CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 SPECIFICATION TECHNIQUE STA 01 - 500 DUCTILE IRON CASTING GENERAL PURCHASE REQUIREMENTS/CAHIER DES CHARGES POUR LA FOURNITURE DE PIECES MOULEES EN FONTE A GRAPHITE SPHEROIDAL 1.0 Scope/ Objet The purpose of this specification is to define the metallurgical and physical property requirements and methods of assessment for all Ductile Iron castings, also known as Spheroidal or Nodular cast iron. Castings may be specified in the as-cast or heat treated condition, subject to the limitations in this specification. Material purchased under this specification shall be manufactured according to the best foundry practice. Le present cahier des charges a pour objet de définir les caractéristiques métallurgiques, mécaniques, géométiques et physiques et les méthodes d'essais mécaniques des piéces moulées en fonte 4 graphite. Cette norme s ‘applique aux piéces moulées en fonte a graphite spheroidal non aliée, dusage courant ou parfois en fonte GS devant subir un traitement thermique. Sauf stipulations contraires, le mode d'élaboration de la fonte GS est laissé 4 Vinitiative du fournisseur qui doit prendre toute disposition utile pour que les caractéristiques définies soient respectées. Whenever this specification is in conflict with an individual STA specification, the individual STA requirements take precedence over STA 01-500. 2.0 Qualifying Specifications The following specifications and requirements apply to all materials purchased under this specification: ‘STA 00-201 Ductile Iron Casting Level 3 Warrant PPAP Checklist Metallurgical Requirements STA 00-300 Foundry Pre-Award Metallurgical Checklist STA 00-303 Foundry Metallurgical Survey Casting Tolerance Standard #0401 dimensional tolerancing drafting standard ‘Supplier Quality System Requirements Manual The following specifications are of technical interest: ‘STA 01-709 Brake Drum and Brake Rotor Metallurgy AFS American Foundry Society, Foundrymen's Guide to Ductile Iron Microstructures, 1984 SAE J434 Automotive Ductile (Nodular) Iron Castings ASTM A247 Evaluating the Microstructure of Graphite in Gray Iron Castings ASTM A536 Ductile Iron Castings ASTM A897 Austempered Ductile Iron Castings ASTM E8 Tension Testing of Metallic Materials ASTM E10 Brinell Hardness of Metallic Materials DUCTILE IRON CASTING GENERAL PURCHASE] 1MARCH | K_ |STAO1-500 REQUIREMENTS. 2005 © Reproductions are Uncontrolled Documents @ Page 1 of 19CORPORATE MATERIAL & PROCES SPECIFICATION STA 01-500 ASTM E23 Notched Bar Impact Testing of Metallic Materials ASTM E29 Using Significant Digits in Test Data to Determine Conformance with Specifications (Rounding Method) 3.0 Grades Whenever a material specification will be used for Axle Housing applications, the Axle Housing Special Requirements and Safety Related Component (SRC) restrictions, shown later in this specification, will also apply. All Axle Housings are considered as Safety Related Components. The production reporting requirements for Safety Related Characteristics are shown in the ‘Supplier Quality System Requirements Manual GRADE ‘STA 01-501 ‘STA 01-502 ‘STA 01-503 ‘STA 01-504 Description FerriiciFemiique | Ferriic-Pearitic | Pearitic/Pertique | PeariticlPeritique brut de coulee | [Fenito-Perltique ‘Typical Applications | “Mechanical Parts_[ Mechanical Parts | Mechanical Paris _|_ Mechanical Parts MINIMUM MECHANICAL PROPERTIES FROM CAST COUPONS ‘Tensile Strength, ps/R 58,000 (400) 72,500 (500) 87,000 (600) 101,500 (700) a ield Strength 0.2% 36,300 (250) 46,400 (320) 53,700 (370) 60,900 (420) Offset, psi/Re 0,002 | ipa) | Elongation, %in2 | 18 (75) 77 38) 22 Linch’A (*%) in 50 mm _ Nodularity ASTM A247 85% minimum ‘85% minimum 80% minimum ‘80% minimum Types! & I Pearite/Perife 20% maximum 25-50% — Femte/Ferrte 80% minimum 50-75% | Carbide/Cementite 3% maximum 3% maximum 0% 0% Special Requirements. Hardness Range HBW 130-180 170-280 180-270 225-305 (3000 kg, 10 mm) __| 7 MINIMUM MECHANICAL PROPERTIES ON TEST BARS MACHINED FROM ACTUAL CASTINGS Tensile Strength, psi/R (Mpa) Yield Strength 0.2% ] Offset, psi/Re 0,002 Mpa) | Elongation, % in 2 inctVA (%) in 50 mm Nodularity ASTM A247 | 88% minimum | 86¥% minimum | 60% minimum | — 60% minimura Types | & Pearite/Perie 20% maximum 25-50% DUCTILE IRON CASTING