1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 04 2014 08 29 Revised See Summary of Revisions G. Weber, NA 2014 04 23 Revised See Summary of Revisions G. Weber, NA 2002 01 31 Activated WSS-M2A165-A R. Thomas, NA Controlled document at www.MATS Copyright 2014, Ford Global Technologies
2、, LLC Page 1 of 5 ALUMINUM CASTING ALLOY, CYLINDER BLOCK, 11% SILICON WSS-M2A165-A ALUMINUM CASTING ALLOY, CYLINDER BLOCK, 9.5% SILICON WSS-M2A165-A2 ALUMINUM CASTING ALLOY, CYLINDER BLOCK, 8.5% SILICON WSS-M2A165-A3 1. SCOPE The materials defined by these specifications are aluminum-silicon-copper-
3、magnesium casting alloys, heat treated to a stabilized condition. 2. APPLICATION This specification was originally released for materials used in the manufacture of die-cast engine cylinder blocks with a T5 heat treatment temper. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Mat
4、erial 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) A A2 A3 Silicon 9.5 - 12.0 8.0 11.0 7.5 9.5 Copper 1.5 - 3.5 2.0 4.0 2.0 4.0 Iron 0.60 - 1.30 0.60 - 1.
5、30 0.60 - 1.30 Magnesium 0.55 max 0.55 max 0.55 max Nickel 0.50 max 0.55 max 0.50 max Manganese 0.55 max 0.55 max 0.55 max Zinc 3.00 max 3.00 max 3.00 max Titanium 0.25 max 0.25 max 0.25 max Chromium 0.10 max 0.15 max 0.10 max Lead 0.10 max 0.35 max 0.10 max Tin 0.30 max 0.30 max 0.30 max Antimony 0
6、.10 max 0.10 max 0.10 max Others (Each) 0.05 max 0.05 max 0.05 max Others (Total) 0.50 max 0.50 max 0.50 max Aluminum Balance Balance Balance %Fe + (2x%Mn) + (3x%Cr) 2.00 max 2.00 max 2.00 max The composition shall be selected from within the above range. Specific composition limits and foundry prac
7、tice to meet performance and manufacturing requirements will form part of the Control Plan for each individual component geometry and supplier. Ford and the supplier shall agree upon the test method(s) used for performing chemical analysis of molten aluminum or cylinder head castings. The recommende
8、d method is optical emission spectroscopy (OES) (ASTM E1251), but inductively-coupled argon plasma spectroscopy (ICP) ENGINEERING MATERIAL SPECIFICATION WSS-M2A165-A/A2/A3 Copyright 2014, Ford Global Technologies, LLC Page 2 of 5 (ASTM E1479) may be used for research and failure analysis. In case of
9、 dispute over OES results, ICP shall be used as an umpire method. 3.3 HEAT TREATMENT (Ford W-HTX, ASTM B917) To achieve specified requirements and dimensional stability, components shall be subjected to a T5 heat treatment consisting of artificial aging in the 200 240 C temperature range for 1 to 4
10、hours duration at temperature prior to machining. 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. Liquid media quenching after die-casting is permitted prior to T5 heat treatmen
11、t, for in-process casting handling or for optimization of mechanical properties. The quench medium temperature and the time between part extraction from the die and application of the quench shall be controlled, and these parameters shall be reflected in the Supplier Control Plan, which is agreed up
12、on between Ford and the supplier. 3.4 CASTING QUALITY The finished block shall be free from cracks, laps, cold shuts, inclusions, blisters, and shall have minimal eutectic segregation/depletion. Radiographic and metallographic assessment for casting defects shall meet the general requirements define
13、d below, and may be further restricted in the Engineering Specification. Evaluation locations shall be defined in the Engineering Specification. 3.4.1 Radiographic Assessment (ASTM E505) Radiographic assessment for voids, air entrapment, and shrinkage porosity shall be performed according to methods
14、 described in ASTM E505. Overall, an assessment of Severity Level 3 or better is required for all defect types, except in bulkheads, where an assessment of Severity Level 2 or better is required for all defect types. 3.4.2 Metallographic Evaluation The volume percent porosity shall be determined by
15、image analysis over an area of 25 square millimeters, on contiguous fields of view, at a recommended magnification of 100X, and shall meet the requirements stated below in critical areas. Critical areas on the casting shall be defined in the Engineering Specification. Maximum size, minimum spacing a
16、nd maximum grouping shall be specified in the Engineering Specification. The average volume percent porosity 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. 3.5 MICROSTRUCTURE (ASTM E3) The microstructure shall consi
