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Die Block Casting Specifications模块铸造说明GENERAL:综述：All die blocks must have sufficient stock allowance for machining .Tolerances for as cast surfaces to be per SFSA standard. Supplier will be responsible for verifying the dimensions from the drawing with the patterns supplied by Kokomo Casting Plant prior to manufacturing the blocks.所有的模块必须具有足够的库存定额供加工生产。铸态表面公差可参考SFSA标准。供应商在制造生产那些模块前将负责核查Kokomo铸造厂提供的模型及图纸的尺寸规格。Castings, which do not meet the quality requirements, specified in this specification, after machining, subsequent to its acceptance at the die builder, will be subjected for rejection. The supplier shall be responsible for the machining labor, cost for transportation, and replacement of the rejected die blocks.那些不能达到这份说明所指定的要求的铸件，在加工生产后送交铸模建造商接收鉴定，之后将被退货。供应商将负责提供生产人员，运输成本和替换铸块。Supplier to be responsible for the up-keep of patterns while they are at the suppliers facility. Supplier is required to notify Chrysler Purchasing in Detroit when the patterns need to be repaired or replaced.供应商将负责维护那些还在其生产设备里的模型。当那些模型需要修理或报废时，供应商被要求通知底特律的克莱斯勒采购。Approval for salvage of cast blocks must be obtained from the Kokomo Tool Engineering Department prior to welding or repair. All die blocks will be stress relieved or quenched and tempered after welding, and the final hardness must be within the specified range.在对模块进行焊接和修复前，维修经费的许可必须经由Kokomo设备工程部门审批。所有的模块在焊接之后必须去除应力或淬火和回火，并且最后的硬度必须在规定的范围内。Die blocks must have manufacturers logo, serial number, and the cast dates, cast on the non-machining surface as specified on the drawing. Casting drawings indicate an area for such information; however this is a suggested area only. The foundry using the following considerations can determine the actual location.模块上必须有制造商的商标，序列号以及铸造日期等信息，浇铸在图纸指定的非加工面上。铸件图纸给出了这样一个信息区域，但这只是一个供参考的区域而已。铸造厂可根据下面的建议来确定实际的位置。a. Must be located in a non-machined area.b. Should be visible, with die in the die cast machine.c. Serial number may be neatly engraved, stamped or cast.(If In Doubt Contact Tool Engineer For Assistance)a. 必须位于非加工区域上。b. 必须可见，固定在压铸机上。c. 序列号可整齐地雕刻、印戳或浇铸。（如有疑问，可联系设备工程师以获取帮助）Casting must conform to Chrysler specifications.铸件必须符合克莱斯勒技术规范Leave all handling rings and lugs on casting to aid in trucking castings. These rings and lugs will be removed when handling holes are installed.铸件上应留有搬运用的吊环和吊耳以方便运输，这些吊环和吊耳将会在搬运孔安装后拆除。Casting to be rough machined on the cope side to a flat surface leaving ample stock for finishing.铸件的上模面将被粗加工成一个平面，并且留有足够的余量以便进行精加工。All short line dimensions on casting layouts are taken from datum X=0, Y=0, Z=0.铸件布局上的所有短线尺寸都是以X=0, Y=0, Z=0为基准。Vendor to return patterns to Kokomo Casting Plant in good usable condition upon request.供应商应在Kokomo铸造厂提出要求后归还模型并保证模型处于良好的使用状态。 Phantom lines representing finish-machined surfaces indicate surfaces needing machine stock. Basic guidelines for machine stock requirements:虚线说明表面需要留有加工余量，虚线就代表精加工面的位置。确定加工余量要求的基本准则有：a. .50” stock on all surfaces parallel to the parting line, except cope side of casting. 除铸件上模面之外的所有平行于分型面的表面留50的余量。b. .75” stock on all walls vertical to the parting line. 所有垂直于分型面的壁留75”的余量c. Required drafted areas should favor additional machine stock. 