GENERAL PURCHASE | 1MARCH | K_ | STA 01-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 2 0f 19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 ‘GRADE (Continued) STAOT-501 ‘STA 04-502 ‘STAOT-503 STA 01-504 Ferrite/Ferrite 80% minimum 50-75% Carbide! Cementite 3% maximum 3% maximum 0%, 0% Special Requirements Hardness Range HBW 30-180 170-230 790-270 | ~~—~«a2B~305 (3000 kg, 10 mm) iz ‘SIMILAR INTERNATIONAL SPECIFICATIONS (Note A) ‘AENOR (France) FGS 400-15 FGS 500-7 FGS600-3___| _ FGS7002 ‘ArvinMeritor (USA) — ‘SAE (USA) — - 7 DIN Germany) GGG40 CEG5O GGG60 GGG70 lS (Japan) * To be determined by ts foundiy proved the lhe microavctare and mechanical poperies are mel ‘Note A: These specifications are presented for reference only. They are similar to the STA 01-8XX specification but may not moot al of the STA 01-5XX specticaton requirements, DUCTILE IRON CASTING GENERAL PURCHASE | 1 MARCH ["« $TAO1-500 REQUIREMENTS. 2005 @ Reproductions are Uncontrolled Documents Page Sof 18CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 GRADE ‘STAOI-505 | STA0I-506 STAOTSI STAOTSIZ jescription Ferritic Annealed’ | Pearitic/Peritque | Feritic/Fertique | Pearitc-Ferrific Ferniique Recuite ‘Perltique- Ferrque ‘Typical Applications | MechanicalParts | Mechanical Pans | Axl Housings, Fate Housings, Wheel Hubs. Dit | Wheet Hubs, of | Cases, Brake Cases, Brake | Housings, Pistons, | Housings, Brake s Covers Spiders. ‘MINIMUM MECHANICAL PROPERTIES FROM CAST COUPONS Tensile Strength, paR | 50,800 (350) 87,000 (600) | — 68,000 (448) | 80,000 (82) 31,800 (220) 35,100 (380) 5,000 (370) 55,000 (379) Elongation, % in 2 2 70 710) BD oe inehiA (3) in 80 mm Nodularity ASTM A247 | 85% minimum | 80% minimum | 60% minimum | 60% minimum Types | & I _ Pearite/Perife 0% 30% maximum? | 60% maximum Ferrte/Ferrte 700% 70% minimum? | 0% minimum” CarbidelCementife 0% aH 0% % Special Requirements | KCV71 fein Note ¢ | (ote B) (4.5 dasiom) Hardness Range HEW | 170 maximum 180-250 15-217 T87=255 (3000 kg, 10 mm) x MINIMUM MECHANICAL PROPERTIES ON TEST BARS MACHINED FROM ACTUAL CASTINGS Tensile Strength, psi 60,000 (474) 75,000 (8777 ce) Yield Strength 0.2% 30,000 (345) Offset, psiRe 0.002 (Mpa) | | Elongation, % in2 77 nl inch/A (96) in 50 mm 7 Nodularty ASTM A247 | 59% minimum —] 8096 minimam | — 80% minimum | — 80% minimum Types 18 I Pearlite/Periite 0% 30% maximum” 50% maximum* | FeniteFerite 00% - 70% minimum” | 50% minimum Carbide Cement —— —| ‘Special Requirements | KCV7i Ribiin Note € (Note B) 1.5 daJicm*) Hardness Range HEW | 170 maximum FB0-250 TeeTT T7255 (3000 kg, 10 mm) = _ ‘SIMILAR INTERNATIONAL SPECIFICATIONS (Note A) DUCTILE IRON CASTING GENERAL PURCHASE| 14MARCH | K_ | STA01-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 4 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION. STA 01-500 GRADE (Continued) | STAOT-505 STAOT-506 STAOT-S11 STAOTSI2 ‘AENOR (France) FGS 370-22 FGS 400-15 FGS 600-7 ‘AnvinMeritor (USA) 25-1 Rev J 025-2 Rev J _ Di Reve Di Reve ‘SAE (USA) 434 04512 1434 05508 | [DIN (Germany) GGG355 [cee 40 ‘GGG 50 lS Japan) FCD4S FCDS0 * To be determined by the foundiy provided the olhar microstructure and mechanical properties are met Note A: These specifications are presented fo reference only. They are simiar Io the STA O1-BXX specification but may not meet all of the STA O1-5XX specication requirements, Note B: KCV = Charpy V Notch impact Test per ASTMEZ® Type A Specimen, KOU = U Notch impact Test per ASTI E23 Type C Specimen: measured in Joules (0.738 foot-paunés) of daJoulesien” (476 footipoundslineh) Longitudinal Direction ‘Note C: Chemical composition for information only. Supplier may mady tne composition, provided the mechanical properties ‘are meVCompesition chimique pour information. Le fournissear pourra adaote Ia composition, 2 condiion que les caractenisties mecaniques soientrespectees. (3.53% C, 2.60% Si, 0.196% Mn, 0.005% Sn, 0.874% Cu, 0.618% Mg, 0.008% §,0.032% P) DUCTILE IRON CASTING GENERAL PURCHASE] 1MARCH | K | STAO1-500 REQUIREMENTS. 