces: Source: GKN Sinter Metals Connover Operations 407 Thornburg Drive Connover, NC 28613 Laboratory
14、Impregnation Vacuum/Pressure Chamber (for Test A) Any of the Laboratory units recommended by the Impregnation Material Manufacturers is acceptable. Materials Required Impregnation Material (for Test A) Material shall be “mixed“ with accelerators, stabilizers, etc., according to the Manufacturers rec
15、ommended procedures, and there should be sufficient material to fill the vacuum chamber to the proper fill level recommended by the equipment manufacturer. NOTE: Impregnated test specimens may also be prepared by the Supplier of the Impregnation Material, in their Laboratory. Distilled or Deionized
16、Water 10-ppm max total dissolved solids (ASTM D 1888) The tank of the Pressure Testing Equipment shall be filled with distilled or deionized water to prevent specimen contamination and/or corrosion. Solvents Test Schedule A Solvents shall be prepared per FLTM AZ 105-02: Solvent 1 - CM15; (15% Methan
17、ol, 85% reference fuel C) Solvent 2 - CM85; (85% Methanol, 15% reference fuel C) Solvent 3 CE10; (10% Ethanol, 90% reference fuel C) Solvent 4 - CE90; (90% Ethanol, 10% reference fuel C) Test Schedule B Solvents shall be diluted per the following mixes, utilizing Ford Specification WSE-M97B44-B for
18、the Ethylene Glycol: Solvent 1 - 50% Ethylene Glycol-based Coolant, 50% Distilled Water Source: Sources are listed in the Ford Approved Source List (ASL) for Ford Specification WSE-M97B44-B. Test Schedule C Solvents shall meet the requirements of Ford Specification WSE-M2C903-A2 per the following: S
19、olvent 1 North American approved source 10W30 oil Solvent 2 - Canadian approved source 10W30 oil Source: Sources are listed in the Ford Approved Source List (ASL) for Ford Specification WSE-M2C903-A2. FORD LABORATORY TEST METHOD BV 131-01 Page 6 of 8 Copyright 2000, Ford Global Technologies, Inc. Co
20、nditioning and Test Conditions All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 + 2 C and 50 + 5 % relative humidity for not less than 24 hours prior to testing under the same conditions unless otherwise specified. Procedure 1. Preparation of Test S
21、pecimens - Thirty test rings shall be carefully cleaned in an ultrasonic bath of Laboratory Alcohol to remove any loose particles from test rings, and then thoroughly dried. The parts must then be inspected for burrs or imperfections that may impede the impregnation process. Each test specimen shall
22、 be scribed with an Identification Number, which gives each specimen a unique number, and also describes the material being tested. An example specimen from the lot of test pieces shall then be pressurized to 345 kPa and checked for leak-down rate. This “Pre-impregnation“ leak-down rate should be gr
23、eater than 100-ml/ minute, and shall describe the leak rate for the lot. Record the “Pre-impregnation“ Leak down Rate in ml/minute. 2a. Impregnation of Test Specimens - This procedure shall cover the impregnation of test specimens in a controlled laboratory environment to enable valid comparisons to
24、 be made of the performance of the various materials in prescribed environments. The samples shall be impregnated in a small Laboratory unit, using the process shown in Table II. TABLE II LABORATORY IMPREGNATION PROCEDURE IMPREGNATION PROCESS Anaerobic A Anaerobic - B Thermoset Resin VACUUM (1.33 kP
25、a) 10 min. 10 min. 10 min. VENT 1 min. 1 min. 1 min. SOAK 4 min. 4 min. 4 min. DRAIN 2 min. 2 min. 2 min. RINSE (H20 at 21 +/- 1 C) - 2 min. 2 min. RINSE (H20 + 5% Detergent at 21 +/- 1 C) ACTIVATOR RINSE 2 min. 2 min. - FINAL RINSE (H20 at 52 +/- 1 C) 2 min. 2 min. - CURE (H20 at 90 +/- 1 C) - - 12
26、 min. AGING 2-4 hours 2-4 hours 1 hour 2b. Impregnation of Test Specimens - This procedure shall cover the impregnation of test specimens in a production environment for the purpose of validating the integrity of the production process. The supplier who is requesting approval of their impregnation p
27、rocess shall place the thirty prepared test rings in with their regular production parts. The test rings shall be placed in the production load and processed as specified by the manufacturer of the equipment, and the manufacturer of the Anaerobic and Thermal Cure Resin materials. The samples should
28、then be submitted to the Ford Central Laboratory or Ford approved outside laboratory for environmental testing to this Ford Laboratory Test Method. FORD LABORATORY TEST METHOD BV 131-01 Page 7 of 8 Copyright 2000, Ford Global Technologies, Inc. After the specimens are impregnated with sealant, the t
29、op and bottom surfaces may be lightly sanded to flatten surfaces and create a good seal against the O-rings of the test fixture (see Figure 2). All thirty specimens from the lot of test pieces shall then be pressurized to 345 kPa and checked for “Post-impregnation“ leak-down rate. This leak-down rat