17、st of primary alpha aluminum, alpha aluminum-silicon eutectic, and intermetallic constituents. Needlelike intermetallics shall be less than 1% by volume, and shall not exceed 0.75 mm in length, determined by image analysis over an area of 25 square millimeters, on contiguous fields of view, at a rec
18、ommended magnification of 100X. ENGINEERING MATERIAL SPECIFICATION WSS-M2A165-A/A2/A3 Copyright 2014, Ford Global Technologies, LLC Page 3 of 5 3.6 MECHANICAL PROPERTIES (As Heat-Treated Components) Test samples shall be machined from the component casting, after the appropriate heat treatment as de
19、scribed in section 3.3. Locations, frequency, and procedures of testing shall be outlined in the Engineering Specification and will form part of the agreed Supplier Control Plan. Elongation shall be determined by extensometer measurement. 3.6.1 Tensile Properties (ASTM B557) Tensile Strength 175 MPa
20、, min 0.2% Proof Stress 170 MPa, min Elongation 0.5% min 3.6.2 Compressive Yield Strength 170 MPa, min (0.2% Offset, ASTM E9) 3.6.3 Shear Strength 170 MPa, min (ASTM B769) 3.6.4 Hardness, HBW (F/D2 = 5 recommended) 85 115 (ASTM E10 / ISO 6506) Reporting of Brinell hardness measurements shall include
21、 the ball diameter (in mm) and the load (in kgf) used to measure the hardness, as required by the referenced test standards. For example, hardness measured using a 10 mm ball and 500 kgf load would be reported as HBW 10/500. 3.6.5 Fatigue Limit at 107 cycles, 65 MPa min (ASTM E466, axial fatigue, R
22、= - 1, test temperature of 120 C) Fatigue test specimens shall have a circular cross-section, with a uniform gage length 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
23、 pieces. 3.7 CONTROL OF MANUFACTURING PROCESS Ford Global Manufacturing Standard W-CMS defines a minimum set of required process controls for various casting processes. The casting process shall meet the requirements of W-CMS for Aluminum High Pressure Die Casting processes. Ford Global Manufacturin
24、g Standard W-HTX defines a minimum set of required process controls for various heat treatment processes. The specified heat treatment process shall meet the requirements of W-HTX for Aluminum Alloy Solution Heat Treating/Age Hardening. 3.8 DIMENSIONAL STABILITY Components in the cubed or finished m
25、achined condition shall be tested in accordance with the Engineering Specification to minimize dimensional growth in service. Maximum allowable dimensional growth shall be specified Engineering Specification or on Engineering Drawing. ENGINEERING MATERIAL SPECIFICATION WSS-M2A165-A/A2/A3 Copyright 2
26、014, Ford Global Technologies, LLC Page 4 of 5 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 SUBJECT REFERENCES Alcan Report
27、 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. Closset. “Castings“, by John Campbell, p. 146, and Section 8.2, p. 264. “Aluminum and Aluminum Alloys“, from the Alumi
28、num Specialty Handbook publication of the American Society for Materials International, pp. 539 - 540. 4.2 CRITICAL AREAS Critical areas of the casting are generally defined as those locations were maximum material properties are required, such as the bulkheads. The component engineer, in cooperatio
29、n with the materials engineer, is responsible for determining and designating critical areas on a casting. All areas deemed critical shall be specified in the Engineering Specification or on the Engineering Drawing. 4.3 ADVISORY MATERIAL PROPERTIES 4.3.1 Rotating Bending Fatigue Strength, MPa, min 7
30、6 4.3.2 Modulus of Elasticity, GPa Value at 20 C 70 Value at 200 C 52 4.3.3 Poissons Ratio 0.33 4.3.4 Coefficient of Linear Thermal Expansion at 25 C (ASTM E228, 10E-6 Ke-1) Temperature Range (C) 20 100 22.1 20 150 22.7 20 200 23.1 20 250 23.1 4.3.5 Thermal Conductivity at 25 C 109 W/m Ke-1 (ASTM E1
31、461) 4.3.6 Density at 25 C 2.71 g/cm3 (ASTM B311) ENGINEERING MATERIAL SPECIFICATION WSS-M2A165-A/A2/A3 Copyright 2014, Ford Global Technologies, LLC Page 5 of 5 5. SUMMARY OF REVISIONS 2014 08 29 Eliminated Mn:Fe ratio requirement 2014 04 23 Corrected %Fe + (2x% Mn) + (3x%Cr) from max value to min
32、value 2013 08 22 Released WSS-M2A165-A2 and WSS-M2A165-A3. Changed order of requirements. Revised chemical composition for WSS-M2A165-A in 3.1 Added sludge factor requirement in 3.2 Clarified 3.4, changed ASTM A155 to ASTM E505 and added severity level requirements. Revised mechanical properties in 3.6 Changed HBS 10/500 to HBW and F/D2=5 in 3.6.4, Clarified quenching in 3.3, added 3.7 (W-CMS, W-HTX) and 4.2. 2004 03 31 Changed shear strength test method from ASTM B565 to B769. 2003 09 23 Revised format and moved standard paragraphs to WSS-M99P1111-A.
