DUCTILE-CAST-IRON-GMS0010002-Rev-3爱科英文版球铁标准

CORPORATE STANDARDSGLOBAL ENGINEERINGMATERIAL STANDARDSSUBJECT: Global Ductile Cast Iron Material Standard1. Introduction1.1 ObjectiveTo provide a uniform material standard that covers all ductile cast iron used in AGCO complete machines, attachments, accessories and implements. It facilitates global part sourcing by providing a single AGCO material specification. It ensures that continuous component quality and integrity is maintained.1.2 ScopeThis standard applies to all ductile iron material purchased after the standards effective date. Ductile iron grades previously used by all AGCO Companies were specified by standards identified in Annex C. This new uniform standard is intended to replace the previously used standards.This standard describes five different grades of ductile cast iron, D250, D300, D360, D420 and D480. These grades include one that was specifically developed for applications where local hardening is required, D420. Grade designations are based on the combination of three factors: mechanical properties, hardness and microstructure of the cast product.Standard grades are specified with the prefix “D”; structural grades with prefix “DX”. Structural grades differ only in that they are more tightly controlled and are required to meet, in serial production, the parameters (mechanical properties, microstructure, chemical composition and heat treatment) of the originally qualified casting.1.3 Reference Documents - None1.4 Definitions Ductile Iron a ferrous based material containing free graphite in spheroidal form characterized by a wide range of mechanical properties. It is a moderate to high strength material with medium impact resistance (toughness). Grade Specification - the grade of material shall be specified by use of this standard number followed by the specific grade required, i.e., AGCO GMS0010002 Grade D300. If a specific grade of ductile iron is not listed on the Engineering Drawing, or if there are any other questions with regard to the requirements, the supplier shall contact the ordering facility and request that the engineering drawing be corrected. Other additional suffix letters that may be used are N and QT, as described in Section 2.5 of this standard. Structural Grades Casting grades designated by prefix “DX” (i.e. AGCO GSM0010002 Grade DX360) are structural grades. “DX” castings are subject to engineering qualification that may include dynamic and/or structural testing. Alloy content of “DX” castings shall be controlled within limits subject to agreement and based upon the composition of the qualified product. No process or product changes are permitted on “DX” castings (any casting grade for that matter) without engineering approval. Structural castings shall be purchased only from approved suppliers, based upon the quality approval process of the ordering AGCO facility.2. Technical Requirements2.1 GeneralAll castings shall be marked (i.e. characters cast-on) with the appropriate AGCO part number, foundry identification, pattern number and either the date of manufacture or the heat number of the melt. For very small castings where cast-on marking is impractical, the ordering facility should agree on alternative arrangements that facilitate, as far as practical, means of batch traceability of components. These markings should be either indented or raised (raised is preferred letters “I”, “O” and “X” are not utilized). Location of these markings shall be such that they are not removed by subsequent machining operations and must be identified on the drawings. Machine fixture locations along with special tolerance requirements involved and machine clamping points shall also be shown on the drawing. Other information that should be shown on the casting drawing is: Casting parting line Area(s) where local hardening is to take place Draft angles Location of in-gates, feeders, runners, risers, etc Fettling and dressing requirements Shot blast surface finish requirement Prime paint requirement Location of test specimenIt is recommended that, where possible, casting drawings be supplied to the foundry with as cast dimensions, tolerances and other information relevant to the as cast piece be included. The foundry would then sign off the casting drawing or request amendments.Alternatively, the foundry could be requested to create a casting drawing from the finish machined component drawing which would be presented to the AGCO machining source for approval. The AGCO machining source would sign off this casting drawing as acceptable or seek amendments prior to the start of production.2.2 Mechanical PropertiesTable 1. Mechanical Properties (Minimum Values Unless Otherwise Specified) AGCO GradeCasting Surface Hardness, HBWDescriptionWall Thickness, mm (in)Tensile Strength, MPa (KSI)Yield Strength, MPa, (KSI)Elongation, PercentD250 DX250130-180Ferritic20 (0.8)390 (57)250 (36)1520 - 40365(53)235(34)(0.8 - 1.6)40 60350(51)225(33)(1.6 - 2.4)D300 DX300156-217Ferritic-Pearlitic20 (0.8)450 (65)300 (44)1020 - 40435(63)290(42)(0.8 - 1.6)40 60420(61)280(41)(1.6 - 2.4)D360 DX360187-255Ferritic-Pearlitic20 (0.8)550 (80)360 (52)520 - 40525(76)345(50)(0.8 - 1.6)40 60500(73)330(48)(1.6 - 2.4)D420 DX420217-277Pearlitic (For Local Hardening)20 (0.8)650 (94)420 (61)320 - 40625(91)405(59)(0.8 - 1.6)40 60600(87)390(57)(1.6 - 2.4)D480 DX480241-302Pearlitic20 (0.8)690 (100)480 (70)320 - 40665(96)465(67)(0.8 - 1.6)40 60650(94)455(66)(1.6 - 2.4)Mechanical properties shall apply to the cast product based on a test specimen cut from the casting. Specimens shall be machined from areas specified on the engineering