1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 1 of 11 NAVISTAR, INC. Material, Parts, and Process Specification
2、s (MPAPS) NUMBER: MPAPS A-1011 Former Designation: TMS-1011 TITLE: Requirements for Steel Frame Rails CURRENT REV. No.: 1508 DATE: August 2015 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: 1404 April. 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This spe
3、cification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits p
4、rior to use. Change Notice: Added thickness KCC requirement; editorial changes 1.0 APPLICATION This specification covers requirements for truck frame side rails, reinforcements, cross members, and other structural applications, which require very high mechanical properties. The steel commonly used f
5、or rails is quenched and tempered by the rail supplier to develop the required properties. Several other steel grades commonly used on Navistar trucks are included in this specification, including HSLA Type 50, Type 80, and Type 87. Both a standard paint finish and an enhanced corrosion protection f
6、inish (MPAPS A-1011 Type II) are offered as options. The part supplier is responsible for meeting all requirements of this specification. 2.0 SCOPE This specification covers the requirements for rail material, heat treatment, mechanical properties, welding, cutting, shot peening, paint finish, sourc
7、e approval and quality control procedures. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest iss
8、ue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS A-0, Part I CFR Title 29, Part 1910 NAVISTAR CEMS A-39 NAVISTAR Manufacturing Standard MS-D-13 NAVIST
9、AR MPAPS G-5 NAVISTAR Service Manual S01-002 NAVISTAR MPAPS B-50 NAVISTAR Eng. Design Std. A-16 ASTM A6/A6M NAVISTAR MPAPS G-PAINT, GT-4D ASTM A 370 NAVISTAR MPAPS G-PAINT, GT-5A ASTM A 673 NAVISTAR MPAPS G-PAINT, GT-7D AWS A5.5/A5.5M NAVISTAR MPAPS G-PAINT, GT-7E MPAPS A-43 MPAPS A-6 Part I SAE J44
10、4 ASTM E 1077 NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1508 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navis
11、tar, Inc. AUGUST 2015 Page 2 of 11 4.0 REQUIREMENTS 4.1 Material Material furnished to this specification shall meet the applicable requirements of ASTM A6/A6M. Open-hearth, basic oxygen, or electric furnace steel, ingot cast or strand cast may be used. Ingot cast steel supplied may be semi-killed o
12、r fully killed. Strand cast steel shall be fully killed. 4.1.1 Steel Quality Steel supplied shall meet the minimum steel cleanliness required for Quality Level I per MPAPS A-0, Part I. Steel shall be free from internal discontinuities such as laminations, pipe, and segregation, its surface will be f
13、ree from scale, rust, scabs, slivers, seams, pits or laps, and other defects which may have an adverse effect on finished product performance. 4.1.2 Thickness Frame rail material thickness is considered a Key Control Characteristic (KCC). As such, frame rail thickness must meet drawing thickness tol
14、erance confirmed with monthly data submission. This characteristic must: Meet drawing tolerances measured throughout the coil, after mill edge removal, both longitudinally and transverse to rolling direction Account for location of minimum thickness of the coil, after mill edge removal Meet drawing
15、tolerances after all fabrication processes, prior to paint 4.1.3 Edge Condition Steel supplied to this specification will have a cut edge condition only. A mill edge is not acceptable. Any changes in the part process must be approved by Navistar Engineering prior to implementation. 4.2 Material Type
16、s 4.2.1 Heat-Treated Steel 4.2.1.1 Chemical Composition for Heat-Treated Steel Listed below are the minimum compositional requirements for heat-treated steel. Other alloy additives including nickel, chrome, molybdenum, and microalloy additions of boron, columbium, vanadium, titanium, nitrogen, etc.,
17、 may be added at the option of the steel supplier. Carbon 0.35% maximum Manganese 1.00 to 1.65% Sulfur 0.035% maximum Phosphorous 0.035% maximum 4.2.1.2 Heat Treatment Heat-treated steel parts produced to this specification may be furnace quenched and tempered or induction hardened and tempered. Unl
18、ess otherwise agreed upon, minimum tempering temperature shall be 450C (850F). All parts shall be shot peened after heat treatment and prior to any finishing process (see Section 4.5). NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1508 This document is restricted and may n
