1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 2 2015 10 01 Revised See Summary of Revisions G. Weber, NA 2010 09 27 Revised G. Weber, NA 2009 06 24 Activated G. Weber, NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Page 1 of 5 DIE CAST ALUMINUM GENE
2、RAL PURPOSE WSS-M2A171-A1 DIE CAST ALUMINUM MEDIUM DUTY APPLICATIONS WSS-M2A171-A2 1. SCOPE The materials defined by these specifications are die cast aluminum alloys for general purpose and medium duty applications. 2. APPLICATION WSS-M2A171-A1 is used to specify die cast components where attribute
3、s such as pressure tightness are the main requirement, such as water pump housings. WSS-M2A171-A2 is used to specify die cast components where a minimum set of mechanical properties are required. These specifications are not intended to specify the material used for safety-critical components. 3. RE
4、QUIREMENTS 3.1 APPROVED SOURCES This specification does not use approved sources. Any reliable supplier meeting these requirements may be used. 3.2 CHEMICAL COMPOSITION, % by Weight (ASTM E34 / ASTM E607 / ASTM E1251) Castings supplied to WSS-M2A171-A1 or -A2 shall be made of a grade chosen from the
5、 following list of national standard grades. The chemical composition shall conform to the requirements in the given standard. The grade chosen for a given application shall be listed for reference on the PPAP documentation, and the supplier shall not change the chosen grade without prior engineerin
6、g approval (SREA). Standard Grades ASTM B85* UNS A03800, UNS A13800, UNS A03830, UNS A03840 EN 1706 AC46000, AC46200, AC46500 JIS H5302 ADC10, ADCZ10, ADC12, ADCZ12 In addition to the chemical composition requirements within the national standard, the following conditions shall apply: A maximum magn
7、esium content of 0.55% is allowed for both grades For castings supplied to WSS-M2A171-A2, iron, manganese and chromium are further restricted (commonly known as the “sludge factor“) such that (%Fe + (2x%Mn) + (3x%Cr) 2.00% ENGINEERING MATERIAL SPECIFICATION WSS-M2A171-A1/A2 Copyright 2015, Ford Glob
8、al Technologies, LLC Page 2 of 5 3.3 MECHANICAL PROPERTIES A1 Castings supplied to WSS-M2A171-A1 are not required to meet a set of minimum mechanical properties. A2 Castings supplied to WSS-M2A171-A2 shall meet the following minimum mechanical properties in the as-cast condition (F Temper): Property
9、 Machined Bars Cast Bars 0.2% Offset Yield, MPa, min 140 150 Elongation, %, min 0.5 1.0 All test samples shall be machined from cast components. Location(s) and procedure for obtaining test specimen shall be outlined in the component Engineering Specification or on the Engineering Drawing/CAD file a
10、nd shall form part of the agreed Control Plan. Upon agreement between Ford and the supplier, separately cast test bars may be used if the component dimensions or geometry prevent the machining of an adequately sized test bar. Upon agreement between Ford and the supplier, functional testing of the pa
11、rt may be substituted for mechanical property testing. Such testing shall stress the part in critical areas to insure that mechanical properties are sufficient for the design. Leak testing is not acceptable as a functional test to assess mechanical properties. Details of the agreed upon functional t
12、est shall be documented in the component Engineering Specification or on the Engineering Drawing/CAD file, and Materials Engineering shall review the test details prior to release. 3.4 HARDNESS (ISO 6506/ASTM E10) A1 Castings supplied to WSS-M2A171-A1 are not required to meet a specific hardness ran
13、ge. A2 80 HB minimum. Location(s) and procedure for testing hardness shall be outlined in the component Engineering Specification or on the Engineering Drawing/CAD file and shall form part of the agreed Control Plan. 3.5 INTERNAL SOUNDNESS AND ACCEPTANCE CRITERIA (ASTM E505) When specified in the co
14、mponent Engineering Specification or on the Engineering Drawing/CAD file, castings shall be checked for internal soundness (for example, shrinkage, porosity and other internal defects) by x-ray inspection. Castings shall display soundness of ASTM E505 Level 3 or better throughout the casting. In loc
15、ations on the casting designated as High Impact Areas, soundness of ASTM E505 Level 2 or better is required. Locations designated as High Impact Areas shall be specified in the component Engineering Specification or on the Engineering Drawing/CAD file. Frequency of testing shall form part of the agr
16、eed Control Plan. Alternate methods of evaluating internal soundness may be utilized, upon agreement between Ford Design Engineering, Ford Materials Engineering, Ford STA and the supplier. Acceptance criteria and frequency of testing shall form part of the agreed Control Plan. 3.6 CONTROL OF CASTING
17、 MANUFACTURING PROCESS Ford Global Manufacturing Standard W-CMS defines a minimum set of required process controls for various casting processes. All castings supplied to WSS-M2A171-A1 or -A2 shall meet the requirements of W-CMS. ENGINEERING MATERIAL SPECIFICATION WSS-M2A171-A1/A2 Copyright 2015, Fo
18、rd Global Technologies, LLC Page 3 of 5 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. Contact for questions concerning Engineering Material Specifications. 4.1 CHEMICAL COMPOSITION At the latest r
19、elease of this specification, the chemical composition requirements of the national standard grades referenced in this specification were as follows. Single figures are maximum unless otherwise specified. A03800 A13800 A03830 A03840 AC46000 AC46200 Si 7.5-9.5% 7.5-9.5% 9.5-11.5% 10.5-12.0% 8.0-11.0%
20、 7.5-9.5% Cu 3.0-4.0% 3.0-4.0% 2.0-3.0% 3.0-4.0% 2.0-4.0% 2.0-3.5% Mg 0.10% 0.10% 0.10% 0.10% 0.05-0.55% 0.05-0.55% Zn 3.0% 3.0% 3.0% 3.0% 1.2% 1.2% Fe 2.0% 1.3% 1.3% 1.3% 1.3% 0.8% Mn 0.50% 0.50% 0.50% 0.50% 0.55% 0.15-0.65% Ni 0.50% 0.50% 0.30% 0.50% 0.55% 0.35% Sn 0.35% 0.35% 0.15% 0.35% 0.25% 0.
