1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 09 22 Revised Para 3.0 inserted; para 3.1, 3.7, 3.8 and 4 deleted 2002 01 30 Revised Revised 3.2, 3.5, 3.6, and 5.1 R. Thomas 2000 02 14 Activated G. Weber Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Pag
2、e 1 of 4 ALUMINUM ALLOY, CASTING WSE-M2A151-A2 THERMALLY TREATED CONDITION WSE-M2A151-A3 WSE-M2A151-A4 1. SCOPE The material defined by these specifications is an aluminum-silicon-copper-magnesium casting alloy in a heat-treated condition. 2. APPLICATION These specifications were originally released
3、 for materials used in manufacture of Precision Sand Cast (PSC) engine cylinder blocks. The A4 designation was originally released for PSC engine cylinder blocks manufactured with metal chills cast in contact with crankcase bulkheads and processed with T7 heat treatment temper. 3. REQUIREMENTS 3.0 S
4、TANDARD REQUIREMENTS 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) (ASTM E1479/ ASTM E1251 Suggested) Silicon 6.5 - 8.0 Copper 3.0 - 4.0 Iron 0.40
5、 max Magnesium 0.20 - 0.45 Nickel 0.10 max Manganese 0.30 max Zinc 0.25 max Titanium 0.25 max Chromium 0.10 max Lead 0.10 max Tin 0.10 max Strontium 0.002 max Sodium 0.002 max Calcium 0.002 max (See para 5.2) Others (Each) 0.05 max Others (Total) 0.50 max Aluminum Balance Customer and supplier shall
6、 agree upon test method(s) for determining molten aluminum or cylinder block casting chemical analysis. It is suggested that ASTM E 1479 Inductively-Coupled Argon Plasma Spectroscopy (ICP) be used for castings and ASTM E 1251 Optical Emission Spectroscopy be used for sampling molten aluminum. ENGINE
7、ERING MATERIAL SPECIFICATIONWSE-M2A151-A2/A3/A4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 4 The composition shall be selected from within the above range in order to meet castability, soundness, machinability consistency, microstructural and strength req
8、uirements. The ratio of manganese to iron shall be maintained at a min of 1:2 respectively. The specific composition limits and foundry practice to meet performance and manufacturing requirements will form part of the Control Plan for each individual component geometry and supplier. 3.3 CASTING QUAL
9、ITY (ASTM E 155) The finished block shall be free from laps, cold shuts, dross, and sludge, and shall have minimal eutectic segregation/depletion. Radiographic assessment levels for gas holes/porosity and shrinkage porosity shall be according to methods of ASTM E 155. 3.3.1 Porosity - Microscopic Ev
10、aluation Metallographic samples for porosity evaluation shall be taken from locations as described in the Engineering Specification or on the Engineering Drawing. Critical areas shall be defined in the Engineering Specification or on the Engineering Drawing. The volume percent porosity shall be dete
11、rmined by image analysis over an area of 25 square millimeters, on contiguous fields of view, at a recommended magnification of 100X. The average shall be no greater than 1%, and no single area shall exceed 2%. The allowable pore size shall not exceed 0.75 mm in any dimension. 3.4 MICROSTRUCTURE (AS
12、TM E 3) The microstructure shall consist of primary alpha aluminum, alpha aluminum-silicon eutectic, and intermetallic constituents. The silicon component of the eutectic may be rounded, which indicates modification. Needlelike intermetallics shall be less than 1% by volume, and shall not exceed 0.7
13、5 mm in length, as measured per the methods described above for porosity. Efforts should be made to minimize copper segregation. 3.4.1 Secondary Dendrite Arm Spacing (SDAS) The Secondary Dendrite Arm Spacing (SDAS) shall be computed as the average of 10 primary dendrites, at 100X. In critical areas,
14、 the SDAS shall be a maximum of 50 micrometers, or as defined in the Engineering Specification or on the Engineering Drawing. No single primary dendrite shall exceed a SDAS of 60 micrometers. The measuring method used shall be described in the Supplier Control Plan. 3.5 MECHANICAL PROPERTIES (As Hea