30、e should be less than 20-ml/minute. Record the “Post-impregnation“ Leak Down Rate in ml/minute for each specimen. 3. Environmental Immersion Testing - Engine Applications Impregnated test rings shall be environmentally tested for solvent resistance and sealing ability per the schedules outlined belo
31、w. For Automotive Engine applications, three different environmental schedules shall be used, with variations of the different solvents under each schedule. Three specimens shall be tested for each solvent, and the pass/fail criteria shall consist of a leak rate of 20-ml/minute maximum, or 100-ml ma
32、ximum over a five-minute interval. Schedule A, shall be used for testing impregnated specimens in fuel environments. There shall be four different fuel solvents used, and three specimens tested for each solvent for a total of 12 tests in Schedule A. Solvent 1 15% Methanol, 85% reference fuel C Solve
33、nt 2 85% Methanol, 15% reference fuel C Solvent 3 - 10% Ethanol, 90% reference fuel C Solvent 4 90% ethanol, 10% reference fuel C FUEL IMMERSION TEST SCHEDULE A 1. Immerse (7 days) at Room Temperature 2. Pressure Test Part & Analyze Fuel 3. Immerse (1 week) at Room Temperature 4. Pressure Test Part
34、 Analyze Fuel 5. Oven Age (16 h) at 70 C 6. Pressure Test Part 7. Freezer Test (8 h) at -40 C 8. Pressure Test Part 9. Immerse (1 week) at Room Temperature 10. Pressure Test Part & Analyze Fuel Schedule B, shall be used for testing impregnated specimens in coolant environments. There shall be one c
35、oolant solvent used at this time, with three specimens tested for the solvent, or 3 tests total in Schedule B. Testing with other coolants may be required for specific applications at the discretion of the affected Ford Component Design activity. Solvent 1 50% Ethylene Glycol-based Coolant, 50% Dist
36、illed Water *COOLANT IMMERSION TEST SCHEDULE B 1. Immerse (1 week) in coolant at 125 C 2. Pressure Test Part & Analyze Coolant 3. Immerse (1 week) in coolant at 125 C 4. Pressure Test Part & Analyze Coolant 5. Freezer Test (8 h) at -40 C FORD LABORATORY TEST METHOD BV 131-01 Page 8 of 8 Copyright 20
37、00, Ford Global Technologies, Inc. 6. Pressure Test Part & Analyze Coolant 7. Immerse (1 week) in coolant at 125 C 8. Pressure Test Part & Analyze Coolant * IMMERSION IS TO BE DONE WITH COOLANT HEATED TO 125 C 3. Environmental Immersion Testing - Engine Applications (cont.) Schedule C, shall be used
38、 for testing impregnated specimens in oil environments. There shall be two different oils used, and three specimens tested for each oil for a total of 6 tests in Schedule C. Solvent 1 North American approved source per WSE-M2C903-A2 10W30 oil Solvent 2 Canadian approved source per WSE-M2C903-A2 10W3
39、0 oil *OIL IMMERSION TEST SCHEDULE C 1. Immerse (1 week) at 150 C 2. Pressure Test Part & Analyze Fuel 3. Immerse (1 week) at 150 C 4. Pressure Test Part & Analyze Fuel 5. Oven Age (16 h) at 70 C 6. Pressure Test Part 7. Freezer Test (8 h) at -40 C 8. Pressure Test Part & Analyze Fuel 9. Immerse (1
40、week) at 150 C 10. Pressure Test Part & Analyze Fuel * OIL FOR IMMERSION TESTING SHALL BE HEATED TO 150 C IN PRESSURE VESSEL 4. Environmental Immersion Testing - Other Automotive Applications Impregnated test rings shall be environmentally tested for solvent resistance and sealing ability per the sc
41、hedules and Test Fluids outlined by the responsible Engineering Activity, i.e., Brake Fluids, Transmissions Fluids, Air Conditioning Materials, etc. Three specimens shall be tested for each solvent. The Authorized Ford Engineering Materials Activity shall specify the acceptance criteria. 5. Pressure
42、 Testing of Specimens Each test piece can only be tested once, and must be pressurized and test begun immediately after being immersed in water. 1. Place test piece in fixture and carefully seal O-rings to top and bottom of test sample by pressing down on fixture handle (Figure 2). 2. Apply 345 kPa
43、pressure to part, and immerse in water tank. 3. If bubbles are appearing from top or bottom of part at O-ring, immediately extract test fixture from tank, and readjust/replace the O-rings. 4. Once the part is fully sealed, replace into the tank and position the funnel of the burette over the part, r
44、ecord initial burette reading, and begin timing immediately (part should not be exposed to water for more than 1 minute before timing begins). 5. After 1 minute, re-read the burette and determine the amount of water displacement in ml, due to air leakage from the test sample. 6. Record the average flow rate for one minute. 7. The acceptance criteria shall be met if all three test specimens of a given test have a recorded leak rate that is less than a maximum of 20 ml/minute.
