1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 07 09 Revised Added C5, see Summary of Revisions for details G. Weber, FNA 2005 04 04 Activated G. Weber Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 1 of 4 SINTER-FORGED COPPER STEEL WSS-M10A69-C1 WS
2、S-M10A69-C4 WSS-M10A69-C5 1. SCOPE The materials defined by these specifications are sinter-forged (also known as powder-forged) copper steels. 2. APPLICATION These specifications were released originally for material used for connecting rods. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION
3、 MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 CHEMICAL COMPOSITION (After Hot Forming), % by Weight (ASTM E415 / ASTM E350 / ASTM E1019) C1 C4 C5 Carbon 0.40 - 0.55 0.40 - 0.55 0.57 - 0.72 Copper 1.8
4、0 - 2.20 2.70 - 3.30 3.00 - 3.50 Manganese 0.30 - 0.50 0.30 - 0.50 0.30 - 0.50 Phosphorus 0.04 max 0.04 max 0.04 max Sulfur 0.15 max 0.15 max 0.15 max Silicon 0.03 max 0.03 max 0.03 max Chromium 0.09 max 0.09 max 0.09 max Nickel 0.10 max 0.10 max 0.10 max Molybdenum 0.05 max 0.05 max 0.05 max Oxygen
5、 0.050 max 0.050 max 0.050 max Others Each 0.02 max 0.02 max 0.02 max Others Total 0.20 max 0.20 max 0.20 max Iron Balance Balance Balance 3.3 DENSITY, g/cc min 7.80 (ISO 3369 / ASTM B311) For in-process (IP) testing, the method and frequency of testing shall be specified in the Supplier Control Pla
6、n, and agreed upon between Ford and the supplier. The location(s) on the component designated for sampling shall be defined in the Engineering Specification or on the Engineering Drawing/CAD file. ENGINEERING MATERIAL SPECIFICATIONWSS-M10A69-C1/C4/C5 Printed copies are uncontrolled Copyright 2009, F
7、ord Global Technologies, LLC Page 2 of 4 3.4 MECHANICAL PROPERTIES In order to confirm Analytical Analysis calculations for new designs, the property specifications below shall be verified. Location(s), frequency and procedures of testing shall be outlined in the Engineering Specification and shall
8、form part of the agreed Control Plan. All test samples shall be machined from the as-sinter forged component, in the location(s) defined in the Engineering Specification or on the Engineering Drawing/CAD file. A sinter-forged test bar or a test bar machined from a sinter-forged blank may be used if
9、the component dimensions or geometry prevent the machining of an adequately sized test bar, and provided that the microstructure and density are representative of the component. Note that these mechanical property limits represent -3 values calculated from historical test data. C1 C4 C5 3.4.1 Tensil
10、e Properties (ISO 6892 / ASTM E 8M) Ultimate Tensile Strength, MPa, min 770 890 1090 0.2% Offset Yield Strength, MPa, min 490 610 720 Elongation, %, min 10 8 6.5 Reduction of Area, %, min 17 13 10 3.4.2 Compressive Yield Strength, MPa, min (ASTM E9M) 510 600 735 3.4.3 Shear Strength, MPa, min (ASTM
11、B565) 500 625 720 3.5 CORE HARDNESS (ISO 6506 / ASTM E10 / ASTM E18 / ASTM E140) Core hardness shall be measured on a section cut from the I-beam. The exact location(s) for testing core hardness shall be defined in the component Engineering Specification or on the Engineering Drawing/CAD file. For i
12、n-process (IP) testing, the method and frequency of testing shall be agreed upon between Ford and the supplier, and documented in the Supplier Control Plan. C1 76 88.5 HRG C4 25 35 HRC C5 30 40 HRC Testing may be conducted using other hardness testers than the one specified for a particular material
13、 with the result converted to the specified hardness scale by use of appropriate conversion tables, such as those found in ASTM E140. When agreed between Ford and the supplier, surface hardness may also be measured. In this case, surface hardness limits shall be stated on the Engineering Drawing. E
14、NGINEERING MATERIAL SPECIFICATIONWSS-M10A69-C1/C4/C5 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 4 3.5 MICROSTRUCTURE (ASTM E3) The part shall have a microstructure consisting of lamellar pearlite and proeutectoid ferrite. The exact location(s) for testing
