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. 2011 by Navistar, Inc. APRIL 2011 Page 1 of 5 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: T
2、MS-6612 srr TITLE: Insulation, Acoustic CURRENT REV No.: 1104 DATE: April 2011 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev 1006 June 2010 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous mat
3、erials, 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: Clarific
4、ation to sound absorption test method Section 4.3.10.2; Added new 3M E-A-R foam and Thinsulate products to Approved Sources, Section 9.0; editorial changes. Reference: File: 30-10 Keywords: Insulation, sound deadening insulation, acoustical insulation 1.0 APPLICATION This material specification outl
5、ines the requirements for under hood acoustical insulation requiring high sound absorptive characteristics. The NAVISTAR Truck Development and Technology Center, Vehicle Acoustics Group must approve material supplied for acoustical applications. Various grades are specified for Type I and/or Type II
6、 requirements for certain thermal environments or operating conditions. Grade 1 Material is a composite blend of synthetic and natural fibers, recommended when under hood temperatures are above 275F. Grade 2 Material is made from polyester fiber and is recommended when under hood temperatures are be
7、low 275F. Grade 3 Material is made from polyether urethane acoustic foam, which may be composited with facing materials. It is recommended when under hood temperatures are below 225F. Specially designed Grade 3 foam composites with facings may be used for under hood temperatures above 275F as long a
8、s the composite does not come into direct contact with the heat source. Grade 4 Material is made from a combination of polypropylene micro fibers and polyester staple fibers. It is designed for use in environments where the operating temperature is less than 250F. 2.0 SCOPE This specification covers
9、 the general requirements, property and performance requirements, quality and inspection tests. An approved source list is included. 2.1 When no Grade is specified on the print, Grade 1 material will be provided. 2.2 If insulating performance is affected by orientation, the attachment side must be i
10、dentified. 2.3 Restricted Chemical Substances Effective JANUARY 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of CEMS B-50. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The fol
11、lowing Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CFR 29, Part 1910 ASTM D 1117 NAVISTAR CEMS B-50 CFR 49, Part 571.302 ASTM D 3574 NUMBER: TMS-6612 TITLE: Insulation, Acoustic REVISION: 1104 This document is restrict
12、ed and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. APRIL 2011 Page 2 of 5 NAVISTAR Manufacturing Std. MS-D-13 SAE J1352 ASTM E 1050 NAVISTAR Eng. Design Std.
13、A-16 ASTM D 461 CEMS DT-13 NAVISTAR TMS-6505 ASTM D 751 4.0 REQUIREMENTS 4.1 Composition 4.1.1 Foam The basic foam shall be acoustical grade (Grade 3) polyether urethane foam. This may be combined with chemically bonded facing materials and/or pressure sensitive adhesives to provide enhanced perform
14、ance characteristics and simplified installation. 4.1.2 Fiber The basic fiber shall be either Grade 1 or Grade 2. This insulation material shall be encased within a scrim material that will be designed to help hold the fibers together and provide a surface for mounting or shall have treated surfaces
15、 that bind the fibers sufficiently to provide an adequate mounting surface. The insulation fibers shall contain 18-22% by weight of a non-water soluble resin (Grade 1) or shall have an appropriate blend of staple and binding fibers to achieve the performance requirements as outlined in this specific
16、ation (Grade 2). 4.1.3 Micro Fiber/Staple Fiber Material Combination materials are comprised of polypropylene micro fibers and polyester staple fibers. Standard combinations may be 50/50 polypropylene/polyester. Scrims comprised of polypropylene or polyester may be used as facing to provide addition