15、t-Treated Components) In order to confirm Analytical Analysis calculations for new designs, the property specifications below shall be verified. Locations, frequency, and procedures of testing are outlined in the Engineering Specification and reflected in the Supplier Control Plan, which is agreed u
16、pon between Ford and the supplier. All test samples shall be machined from the component casting in the designated location(s) per the Engineering Specification, and after the appropriate heat treatments as described in section 3.6. ENGINEERING MATERIAL SPECIFICATIONWSE-M2A151-A2/A3/A4Printed copies
17、 are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 4 3.5.1 Tensile Properties (ASTM B 557) A2 A3 A4 Tensile Strength, MPa, min 200 225 280 0.2% Proof Stress, min 170 200 230 Elongation, min 0.5% 1.0% 1.8% (extensometer measurement) 3.5.2 Comp. Yield Strength, MPa, 170 200 210
18、 Min. (0.2% Offset) (ASTM E 9) 3.5.3 Shear Strength, MPa, min 152 180 190 (ASTM B 769) 3.5.4 Hardness HBS 10/500 85 115 (all heat treatment tempers) (ASTM E 10/ISO 6506) 3.5.5 Fatigue Limit at 10e7 cycles, MPa, min (ASTM E 466, axial fatigue, R = - 1, test temperature of 120 C) 60 65 85 Test specime
19、ns shall have a circular cross-section, with a uniform gage section two times the diameter. Prior to testing, test specimens shall be aged at 120 C for 400 hours. Test bar failure will be constituted by complete separation of the test bar into two pieces. 3.6 HEAT TREATMENTS A2: Components made to t
20、he A2 grade shall be subjected to a T5 heat treatment, consisting of heating to a temperature within the solution treatment temperature range of this alloy for a time period sufficient to remove all sand (known as “Thermal Sand Removal“ or TSR treatment), air quenching, and artificial over-aging to
21、achieve the required mechanical properties and dimensional stability. The process parameters shall be fully specified on the Engineering Drawing and reflected in the Supplier Control Plan, which is agreed upon between Ford and the supplier. A3 and A4: Components made to the A3 and A4 grades shall be
22、 subjected to a T7 heat treatment, consisting of a full solution treatment with a water quench (pressed-in-place liners) or air quench (cast-in-place liners), and artificial over-aging to achieve the required mechanical properties and dimensional stability. The process parameters shall be fully spec
23、ified on the Engineering Drawing and reflected in the Supplier Control Plan, which is agreed upon between Ford and the supplier. ENGINEERING MATERIAL SPECIFICATIONWSE-M2A151-A2/A3/A4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 4 5. GENERAL INFORMATION The
24、information given below is provided for clarification and assistance in meeting the requirements of these specifications. 5.1 REFERENCE DOCUMENTS The following documents are referenced in this specification: ASTM B 311 ASTM E 9 ASTM E 466 ASTM E 1479 ASTM B 557 ASTM E 10 ASTM E 1251 ISO 6506 ASTM B
25、769 ASTM E 155 ASTM E 1451 QS-9000 ASTM E 3 ASTM E 228 ASTM E 1461 WSS-M99P1111-A 5.2 SUBJECT REFERENCES Alcan Report dated 13 July 1994. “The Treatment of Liquid Aluminum-Silicon Alloys“, Section 8.3, Copyright 1990 by American Foundrymans Association; Authored by John E. Gruzleski and Bernard M. C
26、losset. “Castings“, by John Campbell, p. 146, and Section 8.2, p. 264. “Aluminum and Aluminum Alloys“, from the Aluminum Specialty Handbook publication of the American Society for Materials International, pp. 539 - 540. A2/A3/A4 5.3 ROTATING BENDING FATIGUE STRENGTH, MPa, MIN 76 (all heat treatment
27、tempers) 5.4 MODULUS OF ELASTICITY, GPa Value at 20 C 70 (all heat treatment tempers) Value at 200 C 52 (all heat treatment tempers) 5.5 POISSONS RATIO 0.33 (all heat treatment tempers) (ELASTIC REGION) 5.6 COEFFICIENT OF LINEAR THERMAL EXPANSION AT 25 C (ASTM E 228, 10E-6 Ke-1) Temperature Range (C) (all heat treatment tempers) 20 100 22.1 20 150 22.7 20 200 23.1 20 250 23.1 5.7 THERMAL CONDUCTIVITY AT 25 C 109 W/m Ke-1 (all heat (ASTM E 1461) treatment tempers) 5.8 DENSITY AT 25 C 2.760 g/cm3(all heat (ASTM B 311) treatment tempers)