有设计要求的部位应留有额外的加工余量。Pattern and casting certification prints will be provided for pattern and casting layouts.将会提供模型和铸件设计所需的书面证明。MATERIAL & HEAT TREATMENT材料 & 热处理The material to be cast steel per AISI 8620 Type, water quenched and tempered to Brinell hardness between 210 to 250. This harness is required on the finished-machined surfaces of the die block.材料应是符合AISI 8620类型的铸钢，水淬和回火后使其达到210250的布氏硬度，模块精加工表面必须达到这个硬度。Actual chemical composition will be agreed to by Chrysler and must be based on die block maximum heat treated cross section and desired mechanical properties.实际的化学组成将由克莱斯勒公司商定，并且必须以模块热处理后的最大横截面及要求的机械性能为基础。Vendor to furnish heat treat and material certification.供应商将提供热处理及材料证明。NONDESTRUCTIVE TESTING:无损检测 The casting to be inspected 100% with (A) Magnetic Particle Inspection (Dry), (B) Visual Inspection, (C) Hardness Testing, (D) Magnetic Particle Testing (Wet), (E) Ultrasonic Inspection(optional), (F) Radiographic Inspection (optional),(G) Die Penetrate Inspection in selective area as optional testing methods. Tests shall be performed by an Inspector certified to a minimum level 2 in accordance with the American Society of Nondestructive Testing Guide line #ASNT-TC-1A. 铸件通过以下方式100%：（A）磁粉探伤（干）（B）外观检测（C）硬度测量（D）磁粉检测（湿）（E）超声波检测（F）放射线探伤（G）可选择位置的钢模渗透探伤。测试检查均应执行注册到最低水平2按照美国社会的无损检测指标ASNT-TC-1A号。A MAGNETIC PARTICLE INSPECTION (DRY)A磁粉探伤（干法）The acceptance criteria for magnetic particle testing is as follows:磁粉探伤的验收准则是这样的：TYPE（类型） DEGREE（程度）1. Linear Discontinuities HOT TEARS AND QUENCH(1/4” in length Maximum) CRACKS ARE NOT ALLOWED 线状缺陷 热裂和淬火 最大长度1/4” 不允许有裂纹2. Shrinkage 缩孔 23. Inclusions 杂质 24. Chills & Chaplets 冷隔&芯撑 NONE ALLOWED 不允许5. Porosity 气孔 2 The above represents the MINIMUM ACCEPTABLE quality.上述代表最低可接受的质量要求。A permanent record of the location, direction, and size of all reportable indications to be maintained and available for review upon Chryslers request.永久性的记录的位置、方向和大小,所有报告显示维护与供审查后克莱斯勒的要求。All tests are to be conducted in accordance with ASTM E-709.所有的测试将按照E-709 ASTM管理Acceptability is based on ASTM E-125(reference photographs).可接受性是基于ASTME-125（参照照片)B-VISUAL INSPECTION B-外观检验Visual inspection to be performed after final dry magnetic particle test and in accordance with ASTM A-802 as follows:目测检查后的最终进行干燥磁性颗粒的测试和根据ASTM(美国材料试验协会)A-802如下SURFACE FEATURE表面特征MACHINED已加工UNMACHINED未加工Surface Texture 表面结构A3Non-metallic Inc非金属夹杂物B2B4Gas Porosity气孔C2C3Fusion Discontinuities熔断D2D5Expansion Discontinuities胀裂E3Inserts夹渣NOT ACCEPTABL不可接受METAL REMOVAL MARKS 金属切削标记Thermal Dressing 热抛光 G2Mechanical Dressing机械修光 H3Welds 焊接 J2(THE ABOVE REPRESENTS THE MINIMUM ACCEPTABLE SURFACE QUALITY) 上述代表最低可接受的表面质量C HARDNESS TESTINGC-硬度测试Hardness testing to be performed after final heat treatment and at the surface of below as cast surface. Brinell hardness testing method to be used for testing hardness. Result of all tests must be recorded and sent to Kokomo Casting Plant prior to shipping the die block.硬度测试在执行热处理、铸态表面后进行，用布氏硬度测试方法测试硬度。所有的测试结果必须记录在案,并且送到Kokomo铸造厂。