CQI-27铝合金金属模系统评估案例 中英文版

PROCESS TABLE J - Aluminum Metal Mold 过程表 J - 铝合金金属模Item条款Category/Process Step 类别/过程步骤CastingDesign andTooling 铸造设计和模具CastingProcess铸造工艺This Process Table is for aluminum semi-permanent mold and permanent mold castings (except Cylinder HeadsThe company's casting machine equipment for: rotarywhich has its own Table). Includes pistons, aluminum alloy wheels. Cast processes include different types ofequipment such as: gravity die casting, tilt pour, rotary, low pressure die cast, and pressure counter pressure.casting.该工艺表用于铝的半永久性模具和永久性模具铸件（钢瓶头除外，钢瓶头有自己的表）。包括活塞、铝合金车轮。浇铸工本公司铸机设备为：旋转式浇注。艺包括不同类型的设备，如：重力压铸、倾斜式浇铸、旋转式、低压压铸、压力反压式浇铸。Featurecategories特性类别Theevaluationresults 评价结果Requirement 最低要求Observations / Commentsabout Actual Condition对实际情况的观察/评论evaluate 评价1.0J1.1Conformto 符合PassJ1.2DesignSoftware设计软件Conformto 符合1. Casting plant must be compliant to customer specific software requirements.2. Casting plant must have and maintain customer specific requirements for math data transfer for the toolingand for part Drawings / Models.1. 铸造车间必须Conform to 符合客户特定的软件要求。2. 铸造工厂必须有并维护客户对模具和零件图纸/模型的数学数据传输的特定要求。1. Use pro-E design software;2. Be able to use and use email, and be able to use thelanguage and system that are easy to communicateaccording to the requirements of customers1.使用Pro-e设计软件；2.具备且使用，使用邮箱传输，能够根据客户的要求使用便于沟通的语言和系统PassJ1.3FEA Analysis有限元分析Conformto 符合1. The design responsible party must complete an FEA (Finite Element Analysis) for the casting. The ultimatetensile strength, yield strength, and percent elongation used in the FEA must be over the lower limit ofengineering requirement for the specified alloy for similar applications.2. The foundry should know the specific features of the casting where maximum stresses exceed 50% of theYield Strength. For purposes of this assessment, the expression \"high stress\" refers to any feature exceeding50% of the Yield Strength.3. Any high stress features identified in the FEA must be evaluated when casting simulations are reviewed, andwhen establishing product audits such as wall thickness, microstructure, hardness, x-ray, crack inspections.1、设计责任方必须进行有限元分析（Finite Element Analysis FEA）。在有限元分析中，通过对比以往类似待定合金应用的工程规范要求，来确定铸件所采用的极限抗拉强度、屈服强度和延伸率的最低限值。2、铸造厂应知道铸件的最大应力超过极限屈服强度50%时的特征。这种评估的目的是考虑超过屈服强度50%的“高应力”对任何铸件性能的影响。3、在对铸件的有限元分析进行评审时，在对产品壁厚、金相组织、硬度、X射线、裂纹检验等进行产品审核时，必须对有限元分析中所识别出来的所有高应力特征进行评估。1. Most of them are for graphic processing, but havedesign ability; cooperate with Huazhong University forfinite element analysis;2. Be thoughtful;3. Assessment Conform to meet the requirements1.绝大部分为来图加工，但有设计能力，与华中大学合作进行有限元分析；2.有考虑；3.有评估Conform to 符合要求PassJ1.4CastingSimulation铸造模拟Conformto 符合1. The casting plant must use solidification modeling software such as MagmaSoft, AnyCasting, ProCast, EKK,FLOW-3D or similar software approved by the customer Product Engineering on the casting as part of thedesign process for the gating and feeding system prior to tooling construction and prototype part submission.Simulation must include both fill and solidification analysis.2. Results must be reviewed with the Customer Product Engineering.3. At any high stress features in the FEA, the simulation should avoid hot spots, air entrapment, multiple metalfronts converging.1. 