管路标准-罗浮汽车

Issue No. 6Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -CONTENTS1 Scope2 Test Methods3 Approval4 General Requirements5 Pipe Construction6 Brake Pipe Unions7 Initial Supplier Approval8 Specific Requirements 9 Dimensions and Tolerances1 SCOPE This specification details the requirements for double wrapped copper brazed steeltubing, bearing a passivated zinc deposit, and subsequently polymer coated, for use in brake systems.2 TEST METHODS Test methods required in conjunction with this Standard are as follows:RES.22.BF.01 RES.30.CT.118 RES.30.LT.106 RES.30.AD.149 RES.30.CT.900 RES.30.XP.106 RES.30.BT.102 RES.30.HA.106 RES.30.XP.107 RES.30.CR.101 RES.30.HX.148 BS 7479RES.30.IC.1013 APPROVAL Components shall not be used in production without first having completed andsatisfied the approval procedure.3.1.1 Suppliers who can demonstrate compliance with MG Rover Quality SystemSpecifications shall, establish the relevant test schedule for their product with Materials EngineeringIssue No. 6Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -3.2 Samples representative of intended product supply shall be fully tested by thesupplier against the requirements of this standard and the Engineering drawing3.3.1 Full test results, with any necessary additional information and sample components,shall be submitted to Materials Engineering.3.4 Materials Engineering will validate the suppliers test results and arrange for anyselective comparative tests.3.5 Full approval of components conforming to this specification shall be subject tosatisfactory vehicle and engineering performance.3.6 Any alteration to the material formulation or processing of brake pipes requires writtenauthorisation from Product Engineering, Materials Engineering, and Change Control prior to production deliveries of components.4 GENERAL REQUIREMENTS 4.1 Dimensions and Tolerances The dimensions and tolerances of the pipe shall be as specified on the engineeringdrawing.4.2 Appearance Colour and gloss shall be agreed with the supplier.4.3 Performance The pipe shall be free from any defect and/or foreign matter and shall be capable ofperforming satisfactorily in service.4.5 Samples For initial supplier approval to this Standard, straight lengths of tubing which arerepresentative of the production process shall be supplied.5 TUBE CONSTRUCTIONIssue No. 6Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -5.1 Steel The tube shall be formed from low Carbon steel strip with a grain size of ASTM 5 - 8,double wrapped into tubular form (see Figure 3). It shall be free from lamination, surface pits, stringers, or other surface defects which may impair processing, manipulation, function, or corrosion resistance.5.2 Copper Coating The steel strip shall be Copper coated on one or both sides as required by thebrazing process.5.3 Braze The braze shall be continuous and free from significant defects. There shall be nointergranular penetration of Copper beyond two grains from the surface when examined in cross-section. In addition there shall be no excessive carburisation where the strip is thinned to form the seams i.e. not exceeding 0,40mm back along the surface from the tip and not more than 0,15mm at the greatest depth (see Fig.4).5.4 Zinc Coating This shall be continuous and of substantially uniform thickness.5.5 Polymer Coating5.5.1 The polymer coating shall be continuous, adherent, free from pores and foreignmatter, and shall be of a uniform thickness. Flared ends and/or fluid sealing surfaces shall be uncoated. The thickness of the coating shall not interfere with the correct functioning of the end fittings (see note).5.5.2 The coating thickness, when determined by sectioning shall be within the limitsagreed with the supplier and recorded on the initial report for the approved sample.5.6 Internal Cleanliness All tubing shall be cleaned after processing/manipulation by being blown out withclean, dry compressed air.Any residue remaining shall not exceed 0,2 g/m 2 of internal surface area when testedin accordance with RES.30.IC.101. Pipe ends shall be suitably covered to prevent the ingress of contamination.6 BRAKE PIPE UNIONSIssue No. 6Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -All unions for use with brake pipes produced to this specification shall be zinc coatedand passivated in accordance with RES.21.ZS.01.7 INITIAL SUPPLIER APPROVAL 7.1 Testing shall be performed to the requirements of Section 8. 