COPE SIDE Four locations 90 degree apart.DRAG SIDE Four locations 90 degree apart.D MAGNETIC PARTICLE INSPECTION(WET)D-磁粉探伤（湿法）Final inspection in the foundry to be a 100% Wet Magnetic Particle Inspection after final heat treatment . The acceptance criteria for this test is as follow:热处理后，铸造在最终检验是一个100%湿磁粉检测，测试验收标准如下：TYPE（类型） DEGREE（程度）1. Linear Discontinuities HOT TEARS AND QUENCH(1/4” in length Maximum) CRACKS ARE NOT ALLOWED 线状缺陷 热裂和淬火 最大长度1/4” 不允许有裂纹2. Shrinkage 缩孔 23. Inclusions 杂质 24. Chills & Chaplets 冷隔&芯撑 NONE ALLOWED 不允许5. Porosity 气孔 2 The above represents the MINMUM ACCEPTABLE quality.上述代表最低可接受的质量A permanent record of the location, direction, and size of all reportable indications to be maintained and available for review upon Chryslers request. 永久性的记录的位置、方向和大小,所有报告显示维护与供审查后克莱斯勒的要求。All tests are to be conducted in accordance with ASTM E-709.所有的测试将按照ASTM(美国材料试验协会) E-709管理。Acceptability is based on ASTM E- 125 (reference photographs).可接受性基于ASTM(美国材料试验协会)E-125(参考照片)E ULTRASONIC INSPECTIONE-超声波探伤Ultrasonic Inspection to be optional, and be per ASTM A-609, with minimum acceptance criteria, level 1, in all areas.超声波检测，可选择ASTM(美国材料试验协会)A-609,适用于各个领域的最低验收标准,一级, The Ultrasonic Inspection will be performed after final heat treatment with the cope surface rough machined to a minimum 250 RMS surface finish.热处理后进行的表面处理的粗加工降到最低250有效值的表面粗糙度，然后执行超声波检测。F RADIOGRAPHIC INSPECTIONF-射线探伤 Radiographic Inspection is optional. If required by Kokomo Casting Plant, the test will be performed using ASTM E 94. ASTM E-124 to be used to control the quality of radiographic process. Interpretation must be in accordance with ASTM E -280 Vol.2 for thickness over 4-1/2”, 4mev to 30mev.放射性探伤是可选的。如果Kokomo铸造厂需要，测试将会按照ASTM E 94 ASTM E-124进行，用以控制放射过程的质量。G DYE PENETRANT INSPEECTIONG-染料渗透检测Dye penetrate inspection is optional and to be performed on machined surface only. If required by Kokomo Casting Plant in selective areas, the test will be performed in accordance with ASTM E-165. Reference photograph form ASTM E-433. 染料渗透检测法是可选的且只能用于加工面，如果Kokomo铸造厂在特定领域有需要，实验将会按照ASTM E-165规定来进行。参照图来自ASTM E-433。SUPPLEMENTAL TESTS扩展试验Tensile Test 拉伸试验Tensile tests, if required by Kokomo Casting Plant, will be performed as follow:拉伸试验，如果Kokomo铸造厂需要，将按照下面的说明进行：Minimum mechanical properties will be mutually agreed upon. Keel block separately cast to be measured by the formula: “T x T x 6” (T=Thickness). Results of test bar as well as transverse hardness will be take at 1/2” (inch) increments at T/4 and T/2 and shall be recorded and forward to Chrysler Kokomo Casting Plant prior to shipment. 最低的机械性能可互相约定。单独铸造的铸锭可根据公式“T x T x 6（T=厚度）”来测定。测试棒的结果和横向硬度一样占据1/2英寸，增量在T/4和T/2之间。装运前应记录试验结果并提交克莱斯勒Kokomo铸造厂。UPGRADING升级Repair welds are considered MAJOR, when the depth of the cavity exceeds one (1”) inch or 20% of the casting cross section, whichever is less. Or the area exceeds 20 square inches. Repair welds not exceeding these limitations are considered MINOR.当凹腔的深度超过一英寸或超过铸件横截面的20%时，无论哪种情况都是过小了的，这时修补焊接是重要的。或者面积超过20平方英寸。补焊点不超过这些限制可认为是次要的。All cracks or other defects will be chipped or arc-aired to sound bright metal and magnetic particle inspected in accordance with ASTM E-709 to insure complete defect removal prior to welding. Weld area to be free of all dirt, grease, chops, etc., to prevent weld contamination.