2005 @ Reproductions are Uncontrolled Documents @ Page 5 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 GRADE STAOT-513 STAOT-514 STAOL-515 STADI-5I6 Description Pearitic/Periique | Liquid Guenched & | FerriiclFemiique | Pearitc/Peritque Tempered | “Typical Applications induction induction Tale Rousings, induction Hardenable, Bearing | Hardenable, | Wheel Hubs, Steer | Hardenabie, Bearing ‘dusting Rings, | Mechanical Parts | Kavekles, Boaring | Adjusting Rings, Planelay Spiers in Cages Orne Flanges MINIMUM MECHANICAL PROPERTIES FROM CAST COUPONS Tensile Strength, psVR | 100,000 (689) | Properties wil be | 60,000 (474) 80,000 (627) Mpa) _ shown on drawing Yield Strength 0.2% 70,000 (4857 0,000 (276) 705000 7485) Offset, psi/Re 0,002 | pa) Elongation, % in 2 38) 18 (78) 4 inchVA (34) in 50 mm Nodularty ASTM A247 | 80% minimum | 80% minimum | 80% minimum | 80% minimum Types |& I Pearite/Perite— 20% minmum | 10% madmur | 10% madmum™ | 60% minimum 20% maximum* | 10% maximur* | 80% minimum* | 20% maximum Carbide/Cementite 0% 0% 0% O% “Tempered Martensite 80%" Special Requirements | Hardness Range HW 2a=302 170 maximum 228-285 (3000 kg, 10 mm) MINIMUM MECHANICAL PROPERTIES ON TEST BARS MACHINED FROM ACTUAL CASTINGS: Tensile Strength, psi | 80,000 (652) | Properties wilbe | 48,000 (337) "72,000 (496) (Mpa) ‘shown on drawing Yield Strength 0.2% 56,000 (386) | 32,000 224) | 56,000 (386) Offset, psilRe 0,002 (Mpa) { Elongation, % in 2 = | 3@ = Inch/A (9%) in 50 mm | Nodularity ASTM A247_| 60% minimum 80% minimum 80% minimum 80% minimurs Types | & Pearite/Periite 80% minimum | 10% maximum" | 10% maximum’ | 60% minimum Ferrite/Ferrite 20% maximum* | 10% maximum* | 90% minimum” Carbide/Cementite 0% o% | 0% ‘Tempered Martensite 0%" = Special Requirements: — - — Hardness Range HBW 241-302 170 maximum (3000 kg, 10 mm) DUCTILE IRON CASTING GENERAL PURCHASE] MARCH |" K | STAOI-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 6 of 8CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 ‘GRADE (Continued STA 01-813 STAOI-Bi4 | —_STAOI-BI5 | STAOI-BTE ‘SIMILAR INTERNATIONAL SPECIFICATIONS (Note A) | ABNOR (Franca) FGS 370-22 | ‘ArvinMeritor (USA) D25-3RevI 025-4 Rev I D2s-5RevJ | 0258RevI Dt Reve Dt Reve DiReve | Dt Reve SAE (USA) 1434.07003 434 DRT 434 D4018 DIN (Germany) 7 6GG.35-3 {IS Wapan) FODTO FCD37___| To bo determined by the foundry provided the other microstucture and mechanical properties are ret Note A: These specifications are presented for reference only. They are similar tothe STA O1-5KX specHication but may not meet all of the STA O1-5XX spectication requirements REQUIREMENTS DUCTILE IRON CASTING GENERAL PURCHASE +MARCH |" K™ | STAOT-500 2005 @ Reproductions are Uncontrolled Documents @ Page 7 of 18CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 ‘GRADE STAOLSI7 | _ STADT-5I6 STA 01-520 STAOT-S21 | Description FernliciFemtique | Pearitie-Femtiel | FerrticlFemiique | FenitielFerique Perltique- Feritique Typical Applications Pinion Bearing induction Mechanical Pars | Mechanical Pars Gages, Bearing | Hardenabl, Bearing | | Caps ‘Adjusting Rings _—- MINIMUM ME CHANICAL PROPERTIES FROM CAST COUPONS: ‘ensile Strength, psi/R 60,000 (474) 80,000 (552) 53,700 (370) 58,000 (400) Mpa) Js Yield Strength 0.2% “40,000 (276) 55,000 (379) 33,400 (230) 36.300 250) Offset, psi/Re 0,002 (Mpa) a Elongation, % in 2 18 (18) 6 (6) 10: (10) 18 (18) inehiA (36) in 50mm _ | Nodularty ASTM A247] 80% minimum | 80% minimum | 85% minimum | 65% minimum Types 1&1 Pesrite/Perife 25% maximun® | 65% minimum | 20% maximum Ferrite/Ferrte 75% minimum* | 35% maximum | 80% minimum Carbide/ Cement 0% 0% 2% maximum ‘Special Requirements KOV 48 fbn (Note 8) (.0 dauiem’) | Hardness Range HBW 143-189 187~255 163~207 (3000 kg, 10 mm) : ‘MINIMUM MECHANICAL PROPERTIES ON TEST BARS MACHINED FROM ACTUAL CASTINGS. T Tensile Strength, psVR | 48,000 (337) 75,000 (517) Mpa) _ ‘Yield Strength 0.2% 32,000 (221) 50,000 (345) Offset, sie 0,002 (Mpa) | _ Elongation, % in 2 9 33) | inch/A (36) in 50 mm _ _ Nodularty ASTM A247-| 80% minimum | 80% minimum | 85% minimum | 65% minimum | Types 1a i . Pearite/Perite 25% maxmunt | 659% minimum —| 20% maximum Ferrte/Ferrte [75% minimum” —| 35% maximum | 80% minimum Carbide! Cementife 0% O% 29% maximum ‘Special Requirements KOV 48 felbfn (Note B) (1.0 dafcm’) Hardness Range HAW | 143~189 187-255 163-207 730=180 (3000 kg, 10 mm) = DUCTILE IRON CASTING GENERAL PURCHASE | 1MARCH |" K” |STAO?