17、al strength or abrasion resistance. 4.2 Dimensions Thickness of the material shall be indicated on the engineering drawing. 4.2.1 Dimensional Tolerances * (Grade 3 only) Grade 3 material will meet length and width tolerances indicated in the Table below. The thickness tolerance for Grade 3 materials
18、 will be 10%. Width and Length (Inches) Tolerance Width and Length (Inches) Tolerance 0.0 6.0 0.12 6.1 12.0 0.2 12.1 24.0 0.2 24.1 36.0 0.3 36.0 0.5 *This table supersedes the standard blueprint tolerances for Grade 3 materials 4.2.2 Dimensional Tolerances (Grade 4 only) Grade 4 materials will meet
19、the length, width and thickness tolerances as defined on the engineering drawings. 4.3 Property and Performance Requirements 4.3.1 Density 4.3.1.1 Method: ASTM D 1117, Sample 30 x 30 cm (12 x 12 in). 4.3.1.2 Required: Report density value. 4.3.2 Tensile Strength (Grades 1 and 2 only) 4.3.2.1 Method:
20、 Test 5 samples in machine direction (MD) and five samples in counter machine direction (CMD) per ASTM D 751 4.3.2.2 Required: 4.3.2.2.1 Insulation MD 50 lbs and CMD 35 lbs. 4.3.2.2.2 Cover (if applicable) MD 22 lbs and CMD 9 lbs. NUMBER: TMS-6612 TITLE: Insulation, Acoustic REVISION: 1104 This docu
21、ment 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. 2011 by Navistar, Inc. APRIL 2011 Page 3 of 5 4.3.3 Elongation of Scrim (if applicable) 4.3.3.1 Method: Test 5 sam
22、ples MD and five samples CMD per ASTM D 751 4.3.3.2 Required: MD 10% and CMD 30% 4.3.4 Humidity Resistance 4.3.4.1 Method: Expose samples for one week in a humidity chamber at 38C (100F) at 100% relative humidity. 4.3.4.2 Required: The material shall not exhibit visible signs of delamination or warp
23、ing. Also there shall be no visible evidence of mildew and/or any objectionable odor. 4.3.5 Chemical Resistance 4.3.5.1 Method: Immerse specimens into the indicated reagent fluids for four hours. Use a separate specimen for each reagent. 4.3.5.1.1 Reagent fluids are: (1) 5% Salt Solution; (2) 15W-40
24、 Engine Oil; (3) Texaco Extended Life Coolant; (4) Power Steering Fluid; (5) Window Washer Solvent (50% methanol with water); (6) DOT 3 Brake Fluid; (7) Dexron III Automatic Transmission Fluid. 4.3.5.2 Required: Specimens will not dissolve, delaminate or exhibit other objectionable characteristics.
25、4.3.6 Cyclic Aging 4.3.6.1 Method: Subject 3 parts or plaques to the aging cycle below. 4.3.6.1.1 24 hours at 38C (100F) and 100% relative humidity 4.3.6.1.2 24 hours at 121C (250F) 4.3.6.1.3 Cool at room temperature for one hour 4.3.6.1.4 24 hours at -40C (-40F) 4.3.6.1.5 24 hours at 38C (100F) and
26、 100% relative humidity 4.3.6.1.6 7 days at 93C (200F) 4.3.6.1.7 Cool at room temperature for one hour 4.3.6.2 Required: Parts shall be exposed for one cycle and shall not exhibit any delamination, warping, shrinking, or distortion. 4.3.7 Odor Shall be inoffensive both wet and dry. 4.3.8 Air Flow Re
27、sistance (Grade 1 and 2 only) 4.3.8.1 Method: Using a 30 x 30 cm (12 x 12 in) sample, direct a stream of air towards the samples center at an angle of 45, using 620-690 kPa (90-100 psi) air. The air nozzle shall have an opening of 2.16-2.41 mm (.085-.090 in) and shall be held 10 cm (4 in) above the
28、surface for a min of 20 seconds. 4.3.8.2 Required: No visible delamination or separation when tested in two directions 180 apart. 4.3.9 Mildew Resistance 4.3.9.1 Method: Saturate a two inch square of material and place in a sealed plastic bag. Expose the sample for 350 hours in a humidity cabinet se
29、t at 100F and 95% 5% humidity. 4.3.9.2 Required: Shall not exhibit any mildew growth or associated odor. 4.3.10 Sound Absorption Properties 4.3.10.1 Method: Test in accordance with ASTM E1050. 4.3.10.2 Sample Preparation: Test sample/assembly shall include scrim if applicable and be of equivalent co
30、mposition as intended for production. The scrim is to face the sound source with no air NUMBER: TMS-6612 TITLE: Insulation, Acoustic REVISION: 1104 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers ar
31、e required to assume all patent liability. 2011 by Navistar, Inc. APRIL 2011 Page 4 of 5 gap between the sample/assembly and the back plate. Samples shall not be adhered (by adhesive or tape) to the back plate, regardless of intended in-situ attachment method. 4.3.10.3 Sample Size: Material shall be
