1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW15261 Exhaust System Component and Joint Leakage Copyright 2012 General Motors Company All Rights Reserved November 2012 Originating Department: North American Engineering Standards Page 1 of 8 1 Scope Note: Nothing in this standard supercedes appli
2、cable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. The purpose of this procedure is to determine the static leakage, pull-apart load and the torque specification on each attachment of the exha
3、ust system - joint interface. 1.2 Foreword. This document contains four procedures: torque angle to ultimate, hand torque to seal and leakage, static leakage check, and pull-apart load. These tests can be conducted individually. 1.3 Applicability. These tests apply to exhaust systems. Note: Pull-apa
4、rt load test does not apply to flange joints. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. None 2.3 Additional References. TMC003 Material Safety Data Sheet guidance docum
5、ents (available at ). 3 Resources 3.1 Facilities. 3.1.1 Approved Fastener Laboratory for this test procedure. 3.1.2 Testing may also be completed at the following, but not limited to: 3.1.2.1 Supplier or supplier laboratory. 3.1.2.2 GM vehicle or engine plants. 3.1.2.3 GM transmission plants. 3.1.2.
6、4 GM component part plants. 3.1.2.5 Satellite General Motors facilities. 3.2 Equipment. 3.2.1 Standard laboratory slot table. 3.2.2 Microprocessor based data acquisition system. 3.2.3 Torque transducer. 3.2.4 Angle encoder/decoder. 3.2.5 Pressure transducer. 3.2.6 Flow meter. 3.2.7 Tensile tester. 3
7、.2.8 Digital function generator. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15261 Copyright 2012 General Motors Company All Rights R
8、eserved November 2012 Page 2 of 8 3.2.9 Control unit. 3.2.10 Controller. 3.2.11 Linear Variable Displacement Transducer (LVDT). 3.2.12 Force transducer. 3.2.13 Amplifier. 3.2.14 Air regulator with filter. 3.2.15 Break wire. 3.2.16 Power tools adequate to torque the fasteners. 3.2.17 Sockets, assorte
9、d angle supports, adapters. 3.2.18 Special rubber plugs to seal the pipe ends. 3.2.19 Furnace or oven capable of 649 C (1200 F). Note: All instrumentation is to be calibrated as required. Record document instrumentation details and date of calibration, unless the information is otherwise preserved i
10、n the laboratory records. 3.3 Test Vehicle/Test Piece. 3.3.1 Complete exhaust system or specific components being investigated. This could include any or all of the following items: 3.3.1.1 Front and intermediate exhaust pipes. 3.3.1.2 Catalytic converter with required hangers. 3.3.1.3 Muffler and t
11、ailpipe assembly with required hangers. 3.3.1.4 Exhaust manifolds. 3.3.1.5 All required fasteners and clamps. 3.3.2 Recommended sample size is eight for Test 1, eight for Test 2, and eight for Test 3. Completed samples from Test 3 are used to run Test 4. 3.4 Test Time. Calendar time: 2 to 10 days Te
12、st hours: 16 hours for 8 samples Coordination hours: 8 hours for 8 samples 3.5 Test Required Information. Not applicable. 3.6 Personnel/Skills. Not applicable. 4 Procedure 4.1 Preparation. 4.1.1 Cut the exhaust system components into appropriate lengths. Enough material should be retained adjacent t
13、o the joint to insure that the pipe has not been weakened. 4.1.2 The following preparation is only required for those samples that will be used for the joint leakage test. 4.1.2.1 Plug or weld the pipe ends as necessary to prevent leakage from unmonitored interfaces. 4.1.2.2 Drill and tap welded pip
14、e end for pressure adapter. 4.1.2.3 Coat welded areas with epoxy to prevent minute air leakage through welds. 4.2 Conditions. 4.2.1 Environmental Conditions. All measurements are taken at lab ambient temperatures. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have be
15、en agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGIN
16、EERING STANDARDS GMW15261 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 3 of 8 4.3 Instructions. 4.3.1 Test No. 1, Torque Angle to Ultimate (Optional). This portion of the procedure may be conducted when fastener torque specifications do not exist for the joints being
17、tested. 4.3.1.1 Review part quantities and condition. 4.3.1.2 Secure test part to T-slot table or fixture. 4.3.1.3 Select proper tool(s) and torque transducer(s) with angle encoder. 4.3.1.4 Configure data acquisition system to collect torque and angle data (reference Manufacturers Operating Procedur
18、e). 4.3.1.5 Align tool(s) and torque transducer(s) to prevent side loading. 4.3.1.6 Unless otherwise specified, test requestor is to approve test setup. 4.3.1.7 Take photograph or digital image of test configuration. 4.3.1.8 Measure and document tool free spinning speed. 4.3.1.9 Dynamically tighten
19、the nut of the clamp or nuts/bolts of a flanged joint until torque fall-off occurs. Use the same tool speed and the number of spindles as used in production. 4.3.1.10 Measure and record torque and angle. 4.3.1.11 Document the failure mode of the joint. 4.3.1.12 Submit plots of torque/angle data to t