21、15% Ti - - - - 0.25% 0.25% Pb - - - - 0.25% 0.25% Cr - - - - 0.15% - Others (each) - - - - 0.05% 0.05% Others (total) 0.50% 0.50% 0.50% 0.50% 0.25% 0.25% AC46500 ADC10 ADCZ10 ADC12 ADCZ12 Si 8.0-11.0% 7.5-9.5% 7.5-9.5% 9.6-12.0% 9.6-12.0% Cu 2.0-4.0% 2.0-4.0% 2.0-4.0% 1.5-3.5% 1.5-3.5% Mg 0.05-0.55%
22、 0.30% 0.30% 0.30% 0.30% Zn 3.0% 1.0% 3.0% 1.0% 3.0% Fe 1.3% 1.3% 1.3% 1.3% 1.3% Mn 0.55% 0.50% 0.50% 0.50% 0.50% Ni 0.55% 0.50% 0.50% 0.50% 0.50% Sn 0.25% 0.20% 0.20% 0.20% 0.20% Ti 0.25% 0.30% 0.30% 0.30% 0.30% Pb 0.35% 0.20% 0.20% 0.20% 0.20% Cr 0.15% - - - - Others (each) 0.05% - - - - Others (t
23、otal) 0.25% - - - - ENGINEERING MATERIAL SPECIFICATION WSS-M2A171-A1/A2 Copyright 2015, Ford Global Technologies, LLC Page 4 of 5 4.2 INFORMATIVE MATERIAL PROPERTIES (TYPICAL) The following material properties are provided for information only and are not required to be measured or verified prior to
24、 or during component production. Parameter Hardness, HB 80 110 Ultimate Tensile Strength, MPa (as-cast bars) 320 Ultimate Tensile Strength, MPa (bars machined from casting) 230 Compressive Yield Strength, MPa 140 Shear Strength, MPa 200 Fatigue Endurance Limit, MPa 60 Elastic Modulus, GPa 71 Poisson
25、s Ratio 0.33 Density, g/cc 2.7 Coefficient of Linear Thermal Expansion, 20-100 oC, m/m/ oC 21.1 Coefficient of Linear Thermal Expansion, 20-200 oC, m/m/ oC 21.8 Thermal Conductivity, W/m/ oC 100 Specific Heat, J/kg/ oC 960 Melting Range, oC 515 595 4.3 RECYCLING CODE When required, the recycling cod
26、e listed on the part drawing and displayed on the part, as per Ford Engineering CAD and Drafting Standard E-4, shall be . 4.4 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Material
27、s Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for r
28、eview upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.5 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in
29、 all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical
30、 Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications
31、for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.6 RESTRICTED SUBSTANCE MANAGEMENT STANDARD ENGINEERING MATERIAL SPECIFICATION WSS-M2A171-A1/A2 Copyright 2015, Ford Global Technologies, LLC Page 5 of 5 Substan
32、ce restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on
33、 a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2015 10 01 Section 3.3 (A2) Added functional testing as an alternative to tensile testing 2010 09 27 Section 3.2 (A1) Removed sludge factor requirement Section 3.2 (A2) Added A03800 grade and changed sludge factor requir
34、ement from 1.80% Section 3.3 (A2) Eliminated requirement for ultimate tensile strength and changed elongation from 1.0% (machined) and 2.5% (cast) Section 4.2 Added typical hardness range and ultimate tensile strength Section 4.3 Added recycling code Section 3.2 Simplified this section Section 4.2 Corrected CLTE and TC values