drawing and in accordance with the requirements of Annex A.For foundry process control purposes, mechanical properties shall be measured from separately cast test specimens per Annex B. These specimens shall be poured at approximately the same time and under conditions similar to that of the production castings.Hardness of the casting shall be measured at the surface after suitable metal removal, 1.5 mm (0.06 inches) minimum, and at a location specified on the engineering drawing. If no location for testing is specified, the location of test shall be at the option of the receiving facility, unless otherwise agreed. Core hardness of the casting shall not deviate from the measured surface hardness by more than 30 points HBW.2.3 MicrostructureTable 2. MicrostructureCharacteristicGrade D250 / DX250Grade D300 / DX300Grade D360 / DX360Grade D420 / DX420Grade D480 / DX480MatrixFerritic, 25 % PearliteFerritic-Pearlitic, 40 % PearliteFerritic-Pearlitic, 30-70% Pearlite70% Minimum PearlitePearlitic or MartensiticGraphite Size, Diameter Maximum0.09 mm (0.0036 in)0.06 mm (0.0024 in)0.09 mm (0.0036 in)Nodularity85% minimum round shapes and shapes with length to width ratios less than 1.5CarbidesLess than 2% by VolumeMicrostructure requirements defined in Table 2 pertain to areas of the casting away from the cast rim or areas near the riser or gate contact. Cope side surfaces should be avoided when evaluating the overall microstructure.Regarding nodularity, the spheroidal graphite component of the microstructure shall consist of at least 85% graphite spheroids conforming to Type I and II of ASTM A 247.Matrix microstructure of grade D250 shall range from totally ferritic to a combination of ferrite with pearlite that does not cause the hardness to be above the specified upper limit. Grades D300 and D360 shall contain combinations of ferrite and pearlite. Grade D420 shall contain a minimum of 70 percent pearlite for local hardening. Grade D480 shall contain less than 5 percent ferrite and may be produced with a pearlitic matrix microstructure or a tempered martensite matrix microstructure. Carbides are undesirable and shall be kept to less than 2 percent by volume (measurements to be conducted with a photomicrograph with the percentage measured within any field of view).2.4 Chemical CompositionThe composition limits of Table 3 apply to all grades of ductile iron.Table 3. Chemical Composition (Weight Percent)ElementGrade D250 / DX250Grade D300 / DX300Grade D360 / DX360Grade D420 / DX420Grade D480 / DX480Manganese0.75 MaximumPhosphorus0.05 MaximumSulfur0.035 MaximumTypical ranges of other elements are: 3.2 to 4.1 weight percent carbon; 1.8 to 3.0 weight percent silicon; and 0.02 to 0.06 weight percent magnesium (if magnesium is used for inoculation).Elements that are not carbide stabilizers are preferred for use in stabilizing pearlite in grades D360 through D480. Preferred alloying elements are copper, tin and nickel.Alloying elements and the ranges used shall be subject to agreement at the time of sample approval for all DX grades.2.5 Heat TreatmentTable 4. Heat TreatmentGradeConditionD250As Cast or Annealed (Suppliers Option)DX250No Change Allowed from the Original Qualified ProductD300 / DX300As CastD360 / DX360As CastD420 / DX420As CastD480As Cast, Normalized or Quench and Tempered (Suppliers Option)DX480No Change Allowed from the Original Qualified ProductD480-N / DX480-NNormalizedD480-QT / DX480-QTQuench and Temper Heat TreatmentGrade D250 may be provided in the as-cast or annealed condition. Grades D300 through DX420 shall be produced in the as-cast condition without subsequent heat treatment. When heat treatment is required for stress relief purposes, it shall be specified as stress relieved on the engineering drawing along with the required stress relieving temperature. If salvage heat treatment is required in order to achieve the specified tensile strength and hardness, engineering deviation approval is required. Grade D480 may be produced as-cast, normalized or quenched and tempered at the producers option, unless otherwise specified. A heat-treating process may be specified by use of the following suffix letters: D480-N, for normalized; D480-QT, for the quenched and tempered product.2.6 Quality2.6.1 Castings shall conform to the engineering drawing as supplied by the ordering facility, unless otherwise agreed or specified. The removal of gates and riser contacts shall not produce projections or depressions beyond the normal design contour, except as approved by the ordering facility. Cast eyebrows and flats around bolt hole locations shall be flat and free of excess metal.2.6.2 Castings shall be mechanically cleaned to remove all adherent sand, scabs and scale. Fins shall be ground off on all external surfaces and shall not exceed 1.5 mm (0.06 inches) in height on internal surfaces. Internal surfaces shall be free of all material that may loosen during subsequent use of the component in the finished assembly.2.6.3 Castings are subject to inspection for internal soundness. Whether this testing is conducted by radiographic or ultrasonic testing methods, or by sectioning for inspection of cut surfaces is at the option of the receiving facility. In general castings are required to be sound and free from internal shrinkage porosity; however, shrinkage porosity in heavy non-critical locations can be permitted if approved by the responsible product engineering department. Shrinkage porosity when allowed in non-critical locations is not permitted to extend from the interior to the cast and/or machined surfaces.2.6.4 Casting soundness shall be sufficient to prevent leakage