19、ot be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 3 of 11 4.2.1.3 Microstructure Heat-treated steel parts shall exhibit a structure of tempered martensi
20、te with a maximum of 5% pro-eutectoid ferrite and/or bainite. Intergranular oxidation shall not exceed 2% of the steel thickness. Decarburization shall be evaluated and measured in accordance with ASTM E1077, and shall be controlled to the following limits: Total Decarburization: 0.15 mm (0.006 in)
21、max Total plus Partial Decarburization: 0.38 mm (0.015 in) max 4.2.1.4 Mechanical Properties Heat-treated steel rails supplied to this specification shall provide the following mechanical properties when tested in accordance with ASTM A 370: Ultimate Tensile Strength 860-1140 MPa (125-165 ksi) Nomin
22、al Yield Strength* 825 MPa (120 ksi) Yield Strength (0.2% Offset) 760 MPa (110 ksi) min Elongation in 50 mm (2 inches) 12% min Hardness, HB 269-331 *Nominal yield strength, as used in this specification, is defined as the yield strength value below which less than five percent (5 %) of the rail popu
23、lation will exist. Note: Brinell hardness, HB, may be used in lieu of tensile tests providing the supplier can demonstrate correlation between strength and hardness values. 4.2.1.5 Impact Resistance Quenched and tempered steels intrinsically exhibit levels of toughness and impact resistance exceedin
24、g 20 ft-lbs (27 J) min at -20F (-29C) for a full size Charpy impact test as per ASTM A 370. Charpy testing is not specifically required. However, both steel and rail suppliers are expected to control their processing to provide an equivalent level of toughness. When thickness does not permit a full
25、10 mm size, the largest size available from the material thickness may be used and energy values reduced to equivalent levels in accordance with the equivalency table (Table 1) shown in ASTM A 673. 4.2.2 HSLA Steel Rails 4.2.2.1 Type 50 Steel Rails Parts required to be supplied as Type 50 high-stren
26、gth low-alloy steel must meet the requirements for Type 50X per MPAPS A-43 (if material thickness ” thick or greater), or Grade 6, Type 340X per MPAPS A-6 Part I (if thickness less than ”). 4.2.2.2 Type 80 Steel Rails Parts required to be supplied as Type 80 high-strength low-alloy steel must meet t
27、he requirements for Type 80F per MPAPS A-43 (if material thickness ” thick or greater), or Grade 6, Type 550XF per MPAPS A-6 Part I (if thickness less than ”). NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1508 This document is restricted and may not be sent outside Navist
28、ar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 4 of 11 4.2.2.3 Type 87 Steel Rails 4.2.2.3.1 Chemical Composition Material supplied to this type will meet the chemical compos
29、ition requirements below. Other minor alloy additions including boron, molybdenum, niobium, vanadium, and titanium, may be added at the option of the steel supplier. Carbon 0.15% max Manganese 1.90% max Silicon 0.35% max Phosphorus 0.025% max Sulfur 0.015% max 4.2.2.3.2 Mechanical Properties Rails s
30、upplied to this type must meet the following mechanical property requirements: Ultimate tensile strength: 680810 MPa (98-117 ksi) Yield Strength (0.2% offset): 600720 MPa (87-104 ksi) Elongation: 14% minimum 4.3 Welding Welding for field repair/modification should be performed in accordance with pro
31、cedures outlined in the latest revision of the Navistar Service Manual S01-002 (Frame Section). Repair welding within Navistar or frame supplier production facilities requires the prior approval of Navistar Engineering and Materials Engineering. No welding is permitted in the areas indicated in Figu
32、re 1. Welding ahead of the front spring front hanger or aft of the rear spring rear hanger is permissible with Engineering approval. Welding for relocation of holes within the area indicated in Figure 1 is permissible providing that repair procedures have been approved by the Navistar receiving plan
33、t quality dept. No other welding between the front and rear spring hangers is permitted unless specific exception/deviation to this specification is noted on drilling or installation diagrams. The following weld procedure is recommended: 4.3.1 The shielded metal arc welding process (SMAW) shall be u
