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. 2014 by Navistar, Inc. DECEMBER 2014 Page 1 of 8 NAVISTAR, INC. Material, Parts, and Process Specificatio
2、ns (MPAPS) NUMBER: MPAPS B00-5002 Former Designation: EMS B00-5002 TITLE: Dry Film Lubricant Coating CURRENT REV No.: 1412 DATE: Dec. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: EMS B00-5002 - Sept. 2004 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIE
3、D FOR CURRENT REVISION This specification 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 appli
4、cability of regulatory limits prior to use. Change Notice: Converted to MPAPS format; misc. editorial changes. 1.0 APPLICATION This specification covers several types of coatings: 1.1 TYPE I This coating is used on exhaust manifold gaskets to reduce friction between mating surfaces. 1.2 TYPE II - IV
5、, VIII and IX This coating is used as a release agent for paper and graphite gaskets. 1.3 TYPE VII This coating is applied to elastomeric seals to facilitate assembly and provide identification. CAUTION: Certain solvents, rubbing or scraping, and stretching, can remove the coating. The size of the r
6、emoved coating particles can vary (ref. the coating thickness cited in this document; and paragraph 4.5 “Coating Material” solids shall be less than 5 micrometers (.0002inch) and must conform to the limits specified in MPAPS F-2 for the Cleanliness Level designated on the component and/or assembly d
7、rawing. Qualification in the actual application is required to determine if coating debris will be deleterious to the function of the components, e.g. injectors. 1.4 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply w
8、ith the requirements of the MPAPS B-50 specification. 2.0 SCOPE 2.1 TYPE I This specification covers an air dry, spray applied resin bonded MoS2 dry film lubricant coating. 2.2 TYPE II This specification covers a heat cure; roll applied resin bonded MoS2 dry film lubricant coating. 2.3 TYPE III, V a
9、nd VI This specification covers a heat cure, roll applied, resin bonded MoS2/TFE dry film lubricant. 2.4 TYPE IV This specification covers a heat cure, spray applied, resin bonded MoS2/TFE dry film lubricant. NUMBER: MPAPS B00-5002 TITLE: Dry Film Lubricant Coating REVISION: 1412 This document is re
10、stricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 2 of 8 2.5 TYPE VII This specification covers a resin bonded PTFE lubricant. 2.6 T
11、YPE VIII: This specification covers a proprietary heat cure, roll coated, inorganic coating. 2.7 TYPE IX This specification covers a proprietary heat cure, roll coated, polymeric coating. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. Th
12、e following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001/TS16949 ASTM D 2834 NAVISTAR Manufacturing Standard MS-D-13 ASTM D 3363 CFR Title 29, Part 1910 ASTM D4138 NAVISTAR MPAPS F-2 ASTM D 5620 ASTM D 2877 ASTM F 607 ASTM D56 MIL-A
13、-8625 ASTM D70 MIL-P-16232 ASTM D 185 MIL-S-5059 MPAPS B-50 4.0 MATERIAL REQUIREMENTS 4.1 TYPE I 4.1.1 Physical Properties and Specifications Viscosity 15 sec. #4 Zahn Cup Weight per gallon, ASTM D70 1473.8 (12.3) kg/m3 (pounds) Specific gravity, ASTM D70 1.47 Coefficient of friction range, ASTM D28
14、77 .07-.11 Solids Content, ASTM D2834 55.5% Particle Size: Percent passing 200 mesh screen, % 98 74 micrometer (74 microns) Percent passing 325 mesh screen, % 83 44 micrometer (44 microns) Flash Point, C(F)ASTM D56 (Tag Closed Cup) 40.6 (105) Cure (follow one of the following 3 cycles) 3-1/2 hrs. 19
15、0 C (375 F) 1-1/2 hrs. 232 C (450 F) 1/2 hr. 260 C (500 F) Color Grayish black Diluent Toluene Resin Type Thermosetting Lubricating solids effective from -53.9 C to 648.8 C (-65 F to 1200 F) NUMBER: MPAPS B00-5002 TITLE: Dry Film Lubricant Coating REVISION: 1412 This document is restricted and may n
16、ot be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 3 of 8 4.1.2 Thermal Stability The purpose of this requirement is to insure the quality of the bonde
17、d material and does not reflect the ability of the coating to be effective at 648.8 C (1200 F). Requirement 3 hrs exposure at 200 C (500 F) followed by 3 hrs exposure at -53.9 C (-65 F). The fully cured coating shall not show any loss of adhesion, flaking or softening after the above exposure. 4.1.3
18、 Endurance Life The bonded solid film coating, when tested on a Falex Lubricant Tester, shall have an average endurance life of at least 60 minutes 453 kg (1000#) gage load. The endurance life of any single run shall not be less than 50 minutes. Test specimens: Test specimens may be purchased from t