铸件厂必须使用MagmaSoft、AnyCasting、ProCast、EKK、FLOW-3D或客户产品工程师认可的铸件凝固建模软件，作为浇注和进料系统设计过程的一部分，然后才能进行模具施工和原型部件提交。模拟必须包括填充和凝固分析。2. 结果必须与客户产品工程师一起评审。3.在有限元分析中的任何高应力特征下，模拟应避免热点、空气滞留、多个金属前沿会聚。1. China casting CAE software is used to simulate theanalysis of casting filling and solidification process.2. Communicated with customer product engineeringdepartment about simulation design results.3: Attention 1：有使用华铸CAE软件，模拟包括浇注填充和凝固过程的分析。2：模拟设计结果有与顾客产品工程部门沟通。3：有关注PassJ1.5Single Cavity单腔铸模Conformto 符合Single cavity dies are required. If the casting plant predicts a multi-cavity die will work, the proposal must beapproved by customer Product Engineering. Casting simulations must support that multi-cavity would be sameThe company uses a single cavity mold; There are alsoquality, or better, than single cavity.products that use multi-cavity moulds.需要单腔模具。如果铸造厂预测多型腔模具将会工作，该建议必须得到客户产品工程部门的批准。铸造模拟必须支持多型本公司使用单腔铸模；也有产品使用多腔铸模。腔与单型腔质量相同或更好。1. If the casting plant creates the raw casting drawing, that drawing must be approved and released per thecustomer Product Engineering requirements.2. If the casting plant creates the tolerance limits between the raw casting drawing and any other drawing,those tolerance limits must be approved by the customer Product Engineering.3. Whenever possible, the X-Y-Z datum surfaces used on the machined components should be the same X-Y-Zdatum surfaces as the raw castings. This is for dimensional control purposes and minimizing datum shiftsbetween the casting and machined surfaces (one of the causal factors related to thin-wall conditions).4. Tooling design must allow all raw casting locators (datum surfaces) to be on one piece of the tooling steel.This is for dimensional control purposes. Customer Product Engineering approval is required for any deviationfrom this concept.5. The raw casting datum surfaces must not be removed by any post-processing or machining unless customerProduct Engineering has approved it.1. 如果铸造车间创建了原始铸造图纸，该图纸必须根据客户产品工程要求得到批准和发布。2. 如果铸件厂在原始铸件图纸和任何其他图纸之间建立公差限制，这些公差限制必须得到客户产品工程师的批准。3.在可能的情况下，用于加工零件的X-Y-Z基准面应与原始铸件的X-Y-Z基准面相同。这是为了尺寸控制和最小化铸件和加工表面之间的基准位移(这是与薄壁条件相关的原因之一)。4. 模具设计必须允许所有原始铸件定位器(基准面)位于模具钢的一块上。这是为了尺寸控制的目的。任何偏离此概念的地方都需要客户产品工程批准。5. 未经客户产品工程批准，未经任何后处理或机加工的铸件基准表面不得去除。All production dies / molds should be made from steel alloys unless customer Product Engineering approvesalternate material.1、模具钢必须Conform to 符合行业标准的材料规格和指定模具零件图。典型合金H11和H13。1a、插入材料的最低要求是Conform to 符合NADCA（北美压铸协会）标准207-(最新版)。1b、当适用时，铸造工厂必须能够证明插入件和型腔应用的材料Conform to 符合顾客特殊要求。2、固定块应由钢铁制造并按顾客特殊要求控制材料硬度。典型合金P20、4140、8620。1. Vents or Risers should be located where simulations show the last places to fill.2. All molds should be vented to atmosphere unless the application includes vacuum or counter pressure.3. Only slotted vents are to be used in the molds unless other types approved by customer.1、溢流应在模拟填充最末端位置。2、所有模具的排放应到大气中，除非应用真空辅助通风。3、所有的模具都应该至少有一个冷却通风道或其他顾客的要求。PassJ1.6CastingDatum铸造基准Conformto 符合1.Conform to2.Conform to3.The same4.Conform to ，On the whole1. 