1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions Rev 03 2011 12 15 N Status No Usage S. Ryzyi, NA 2002 09 26 Revised Updated and renumbered 1990 06 15 C10079663 Released G. Lane/N. Riley EAO/R. Graham NAAO Controlled document at www.MATS Page 1 of 5 Copyri
2、ght 2011, Ford Global Technologies, Inc. GRAY CAST IRON - HARDENABLE CAMSHAFT WSE-M1A303-A1 GRAY CAST IRON - HARDENABLE CAMSHAFT WSE-M1A303-A2 NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a chromium and molybdenum alloy gray cast iron. Grade A2 specifies highe
3、r bearing journal hardness. 2. APPLICATION This specification was released originally for material used for camshafts and oil pump drive gear shafts made by the shell mold or green sand casting process. The lobes are subsequently flame or induction hardened. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS
4、 FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 CHEMICAL COMPOSITION (Weight Percent) Carbon (total) 3.15 - 3.75 Silicon 1.95 - 2.60 Manganese 0.60 - 1.10 Phosphorus 0.20 max Sulphur 0.1
5、5 max Chromium 0.85 - 1.30 Molybdenum 0.35 - 0.60 Copper 1.0 max * Specific composition limits and foundry practices to meet performance and manufacturing requirements will form part of an agreed Control Plan for individual component geometries and process routes. Composition shall be selected gener
6、ally from within the above range in order to meet microstructural, machinability, hardenability and strength requirements. Note; * Copper, optional, increases matrix hardness without significant increase in carbide content which can be detrimental to machining. ENGINEERING MATERIAL SPECIFICATION WSE
7、-M1A303-A1/A2 Page 2 of 5 Copyright 2011, Ford Global Technologies, Inc. 3.3 MECHANICAL PROPERTIES 3.3.1 ULTIMATE TENSILE STRENGTH (UTS) (ASTM E 8M/ISO 6892) Standard Test Bar, MPa, min 220 or Diabolo Test Bar, MPa, min 230 (DIN 50109) The UTS values above are for information only and refer to separ
8、ately cast test bars. Test bar diameters and solidification rates should be such that the microstructure and properties are commensurate with the shaft area of the component. Test bars machined from components should be taken from camshaft quill locations (shaft), and these values can be used as a m
9、easure of flexural strength. Unless otherwise specified on the print, the minimum value for UTS in test bars machined from components shall be 220 MPa. 3.3.2 HARDNESS (unless otherwise stated on Engineering drawing) (ASTM E 10/ISO 6506; ASTM E 18/ISO 6508) A1 A2 Bearing Journals HB 183-341 HB 235-34
10、1 For large volume survey on as cast shafts, agreement may be reached between foundry and manufacturing on the position of checking bearing hardness providing the finished component hardness is met. This agreement is to be part of the control plan. On finished shafts, bearing hardness to be measured
11、 on the centre line to avoid possible influence of adjacent cam hardening. Distributor Drive Gear, HB 183-341 HB 235-341 Cams, Eccentric Separately Cast Gears eg: Distributor Drive Gear HB 183 min HB 235 min Note: By agreement between manufacturing and foundry, the above values may be modified local
12、ly for machinability purposes provided final component hardness requirements are fully met. Hardness and microstructure should be considered attribute data only. Cam and Eccentric (after surface hardening) HRC 50 - 62 Note: Correction factors for surface curvature are applicable on the above HRC val
13、ues. ENGINEERING MATERIAL SPECIFICATION WSE-M1A303-A1/A2 Page 3 of 5 Copyright 2011, Ford Global Technologies, Inc. 3.4 MICROSTRUCTURE - As Cast Camshaft Only 3.4.1 Carbide Pattern Location (Unless otherwise specified.) A carbide containing zone shall be present as per 3.5 which must be examined in
14、an area which will represent the finish machined surface ie. allowing for machine stock removal. 3.4.2 Carbide Distribution and Content (Unless otherwise specified) After allowing for machining, carbide distribution and content as per 3.5 in a matrix of predominantly fine lamellar pearlite. (See par
