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. 2013 by Navistar, Inc. AUGUST 2013 Page 1 of 5 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER:
2、TMS-1068 srr TITLE: Bellows Flexible Pipe CURRENT REV No.: 1308 DATE: August 2013 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. 0812 December 2008 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazar
3、dous 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 to use. Change Notice:
4、Added section 7.1; editorial changes. Reference: 07 Keywords: Exhaust Pipe; Flexible Pipe/Hose; Bellows 1.0 APPLICATION This specification covers two types of bellows (flexible steel pipe) used for making connections between pipes used in the exhaust system. Each application needs to be developed on
5、 a case by case basis due to the differences in displacement and/or vibrations in the different vehicle/application/location. The bellows described in this document is to be used when raw fuel is present in the exhaust gas traveling through the piping, or when spiral wound flex (TMS-1050) cannot mee
6、t the leak rate required by the engine/aftertreatment provider. Spiral wound flex per TMS-1050 may be used if it is after the treatment areas (DOC, DPF, SCR) of the exhaust system or there is no raw fuel or other reactant present in the exhaust gas at that point. 2.0 SCOPE This specification covers
7、requirements for the material, construction, dimensions, quality, leakage, installation, design guidance, source approval and quality control, for both types of bellows. TYPE I is meant to be used in high temperature applications as the liner insulates the bellows from the exhaust gas heat, or to ac
8、t as a dual wall pipe to insulate surrounding components from the exhaust heat. TYPE I - Bellows with inner liner TYPE II - Bellows only Additional qualifiers: A Materials Engineering and Aftertreatment Engineering group must provide written approval prior to use of alternate materials. Aftertreatme
9、nt Engineering may make modifications to the material requirements when application guidelines from Engine Manufacturers dictate. All vendor prints must indicate all material types and specifications comprising a bellows assembly. 4.2 Construction Bellows shall be constructed of a series of corrugat
10、ions that allow flexibility, so as to require a maximum pulling force of 35 pounds to achieve an extension of 15% from the nominal length. Extension shall be 2.5 in/ft minimum from the compressed position. The end treatment of the bellows should be designed for welding or attachment to pipes with cl
11、amps based on TMS 1058, Figure 5B. Both ends shall have all burrs removed. 4.3 Leakage Rate Maximum leakage rate of bellows in the designed to position shall be less than 0.01 standard cubic feet of air per minute at 10 psig. 4.4 Dimensions Bore Diameter - Type I this only applies to the interface a
12、rea between the pipe and the bellows. NUMBER: TMS-1068 TITLE Bellows Flexible Pipe REVISION: 1308 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. 2013 by
13、 Navistar, Inc. AUGUST 2013 Page 3 of 5 4.5 Length - applies to both Type I and Type II There is no rule of thumb for the proper length for bellows as there is with spiral wound flex pipe. The required length for a design will depend on how much movement is necessary, and the vibration loads from th
14、e engine. Packaging also plays a role in the length. The supplier will need to determine the length of the bellows based on their design (number height and size of ribs/corrugations). Nominal length is the non-stressed length or free length of the bellows. 4.6 Installation Install bellows such that
15、it is at its nominal or non-stressed state. The inlet and outlet of the bellows should be in a straight line when installed in the vehicle. 4.6.1 Flow Direction The flex hose shall be installed in the truck exhaust system in such a manner that the flow direction label on the hose is aligned with the
16、 direction of the exhaust gas flow. 4.6.1.1 Flow Direction Labeling Type I bellows construction having an inner liner may have a preferential direction of gas flow through the bellows. The bellows shall be marked on the outside of the bellows to indicate the preferred direction of flow. The method o
17、f marking and frequency of the markings shall be agreed upon between Engineering, the Quality Department of the receiving NAVISTAR Plant(s), and the supplier. Upon agreement, no changes in the marking procedure/process will be made without the prior approval of Engineering and the Plant Quality Depa
18、rtment(s). An example of an approved marking is shown in Figure 1. NAVISTAR engineering assembly drawings should specify the flow direction when this type of bellows is used in the assembly. 4.7 Welding bellows to pipe 4.7.1 Weld Quality 4.7.1.1 Appearance Welds should be smooth, continuous, and enc
19、ompass the entire flex hose-to-pipe joint. Start and stop points, which create stress risers in the bellows assembly which could lead to premature failure, are prohibited. Welds and surrounding areas should be free of excessive weld spatter and/or heat damage. 4.7.1.2 Leak Rate The total leak rate f
