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. APRIL 2015 Page 1 of 17 NAVISTAR, INC. Material, Parts, and Process Specification
2、s (MPAPS) NUMBER: MPAPS E-10 Former Designation: CEMS E-10 TITLE: Ductile (Nodular) Iron Castings CURRENT REV No.: 1504 DATE: April. 2015 WRITTEN/EDITED BY: W. Cook APPROVED BY: K. Chapman SUPERSEDES: Rev. 1408 Aug. 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This spec
3、ification 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 pr
4、ior to use. Change Notice: Added tensile requirements to Table II; changes to the microstructural requirements for Si-Mo Ductile Iron; added references to ASTM E689; editorial changes. 1.0 SCOPE This specification covers the Companys requirements for castings made of ductile iron (also known as nodu
5、lar or spheroidal graphite iron). Ductile irons may be used in the as-cast condition, or when design considerations require improved properties may be heat treated. 2.0 INTRODUCTION Ductile iron (DI) is a versatile material with strength similar to cast steels but with castability and machinability
6、similar to gray iron. The most economical is making parts from as-cast grades. Annealed, ferritic DI grades offer lower strength with the best ductility and toughness. Higher strength in the unalloyed ductile iron grades is obtained by normalizing (pearlitic) or by quenching and tempering (martensit
7、ic). These heat treatments provide increased strength with a subsequent reduction in ductility and toughness. Austempered ductile iron (ADI) grades are produced by giving conventional ductile iron a special austempering heat treatment that makes them twice as strong as pearlitic ductile iron, but al
8、lows them to retain high elongation and toughness. ADI grades provide superior wear resistance and fatigue strength compare to conventional ductile iron. Their matrix microstructure consists of acicular ferrite and carbon stabilized austenite. High Temperature Ductile Iron - To meet the demands of s
9、ervice conditions that are too severe for conventional or austempered ductile irons, ferritic ductile irons with high silicon-molybdenum levels have been added. The high silicon levels, combined with molybdenum, give the ferritic ductile irons superior mechanical properties at high temperatures and
10、improved resistance to high temperature oxidation. 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. NUMBER: MPAPS E-10 TITLE: Ductile Iron Castings REVISION:
11、 1504 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. APRIL 2015 Page 2 of 17 3.0 CONTENTS PAGE REFERENCE DOCUMENTS 2 GENERAL REQU
12、IREMENTS 2 QUALITY 6 METHODS OF TEST 7 SOURCE APPROVAL AND QUALITY CONTROL 8 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS 8 PACKING AND SHIPPING 9 SECTION A.0 - Critical Component List 11 SECTION A.1 - Critical Component Product Lifecycle DVP given for information only. NUMBER: MPAPS E-10 TITLE: Duct
13、ile Iron Castings REVISION: 1504 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. APRIL 2015 Page 6 of 17 6.3 Metallurgical Require
14、ments 6.3.1 Conventional Ductile Iron Microstructure 6.3.1.1 Graphite Form The graphite form will be essentially spheroidal with not less than 85% conforming to Types I and II and no more than a total of 15% of Types III, IV and VI per ASTM A 247. Types V and VII are prohibited. (See ASTM A 247, Pla
15、te I, for graphite types) 6.3.1.2 Carbides Massive carbides, excessive carbon flotation, or other micro constituents which would be detrimental to engineering properties or normal processing, are prohibited. A maximum of 10% well distributed, fine carbides is permitted, provided machinability is not
16、 adversely affected. 6.3.1.3 Matrix Structure The fully annealed grade, 4318, will have a minimum of 95% matrix ferrite. However, some centerline pearlite is permitted in heavy sections. Grade 6503N will not have less than 85% pearlite in the matrix. 6.3.2 Austempered Ductile Iron Microstructure Gra
17、phite form and carbides will meet requirements of Sections 6.3.1.1 and 6.3.1.2, respectively; the austempering heat treatment should produce a bainitic matrix microstructure consisting substantially of acicular ferrite and austenite. Depending on cooling rate in some sections of the casting, pearlit
18、e or other high-temperature transformation products may be present. The maximum acceptable quantities of these micro constituents at various locations within the casting should be established by agreement between Engineering, the using plant, and the foundry supplier. 6.3.3 High Temperature Ductile
