1、This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2008 International Truck and Engine Corporation April 2008 Page 1 of 5 INTERN
2、ATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS- 1045 TITLE: Corrosion Resistant Steel Tubing REVISION: J WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: April 2008 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRE
3、NT 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 applicability of
4、 regulatory limits prior to use. Change Notice: Revised Section 4.3; added Fluid Resistance Testing as Section 4.3.4. Reference: File 04, 30-13G Keywords: Brake Line Tubing, Galfan, Nyclad, 1.0 APPLICATION This specification covers three types of double wall, furnace brazed steel tubing, with corros
5、ion resistant coatings, suitable for use in hydraulic brake lines or other applications where improved corrosion resistance is required. Type 1 tubing (hot dip terne coating overlaid with a zinc rich organic topcoat) is obsolete, and not to be used in International products. Type 2 uses a hot dip zi
6、nc-aluminum coating overlaid with an aluminum rich organic (epoxy) topcoat. Type 3 tubing consists of Type 2 tubing with a nylon/polyamide covering. 2.0 SCOPE This specification covers the performance requirements of the tubing and tube assemblies, including coating thickness, corrosion resistance,
7、dimensional tolerances, quality, and source approval. The control of the corrosion protective properties of the tubing is the responsibility of the manufacturer. 2.1 Restricted Chemical SubstancesEffective January 1, 2007, all product supplied to the requirements of this specification must comply wi
8、th the requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue 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
9、 CFR Title 29, Part 1910 SAE J527 INTERNATIONAL Manufacturing Standard D-13 ASTM B 117 SAE J400 INTERNATIONAL Engineering Design Std. A-16 SAE J2334 ASTM A 254 INTERNATIONAL CEMS A-45, Part I GM9505P INTERNATIONAL CEMS B-50 NUMBER: TITLE: REVISION TMS-1045 Corrosion Resistant Steel Tubing J This doc
10、ument is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2008 International Truck and Engine Corporation 4.0 REQUIREMENTS 4.1 Description of T
11、ubing Types4.1.1 Type 1 Tube NOT TO BE USED FOR NEW DESIGN 4.1.2 Type 2 Tube This tubing consists of a standard double wall brazed steel tubing (SAE J527) meeting the performance requirements of Grade 1 ST of CEMS A-45, Part I. The hot dip coating consists of 95% zinc and 5% aluminum with minor trac
12、e elements. Minimum coating weight is 39 g/m (0.13 oz/ft). The tubing is then coated with epoxy paint containing uniformly dispersed aluminum flakes or platelets, and then baked. 4.1.3 Type 3 Tube Type 3 consists of a standard double wall brazed steel tubing (SAE J527) having the same coating as Typ
13、e 2 above, followed by an adhesive primer layer and a polyamide 12 topcoat. 4.2 Coating Thickness4.2.1 Type 2 Tube When examined metallographically, the zinc-aluminum metal coating and the aluminum rich epoxy dry film coating will each exhibit a minimum thickness of 3m as measured at any point on th
14、e circumference of the tube. 4.2.2 Type 3 Tube Type 3 tubing will meet the coating requirements for Type 2 tubing above. In addition, the polyamide 12 coating for Type 3 will have a film thickness of 150 m minimum. 4.3 Environmental Resistance Evaluation 4.3.1 General Required testing will be perfor
15、med using production representative tubing samples and fittings. In order to allow fittings to remain functional when pressure testing is required after corrosion testing, the system should be protected during exposure (such as inserting tube fittings into a solid block of aluminum, or placing wax i
16、nto openings to protect interior tubing surfaces). 4.3.2 Gravelometer/Salt Spray Testing 4.3.2.1 Type 2 TubingAt least 2 samples of Type 2 tubing representative of production tubing will be subjected to 1000 hr salt spray exposure per ASTM B 117. 4.3.2.1.1 RequirementsTested tubes will not exhibit m
17、ore than 1.5 mm creepback from scribes placed longitudinally along the tubing. No other loss of adhesion will be evident after testing. 4.3.2.2 Type 3 Tubing At least 2 samples representative of Type 3 production tubing will be conditioned at -40C for a minimum of 4 hrs prior to performing gravelome
18、ter testing per SAE J400 using 5 pints of gravel. Tubing should be impacted with gravel within 30 seconds of removal from freezer. Within 24 hr of gravelometer exposure, the specimens will be placed in salt spray per ASTM B 117 for 2000 hr. April 2008 Page 2 of 5 NUMBER: TITLE: REVISION TMS-1045 Cor
19、rosion Resistant Steel Tubing J This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2008 International Truck and Engine Corporati
20、on 4.3.2.2.1 RequirementsTested samples will show no red rust in non-gravel impacted areas; red rust is allowed up to 1 mm from impacted areas. No peeling or delamination (i.e., splitting or separation of the nylon into layers) of coating is allowed after testing. 4.3.3 Cyclic Corrosion Testing4.3.3
21、.1 Type 2 Tubing Type 2 tubing assemblies (at least 3 production-representative samples) will be subjected to 80 cycles cyclic corrosion testing per SAE J2334 or 10 cycles of GM9505P (Cycle J). 4.3.3.1.1 Requirements After testing, the assemblies will be capable of meeting a 20.7 MPa (3000 psi) burs
22、t pressure check. 4.3.3.2 Type 3 Tubing Before testing, make parallel cuts 2.4 mm apart and 4 cm long longitudinal to the tube. The cuts must be deep enough to expose the underlying steel substrate. Within 24 hr of scribing, perform cyclic corrosion testing on at least 3 production-representative tu