符合2. 符合3.相同4.符合，在一个整体面上PassJ1.7Casting ToolMaterial模具材料Conformto 符合Use die steel 使用模具钢PassJ1.8Mold Vents模具排气槽Conformto 符合The exhaust duct is arranged on the upper and lowerparting surfaces.排气道设置在上下分型面上。PassJ1.9Internal MoldCoolingCircuit Design模具冷却回路设计Conformto 符合The mold should have internal circuit connections to air and/or water lines with regulated temperature andflow rates. The mold must be design with sufficient internal cooling circuits. These circuits must be confirmedThe mold has no water cooling system and is cooledwith simulation software, and approved by the customer.by its own heat dissipation.模具应具有与空气和/或水管线的内部电路连接，并具有调节的温度和流速。模具必须设计有足够的内部冷却回路。这些电模具没有水冷系统，靠模具自身散热冷却。路必须用仿真软件确认，并得到客户的批准。1. Check-sheet verification to account for potential issues outside of the standard Preventative MaintenanceDo not apply 不适用scope of work.2. Internal mold water lines must be checked for water flow rate when the mold is new and during maintenanceunless customer Product Engineering waives this requirement. A qualitative inspection for flow is unacceptable.A quantitative measure of the flow rate is required. The intent is to maintain the tooling with the flow rate usedin the design simulations.1.检查表验证，以说明标准预防性维护工作范围之外的潜在问题。2.当模具是新的时侯和维护期间，必须检查内部模具水管的水流量，除非客户产品工程部门放弃这一要求。流量的定性检查是不可接受的。需要对流量进行定量测量。目的是用设计模拟中使用的流速来维持工具。1. Molds must be recoated at a fixed frequency for preventative maintenance.2. Gages to check coating thickness are required.1.模具必须以固定的频率重新涂覆，以进行预防性维护。2.需要测量涂层厚度的仪表。1. Confirmation of de-calcification of the water flow lines.2. Water and air line plumbing flow checks.3. Thermocouple function check.4. Ejector pin function check.5. Steel Core and slide condition.6. Other Items ( Hydraulic Connections, Air line Connections, Limit Switches).1.水流管线去钙化的确认。2.水和空气管道流量检查。3.热电偶功能检查。4.顶杆功能检查。5.钢芯和滑动条件。6.其他项目(液压连接、空气管线连接、限位开关)。1. The life of the tooling is tracked based on number of cycles.2. There is an itemized list of regular maintenance items completed at pre-defined frequencies; includingsealing surfaces of core boxes and molds.3. Checksheet to track completion of regular maintenance.4. Abrasive systems (such as shot blast and hand grinding) not permitted for cleaning tooling. Non-abrasivesystems (such as dry ice, high pressure water blast, solvent washing and ultrasonic) are required.1. 工具的生命周期是根据循环数来跟踪的。2. 有按预定频率完成的定期维修项目的分项清单;包括芯盒和模具的密封面。3.检查表跟踪定期维护的完成情况。4. 研磨系统(如喷丸和手工研磨)不允许用于清洗工具。需要非磨料系统(如干冰、高压水鼓风、溶剂清洗和超声波)。PassJ1.10MoldInspection(Such as Endof RunInspection)模具检查(如运行结束检查)J1.11MoldPreparation模具准备Conformto 符合Clean the original coating on the mold before painting,and then paint the new one. 模具上涂装前将原涂层清理干净，再涂新装。PassPre- ReleaseChecklistElements ToolRoomJ1.12Specific 模具库内使用前检查清单Conformto 符合Check as per checklist requirement.按检查清单要求检查。PassJ1.13ToolingMaintenance模具保养Conformto 符合1. Developed standards for periodic validation orscrapping according to the use of modules;2. Established the standard of regular maintenance;3. Maintenance checklist;4. Use a hand mill for cleaning1.制定了根据使用模次定期验证或报废的标准；2.制定了定期维护保养的标准；3.有保养检查表；4.