7.2 For initial supplier approval only, the following procedure shall apply in performingthose tests required by Table 3 and referred to below.7.3.1 The chip resistance test, RES.30.AD.149 shall be performed on grouped (more thansix tubes) tubing. The rating shall then be determined.7.3.2 Samples shall be subjected to the bending properties test, RES.30.XP.106 The formed area shall then be examined for damage.7.3.4 A brake pipe clip of a type used in production shall then be attached to samples.7.3.5 Scribing to RES.30.CT.118 shall be performed on the tubing7.3.6 All of the above samples are then subjected to the corrosion test BS 7479 7.4 The heat ageing test RES.30.HA.106 shall be performed on straight lengths of tubingas received, with two brake pipe clips of a type used in production attached equidistant from each end and from each other.8 GENERAL REQUIREMENTS 8.1 Specific requirements are detailed in Table 2. 8.2 All testing shall be performed at 20°C ± 5°C, except where stated in Table 2 or in theappropriate test method.8.3 All samples subjected to corrosion and humidity resistance tests shall have their endssealed.8.4 For hydrostatic testing to RES.30.BT.102 the relationship between outside diameter,proof pressure, and burst pressure, are as given in Table 1 (refer also to Table 2).Table 1Outside diameter Proof pressure Burst pressureIssue No. 6Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -(nominal) mm N/mm min N/mm min4,75 45 110 6 37 90 8 30 72 *10 20 50 *12 10 30Note : * Non-preferred sizesTable 2 PropertyTest MethodRequirementsSteel-BS 1449 Pt 1 Grade CS4 or agreed alternative. Non strain ageing quality HardnessSteel tubing HV5Polymer coating, as received -RES.30.HX.148 140 max. No hardness tests in vicinity of seams 2H maxZinc coating-25µm min thickness, passivatedCorrosion resistance. 600h.Using a representative formed area. BS 7479 NSS RES.30.CT.118 No corrosion on undamaged area. No blistering, flaking, lifting, or rusting shall extend beyond 1mm from edges of the scribed line.Humidity resistance. 800h Using a representative formed area.RES.30.CT.900 RES.30.CT.118 No corrosion on undamaged area. No blistering, flaking, lifting, or rusting shall extend beyond 1mm from edges of the scribed line.Heat ageing at 150°C ± 2°C for 24h RES.30.HA.106 No deformation, degradation, loss of adhesion, or embrittlement of the polymer coating. Chip resistance, as received RES.30.AD.148 Rating 2 max.Low temperature impact at -40°C ± 2°CBLS.30.LT.106 No cracking, flaking, lifting, or detachment from substrate. Bending propertiesRES.30.XP.106No cracking, kinking, or loss of adhesion.Resistance to Oil No. 1 BS 903 Part A16, 168h at120°C ± 2°C (ASTM Oil No. 1)Resistance to fuel, BS 903 Part A16, liquid C + 15% methanol. (ASTM fuel C) 168H.Resistance to battery acid, S.G. 1,275 + 0,025, 24h) ) )) RES.30.CR.101 ) ) ) ) No significant softening or other detrimental effect on the polymer coating.Resistance to brake fluidBLS.22.BF.01. Immerse for 5 mins. Vertical drain, 48h. Chip resistance Polymer coat hardnessRES.30.AD.148 RES.30.HX.148Rating 2 max 2HResistance to the current initial fill coolant, (boiling), Immerse for 5 mins.Vertical drain, 24h-No significant softening or other detrimental effect on the polymer coating.Issue No. 6Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -Flaring properties. 20% O.D. RES.30.XP.107 No crack or flawsHydro static testRES.30.BT.102Shall withstand the proof and burst pressures appropriate to size as stated in Table 2.Note : Fluid resistance tests to be performed on 150mm lengths of tube suitably sealed atboth ends with rubber caps9 DIMENSIONS AND TOLERANCES Concave (90 x 90) tube flares. To be used only with metric female tube nuts asspecified in RES.06.15.001. See Figure 1.Tube Size ‘A’ Dia ‘B’ Dia ‘C’ Dim ‘D’ Dia 4,75 4.81 4.68 7.186.821.00 3.593.096,00 6.05 5.92 8.688.321.00 4.834.338,00 8.05 7.92 11.1110.691.50 6.836.3310,00 * 10.05 9.92 13.1812.821.50 8.838.3312,00 * 12.05 11.92 15.4815.121.50 10.8310.33Note : *Non-preferred sizesFigure 1.Issue No. 6 Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -Issue No. 6Title : Metalic Materials Specifications - Brake PipesPublished : October 2003- Printed Copy is Uncontrolled – Check Issue is Correct -Convex (continental) tube flares. To be used only with metric male tube nuts asspecified in RES.06.15.002. See Figure 2.Tube Size ‘A’ Dia ‘B’ Dia ‘C’ Dim‘D’ Dia ‘E’‘F’ Dia 4,75 4.81 4.68 3.503.007.28 6.92 6.0 2.8 2.25.56,00 6.05 5.92 4.804.308.58 8.22 7.3 2.8 2.26.88,00 8.05 7.92 6.806.3010.92 10.48 9.3 3.0 2.48.810,00 * 10.05 9.92 8.808.3012.92 12.48 11.3 3.3 2.710.8012,00 * 12.05 11.92 10.8010.3014.92 14.4813.3 3.6 3.012.80Note : *Non-preferred sizesFigure 2.Issue No. 6 Title : Metalic Materials Specifications - Brake PipesPublished : October 2003Figure 3. Nominal Construction of Double Wrapped Brake TubingFigure 4. Carburised Zone at the Seam of Double Wrapped Brake Tubing.- Printed Copy is Uncontrolled – Check Issue is Correct -。