15、a 4.2 GENERAL INFORMATION for measurement procedure) Note: Microstructure should be considered attribute data only. 3.5 MICROSTRUCTURE - Finished camshaft only 3.5.1 General A carbide containing zone shall be present at the cam nose and flanks. The zone depth shall be, at minimum, 3 mm at the nose,
16、tapering down the flanks to the flank/base circle run out. The section for determining the carbide containing zone dimensions shall be taken 3.0 mm from the cam edge. The matrix of the surface and immediate supporting layer, within the hardened zone, shall consist of martensite without excessive amo
17、unts of retained austenite; see para 4.2.3. Microstructural transformations caused by machining processes after surface hardening are not allowed. 3.5.2 Carbide content WSE-M1A303-A1: Unless otherwise specified on the drawing (depending upon the specific cam/tappet geometries and material combinatio
18、n), the cam contact surface (within the designated zone) shall contain an average value of 5 % min to 30 % max carbide, by area, when 9 fields are viewed at 100 to 250X mag.immediately below the surface. 3.5.3 WSE-M1A303-A2: Unless otherwise specified on the drawing, the cam contact surface within t
19、he designated zone shall contain an average value of 7 % max carbide, by area, when 9 fields are viewed at 100 to 250X mag. immediately below the surface. No one field shall be less than 5 % or greater than 30 % carbide. A cellular carbide network with an 0.8 mm max mesh size is acceptable. Local br
20、eaks or discontinuities in the carbide network are permitted. (See para 4.2 GENERAL INFORMATION for measurement procedure.) ENGINEERING MATERIAL SPECIFICATION WSE-M1A303-A1/A2 Page 4 of 5 Copyright 2011, Ford Global Technologies, Inc. 3.5.4 Gears and Bearings The structure shall be Type VII flake gr
21、aphite predominantly distribution A size 4 (ASTM A 247) in a matrix of fine pearlite with some carbide networks. 3.6 CLEANLINESS Finished component shall be free of loose sand, oxide and scale. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting
22、 the requirements of the specification. 4.1 HARDENING RESPONSE The achievement of HRC 50-62 at the cam lobe and eccentric surface is dependent not only on camshaft characteristics but the employment of correct hardening parameters. It may be necessary to specify quench type and temperature, e.g. ESE
23、-M99C43-A Fast Quench Oil at 54-66 C, to obtain optimum response. ENGINEERING MATERIAL SPECIFICATION WSE-M1A303-A1/A2 Page 5 of 5 Copyright 2011, Ford Global Technologies, Inc. 4.2 ASSESSMENT OF MICROSTRUCTURE 4.2.1 Carbide Distribution (Machined Camshaft) Macrosection, nital etch, view at 15 x magn
24、ification nominal. (Non-destructively, view phosphated nose sector over designated chill zone at suitable known magnification, to assess surface distribution only). 4.2.2 Carbide Content Carbide content may be assessed using ASTM E 562, WSD-M99A4-A or acceptable Image Analysis techniques. In cases o
25、f dispute, the referee method of assessment to be ASTM E 562. Note: For purposes of control and in cases of supply dispute, carbide distribution and content may be determined on as cast components making due allowance for machining. Content may vary from the lower specified amount at the gated end t
26、o the higher specified amount at the non-gated end. 4.2.3 Retained Austenite High levels of retained austenite are considered undesirable because of its affect on wear properties and increased risk of cracking during manufacturing. Levels may be assessed metallographically and if above 20%, should be more accurately determined by X-ray diffraction. Confirmed levels above 25 % are considered unacceptable. 4.3 BEARING HARDNESS WSE-M1A303-A2 with higher bearing hardness will generally be required for smaller bearings having relatively lower surface contact area.