所有的裂纹或其他缺陷应去除以便测量光洁的金属，在焊接前应按照ASTM E-709来进行磁粉检测以确保完全去除缺陷，焊接区域应避免污垢、油脂、切屑等以防止焊接污染。All major weld repairs must be done prior to final quench and temper heat treatment using heat treatable electrodes.所有主要的焊接修补要使用可热处理的电焊条，并且在最终的淬火和回火热处理前进行。Chrysler (Kokomo Casting Plant) reserves the option to approve major weld repair.克莱斯勒（Kokomo铸造厂）保留核准焊接修补的选择权。Welding process焊接工艺All welding to be performed by qualified person in accordance to ASTM A-488. All welding procedures shall be qualified in accordance with ASTM A-488.所有的焊接都由符合ASTM A-488规定的专业人员来执行。所有的焊接流程都应该根据ASTM A-488规定来进行。Repair welding will be by the Manual Arc (coated electrode) and/or the Carbon Dioxide Shielded Flux Core Wire Processes.补焊可用人工电弧焊（涂剂焊条）或采用二氧化碳屏蔽气流保护焊条芯工艺。Filler Metal熔填金属Prior to final quench and temper heat treatment, major or minor repair welding will be done by either the Manual Arc Process or the Co2 Shielded Flux Core Wire Process as outlined in applicable approved weld procedures, using heat treatable electrodes.大小补焊通过采用可热处理的电焊条和在可适用核准焊接流程里论述到的人工电弧焊工艺或者二氧化碳屏蔽气流保护焊条芯工艺，在最终的淬火和回火热处理前进行。After final quench and temper heat treatment, minor repair welding to be done by either the Manual Arc Process or the Co2 shielded Flux Core Wire Process as outlined in applicable approved weld procedures. Filler metal selection will be based on matching the hardness of the parent metal.小的补焊采用在可适用核准焊接流程里论述到的人工电弧焊工艺或者二氧化碳屏蔽气流保护焊条芯工艺，在最终的淬火和回火热处理后进行。熔填金属的选用应该基于与母材硬度匹配的原则。Moisture must be controlled on low hydrogen type electrodes per manufacturer specifications.按照厂商的技术规范，湿度必须控制在低氢型焊条要求的条件以下。Minimum pre-heat must be per applicable approved weld procedures.最低限度的预热必须符合可适用核准焊接流程要求。When required, welding by the Manual Arc Process must be in any position consistent with the qualified weld procedure. Position for welding will be suitable for the electrode being used. Welding by the Co2 shielded Flux Core Wire Process must be in the flat position only.当需要时，采用手工电弧焊工艺的焊接在任何位置都要按照规范的焊接流程来进行。焊接位置应适合使用电焊条。采用二氧化碳屏蔽气流保护焊条芯工艺的焊接只能在平整的位置使用。Immediately after repair welding, casting (die block) must be heat-treated and/or stress relieved per quality welding procedures. 修复焊接之后，按照焊接质量流程，铸件（模块）必须立即进行热处理并且/或者消除应力。Inspection检测Repair welded areas will be ground smooth to bright sound metal, dry and magnetic particle inspected after post-weld heat treatment in accordance with ASTM E-709 and ASTM E-125. 修补焊接区域将被打磨成光亮平滑的金属，焊后热处理完成后，干法磁粉检测按照ASTM E-709 和 ASTM E-125技术规范进行。DOCUMENTATION文件材料The following certification must be required unless waived by Chrysler at Kokomo Casting Plant: 以下证明是必备的，除非克莱斯勒Kokomo铸造厂放弃不用。* Chemistry 化学成分* Hardness 硬度* Heat Treat Records (charts) 热处理记录（图表形式）* Tempering Temperature 回火温度* Final Wet or Dry MPI Results 最终湿度和干燥度的平均结果* Weld Maps 焊接示意图* Tensile Test Results (optional) 拉伸测试结果（可选）* Ultrasonic Report (optional) 超声波检测报告（可选）* Radiographic Report (optional) 射线图报告（可选）Standard Die Cast Die Build Specification标准的压铸磨具建造规范1. Vendor will be responsible for producing the tools within the dimensional tolerances indicated on the tool drawings. Vendor to assume all monetary cost to make corrections to tool as required in bringing tool within drawing specifications and dimensions. 