-500 REQUIREMENTS: 2005 Page 8 of 18 @ Reproductions are Uncontrolled Documents ©CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 GRADE (Continued) [STA 01-517. ‘STA 01-518 ‘STA 01-520 ‘STA 01-521 SIMILAR INTERNATIONAL SPECIFICATIONS (Note A) ‘AFNOR (France), FGS 370-22 FGS 500-7 FOS 400-18 ‘ArvinMeritor (USA) 025-7 Rev J 025-2. Rev J Dt RevE Dt Reve 7 ‘SAE (USA) 434 04018 1434 05506 DIN (Germany) GGG 35-3 GG650_—_ | ‘IS (Japan) FCD37 FCDSO * To be determined by the foundry provided the other Microstructure and mechanical properies are met Note A These specifications are presented for reference only. They are similar tothe STA 01-5XX specication but may not meet all of the STA O1-5XX specification requirements, Note B: KCV = Charpy V Notch Impact Test per ASTM E23 Type A Specirjen, KCU = U Notch impact Test per ASTM E23 ‘Type C Specimen; measured in Joules (0.738 foot-pounds) or daJoules/cm* (47.6 foot-pounds/inch’) Longitudinal Direction 4.0 Chemical Composition 4.1 Phosphorus, Silicon Alll Safety Related Component (SRC) castings must have Phosphorus and Silicon contents within the following limits in order to maintain low temperature impact properties: Phosphorus 0.030% maximum, Silicon 2.75% maximum. Higher phosphorus levels, up to 0.05% maximum, are permitted, provided the maximum silicon content is restricted according to the following schedule: Maximum % Phosphorus Maximum % Silicon 0.030 2.75 0.035 271 0.040 2.68 0.045 2.64 0.050 2.60 4.2 Aluminum, Titanium Aluminum or Titanium contents shall be restricted to 0.015%. Higher limits may cause machinability problems due to the formation of aluminum and titanium nitrides. 5.0 Heat Treatment Only sub-critical annealing at temperatures below 1325°F (718°C) is permitted on Grades 502, 503, 506, 511, 512, and 518 Safety Related Component (SRC) castings if the service stress levels are above the 0.2% offset yield strength. Hyper-critical heat treating results in a loss of impact toughness and reduced fatigue performance at stress levels above the 0.2% offset yield strength and an increase in fatigue performance at stress levels less than or equal to the 0.2% offset yield strength. Metallurgical Engineering approval is required prior to hyper-critical heat treating on these casting grades. 6.0 In-Mold Inoculation DUCTILE IRON CASTING GENERAL PURCHASE] 1MARCH | K | STAO1-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 9 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 If "in mold” inoculation techniques are used, the foundry shall inspect 100% of the castings using an Ultrasonic Velocity testing method. The foundry's sampling plan, ultrasonic test procedure, and test standards must be approved by Metallurgical Engineering, 7.0 Casting Soundness Criteria The submitted PPAP (Production Part Approval Process, Initial Sample Process) castings shall be fully representative of the foundry practice to be used in production. No change in gating, riser, and mold design will be done by the supplier after the PPAP casting has been X-Rayed and approved. Any changes will require new sample approval. 7.1 Intemal Soundness Requirements The required intemal soundness requirements are shown in the Family Soundness Drawing number 4-36465 or equivalent. The Family Drawing takes precedence over the requirements shown in Table 1 if a specific soundness level is designated on the Family Drawing. If a soundness drawing is not referenced on the part drawing, the supplier must contact Metallurgical Engineering for an applicable soundness drawing prior to pouring PPAP samples. If medium-high soundness areas are specified, the level will be designated on the Family Drawing. ASTM E446 and the radiographs referenced in that specification shall be used for cross- sections up to 2 inch thick. Cross-sections greater than 2 inch require ASTM E186 and the radiographs referenced in that specification. The minimum quality level required is 2- 2T, as described in ASTM E1025, unless otherwise specified ‘The penetrameter (Image Quality Indicator) shall be a Hole Type penetrameter with a thickness that is 2% of the thickness of the cross-sectional area of interest and the 2T hole, the hole that represents 2% of the penetrameter thickness, must be clearly visible in the radiograph. Penetrameters must be displayed for every cross-sectional area of the radiograph that is of interest. The radiographic report should include a technique sheet that fully describes the processing parameters and radiographic conditions and a shooting sketch that describes the views and angles, as described in ASTM E94 and the referenced documents. 