使用手磨清理PassJ1.14Tool Changes模具变更☆Conformto 符合1. Replacement inserts (new steel), where there is a customer specific requirement, a PPAP approval may berequired. Customer specific requirements may require a process change request submission with possibleproduction trial run requirements.2. All tooling repair (welding, grinding, machining, insert replacement) requires dimensional verification(internal approval) prior to re-instituting the tool for production volumes.3. The supplier complies with all customer requirements related to which PPAP requirements are needed whentooling is corrected.1、更换镶件（新钢），如果有客户特殊要求，可能要求PPAP批准。客户特定要求可能要求过程变更申请，随同可能的生产试制要求一并提交2、所有模具维修（补焊，磨光，加工，更换插件）要求在重新投入到生产前，进行尺寸确认（内部批准）。3、当模具维修后，供应商需要Conform to 符合所有顾客PPAP相关要求。1. All castings produced must be identified with customer branding requirements, casting plant logo (asapplicable), casting part number, cavity number, and cast date in designated locations per customerrequirements.2. In some applications, traceability to both casting machine and/or measured process parameters specific tothe casting may be required. Identification must be accurate and readily visible on non-machined surfaces, andmust not interfere with parting lines, appearance, function, processing or assembly.1. 所有生产的铸件都必须按照客户的要求在指定的位置标识客户的品牌要求、铸件工厂标识(如适用)、铸件零件号、型腔号和铸件日期。2. 在某些应用中，可能需要对铸造机和/或特定于铸造的测量工艺参数进行追溯。标识必须准确，在非加工表面上容易看到，并且不得干扰分型线、外观、功能、加工或装配。1. Gage and fixture plan must be reviewed and approved by customer. (May include in-line gage equipment for100% check of critical dimensions as identified on part specification and/or part drawing.).2. All features on fixtures and gages which measure a dimensional aspect of the part must be built within +/- 5-micron accuracy. This is the dimensional accuracy of the fixture and gage; not the dimensional accuracy of thepart. Customer approval is required for any other accuracy such as 10% or less of part working tolerance.3. All surfaces of fixtures and gages which touch the part must be made from hard tool steel unless customerProduct Engineering approves other materials.4. The tips of all clamps on fixtures and gages must be built with replaceable tips unless customer ProductEngineering approves a different design.5. Variable gages must pass Gage R&R per AIAG or similar standard.6. Production fixtures must use hydraulic or pneumatic clamping during the machining operations. Manualclamping is not allowed.7. All fixtures and gages must be certified periodically either by in-house if capable or by third party.1.量具和夹具计划必须由客户审查和批准。(可能包括在线仪表设备，用于100%检查零件规格和/或零件图纸上确定的关键尺寸。)。2.测量零件尺寸的夹具和量具上的所有特征必须建立在+/- 5微米的精度范围内。这是夹具和量具的尺寸精度；不是零件的尺寸精度。任何其他精度，如零件工作公差的10%或更小，都需要客户批准。3.接触零件的夹具和量具的所有表面必须由硬工具钢制成，除非客户产品工程部门批准其他材料。4.除非客户产品工程部门批准不同的设计，否则夹具和量具上所有夹具的尖端必须用可更换的尖端制造。5.根据AIAG或类似标准，可变量具必须通过计量器具R&R。6.生产夹具必须在加工操作过程中使用液压或气动夹紧。不允许手动夹紧。7.所有夹具和量具必须定期由内部人员(如果有能力)或第三方进行认证。1. Provision of change process, including submissionof customer approval and pilot productionconfirmation when necessary;2. After maintenance, make new samples to verify theblank size;3. In accordance with 1.有变更流程规定，包括提交顾客批准及必要时的试生产确认等；2.维修后，重新做样件验证毛坯尺寸；3.