供应商将负责生产符合设备图纸所要求的尺寸公差的设备。根据图纸规格和尺寸要求对设备进行修改而产生的一切成本费用将由供应商承担。2. Vendor will be responsible at time of delivery as to agreement of drawings to finished tool. Tool Engineering must approve any deviation from tool drawings during construction. If approved, marked-up prints must be furnished showing dimensional deviations to Tool Engineering Department, prior to shipping the tool.供应商将负责在图纸协议规定的交货时间前制造出设备。设备工程师必须核准一切跟设备图纸有出入的误差。如果已通过核准，则必须在装运设备前把更改后且标有尺寸差异的纸质文档提交给设备工程部门。3. Vendor will be liable for the monetary cost to correct tool drawings and tools built, if they fail to comply to Items 1 & 2 above. 供应商如果违反上面第1、2条规定，那么他们将承担修改设备图纸和制造设备所产生的费用。4. The below items belong to Kokomo Casting Plant upon completion. 完工后以下物品属于Kokomo铸造厂所有a) All Layouts and Drawings. 所有的设计和图纸b) All Styles of Electrodes 所有电焊条的类型c) All NC Toll Paths (E.D.M & CNC)d) All Templates 所有的模板e) All Patterns and Model 所有的复制品和模型All tooling aids made by vendor to construct the tool shall be considered the property of Kokomo Casting Plant. All tool aids to be identified as such, with drawing and detail number stamped on each article. These items shall be called out in the design and sent to KCP upon completion of purchase order. Vendor shall deliver all equipment in goof usable condition to latest engineering change.所有供应商生产的用于建造设备的安装辅助设备都应当被确定为Kokomo铸造厂的财产。同样地，所有的工具辅助设备，通过把图纸和具体数量列在每一条款的方式，都应当被确定下来。这些条款在设计中将会被罗列出来，并且在完成采购订单前提交到Kokomo铸造厂。供应商应递交所有使用状况良好的器材及其最新的工程变更。5. Vendors to stress relieve all die blocks.供应商应对所有模块进行应力去除。6. Vendor must follow the procedure for welding of steel, if in the event welding is needed. Listed are steel types H-13, 4130, 4140, 6150, 8620, 8640 and O1. The procedures below shall be followed:在需要焊接的情况下，供应商必须遵守钢制品的焊接流程。所登记的是钢材的类型：H-13，4130，4140，6150，8620，8640 和 O1。以下的流程必须遵守：a) Vendor must first obtain approval in writing from Kokomo Casting Plant Tool Engineering Department prior to any welding.供应商在进行任何焊接之前必须先获得Kokomo铸造厂设备工程部门的书面批准。b) Vendor to follow the weld specification called out on the cover letter. 供应商应遵循封面文字所列出的焊接说明。7. H-13 DETAILSH-13的详细说明a) All materials will be supplied by vendor and shall be new.所有的材料将由供应商提供并且应该是新的。b) Vendor to furnish steel certification for all details, excluding standard commercial items and details fabricated from pre-hardened material. (Annealed or non-annealed)供应商应提供钢材鉴定的所有细节，但不包括标准的商业条例和预硬材料（退火的或非退火的）的组装细节。c) The Tool Builder shall supply KCP with a certificate of analysis from the Steel Supplier and a small corner section of each block for metallographic examination on heat-treated and not heat-treated details. This section shall be about 1/2” long and 1/4” thick, identified by the die number and detail number, and to be sent to the attention of the Tool and Process Engineering Manager at KCP. These steel samples shall be approved by KCP before the vendor initiates any machining of parent steel. Vendor shall supply another like sample from each piece after heat treat, and these steel samples shall be approved by KCP before the vendor initiates any more machining of parents steel. When ordering steel the Vendor SHALL specify that it is for