7.2As Cast Surface Requirement All castings must meet visual acceptance standards for as-cast surfaces as referenced in Manufacturers Standardization Society Specification MSS SP-55. The surface requirements and exceptions are shown in the Family Soundness Drawing number 4- 36465 or equivalent and take precedence over the requirements shown in Table 2A if a specific surface level is designated on the Family Drawing, No metallic filers or organic fillers are permitted to repair or hide surface defects. DUCTILE IRON CASTING GENERAL PURCHASE] 1MARCH | K | STAO1-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 10 of19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 7.3 Machined Surface Requirement Machined and high soundness as-cast surface quality visual acceptance standards for iron castings are shown in Table 2B. TABLE 1 INTERNAL SOUNDNESS LEVELS FOR CASTINGS SOUNDNESS INTEGRITY AREAS AS SPECIFIED ON PART OR FAMILY DRAWING HIGHEST QUALITY LOWEST QUALITY SECTION ANOMALY LEVEL (SHADED OR NORMAL QUALITY —_LEVEL OR GATE & CATEGORY CROSSHATCHED LEVEL (UNSHADED —_RISER AREAS. AREAS) AREAS) (DASHED AREAS) GAS HOLES & POROSITY 2 4 5 INCLUSION (8) 2 4 5 ‘SHRINKAGE (CC) 2 4 5 TABLE 2A AS-CAST SURFACE QUALITY REQUIREMENTS MSS SP-55 ‘APPLY TO ISOLATED TYPE ANOMALY NAME, ‘ACCEPTANCE LEVEL’ AREA ONLY * 1 HOT TEARS AND CRACKS oe u SHRINK c mM ‘SAND INCLUSIONS e * Iv GASPOROSITY ce + v VEINING e + Vis RATTAILS ce VI WRINKLES, LAPS, FOLDS, COLD b + SHUTS* Vill CUTTING MARKS* b + DUCTILE IRON CASTING GENERAL PURCHASE | 1MARCH | K | STAO1-500 REQUIREMENTS: 2005 @ Reproductions are Uncontrolled Documents @ Page 11 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 Ik SCABS. e + x CHAPLETS* c XI WELD REPAIR AREAS’ b Xil_ SURFACE ROUGHNESS ce + The acceptable level shown applies only to isolated areas of the casting ia + symbol is shown in the next, APPLY TO ISOLATED AREA ONLY, column or on the Family Drawing. If'no + symbol is shown, the acceptance level shown applies to all Normal soundness and Lower soundness areas. Under all sircumstances, High soundness areas require one level higher acceptance level for each category. ? These extreme conditions are restricted to isolated areas of the casting and are not to be considered applicable to the entire unmachined surface 8 No hot tears and cracks are acceptable under MSS SP-55 * Cold shuts are not acceptable 5 Cutting marks must be approved by Metallurgical Engineering ® Chaplets to be used only with approval of Metallurgical Engineering. Housing-type castings, cases, and similar oll reservoirs type castings must pass a 6.0 psi (0.4 Bar minimum) pressure test. ” Brazing and weld repair must be approved by Metallurgical Engineering TABLE 2B MACHINED AND HIGH SOUNDNESS AS-CAST SURFACE QUALITY VISUAL ACCEPTANCE STANDARDS FOR IRON CASTINGS HIGH SOUNDNESS AREA ~ NORMAL AND LOWER TYPE ANOMALY MACHINED AND AS-CAST SOUNDNESS AREA- MACHINED NAME ‘SURFACES. ‘SURFACES ONLY GAS (BLOW —_0.080 inch diameter & 0.030 inch 0.125 inch diameter & 0.080 inch HOLES) deep, 12 holes total, 3 holes on any 1 deep, 12 holes total, 3 holes on any 1 square inch area square inch area Any holes below 0.030 inch diameter Depth in excess of 25% of section are are not to be included in the 12 on as- _unsalvageable cast surfaces Any holes below 0.060 inch diameter ‘are not to be included in the 12 No repairs allowed Repairs allowed! 0 ANOMALIES 0.060 inch diameter & 0.030 inch 0.128 inch diameter & 0.080 inch RESULTING deep, 12 holes total, 3 holes on any 1 deep, 12 holes total, 3 holes on any 1 FROM SAND square inch area square inch area AND SLAG K_ | STA 01-506 DUCTILE IRON CASTING GENERAL PURCHASE REQUIREMENTS @ Reproductions are Uncontrolled Documents @ Page 12 0119CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 Any holes below 0.030 inch diameter are not to be included in the 12 on as cast surfaces No repairs allowed Depth in excess of 25% of section are unsalvageable Any holes below 0.080 inch diameter are not to be included in the 12 Repairs allowed! I SHRINK 0.3 square inch area, 0.080 inch deep, 