符合PassJ1.15CastingTraceability铸造可追溯性☆Conformto 符合1: the production of castings are made according tocustomers drawings and inspection2: strictly according to the requirements of customeroperation1：生产的铸件都按客户提供的图纸生产和检验2：严格按照客户的要求操作PassJ1.16Fixtures andGages夹具和量具☆Conformto 符合1: Measuring instruments and fixtures are verified, andPPAP is provided to customers for approval throughthe products. 2: The dimensional accuracy of allfixtures and measuring tools can meet therequirements of customers3: Accord with 4:Comply with 5:Conformance 6: Allfixtures and gauges have internal and third partyvalidations1：计量器具和夹具都有进行校验，并通过产品对顾客提供PPAP进行批准2：所有夹具和量具的尺寸精度都能满足顾客的要求3：符合4： 符合5：符合6：所有夹具和量具都有内部校验和第三方校验Pass2.0CastMachines 铸造机J2.1Start-UpProcedures启动程序Conform2、要求应用防错方法或颜色区分管线。to 符合1、必须使用铸造机启动检查表来确认所有的水喝空气管线按照规定进行了连接。3、每一次启动必须按照检查表进行确认。1. Startup sequence must account for cycles used to warm up the mold.2. Auto scrap or manual method is used to segregate warm up parts as scrap.3. Cycle time must be measured for each casting cycle to account for cycle interruptions, should they occur.4. Auto scrap or manual method is used to separate parts after restarting from interrupted cycles.5. The foundry must correlate the number of start-up cycles with the finish machined / thoroughly inspectedpart quality. The number of parts to scrap is not based on the first good part, it is based on the last bad part.There can be some overlap of good and bad as the die heats up. Must assure that none of the bad parts areshipped.1.启动顺序必须考虑用于加热模具的循环。2.自动报废或手动方法用于将预热零件分离为废品。3.如果出现周期中断，必须测量每个铸造周期的周期时间，以说明周期中断的原因。4.自动报废或手动方法用于从中断的循环中重启后分离零件。5.铸造厂必须将启动周期数与精加工/彻底检查的零件质量相关联。要报废的零件数量不是基于第一个好零件，而是基于最后一个坏零件。随着芯片温度的升高，好坏之间可能会有一些重叠。必须确保没有坏零件被装运。Unless customer Product Engineering approves an alternative concept for die temperature control, the dietemperature must be controlled with thermocouples as described in this section.1. Thermocouples in the molds are required. The temperature must be continuously displayed. There must bean alarm to indicate when the temperature is out of range. Automatic temperature adjustment is required.2. The thermocouples in the die must target the same temperature as the Solidification simulation model.3. Flow meters are required on all mold water / air lines. The PLC must turn the cooling water / air On and Offbased on the thermocouple temperatures. Maintain the die temperatures within +/- 50ºC of the setpoint;preferably within +/- 25ºC.除非客户产品工程部门批准另一种模具温度控制的概念，否则模具温度必须按照本节所述用热电偶控制。1. 需要模具中的热电偶。每个燃烧室都必须有一个热电偶。温度必须连续显示。当温度超出范围时，必须发出警报。需要自动温度调节。2. 燃烧室热电偶的目标温度必须与凝固模拟模型相同。3. 所有模具水/空气管线都需要流量计。可编程控制器必须根据热电偶温度打开和关闭冷却水/空气。将燃烧室温度保持在设定点+/-50℃以内；优选在+/-25℃内Work instruction is made 制定了作业指导书PassJ2.2Startup andDowntimeRecovery启动和停机恢复Conformto 符合Have equipment operation rules; Process parametersof inverted pouring machine; Restore procedures forstartup and shutdown.有设备操作规程；翻转浇注机工艺参数；启动和停机的恢复操作规程。PassJ2.3DieTemperature铸模温度Conformto 符合The mold has a special temperature measuring systemto set different mold temperature requirements fordifferent castings.模具有专门测温系统，针对不同的铸件设定不同的模具温度要求。