20、he Test Engineer. 4.3.2 Test No. 2, Hand Torque to Seal and Leakage (Optional). This portion of the procedure may be conducted when fastener torque specifications do not exist for the joints being tested. 4.3.2.1 Pressurize the system per 4.3.3.2 to a pressure specified by the requestor. Using a dig
21、ital hand torque wrench, alternately tighten the nut of the clamp or nuts/bolts of a flanged joint in 2 Nm increments unless otherwise specified by the requestor. Record leak rate in Standard Liters per Minute (SLPM), at the specified pressure, after each fastener in the joint has been tightened to
22、its 2 Nm or specified increment. Continue until joint failure, recording leak rate after each tightening increment. 4.3.2.2 Document the failure mode of the joint. 4.3.3 Test No. 3, Static Leakage Check. 4.3.3.1 Obtain the minimum dynamic torque specification for the joint from the test requestor. T
23、ighten the joint to the minimum torque value using production tightening strategy and setup. 4.3.3.2 Seal-off the ends of the joint using special rubber plugs. 4.3.3.3 Pressurize the system to 15.0 kPa (2.2 psi) and record the flow rate with the static flow meter. Repeat for 34.5 kPa (5.0 psi) and f
24、or any other pressure(s) specified by the requestor. 4.3.3.4 Place samples in the oven at room temperature. 4.3.3.5 Heat to 399 C (750 F) over a 2 h period or heat to required temperature from requestor. 4.3.3.6 Stabilize at 399 C +0/-14 C (750 F +0/-25 F) or at required temperature from requestor f
25、or 30 minutes. 4.3.3.7 Remove samples and air cool to ambient temperature. 4.3.3.8 After heat treat, repeat the static leakage check (4.3.3.2 and 4.3.3.3). 4.3.3.9 Optional: Repeat 4.3.3.4 thru 4.3.3.8 for an oven temperature of 649 C +0/-14 C (1200 F +0/-25 F). 4.3.3.10 Measure and record joint fas
26、tener audit torque to evaluate heat treat effects. 4.3.3.11 Submit plots of torque/angle data to the Test Engineer. 4.3.4 Test No. 4, Pull-apart Load (Optional). 4.3.4.1 If pull-apart load is required by the test requestor, three joints from the 4.3.3 test should be equipped with a single conductor
27、wire epoxied across the two pipes and used as part of 5 volt circuit. Breakage of wire will indicate slippage of the pipes. 4.3.4.2 Install assemblies into tensile machine with a ramp rate of 1.5 kN/s with a load cell. 4.3.4.3 Pull joint apart, recording load vs. displacement. 4.3.4.4 Document date,
28、 time, part numbers, sizes, etc. 4.3.4.5 Photograph test setups. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15261 Copyright 2012 Gen
29、eral Motors Company All Rights Reserved November 2012 Page 4 of 8 4.3.4.6 Retain samples for documentation. 4.3.4.7 Submit plots of load and break wire voltage vs. displacement data to the Test Engineer. 5 Data 5.1 Calculations. The data will be tabulated and summarized by the Test Engineer. 5.2 Int
30、erpretation of Results. Use the analyzed data from 5.1 to determine the appropriate torque specification and pass/fail conclusion based on leak rate requirement provided. 5.3 Test Documentation. Record the appropriate data using data sheets provided in Appendix A. 6 Safety This standard may involve
31、hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitati
32、ons prior to use. 7 Notes 7.1 Glossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. GHS Globally Harmonized System of Classification and Labeling of Chemicals LVDT Linear Variable Displacement Transducer MSDS Material Safety Data Sheet SDS Safety Data Sheet Seq. Sequence SLPM Standard
33、Liters per Minute 8 Coding System This standard shall be referenced in other documents, drawings, etc., as follows: Test to GMW15261 9 Release and Revisions This standard was originated in March 2006. It was first approved by the Fastening & Sealing Test Lab Global Subsystem Leadership Team in April
34、 2006. It was first published in January 2007. Issue Publication Date Description (Organization) 1 JAN 2007 Initial publication. 2 NOV 2012 Five year refresh of standard. Updated GMW specifications, furnace temperature requirements and data reporting requirements allowed to be more flexible. (Fasten
35、ing & Sealing Test Lab Global Subsystem Leadership Team) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15261 Copyright 2012 General Mot
36、ors Company All Rights Reserved November 2012 Page 5 of 8 Appendix A Data Sheet A1: Test No. 1, Torque Angle to Ultimate Seq. = Sequence Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license fro
37、m IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15261 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 6 of 8 Data Sheet A2: Test No. 2, Hand Torque to Seal and Leakage Seq. = Sequence Copyright General Motors Company Provided by IHS under license with General Motors Comp
38、anyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15261 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 7 of 8 Data Sheet A3: Test No. 3, Static Leakage Check Seq. = Sequence SLPM = Standard Liters
39、 per Minute Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15261 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 8 of 8 Data Sheet A4: Test No. 4, Pull-apart Load Seq. = Sequence Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