1 square inch area, (SPONGE) 3 per area allowed, 2 inch apart 0.125 inch deep, 3 areas allowed, 2 minimum Inch apart minimum ‘Any hole below 0.030 Inch diameter is Depth in excess of 25% of section are not to be included in the 12 on as-cast _unsalvageable surfaces No repairs allowed Repairs allowed IV -HOT TEAR No indications or No indications or CRACKS, COLD repairs allowed repairs allowed SHUT, CORE FIN VOIDS { Repairs in lower soundness areas allowed with approval of Metallurgical Engineering ? Centeriine shrink or porosity in the gating area is allowed with approval of Metallurgical Engineering 8.0 General Requirements 8.1 Machinability Castings shall machine satisfactorily. 8.2 Hardness The foundry shall exercise the necessary controls and inspection technique to insure compliance with the specified hardness range. Brinell hardness shall be determined according to ASTM E10, Test for Brinell Hardness of Metallic Materials, after sufficient material has been removed from the casting surface to insure representative hardness readings. The 10 mm ball and 3000 Kg load shall be used unless otherwise agreed upon. Unless an area of the casting is designated on the drawing for hardness checking the part will be expected to meet the required surface hardness in all areas. 8.3 Mechanical Properties The Minimum Mechanical Properties must be taken from test bars machined from Cast Coupons, however individual STA specifications may required test bars to be taken from Actual Castings. Where Mechanical Properties are required only from Cast Coupons, the coupons must be separately cast Keel or Block coupons or coupons attached to the castings, as shown in ASTM A536 Ductile Iron Castings. Where Mechanical Properties are required from Actual Castings, the test bars must be machined from the DUCTILE IRON CASTING GENERAL PURCHASE] MARCH | Kk. REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ STA 01-500 Page 13 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 Critical Cross-Section of the casting. The Critical Cross-Sections must be identified on the part blueprint or agreed upon between the foundry and Metallurgical Engineering, with the coupon type and coupon location documented in the Control Plan. Testing frequencies on Mechanical Properties from Actual Castings will be agreed upon in the Control Plan. Under all circumstances where the foundry uses Cast Coupons to control the casting process, the Cast Coupons must accurately reproduce the cross-sectional area of the Critical Section, the cooling rates, and the Thermal History of the castings and must be poured from the same ladle or heat as the castings they represent. During PPAP submission, the foundry is required to submit to Metallurgical Engineering mechanical property data from test bars machined from the Critical Cross-Section of a production- representative casting and also mechanical property data from test bars from the proposed Cast Coupon in order to verify the correlation between coupons and actual castings, The foundry must maintain sufficient process controls and control documentation to assure AxleTech that mechanical properties determined from Cast Coupons are representative of castings shipped. The supplier shall cast at least two test coupons from each lot of castings during production runs. One machined test coupon, made in accordance with the dimensions prescribed in ASTM E8 Tension Testing of Metallic Materials, shall be tested from each lot of castings. If this coupon fails to meet the STA requirements, another bar shall be required. If the second test bar fails to meet the requirements, the lot of castings shall be subject to rejection. In this event, one or more test bars of the largest practical size, shall be machined from an actual casting for review by Metallurgical Engineering and shipment disposition. The preferred locations for mechanical properties on disc brake rotor and brake drum castings are shown in Figure 1. Where suppliers use alternative locations, these locations must be shown in the Control Plan. DUCTILE IRON CASTING GENERAL PURCHASE MARCH | K | STA01-500 REQUIREMENTS. 