through the cross section of fluids that are contained within the assemblies where these castings are used.2.6.5 Linear defects such as cracks and hot tears are not permissible. All castings are subject to inspection for these defects and inspection methods that may be used to detect the defects include magnetic particle, dye penetrant, visual and other methods.2.6.6 Generally, welding is not permitted for repair of casting defects. Salvage repair of cosmetic defects can be permitted in non-structural areas or in non-structural castings if specified either on the engineering drawing or by written approval of the controlling product engineering group. Under no circumstances may organic fillers (e.g. polyester or epoxy) be used to repair cosmetic defects.3. First Article Approval RequirementCastings shall be subject to the approval of the ordering facility based on the currently accepted AGCO Initial Sample Inspection Report practice for the ordering facility. Continuing acceptance or rejection will be based on the conformance to the engineering drawing (or signed-off casting drawing), material specifications and other items of agreement between the ordering facility, Product Engineering and the supplier as stated in the Purchase Order. Suppliers should clarify with the ordering AGCO plant location if there is any requirement to pre-machine location pads both for the initial machining sample and ongoing supply.Structural castings (i.e. AGCO GSM001002 Grade DX360) shall be subject to engineering qualification that may include dynamic and/or other structural testing.4. Continuing Quality Control RequirementsCertified reports of mechanical property test results, microstructural examination and chemical composition shall be submitted to the ordering facility or are available in the suppliers files for further evaluation according to the agreement between the supplier and the ordering facility. They shall indicate the range of test results obtained for that period, unless otherwise specified or required by the ordering facility. These reports may summarize the monthly activity of the foundry by listing the part numbers and quantity of parts produced.Dimensional: If a supplier plans to use a casting checking fixture for routine inspection of production castings, he should identify the frequency of calibration of the fixture(s). Also, the supplier should produce, prior to volume production, an approved master sample casting for which a full three-axis CMM inspection report exists.5. RecordsEach foundry supplier shall retain records of chemical composition and mechanical property test results and shall be able to show or supply those records upon request for a minimum of 3 years. The supplier shall also be able to furnish test bars upon request from the approximate time the castings were made, for a minimum period of up to 6 months (test bar storage should be negotiated between Purchasing and the supplier due to the necessary structure to store a big quantity of test bars).6. Attachments Annex A Test Bars Machined from Castings Annex B Separately Cast Test Specimen Annex C Previously Used Standards7. Document Control DOCUMENT CHANGE CONTROLREV. CHANGE DATEREVISED BYCHANGE DESCRIPTION108-June-06GARY MARCHIINITIAL RELEASE231 July 2007Ed FritzCombined reference standards in Annex C, Stuart Watkin suggested changes36 September 2007Ed FritzI1) Incorporated suggestions from balloting; 2) Removed Annex D, ADI DOCUMENT OWNERSHIPDATEOWNED BY / SITEAUTHOR18-Jul-05Global Components Engineering / HesstonEd Fritz8. Leadership / ApproversDocument approvals shall be solicited from the Senior Vice-President of Engineering and his direct reports, as he directs, along with other affected departments and functions. Refer to GOP0010002, Creation and Approval of Global Documents, for the document approval procedure.ANNEX A Test Bars Machined from CastingsTest bars machined from castings shall be located in the cross section as near the surface of the casting as possible. In keeping with this requirement the centerline of the test specimen should be located less than 0.25 X the section thickness from the cast surface.Preferred sizes for the tensile test bars are listed as a function of the casting section thickness as shown below. Alternative sizes may be used if approved by Product Engineering.Test BarTest Bar, Nominal Gage DiameterCasting Section ThicknessA14 mm or 0.505 inchesGreater than 40 mm (1.60 inches)B7 mm or 0.252 inches19 to 40 mm (0.75 to 1.60 inches)Test specimens may be located on the centerline of the cast section when the section thickness does not exceed two times the gage diameter of the machined test bar.Test specimens that have shrinkage porosity or any casting defect in the test gage length shall not be used. However, such porosity or defects shall be judged on the basis of the effect on part and/or function of the casting.Note: For a given casting, mechanical properties measured with the use of test bars cut from the casting may be somewhat lower than those measured from separately cast test specimens.ANNEX B Separately Cast Test SpecimensThe separately cast test specimens from which the tensile bars are machined shall be cast in molds that yield standard Y or Keel blocks (Figures 1 and 2). These molds shall be made from a suitable core sand and have a minimum wall thickness of 40 mm (1 inches). The castings shall be cooled in the mold to a black color, approximately 480C (900F). Length of the Keel and Y block specimens shall be approximately 150 to 175 mm (6 to 7 inches).Figure 1. Y BlockFigure 2. Keel BlockA 25 mm or 1 InchA 25 mm or 1 InchB 55 mm or 2.125 Inch