19、Iron Microstructure (High Silicon and Molybdenum DI) Graphite form shall meet the requirements of Sections 6.3.1.1. The minimum acceptable levels of ferrite in the matrix microstructure depends on Grade as shown in Table IV. For all grades, the remainder of the microstructure shall consist of unifor
20、mly distributed pearlite and non-networked carbides. Table IV - Grades of High Temperature Ductile Iron Grade Hardness, HBW Silicon % Molybdenum% % Ferrite, Minimum 1 187-241 3.50-4.50 0.50 max 75 2* 187-241 3.50-4.50 0.51-0.70 95 3 196-269 3.50-4.50 0.71-1.00 95 * Previously covered by EMS E10-5006
21、 6.4 Heat Treatment 6.4.1 Conventional Ductile Iron For ductile iron castings, grades 4318, 5006N, 6503N and Q ASTM A247 ASTM 4585 Sample Size 5 Intercoat Adhesion CEMS GT-5B Control Plan Required Visual inspection of finish quality Rust preventative per MS-D-13 or TMS-4516 for ocean transit Samples
22、 must be chosen at random from entire cavity or traceable lot 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. APRIL 2014 Page 1 of
23、 22 NAVISTAR, INC. Material, Parts, and Process Specifications (MPAPS) NUMBER: MPAPS E-10, APPX Former Designation: CEMS E-10, APPX TITLE: Ductile (Nodular) Iron Castings - Appendix CURRENT REV No.: 1404 DATE: April 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUP
24、ERSEDES: CEMS E-10 APPX Dec. 2002 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED 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 responsi
25、ble to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to use. Change Notice: New MPAPS format; addition of high temperature DI (EMS E10-5006); editorial changes. APPENDIX GENERAL INFORMATION (Not a Requirement) CONTENTS PAGE INTRODUCTION
26、 1 DESCRIPTION OF GRADES 2 RADIOGRAPHIC STANDARDS 3 DESIGN INFORMATION 4 Conventional Ductile Iron 4 Austempered Ductile Iron 10 HEAT TREATMENT 15 WELDABILITY 20 MACHINABILITY 20 A.1.0 INTRODUCTION A.1.1 Ductile iron (also referred to as nodular or spheroidal iron) is a versatile engineering materia
27、l, because of its relatively good castability, machinability, and potential to be produced to a wide range of mechanical properties. It is similar to gray iron in chemistry but varies significantly in that its graphite forms as spheroids or nodules rather than flakes. This results in a material with
28、 properties more like those of steel than gray iron. It is because of this graphite morphology and the improved ductility that nodular iron is also known as Spheroidal Graphite Iron (SG) or Ductile Iron. A.1.2 Austempered ductile iron (ADI) offers a superior combination of properties because it can
29、be cast like other members of the ductile iron family, thus offering the production advantages of conventional castings. Subsequently subjected to the austempering heat treatment process, these castings can provide mechanical properties superior to conventional ductile iron, cast and forged aluminum
30、 and to many of the cast and forged steels A.1.3 High temperature (Silicon-Molybdenum) Ductile Irons were developed to meet the increasing demands for high strength Ductile Irons capable of operating at high temperatures ( up to 1600 F) in applications such as exhaust manifolds or turbocharger casin
31、gs. The primary properties required for such NUMBER: MPAPS E-10, APPX TITLE: Ductile Iron Castings - Appendix CURRENT ISSUE DATE: April 2014 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are requi
32、red to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 2 of 22 applications are oxidation resistance, structural stability, strength, and resistance to thermal cycling. They fill a niche between unalloyed ductile irons and heavily-alloyed austenitic ductile iron. Unalloyed grades
33、 retain their strength to moderate temperatures and perform well under low to moderate severity thermal cycling and exhibit resistance to growth and oxidation that is superior to that of unalloyed Gray Iron. A.1.4 Most of the castings produced or purchased by the Company are sand cast. Other more pr
34、ecise casting methods, such as shell molding, are applicable when engineering requirements justify the increased costs. A.1.5 The portion of this specification covering conventional ductile iron castings follows a format similar to other standards such as SAE J434 wherein the basic requirements have