23、be assemblies per GM9505P (Cycle J) for 10 cycles. 4.3.3.2.1 RequirementsThe tested assemblies must be capable of meeting a 20.7 MPa (3000 psi) burst pressure check. Also, the polyamide coating shall show no peeling, lifting, or delamination; red rust is allowed only at knife cuts. 4.3.4 Fluid Resis
24、tance Testing 4.3.4.1 Type 2 Tubing Tubing samples will be immersed for 24 hr in DOT 3 brake fluid, diesel fuel, biodiesel, automotive fuel, E85, battery acid, and power steering fluid. 4.3.4.1.1 RequirementsAfter testing, tubing shall show no softening or film defects. 4.3.4.2 Type 3 Tubing Two par
25、allel cuts along the entire length of the tube and spaced 2.4 mm apart will be made through the nylon, exposing the steel substrate. Place six samples per fluid in a sealable container, and fill each jar with the test fluids (same as for Type 2 above) such that about half of each sample is submerged
26、 in the test fluid. Seal the container and soak the samples at 23C (73F) for 504 hr brake fluid test temperature will be 60C (140F). After the required soak time, remove the samples and dry them with a paper towel. Using a utility knife, make a perpendicular cut between the two parallel cuts near th
27、e end of the sample (which was submerged). With the edge of the blade in the cut, try to lift up or peel back the nylon strip and grab with pliers. Peel until either the section breaks, or the section is removed from the length of the tube. 4.3.4.2.1 Requirements There shall be no evidence of bliste
28、ring or delamination of the nylon prior to the described coating separation procedure. After the coating separation procedure, the sample is considered acceptable if the nylon strip breaks. If it does not break, the strip must show cohesive failure of the primer (i.e., visible evidence that the prim
29、er remains on the nylon strip and tube substrate). 4.4 Dimensional Tolerances Finished tube assemblies will conform to specified centerline length with the tolerance shown below. April 2008 Page 3 of 5 NUMBER: TITLE: REVISION TMS-1045 Corrosion Resistant Steel Tubing J This document is restricted an
30、d may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2008 International Truck and Engine Corporation Tube Length Tolerancemm (inches) mm (inch) 0 - 305 0 to 12
31、3.0 0.118 306 - 610 over 12 to 24 3.3 0.130 611 - 915 over 24 to 36 4.8 0.189 916 -1525 over 36 to 60 6.3 0.250 1526-2134 over 60 to 84 9.7 0.382 2135-3050 over 84 to 120 12.7 0.500 over 3051 over 120 12.7 0.500 5.0 QUALITY 5.1 Quality Control PlanA Quality Control Plan for this product may be estab
32、lished by mutual agreement between International and the supplier. KCC requirements may be specified on the engineering drawing as required, and will be included in the quality control plan for management by statistical process control. The following is an example of KCC requirements which may be sp
33、ecified on the drawing.* KCC1. Length, overall length (the shortest straight line distance end to end). * See Engineering Design Standard A-16 5.2 Finished Appearance and QualityParts and assemblies supplied to the requirements of this specification shall be free of rust, stains, oil, dirt, metal ch
34、ips, grease, sharp edges, etc., and shall be clean and dry to the touch. The coating shall be uniform and consistent in color, and free from discontinuities, abnormal roughness, chipping, flaking, or loss of adhesion. Type 3 tubing will be supplied as black in color, unless otherwise specified. 5.2.
35、1 Cleanliness Requirements Tubing used for hydraulic brake lines will have internal cleanliness conforming to 0.20 g/m2of internal surface when determined by ASTM A 254, Section 8. Tube ends shall be capped to prevent contamination in shipping and handling. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.
36、1 Supplier Requirements All suppliers to International Truck and Engine are required to be registered to ISO 9001 Quality System Requirements. International will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation
37、and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their International Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification sha
38、ll be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are requi
39、red, the supplier shall notify Truck Development and Technology Center and International Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this April 2008 Page 4 of 5 NUMBER: TITLE: REVISION TMS-1045 Corrosion Resistant Steel Tubin
40、g J This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2008 International Truck and Engine Corporation specification, test sampl
41、es, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS
42、-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the plant metallurgist and/or the quality control manager of the using International plant may d
43、etermine testing and reporting requirements on specific products. 7.0 SHIPPING AND IDENTIFICATION Loading, packaging, and identification shall be in accordance with Manufacturing Std. D-13. 8.0 DESIGNATION ON DRAWINGS Example: Steel Tubing, Type 2, per TMS-1045 9.0 CONTACT INFORMATION For further in
44、formation related to the technical content of this specification, contact: Suppliers may obtain controlled copies of this specification by contacting: Materials Engineering and Technology Dept. Truck Development and Technology Center 2911 Meyer Road Fort Wayne, IN 46803 E-mail: MaterialsEngineeringN Information Handling Service (IHS) 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/April 2008 Page 5 of 5