PassJ2.4Mold Coating模具涂层MoldCleanliness模具清洁度ConformWhen needed, masks should be designed to protect critical areas from coating buildup.to 符合需要时，面罩的设计应能保护关键区域免受涂层堆积的影响。ConformMolds must be blown out each cycle before the slides close.to 符合在模具关闭之前，必须在每个循环中吹出异物。1. Each part may be cooled with water or air.2. Extraction tools should be designed to clamp on the gating or risers without touching the finalcasting product.3. Automatic extraction is preferred.Conform4. Automatic extractors should be programmed to scrap castings when parameters, such as moldto 符合temperature, are out of range.1.每个部件可以用水或空气冷却。2.抽取工具应设计成夹紧浇口或冒口，而不接触最终铸件。3.优选自动提取。4.当参数(如模具温度)超出范围时，自动提取器应编程报废铸件。Use masking tape to protect important areas whenspraying喷涂时用遮掩罩来保护重要的位置The cavity must be blown clean.必须吹干净模腔。PassJ2.5PassJ2.6ExtractionTools铸件取出装置Each casting is cooled by air; The casting is removedmanually from the runner or riser.每个铸件通过空气冷却；手动取出铸件，在浇道或冒口处取铸件。Pass3.0Metal Control金属控制Incoming/RetJ3.1urnedMaterialStorageSource ofJ3.2Material材料来源MetalJ3.3Chemistry金属化学ConformRaw /Returned materials must be stored without mixing them in marked storage areas by type.Areas are separated and marked with lines有用线划区域to 符合原料/退回的原料必须储存在标有类型的储存区域，不得混合存放。分开放置并进行标识PassPrimary metal may be required for some applications based on customer specific requirements.When the return charge and the new material areConform根据客户的具体要求，某些应用可能需要初级金属。added, the electronic scale is used for weighing, and ato 符合certain proportion is prepared.回炉料和新料添加时都有Pass用电子称进行称重，并按一定比例配制。1. Chemistry must be controlled at each key point in the process (melting, holding, and pouring).2. It is required to use ASTM E716 disk book molds (or approved equivalent) for chemistry samples.1. To control the chemical composition of aluminum3. There must be a spectrometer on site for chemistry control. Industry Standards, such as ASTMwater during smelting, it is required that the water inE1251, must be followed for sampling, verification, standardization and calibration.the melting furnace must pass the test before being4. The Spectrometer must have certified Master Calibration Standards which cover the range oftransferred.each chemistry element being controlled. Sufficient Calibration Masters must be on site in order to2. Direct reading spectrometer is available on theaudit each element being controlled in direct comparison with a Calibration Master.melting site, in accordance with industry standards;5. A procedure must be posted near the spectrometer which clearly defines the permissible3. Have a special physical and chemical laboratory totolerance range of the Master calibration Standards.detect the ingredients;6. There must be control limits for all key elements of the material grade.4. The direct reading spectrometer has qualified7. The Sludge Factor must be measured and controlled below 2.0, preferably below 1.8. SF = %Fecalibration standard samples, including each chemical+ 2X %Mn + 3X %Cr. The Iron (Fe), Manganese (Mn), and Chromium (Cr) specification limits for rawelement that needs to be controlled. The standardmaterial suppliers must take into account the maximum