2005 @ Reproductions are Uncontrolled Documents @ Page 14 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 Figure 1 8.4 Microstructure The microstructure control requirements are shown in the individual STA specifications. Control is also required of several other microstructural defects which may result in rejected castings because of their deleterious effects on the mechanical properties. Most notable of these defects are Carbon Flotation, Rims, and Dross. Carbon Flotation is a dense distribution of graphite nodules near a casting surface that contains malformed and “exploded” nodules and is caused by Carbon Equivalents that are too high for the section size, high pouring temperature, and slow cooling in heavy cross- sections. Rims are carbon free surface layers that may occur on heat treated castings where heat treating is permitted. Dross is the entrapment of oxidized Magnesium and Silicon and dirt. High retained Magnesium and Carbon contents and high pouring temperatures should be avoided, the ladle should be thoroughly skimmed after inoculation, fluxes should be properly used, and the gating system should be modified. These defects are referenced in the AFS Foundrymen’s Guide to Ductile Iron Microstructures. 8.5 Physical Characteristics/Caracteristiques Physiques Castings must be trimmed and cleaned, with all gates and runners removed so as not to adversely affect the appearance and intended use of the castings or interfere with machining 8.6 Radioactivity Castings shall not contain levels of Radioactivity above background radiation levels, Foundries should ensure that castings are not contaminated through the thorough inspection of incoming scrap, charge material, etc. 9.0 Production Shipment Material Certification Requirements ‘The foundry shall maintain on file and submit to the laboratory of the purchasing plant, in DUCTILE IRON CASTING GENERAL PURCHASE | 1 MARCH K | STA01-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 15 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION STA 01-500 sam Zone citique Figure 2 13.2 Pressure Tightness/Etanchelté Housings, Cases, and similar oil reservoirs must retain oil with no leaks, as defined by STC 05-101. Components must be pressure tight under 0.4 bar minimum (6.0 psi minimum) using procedure SMF 031712. In the event of test failure, repairs may be allowed at the responsibilty of the foundry, provided the repair procedures are documented in the Control Plan or approved by deviation. Les piéces doivent étre étanches 4 Ihuile définie par notre norme STC 05-101. Le contéle s’éffectue, lors du montage du pont, au moyen d'air comprimé & 0,4 bar maxi (essai suivant SMF 0311124). En cas de fuite une imprégnation est admise (elle sera & la charge du fondeur). 13.3 Control Locations ‘The preferred Brinell Hardness (Durefé HB), Microstructure (Micrographie), Tensile Test (Résistance a la Traction), and Impact Test (Résilience) locations are shown in Figure 4. Where suppliers use alternative locations, these locations must be shown in the Control Plan. DUCTILE IRON CASTING GENERAL PURCHASE| 1MARCH | K_ | STAO1-500 REQUIREMENTS. 2005 @ Reproductions are Uncontrolled Documents @ Page 17 of 19RPI CESS SPECIFICATION advance of or with each production shipment, a Certified report of the chemical analysis, mechanical properties, microstructural evaluation, and any other properties specified in the STA specification. The certification must be traceable to the heat code and/or cast date for all material used in the manufacture of the castings. 10.0 PPAP Material Certification Requirements All PPAP documentation requirements are outlined in STA 00-201 Ductile Iron Casting Level 3 Warrant PPAP Checklist Metallurgical Requirements. 11.0 Casting Identification Official trademark, part number, revision heat or date code, and cavity number when applicable shall be shown on the casting. The AxleTech logo, described on drawing 4-66897 Emblem Identity, shall be shown on each casting. Additional marking requirements are shown in STA 03-502 12.0 Repairs and Welding No repair, even of surface defects, will be carried out without Control Plan approval or a deviation request from Metallurgical Engineering. Extreme caution must be taken when welding ductile iron. Welded ductile iron produces a very hard heat affected zone and is very susceptible to cracking. Each welded application must have Control Plan approval from Metallurgical Engineering. ‘The foundry is responsible for minimizing weld repair on castings. Defects occurring at similar locations on repeated castings lots should be corrected with permanent gating, risers, etc changes. Where welding is approved, weld wire such as these materials are recommended. Huntington Alloys Ni-Rod FC 56, Alloy Rods Ni-Core 55, or Hobart 44-G with typical chemical compositions of Nickel 42.0~50.0%, Iron 44.0~55.5%, Carbon 0.30~1.10%, Manganese 0.40~12.0%, Silicon 0.20~0.75%, Phosphorus 0.0-0.11% and typical minimum mechanical properties of Tensile Strength 70,000 psi (483 MPa), Yield Strength 45,000 psi (310 MPa), Elongation 12%. 