32、 acquired from a minimum of three manufacturing lots for final validation, with at least three sample sets from each lot. 4.3.10.4 Required: Shall meet the following minimum requirements for absorption coefficients. Shall also report density, thickness, and composition of test sample/assembly. 4.3.1
33、0.4.1 Type I: Normal-incidence absorption will be measured at 500, 630, 800, 1000, 1250, 1600, 2000, 2500, 3150, and 4000 Hz. The normal-incidence absorption coefficient at any one frequency shall not be less than 0.40 and the average of the absorption coefficients shall not be less than 0.70. 4.3.1
34、0.4.2 Type II: Normal-incidence absorption will be measured at 1250, 1600, 2000, 2500, 3150, and 4000 Hz. The normal-incidence absorption coefficient at any one frequency shall not be less than 0.60 and the average absorption coefficients shall not be less than 0.75. 4.3.10.4.3 Type III: Normal-inci
35、dence absorption will be measured at 1250, 1600, 2000, 2500, 3150, and 4000 Hz. The normal-incidence absorption coefficient at any one frequency shall not be less than 0.70 and the average of the absorption coefficients shall not be less that 0.85. 4.3.11 Constant Deflection Compression (Grade 3 onl
36、y) 4.3.11.1 Method: ASTM D 3574 Method D (50% Deflection) 4.3.11.2 Required: 40% maximum set 5.0 QUALITY This material shall have necessary flexibility to meet contour requirements without separation, and be free from defects. Defect definitions shall be established by mutual agreement between NAVIS
37、TAR and the supplier. 5.1 Quality Control Plan A Quality Control Plan for this product will be established by mutual agreement between NAVISTAR and the supplier. Unless specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features for manage
38、ment by statistical process control.* Density and One Critical Dimension if Applicable * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. Density and thickness are not designated as KCCs for Grade 3 materials because they are
39、composites. One KCC, length or width, will be required for Grade 3 materials unless otherwise agreed upon by both NAVISTAR and the supplier. * See Engineering Design Standard A-16. 5.1.1 The quality control plan will include periodic evaluation of sound transmission losses as applicable. 6.0 SOURCE
40、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 AIAG PPAP (Production Part Approval Process) documentat
41、ion 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. NUMBER: TMS-6612 TITLE: Insulation, Acoustic REVISION: 1104 This document is restricted and may not be s
42、ent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. APRIL 2011 Page 5 of 5 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equ
43、ivalent 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 required, the
44、supplier shall notify Materials Engineering at NAVISTAR Truck Development and Technology Center (TDTC) 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 S
45、afety 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-16949 guidelines, or provide statistical ev
46、idence 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 NAVISTAR plant may determine testing and reporting requirements on sp
47、ecific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing, and identification shall be in accordance with Manufacturing Std. MS-D-13. 8.0 DESIGNATION ON DRAWINGS Drawing shall designate the thickness required (1/4”, 3/8”, etc.). Example: Material per TMS-6612, Grade 1, Type III, 35
48、mm thickness NOTE: Drawings specifying TMS-6612 without indicating Grade designation shall meet Grade 3, Type I requirements. Drawings with no Type designation shall meet Type I requirements. 9.0 APPROVED SOURCES Grade 1, Type III CTA Acoustics, Inc. (34 mm QuietBlend, 36 kg/m3 , non-woven scrim: 90 g/m2) Grade 2, Type I Owens Corning (VersaMat 2000, 36.5mm PET, 34.8 kg/m3; scrim: Polyester/Rayon scrim, 0.4mm) Grade 3, Type I 3M E-A-R Specialty Composites (E112SF, E112PSM, M100PSM) Grade 3, Type II 3M E-A-R