permissible Sludge Factor. Be aware thatsamples are stored in the field spectral room, andthe temperature of holders should not be turned down low when there is no production. The lowerstandardized calibration is performed once per shift.5. Calibration standard sample tolerance range isConformthe temperature, the faster the rate of Sludge formation.posted near the spectrometer;to 符合8. The Iron:Manganese ratio must be calculated and controlled. The recommendedIron:Manganese ratio target is 2:1.6. Controlled all chemical elements specified byPass1.化学必须在过程的每个关键点进行控制(熔化、保持和倾倒)。customers;2.化学样品需要使用美国材料试验学会E716圆盘书模具(或批准的等效物)。7. The total amount of impurities shall not be greater3.化学控制现场必须有分光计。取样、验证、标准化和校准必须遵循行业标准，如美国材料试验标准E1251than 0.2%; 8: /。1.熔炼时控制铝水化学成分，要求熔炼炉水转移前，必需化4.分光计必须具有认证的主校准标准，该标准涵盖每个受控化学元素的范围。必须有足够的校准主设备在现验合格才能使用。场，以便与校准主设备直接比较，对每个被控制的元件进行审计。2.熔炼现场有直读光谱仪，遵循行业标准；5.必须在分光计附近张贴一个程序，明确规定主校准标准的允许公差范围。3.有专用的理化室来检测成份；6.材料等级的所有关键元素必须有控制限制。4.直读光谱仪有合格的校准标准样件，包含每个需要被控制7.污泥系数必须测量并控制在2.0以下，最好低于1.8。SF = %铁+2X %锰+3X %铬。原材料供应商的铁(铁)的化学元素，标样存放在现场光谱室，每班做一次标准化校、锰(锰)和铬(铬)规格限值必须考虑最大容许污泥系数。请注意，当没有生产时，支架的温度不应调低。温度准。越低，污泥形成速度越快。5.光谱仪附近张贴了校准标样的公差范围；8.铁锰比必须计算和控制。推荐的铁锰比目标是2:1。6.控制了所有顾客指定的化学元素；7.杂质总量不大于0.2%；8：/For any elements with customer specified mandatory limits, these limits must be reduced by thetolerance permitted on the Master calibration Standards. 对于任何具有客户指定强制限值的元素，这些限值必须减少到主校准标准允许的公差范围内。J3.4Chemistry 化学☆Conformto 符合Aluminum water test chemical composition, qualifiedto use; After treatment, the chemical composition isdetected, and the unqualified whole furnace is isolated.The chemical elements can meet the mandatoryrequirements of customers within the tolerance range铝水检测化学成分，合格才能使用；处理后检测化学成分，不合格整炉隔离，可以满足顾客强制性规定的化学元素在公差范围内PassJ3.5GrainRefinement晶粒细化The most frequent grain refinement additive is Titanium Boron.1. If Titanium Boron is added either in-stream or in the ladle by an automated system there mustbe an audit to confirm that wire is being measured for correct length and confirmation that wire isbeing dissolved for each mold cycle.Conform2. Grain refinement may be required by customer Product Engineering.to 符合最常见的晶粒细化添加剂是钛硼。1.如果钛硼是通过自动系统在流中或钢包中添加的，必须进行审核，以确认线材的测量长度正确，并确认线材在每个模具循环中溶解。2.客户产品工程可能需要晶粒细化。1. The most frequent silicon modification element is Strontium.2. Silicon modification may be required by customer Product Engineering.Conform3. A common target is150 ppm.to 符合1.最常见的硅改性元素是锶。2.客户产品工程部门可能需要硅改性。3.一个共同的目标是150 ppm。1: Add titanium boride manually, and there is a meltingoperation instruction on how to add.2: Standard metallographic pictures of grainrefinement are provided by the customer.1：手工加入硼化钛，有熔解作业指导书规定怎么添加2：晶粒细化的标准金相图片由客户提供。