1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 01 19 Revised See Summary of Revisions M. Swain 2004 08 31 Revised Para 3.0 inserted; para 3.19 20 h) Used bearing shear loss after run in period with Reference Oil RL 181/6 9 to 13% 3.3.5 Viscosity Index, min 195 (ISO 2909) 3.4 POUR POIN
2、T, max -51 C (ISO 3016) 3.5 FLASH POINT, min 180 C (ISO 2592) ENGINEERING MATERIAL SPECIFICATIONWSD-M2C200-C Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 2 of 6 3.6 COPPER CORROSION (ISO 2160) 3 h at room temperature, max 1 3 h at 120 +/- 2 C, max 1 3.7 ANTI FOA
3、MING PROPERTIES Foam Tendency Foam Stability (ASTM D 892 / D 6082) at end of 5 min at end of 1 min blowing period settling period Sequence 1, max 10 mL 0 mL Sequence 2, max 10 mL 0 mL Sequence 3, max 10 mL 0 mL Sequence 4, max 240 mL 0 mL (For Sequence 4 use ASTM D 6082, static foam, 150 +/- 3 C, 20
4、0 mL air/minute) 3.8 FOAMING AFTER AGEING Foam Tendency Foam Stability (CEC-L48-A-00(B) 40C / 24 hours / 5 L air/ hour) at end of 5 min at end of 20 sec (ASTM D 892) blowing period settling period Sequence 1, max 10 mL 10 mL Sequence 2, max 20 mL 10 mL Sequence 3, max 10 mL 10 mL 3.9 MOISTURE, max 0
5、.1% (ISO 3733) 3.10 ODOR Materials shall produce no objectionable odor under any test performed herein, particularly the tests described in paragraph 3.6 (30 minute and 60 minute intervals during the 3-hour test) and paragraph 3.12. 3.11 RUBBER COMPATIBILITY (ASTM D 471, paragraph 6.1, with aluminum
6、 block or approved equivalents) 168 hours at 150 +/- 3 C Material 70 ACM 121433 (acrylic rubber) Volume change from original + 5 +/- 3% Durometer hardness change from original + 3 / -6 Material 75 FKM 595 (fluorinated rubber) Volume change from original + 3 +/- 3% Durometer hardness change from orig
7、inal 0 / + 6 HNBR 75178 (Hydrogenated Acrylonitrile-Butadiene Rubber) Volume change from original Report Durometer hardness change from original Report ENGINEERING MATERIAL SPECIFICATIONWSD-M2C200-C Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 3 of 6 3.12 OXIDAT
8、ION TEST (CEC L-48-A-00, 160C, 192h) Blotter spot test, min 100 Viscosity increase at 100 C, max 15% Change in TAN (ASTM D 664, max) 2 mgKOH/g Sludge Not permitted 3.13 CONTAMINATION BY SOLID PARTICLES, scale number 20/16 (ISO 4406) 3.14 FRICTION AND WEAR BEHAVIOUR OF DOUBLE-CONE SYNCHRONISER DEVICE
9、S The material must fulfil the following requirements on friction and wear behaviour in one-step endurance life tests. The results must be confirmed by at least two tests with less than 20% standard deviation of the mean endurance life of the tests. 3.14.1 Shifts to Failure, min 100,000 3.14.2 Coeff
10、icient of Friction See Figure 1 Figure 1 3.14.3 Clashing and Wear Report number of cycles up to clashing for each individual test and rate of wear for 1st and 2nd gears. 3.14.4 Ring Clearance Report difference in ring clearance between test start and end. Mean value of three determinations. ENGINEER
11、ING MATERIAL SPECIFICATIONWSD-M2C200-C Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 4 of 6 3.14.5 Trend Plots Submit trend plots for each individual test with the following data. 3.14.5.1 Axial Load 3.14.5.2 Coefficient of Friction 3.14.5.3 Friction Torque vs. S
12、liding Time 3.14.6 Test Plots Submit test plots of the following shifts with data from 3.14.5 versus carried out shifts. Shifts 2, 5, 10, 50, 100, 1000, 10,000, 20,000 etc. 3.14.7 Problems and Difficulties Report any observed problems or difficulties during the test run. Test Method: A complete sync
