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. 2018 by Navistar, Inc. APRIL 2018 Page 1 of 13 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.: 1804 DATE: Apr. 2018 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: 1708 Aug 2017 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specific
3、ation 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 prior
4、to use. 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 high strength steel commonly used for rails is quenched and tempered (heat treated) by the r
5、ail 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. A standard paint finish and an enhanced corrosion protection finishes (MPAPS A-1011 Type II and Type III) are
6、 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, source approval and quality control p
7、rocedures. 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 issue of all referenced standards s
8、hall apply. The following Specifications, Standards, and Regulations are referenced in this specification. ISO 9001/TS 16949 Quality Management Systems- Requirements CFR Title 29, Part 1910 Occupational Health and Safety Standards NAVISTAR ISQ-001-QM Integrated Suppler Quality Requirements NAVISTAR
9、D-13 Supplier Packing and Shipping Standard. NAVISTAR Service Manual S01-002 - Frame Section NAVISTAR MPAPS GT-PAINT, GT-4D - Hardness of Paint NAVISTAR MPAPS GT-PAINT, GT-7D -Corrosion Tests to Evaluate Paint or Painted Parts (Salt Spray Test) NAVISTAR MPAPS GT-PAINT, GT-7E - Humidity Test for Pain
10、t NAVISTAR MPAPS A-43 - High Strength Low Alloy (HSLA) Steel Plate/Bar NAVISTAR MPAPS A-6 Part I - Low Carbon Steel, Flat Rolled and Structural Shapes NAVISTAR MPAPS A-0, Part I - Chemical Composition of Standard Steels NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1804 Th
11、is 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. 2018 by Navistar, Inc. APRIL 2018 Page 2 of 13 NAVISTAR MPAPS P-39 - Shot Peening of Metal Parts NAVISTAR M
12、PAPS G-5 - Paint Material Requirements NAVISTAR MPAPS GT-31 - Accelerated Weathering of Non-Metallic Materials NAVISTAR MPAPS B-50 - Restricted Chemical Substances ASTM A123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products ASTM A143 Standard Practice for Safeg
13、uarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement ASTM A384 Standard Practice for Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies ASTM A6/A6M Standard Specification for General Requiremen
14、ts for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products ASTM A673 Standard Specification for Sampling Procedure for Impact Testing of Structural Steel AWS A5.5/A5.5M - Specification for Low-Alloy S
15、teel Electrodes for Shielded Metal Arc Welding SAE J444 - Cast Shot and Grit Size Specifications for Peening and Cleaning SAE J2334 - Laboratory Cyclic Corrosion Test ASTM E1077 Standard Test Methods for Estimating the Depth of Decarburization of Steel Specimens ASTM A385 Standard Practice for Provi
16、ding High-Quality Zinc Coatings (Hot-Dip) ASTM D6386 Standard Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and Hardware Surfaces for Painting ASTM D7803 Standard Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and Hardware Su
17、rfaces for Powder Coating ASTM E376 Standard Practice for Measuring Coating Thickness by Magnetic-Field or Eddy Current (Electromagnetic) Testing Methods ASTM B487 Standard Test Method for Measurement of Metal and Oxide Coating Thickness by Microscopical Examination of Cross Section ASTM D3359 Stand
18、ard Test Methods for Rating Adhesion by Tape Test 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 b
19、e semi-killed or 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 su
20、rface will be free 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 drawin
21、g thickness tolerance 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 remova
22、l Meet drawing tolerances after all fabrication processes, prior to paint NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1804 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Supplier
23、s are required to assume all patent liability. 2018 by Navistar, Inc. APRIL 2018 Page 3 of 13 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 t
24、o implementation. 4.2 Material Types 4.2.1 Heat-Treated High Strength 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 boro
25、n, Niobium, vanadium, titanium, nitrogen, etc., 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 (high strength) steel parts produced to this specification may be furnac
26、e quenched and tempered or induction hardened and tempered. Unless 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). 4.2.1.3 Microstructure Heat-treated steel parts shal
27、l exhibit a structure of tempered martensite 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:
28、Total Decarburization: 0.15 mm (0.006 in) 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 A370: Ultimate Tensile
29、Strength 860-1140 MPa (125-165 ksi) Yield Strength (0.2% Offset) 825 MPa (120 ksi) min Elongation in 50 mm (2 inches) 12% min Hardness, HB 269-331 Note: Brinell hardness, HB, may be used in lieu of tensile tests providing the supplier can demonstrate correlation between strength and hardness values.
30、 4.2.1.5 Impact Resistance Quenched and tempered steels intrinsically exhibit levels of toughness and impact resistance exceeding 20 ft-lbs (27 J) min at -20F (-29C) for a full size Charpy impact test as per ASTM A370. Charpy testing is not specifically required. However, both steel and rail supplie
31、rs are expected to control their processing to provide an equivalent level of toughness. When thickness does not permit a full 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
32、 1) shown in ASTM A673. NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1804 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. 201
33、8 by Navistar, Inc. APRIL 2018 Page 4 of 13 4.2.2 HSLA Steel Rails 4.2.2.1 Type 50 Steel Rails Parts required to be supplied as Type 50 high-strength 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
34、 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 the 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 tha
35、n ”). 4.2.2.3 Type 87 Steel Rails 4.2.2.3.1 Chemical Composition Material supplied to this type will meet the chemical composition 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.
36、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 supplied 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-
37、104 ksi) Elongation: 14% minimum 4.3 Welding Welding for field repair/modification should be performed in accordance with procedures outlined in the latest revision of the Navistar Service Manual S01-002 (Frame Section). Repair welding within Navistar or frame supplier production facilities requires
38、 the prior approval of Navistar Engineering and Materials Engineering. No welding is permitted in the areas indicated in Figure 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
39、 area indicated in Figure 1 is permissible providing that repair procedures have been approved by the Navistar receiving plant 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 insta
40、llation diagrams. The following weld procedure is recommended: 4.3.1 The shielded metal arc welding process (SMAW) shall be used. 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.
41、3.4 Use of chill blocks is mandatory. 4.3.5 Welds shall be free from undercutting, cracks, porosity, excessive spatter, or other 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 pa
42、rent metal. NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1804 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. 2018 by Navista
43、r, Inc. APRIL 2018 Page 5 of 13 Figure 1 4.4 Cutting Cutting by thermal 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
44、engine clearances, after heat treatment, is permitted if appropriate process 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-af
45、fected zone (HAZ) does not exceed the depth of 0.7 mm (0.028 in.) measured 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, MPAPS P-39, e
46、xcept shot size CS550 per SAE J444. The minimum residual compressive stress 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
47、any finishing processes to remove surface scale, grit, etc. 38 mm (1.5 in) 38 mm (1.5 in) NO WELDING IN THIS AREA NUMBER: MPAPS A-1011 TITLE: Requirements for Steel Frame Rails REVISION: 1804 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from
48、 Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc. APRIL 2018 Page 6 of 13 4.6 Base Metal 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 b