34、sed. 4.3.2 Electrodes shall be E11018 or E12018 (AWS A5.5/A5.5M) low hydrogen, coated. 4.3.3 All welding must be performed in a dry condition with moisture free electrodes. 4.3.4 Use of chill blocks is mandatory. 4.3.5 Welds shall be free from undercutting, cracks, porosity, excessive spatter, or ot
35、her defects detrimental to performance. All weld craters shall be filled and welds must have a good appearance. Welds must have good penetration and blend smoothly with the parent metal. Figure 1 38 mm (1.5 in) 38 mm (1.5 in) NO WELDING IN THIS AREA NUMBER: MPAPS A-1011 TITLE: Requirements for Steel
36、 Frame Rails REVISION: 1508 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 5 of 11 4.4 Cutting Cutting by therma
37、l processes (e.g., flame, plasma or laser) after heat treatment is not permitted without prior approval from Navistar Materials Engineering Dept. with the following exception: The plasma or laser cutting of frame rail flanges for engine clearances, after heat treatment, is permitted if appropriate p
38、rocess controls are used to assure: (a) Cut angle as shown in Figure 2 does not exceed 15 degrees. (b) The cut edge is free from notches or sharp radii and does not exceed a surface roughness of 2.8 m (110 in.) Ra. (c) The heat-affected zone (HAZ) does not exceed the depth of 0.7 mm (0.028 in.) meas
39、ured metallographically at mid-point of the thickness as shown in Figure 3. Figure 2 Figure 3 4.5 Shot Peening For induction hardened rails, parts shall be shot peened after any required heat treatment, to Class 16A, CEMS A-39, except shot size CS550 per SAE J444. The minimum residual compressive st
40、ress after peening shall be 415 MPa (60 ksi) measured at 0.10 mm (0.004 in) below the surface at the center of the flange in the longitudinal direction. For parts not induction hardened, shot blasting shall be performed prior to any finishing processes to remove surface scale, grit, etc. 4.6 Base Me
41、tal Finish As noted in this section, the base metal should be free of objectionable scratches, gouges, burrs, and weld spatter. Any substantial welding repair, which could result in alteration of the materials microstructure, shall be performed prior to heat treatment. 4.6.1 Acceptance Criteria 4.6.
42、1.1 Scratches: Scratches perpendicular to the rail length shall be no deeper than 0.5mm (0.020 inch) and shall not be longer than of the web height (or rail width) and shall be limited to no more than one scratch per 1000 mm (40 inches) of rail length. Scratches parallel to the rail length shall not
43、 be longer than 1000 mm (40 inches). See Table 1 for further information. NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1508 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Supplier
44、s are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 6 of 11 4.6.1.2 Gouges: Gouges on the rail web or flanges shall be no deeper than 0.8 mm (0.032 inch). See Table 1 for further information. 4.6.1.3 Burr Height: Shear burrs on the edges of the rails and on punched
45、 holes shall be less than 10 % of the material thickness. 4.6.1.4 Weld Spatter: Weld spatter must be removed. Scratches introduced from grinding, chipping, or chisel removal of weld spatter will meet requirements of 4.6.1.1. 4.6.1.5 Surface Appearance Acceptance Criteria: The finish painted appearan
46、ce of the rail is affected by many factors. Scratches, gouges, weld spatter, dents and dings visible prior to painting will remain visible after the rail is painted. To improve painted appearance of the rails, all such surface conditions should be minimized. However, the complete removal of all such
47、 surface conditions may be neither practical nor economical. See Table 1 for further guidance regarding acceptable appearance. 4.6.2 Repair Larger scratches, gouges, excess burr height, or weld spatter shall be removed/repaired, and after repair, there shall be no visible visible when viewed at a di
48、stance of 36 6 inches (1 0.15 m) grinding marks left on the surface. The repaired area shall be flush with the surrounding surface within 0.04 mm (0.016 inch). Repair methods to be in accordance with the latest revision of the Navistar Frame Service Manual S01-002. 4.7 Delivery Rails and reinforcements shall be supplied to us