19、he Falex Corporation, 2055 Comprehensive Drive, Aurora, IL 60505, and each set of specimens shall consist of the following: Two V-blocks of AISI C1137 steel having a Rockwell hardness of 20-24 HRC and a surface finish of 0.304 to 0.355 micrometer (12 to 14AA). One test pin of 3135 steel having a Roc
20、kwell hardness of 80-83 HRB, and a surface finish of 0.152 to 0.203 micrometer (6 to 8 AA). 4.1.3.1 Specimen Preparation The test specimens shall be prepared in accordance with the following procedure: IMPORTANT: CHLORINATED OR OTHER CLASS 1 OZONE DEPLETING SUBSTANCES SHOULD NOT BE USED. a) Degrease
21、 all test specimens using an Ultrasonic Cleaner (Falex Corporation F100-34 Ultrasonic Cleaner), immerse test specimens in Stoddard Solvent and clean for 10 minutes. b) Remove test specimens and wipe dry with a lint free cloth. c) Place test specimens in a second bath of Analytical Grade Isopropyl Al
22、cohol and clean for 10 minutes using the Ultrasonic Cleaner. d) Remove test specimens, allow to air dry, then place in a desiccator until ready to use. All degreased test specimens in the desiccator must be used within an 8 hour time frame. NOTE: To facilitate cleaning small test specimens, separate
23、 containers (500 ml approx.) may be used to hold the Stoddard Solvent and Analytical Grade Isopropyl Alcohol, which can then be placed in the Ultrasonic Cleaner tank containing tap water. Refer to ASTM D 5620, ANNEX, A1 SPECIMEN PREPARATION. e) Phosphate - as specified for type M, Class 3 of MIL-P-1
24、6232. f) Apply lubricant to pin and V-block as specified below. NUMBER: MPAPS B00-5002 TITLE: Dry Film Lubricant Coating REVISION: 1412 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required t
25、o assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 4 of 8 Samples of lubricant in solid film solution form shall be used to prepare solid film specimen on test panes in accordance with this application procedure: The panel shall be made from Al, conforming to QQ A362 and anodiz
26、ed to conform to MIL-A-8625 Type I, measuring approximately 0.05mm thick x 76.2mm X 152.4mm (0.02 thick x 3” x 6”) the corrosion resistance still conforming to MIL-S-5059, composition 301, condition annealed, finish #2 dull,measuring approximately 0.9mm thick x 76.2mm x 152.4mm (.035 x 3” x 6”) prio
27、r to application of lubricant, the panel shall be pre cleaned as indicated above. Application shall be conducted in a well vented area or hood, where no flame sources are present. One side only of each panel shall be fully coated, except for 2 anodized panels which have a lubricant applied to (1”) 2
28、5.4mm wide strip to enable measurement of film thickness. Spray application technique shall be used to coat the panels for test specimens herein. The film thickness after cure shall be 0.005mm to 0.012mm (0.0002 to 0.0005 inch). Two (2) to three (3) coats may be required to obtain desired thickness.
29、 Air dry 25 1-1/2C (77 3 F) for ten min. between coating shall be allowed. After the first coat has been applied, coating shall be allowed to dry 15 min. The coated specimen shall be placed in air circulating oven at 149 C (300 F) for one hour. The coated specimen shall be removed from oven and allo
30、wed to cool to room temperature. At least two (2) specimens shall be used in each test method requiring test panel specimens. Procedure The bonded lubricant coated V-blocks shall be in their sockets in the jaws of the loading device. The dry solid film lubricant test pin shall be mounted in the pin
31、holder. Pressure shall be applied by the loading mechanism. The ratchet wheel shall be turned by hand until the loading mechanism as indicated by the load gage engages, at which time the load - applying arm is positioned and the drive motor is energized. When the gage load indicates 136 kg (300 poun
32、ds), the load-applying arm shall be removed and the tester operated at 29010 rpm for 3 minutes, after which time the load shall be increased to 226.7 kg (500 pounds) with 1 minute operating time at each load, until a 453.5 kg (1000 pound) gage load is reached on the 2040.7 kg (4500 pound) gage. The
33、load shall be maintained at 453.5 kg (1000 pound) until failure. Failure shall be determined by a torque rise of 0.56 Nm (5 inch-pounds) above the steady state value, seizure or breakage of the test pin, or breakage of the shear pin. Four tests shall be conducted. 4.1.3.2 Load Carrying Capacity The
34、bonded solid film lubricant, when tested in accordance with below procedure, shall have a load carrying capacity of at least 1133.7 kg (2500 pound) gage load. Procedure The apparatus and preparation of test specimens shall be similar to that specified for Endurance life. The procedure for conducting