20、or the welded assembly should not exceed the leak rate of just the flex hose as specified in Section 4.3. In other words, the weld should be airtight at the pressure specified in Section 4.3. 4.7.1.3 Engagement/Overlap For welded assemblies, the overlap of the bellows to the pipe should match what t
21、he supplier specifies for each application. Also, NAVISTAR recommends the use of a sacrificial weld ring due to the thin wall of the bellows. Flow Direction Bellows Flex Liner Figure 1 NUMBER: TMS-1068 TITLE Bellows Flexible Pipe REVISION: 1308 This document is restricted and may not be sent outside
22、 Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2013 by Navistar, Inc. AUGUST 2013 Page 4 of 5 4.7.1.4 Filler Metal Use of weld filler metals as described in Table XV in CEMS A-37 Appendix is highly recommend
23、ed for welding various combinations of stainless steel and low carbon steel. CAUTION - Weldability: Currently, welding of bellows to pipe is acceptable as long as a weld ring is part of the bellows assembly. Due to the thin material needed for the formation of bellows tube, the addition of a weld ri
24、ng is recommended that brings the thickness of all parts being welded to at least the thickness of the pipe. 5.0 QUALITY Bellows shall be clean and free from chips, burrs, slivers, nicks, and gouges. Ends shall be deburred on the inside and outside of the bellows. 5.1 KCC - Key Control Characteristi
25、cs In accordance with Engineering Design Standard A-16, Engineering may designate certain features as key characteristics for which management by statistical process control is mandatory. The following features are designated Key Control Characteristics for bellows supplied to the requirements of th
26、e specification. 1. ID sizing per TMS-1058 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all A
27、IAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or p
28、urchase orders citing this specification shall 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,
29、 color, or labeling of the product are required, the supplier shall notify Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety
30、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 both perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence o
31、f 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 quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. NUMBER: TMS-1068 TITL
32、E Bellows Flexible Pipe REVISION: 1308 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. 2013 by Navistar, Inc. AUGUST 2013 Page 5 of 5 7.0 SHIPPING, PACKI
33、NG AND IDENTIFICATION Consideration in packaging must be given to preventing compression or extension of the bellows pipes from their nominal lengths during transportation. It may be necessary to cap ends during shipment to keep the inside clean. Loading, packing and identification shall be in accor
34、dance with Manufacturing Std. MS-D-13, unless otherwise specified. 7.1 Part Identification All pipe assemblies shall be clearly marked with part number and manufacture date (Julian format or Month/Year). Approved methods of marking is stamped (either Roll or Pin), etched, barcode labels. The part nu
35、mber and date shall be clearly visible on the final assembly. No markings shall be made on mating surfaces. No markings shall be made in joint areas or weld areas. Insulating wraps shall not hide the part number. Unless part number location is specified on the drawing; the recommended minimum distan
36、ce from mating surfaces and joints is 10 mm. The part number and Julian date can be placed either along the centerline or perpendicular to the centerline as needed to meet the above criteria for clearance to mating surfaces. Height of lettering shall be within the following range: 3.175mm (0.125”) t
37、o 7.9mm (0.3125”). Where the assembly uses foil insulating wraps, the part number and manufacture date can be applied to the foil surface using a label or indelible ink stamp in addition to the above methods. Where a sock type insulation is used; the part number and manufacture date shall be at the
38、inlet end of the pipe and the sock will be secured such that it can be rolled back to reveal the part number. Supplier recommended alternatives for part identification must reviewed and be approved by Navistar Engineering. 8.0 DESIGNATION ON DRAWING The drawing shall indicate the type of bellows to
39、be used depending upon the method of clamping selected. Example: TMS-1068, Type IA Drawings should specify flow direction when flex pipe is used in the assembly. All drawings specifying TMS-1068 bellows should include a note in the body of the drawing: “Bellows and welded assemblies will meet the qu
40、ality and performance requirements per TMS-1068.” 9.0 APPROVED SOURCES Witzenmann Senior Flexonics Division 10.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Ave. Melrose Park, IL 60160 E-mail: MaterialsEngineeringN HIS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/