13、hroniser unit type IB5 1st/2nd gear comprising the following parts must be used for the investigations. Latest level parts must be obtained from Ford Manual Transmission Engineering and are to be returned after testing. 1 x gear, transaxle, 1st speed 7100 1 x gear, transaxle, 2nd speed 7102 1 x hub,
14、 transaxle, synchroniser 7C115 2 x ring, transaxle, inner blocking 7107 2 x ring, transaxle, outer blocking 7107 2 x cone, transaxle, synchroniser mesh 7M000 3 x insert, transaxle, synchroniser hub 7C396 2 x spring, transaxle, synchroniser retain 7109 1 x gear, transaxle, reverse mainshaft (sleeve)
15、7K013 Test Conditions: Speed difference 1,100 rpm Axial load 500 N Reduced inertia 0.06 kg.m2Cycle time 4 s Oil temperature 80 C Oil flow 5 L/minute (Injection lubrication on FZG Standard Synchroniser Test Rig) Sliding speed 4 m/s Contact pressure 3.1 N/mm2Running-in conditions Speed difference 50%
16、of Test Conditions Axial load 50% of Test Conditions Cycles 20 ENGINEERING MATERIAL SPECIFICATIONWSD-M2C200-C Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 6 3.15 GEAR PROTECTION PROPERTIES FZG Step Test A10/16.6R/90, failure stage (FVA sheet 243/2, May 1996
17、) Number of runs, min 3 Failure stage, min 8 Pitting capacity test PT C/9/90 (FVA sheet 2/4, July 1997) Number of runs (initial approval only), min 5 Number of runs (yearly confirmation), min 1 LW10%, LW50% Report 3.16 BEARING WEAR TEST (E DIN 51819 at 50, 80, 110 and 140 C) Fe-8, 80h Rollers, weigh
18、t loss, max 30 mg Cage, weight loss Report One run at 50C and one run at 140C for yearly confirmation required 3.17 FUNCTIONAL APPROVAL Materials being evaluated for initial approval may be subjected to a functional trial. Functional trial results shall be evaluated by GETRAG Engineering prior to ma
19、terial approval and release. 3.18 APPROVAL OF TEST FACILITIES The test facilities used for tests described in paragraphs 3.3.4, 3.12, 3.14, 3.15, 3.16, and 3.17 must have prior approval from GETRAG Engineering. 3.19 COLOR (Visual) Brown Subsequent batches must be visually consistent with the origina
20、l sample color. 3.20 DENSITY Report (ISO 12185, 15C) ENGINEERING MATERIAL SPECIFICATIONWSD-M2C200-C Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 6 of 6 4. SUMMARY OF REVISIONS 2010 01 19 3.3.1 Added alternate test method ASTM D 445. 3.3.1 Added alternate test me
21、thod DIN 51398. 3.3.3 Added alternate test method DIN 51398. 3.3.4 Updated test method and Reference Oil designation. 3.6 Changed corrosion categories to “1” from “1a “ (room temperature) and 1b (120C). 3.7 Added new ASTM method D 6082 for Sequence 4, revised parameters and 5 minute max for new meth
22、od. 3.8 Added CEC method to define ageing technique, 3.10 Added more specificity to tests 3.6 and 3.12 3.11 Added generic description of test materials and added HNBR. 3.12 Updated test method to latest version. 3.14 Corrected formatting errors 3.15 Added minimum number of runs to FZG test. Added “L
23、W10%, LW50% requirement” and minimum number of runs for qualification and yearly report. 3.16 Clarified test conditions and changed “cage weight loss” to “report” 3.17 Changed department to reflect move to GETRAG 3.18 Changed department to reflect move to GETRAG and removed incorrect reference to 3.3.5 Viscosity Index. Added paragraphs 3.19 Color and 3.20 Density