35、 this test shall be the same as specified for Endurance life, except that the endurance life at 453.5 kg (1000 pounds) is eliminated and a NUMBER: MPAPS B00-5002 TITLE: Dry Film Lubricant Coating REVISION: 1412 This document is restricted and may not be sent outside Navistar, Inc. or reproduced with
36、out permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. DECEMBER 2014 Page 5 of 8 1-minute run at this load is substituted. Runs shall then be continued at increasing loads of 113.3 kg (250 pound) increments for 1-minute interv
37、als until a run of 1153.7 kg (2500 pounds) has been completed or to failure, whichever occurs first. Failure shall be indicated by inability to maintain the load for 1 minute; breakage of shear pin, the test pin or a sharp increase in torque over the gradual increase accompanying increasing loads. D
38、uplicate tests shall be made. 4.2 TYPE II Physical Properties and Specifications Viscosity 2-1/2 min #4 Zahn Cup Weight per gallon, ASTM D70 1417.9 (11.84) kg/m3 (pounds) Specific gravity, ASTM D70 1.42 Coefficient of friction range, ASTM D2877 .07-.11 Solids Content, ASTM D2834 59% Particle Size: P
39、ercent passing 200 mesh screen, % 98 74 micrometer (74 microns) Percent passing 325 mesh screen, % 83 44 micrometer (44 microns) Flash Point, C(F)ASTM D56 (Tag Closed Cup) N/A Cure 15 minutes 190 C (375 F) Color Grayish black Diluent Water Resin Type Thermosetting Lubricating solids effective from -
40、53.9 C to 648.8 C (-65 F to 1200 F) 4.3 TYPE III, V, VI Physical Properties and Specifications Viscosity, Bkfld. RVT #4 sp 10 RPM 77F 5000 CPS Weight per gallon, ASTM D70 1515.5 (12.65) kg/m3 (pounds) Specific gravity, ASTM D70 1.52 Solids Content, ASTM D2834 59% Particle Size: Percent passing 200 m
41、esh screen, % 98 74 micrometer (74 microns) Percent passing 325 mesh screen, % 83 44 micrometer (44 microns) Flash Point, C(F)ASTM D56 (Tag Closed Cup) N/A Cure 7 minutes 190 C (375 F) Color Grayish black Diluent Water soluble Resin Type Film former Lubricating solids effective from -53.9 C to 648.8
42、 C (-65 F to 1200 F) NUMBER: MPAPS B00-5002 TITLE: Dry Film Lubricant Coating REVISION: 1412 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. 2014 by Navi
43、star, Inc. DECEMBER 2014 Page 6 of 8 4.4 TYPE IV Physical Properties and Specifications Viscosity, Bkfld. RVT #4 sp 10 RPM 77F 600 1000 CPS Weight per gallon, ASTM D70 1347.8 (11.25) kg/m3 (pounds) Specific gravity, ASTM D70 1.35 Solids Content, ASTM D2834 41% Particle Size: Percent passing 200 mesh
44、 screen, % 98 74 micrometer (74 microns) Percent passing 325 mesh screen, % 83 44 micrometer (44 microns) Flash Point, C(F)ASTM D56 (Tag Closed Cup) N/A Cure 7 minutes 190 C (375 F) Color Grayish black Diluent Water Binder Type Water soluble film former Lubricating solids effective from -53.9 C to 6
45、48.8 C (-65 F to 1200 F) 4.5 TYPE VII Coating Material The coating material shall be a dispersion of polytetrafluoroethylene (PTFE) resin solids, pigment(s) and a coalescing resin in a water medium. If inorganic pigment is included, it shall comprise no more than 10% of the total weight of the appli
46、ed dried coating. Particle size of all solids present in the coating material shall be 5m or less, as determined by ASTM D185 and as certified by the coating manufacturer. Clear coatings are not acceptable. Cleaning Seals to be coated shall be examined for surface bloom. If it is present, it shall b
47、e removed by tumbling in an abrasive media at 255.5 C. Surfaces to be coated shall then be cleaned in a solvent or detergent recommended and approved by the seal manufacturer. Parts shall be air dried before the coating process. Coating Application The coating shall be applied by spraying. The coati
48、ng shall be applied in such a manner as to produce a uniform coating thickness of .005 - .015mm. The temperature of the parts shall be held at 575.5 C during the coating process. A witness coupon is allowable for determining thickness of the coating, so long as correlation can be shown between the c
49、oupon and the seals by the coating vendor. Curing The coated parts shall be cured in a forced air oven at 1355.5 C. Curing time shall be 30 2 minutes from the time that all parts reach curing temperature. Adequate ventilation shall be provided in oven areas to prevent inhalation of toxic fumes. Damaged Areas No reworking of coated seals is allowable. Non-uniform or incomplete coating application shall be cau