15、 shall be defined in the Engineering Specification or on the Engineering Drawing/CAD file. All features shall be viewed at 200X unless otherwise specified. C1 & C4 C5 3.5.1 Ferrite (ASTM E562) 50% max 35% max 3.5.2 Surface Decarburization (ASTM E1077) Complete 0.04 mm max 0.04 mm max Total 0.25 mm m
16、ax 0.25 mm max 3.5.3 Macro Porosity (viewed at 10X) None permitted None permitted 3.5.4 Surface Oxide Penetration (ASTM B797) 0.25 mm max 0.25 mm max 3.5.5 Non-Metallic Inclusions (ASTM B796) 0.25 mm max 0.25 mm max 3.7 COMPONENT FATIGUE ENDURANCE LIMIT Connecting rods shall be tested on a dedicated
17、 test rig to determine the endurance limit of the component. Loads, test procedure, and method for analyzing data shall be specified in the component Engineering Specification or on the Engineering Drawing/CAD file. See section 4.2.2 for historical data on component fatigue. 3.8 SHOT PEENING An impr
18、ovement in component fatigue strength is realized as a result of shot peening. Because of this, the shot peening process, including shot size and Almen Arc height, shall be detailed on the Engineering Drawing/CAD file. Once component production has begun, changes to the shot peening process shall be
19、 approved by Product Engineering prior to implementation. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. 4.1 SUBJECT REFERENCES “Forged Powder Metal Copper Steel Data Sheet“, summary of property dat
20、a from Ford FRL testing MPIF Standard 35 for P/F Steel Parts, 2007 Edition ENGINEERING MATERIAL SPECIFICATIONWSS-M10A69-C1/C4/C5 Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 4 4.2 INFORMATIVE MATERIAL PROPERTIES The following material properties are provide
21、d for information only, and are not required to be measured or verified prior to component production. Unless otherwise noted, they represent typical values for the property listed. 4.2.1 Sinter-Forged Blank Test Data The values in the table below were determined from specimens machined from sinter-
22、forged blanks. C1 C4 C5 Impact Strength, Charpy V-Notch, J (ASTM E23) Room Temperature 6.0 10.0 - - -18 C 4.5 6.0 - - -51 C 3.0 4.5 - - Ultimate Compressive Strength, MPa 922 - - Elastic Modulus, GPa 213.5 213.5 213.5 Poissons Ratio 0.3 0.3 0.3 Cyclic Strength Coefficient, MPa (K) 1820 - - Strain Ha
23、rdening Exponent (n) 0.181 - - Fatigue Strength Coefficient, MPa (Sf) 1579 - - Fatigue Ductility Exponent (C) -0.563 - - Axial Fatigue Endurance Limit, MPa, -3 (ASTM E466, E467, E468, E606, E1012, stress ratio R = -1) 259 369 - 4.2.2 Component Fatigue Endurance Limits The values in the table below w
24、ere determined from component test rig testing on sinter-forged connecting rods, based on Metaldyne historical testing using 107cycles as the run-out criteria. C1 C4 C5 Axial Fatigue Endurance Limit, MPa, -3 (ASTM E466, E467, E468, E606, E1012) Stress ratio R = -1.0 288 320 350 Stress ratio R = -5.4
25、 306 - Stress ratio R = -6.3 - - 428 Stress ratio R = -6.5 - 376 - 5. SUMMARY OF REVISIONS 2009 07 09 Modified title and scope to better define the material. Added C5 specification. Added requirement to report whether samples for mechanical property determination were obtained from components, sinte
26、r-forged test bars or sinter-forged blanks section 3.4. Adjusted tensile, compressive and shear property requirements for C1 and C4, based on additional test data section 3.4. Changed hardness requirement from surface to core, making provision for a surface hardness requirement on the drawing. Made
27、it a separate section (3.5) and renumbered subsequent sections. Adjusted C4 hardness based on additional test data section 3.4. Added magnification for microstructural evaluations section 3.6 Moved requirement to document shot peening process on the Engineering Drawing from General Information to Requirement section 3.8.