35、 been related to casting hardness and microstructure since these are the most practical variables for foundries to control and check. Because of the nominal and consistent influence of the spheroidal graphite, the tensile properties are well related to the Brinell hardness of ductile iron. Experienc
36、e over several years has shown that the relationships between hardness vs. yield strength, hardness vs. tensile strength, and hardness vs. elongation are quite stable. To satisfy designers needs, a statistically reliable correlation between casting hardness and mechanical properties has been develop
37、ed. These correlations are shown in figures and tables included in this appendix. Emphasis is placed on the foundry base iron as cast ductile iron. Grade 5006 is the preferred grade for design use because it represents the greatest overall economy in ductile iron castings both in material cost and e
38、nergy conservation. Requirements for cast test bar properties have recently been deleted from specifications because of the questionable relationship between the mechanical properties of test bars and castings. Test bars generally represent different casting conditions than actual castings. Neverthe
39、less, test bars are, and should be, poured and tested for foundry control purposes. A.1.6 The requirements in this specification for the ADI casting grades are based upon ASTM A897. The ADI grades are classified according to the tensile properties of test bars machined from keel blocks poured from t
40、he same iron as the castings. This practice is in contrast to the conventional ductile iron classification based upon the casting hardness. It is recognized that the ADI castings and keel blocks represent different casting conditions and that mechanical properties of test bars (from keel blocks) may
41、 not fully represent the mechanical properties of the castings. However, in the case of the ADI grades, the correlation between casting tensile properties and hardness has not, as yet, been fully developed and correlated as consistently as the conventional ductile irons. Therefore the ADI castings a
42、re classified according to mechanical properties as determined from samples obtained from keel blocks as described in ASTM A897. A.1.7 The requirements in this specification for the Si-Mo casting grades are based upon SAE J2582. The Si-Mo DI grades are classified according to the chemical compositio
43、n and casting hardness. NUMBER: MPAPS E-10, APPX TITLE: Ductile Iron Castings - Appendix CURRENT ISSUE DATE: April 2014 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 pat
44、ent liability. 2014 by Navistar, Inc. APRIL 2014 Page 3 of 22 A.2.0 DESCRIPTION OF GRADES A.2.1 Conventional Ductile Iron The general characteristics of the various grades are shown in the table below: Grade Characteristics 4318 This is a fully annealed ferritic grade which should be specified when
45、design requirements dictate the need for good low temperature impact properties and closer overall control of properties than afforded by Grade 4512. The fully annealed heat treatment required makes this grade more expensive than Grade 4512 and Grade 5006. 4512 This is a ferritic-pearlitic grade whi
46、ch may be furnished as-cast or heat treated with a subcritical or a full anneal. It may be specified when good ductility and/or machinability are desired. Better machinability than Grade 5006 could make this grade lower in total cost for the finished part if considerable machining is required. 5006
47、This is a pearlitic-ferritic grade of intermediate strength, ductility and toughness. It is normally and most economically produced as-cast, but may be furnished in the normalized condition. This grade is the most common currently available and should be specified wherever possible. Specifying the n
48、ormalized version, 5006N, should be avoided because the normalizing heat treating is costly and may not be available from all suppliers. 6503 A pearlitic grade of higher strength than previously listed grades. Most economically produced as-cast, usually with the addition of copper or other pearlite stabilizers. It may also be produced by normalizing. This grade generally has better wear resistance than the previous grades. Q BCIRA (British Cast Iron Research Association), Proceedings, 1970; MS Report 79-1131M, 1969. A.4.1.5 Elevated Temperature Applications Becaus