13.0 Axle Housing Special Requirements 13.1 Geometric Tolerances Refer to Casting Tolerance Standard #0401 for all required dimensional tolerances. Sur Jes autres cotes appliquer les tolérances de la Classe du Standard #0401. ‘The maximum tolerance on the Carrier Opening dimension is +2.5 mm (+0.098 inch) with respect to Axis XX’ or Axis Ju’, as shown in Figure 2. Ele sera controlee au centre du carter de pont par rapport a axe des alesages. Soit |axe JJ’ materialisant axe des alesages des extremites du carter de pont. Soit /axe XX’ materialisant l'axe du centre du carter de pont. Ecart maxi au repos entre JJ’ et XX": 22.5 mm (20.098 inch). DUCTILE IRON CASTING GENERAL PURCHASE | 1MARCH | K | STAOT-500 REQUIREMENTS 2005. @ Reproductions are Uncontrolled Documents @ Page 16 of 19AxleTech international CORPORATE MATERIAL & PROCESS SPECIFICATION. STA 01-500 Résistance ot résilience Figure 4 14.0 Unauthorized Process Changes Foundries are not to make unauthorized changes to the process, manufacturing method, equipment, raw material and other factors which could affect product quality on previously PPAP approved components. Changes that would require such prior authorization are clearly documented in the current Automotive Industry Action Group's (AIAG's) Production Part Approval Process (PPAP) manual. The foundry is required to use best engineering judgment in order to determine if possible changes will affect product quality or contact Metallurgical Engineering if doubts exist. Any such change made without prior written approval by Metallurgical Engineering would not only constitute a breach of the purchase order terms and conditions, but would also be a serious breach of standard automotive practice. Foundry process changes may require re-PPAP qualification, 1.0 Control Characteristics Defined A Control Characteristic is either a Safety Related Characteristic of a Safety Related Component or a Major Characteristic. All Control Characteristics must be addressed in the Control Plan and Process FMEA. The supplier must specify for each Control Characteristic the control method, inspection, and testing frequencies for incoming, in-process, and final DUCTILE IRON CASTING GENERAL PURCHASE| 1MARCH | K | STAO1-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 18 of 19CORPORATE MATERIAL & PROCESS SPECIFICATION inspection, A Safety Related Component is defined as any part, component, assembly, or system that contains one or more Safety Related Characteristics. A Safety Related Characteristic is any dimensional, material, process, or performance specification or standard which, if violated, may cause failure or malfunction which could result in an unreasonable risk of personal injury or death or a condition of non-compliance with a Government Regulation. Refer to the drawing to determine if a component is a Safety Related Component or contact Metallurgical Engineering The production reporting requirements for Safety Related Characteristics are shown in the ‘Supplier Quality System Requirements Manual ‘A Major Characteristic is a dimensional, material, process, or performance specification or standard which, if violated, may cause a failure or malfunction which would result in a major repair, significant customer dissatisfaction, or the inability to manufacture or assemble the product. All symbols are shown in STA 00-201 DATE/DATE RECN REVISION DESCRIPTION/DESCRIPTION de REVISION 5 AUG 2004 == __| Initial Release /Dégagement Inifal—R. Sieber 11 MAR 2005 K__| Publication Release - R, Sieber DUCTILE IRON CASTING GENERAL PURCHASE | MARCH | K | STAO!-500 REQUIREMENTS 2005 @ Reproductions are Uncontrolled Documents @ Page 19 of 19