PassJ3.6SiliconModification硅变质1: Meet the requirements2: Have the requirements1：符合2：有要求PassJ3.7Degassing除气1. All metal should be rotary degassed before pouring. Degassing may be in a transfer ladle or in aholder at the cast machine. The preferred design of the degassing unit is a baffle plate or anti-vortex system.2. The use of cast machines with integral melter/holders is discouraged. It is often difficult to meetrequirements for metal cleanliness and degassing. A minimum expectation is a baffled chamberwith a rotary degassing unit running continuously.3. After rotary degassing, a vacuum gas sample must be taken in order to determine the specificgravity. Calculate specific gravity of sample using weight in air vs. weight in water method. Thespecific gravity must be within 0.10 of the theoretical maximum based on the chemistry of the alloyand a maximum of -27 inches of Mercury vacuum pressure. For many alloys, the theoreticalmaximum is around 2.70.Conform4. Depending on customer-specific requirements, vacuum gas sample testing may not be requiredto 符合for each degassing cycle if the degassing unit monitors process parameters including flow rate,RPM, and gas pressure.1、所有金属都应该旋转浇注前脱气。脱气可能是传输包或持有人在铸造机。首选的脱气装置的设计是一个隔板或本系统。2、铸机的使用与整体熔化器/持有人是气馁。往往很难满足要求金属清洁和消毒。最低的期望是一个困惑室旋转脱气单元持续运行。3、旋转脱气后，必须采取真空气体样本以确定比重。计算样品的比重在空气与重量的水使用重量的方法。比重必须在0、10的理论最大值基于合金的化学和最多-27英寸的水银真空压力。对于许多合金来说，理论最大大约是2、70。4、根据顾客的特定要求，真空气体样品测试可能不需要为每一个脱气周期如果德加单位监控工艺参数包括流量、转速、气体压力。1: Degassing was carried out before pouring2: The graphite degassing rod was used to pass to thefurnace bottom to rotate degassing.3. Confirm the degassing effect after degassing.4: Each furnace has the detection degassing amount,after reaching the standard value can produce.1：浇注前有进行脱气2：用的是石墨除气棒通到炉底旋转脱气。3：脱气后有进行脱气效果确认 。4：每一炉都有检测脱气量，达到标准值后才能生产。PassJ3.8MetalTransfer金属转运Molten metal from the melting furnaces may be tapped directly to go to the cast line, or it may beMetal transfer is completed before degassing, that is,transferred to intermediate holders. If intermediate holders are used, they must have heat.melting in the gas furnace, low temperature熔融金属的熔化炉会直接去投线，或者它可能被转移到中间持有人。如果使用中间持有人，他们一定热量。Conformdeslagging and then deteriorated, transferred to theto 符合resistance insulation furnace.金属转运是在除气这前完成的，即在燃气炉内熔解，低温除渣再变质后，转到电阻保温炉内。The temperature of metal being delivered to a cast machine holding furnace must be checked. TheConformtemperature of metal being delivered must be within internally specified control limits such thatto 符合the cast machine holding furnace stays in specification. 金属被送到铸机的温度保温炉必须检查。金属的温度必须交付指定的内部控制范围内，铸机保温炉停留在规范。After turning to the heat preservation must check itscomposition, heat preservation furnace automatic heatpreservation.转到保温后必须对其成份进行检查，保温炉自动保温。PassJ3.9MetalTransfer金属转运PassJ3.10HoldingMetalTreatmentandTemperatureControl金属处理和温度控制1. Metal at the cast line may be in a ladle or in a holder.2. If holders are used at the cast line, they must have heat.3. If holders are used, the temperature output must be readable by the machine operator. If themetal temperature in the holding furnace falls outside of the specified range, an alarm must beestablished to indicate an out of tolerance condition.4. Holding furnaces at the cast machines must be capable of controlling metal temperature at themetal extraction point to within +/- 5°C, unless the customer agrees to a wider range.Conform5. Alloying into the cast machine holding furnaces or ladles is allowed, but must be minimized into 符合order to prevent defects such as inclusions.1.铸造生产线上的金属可能在钢包或保持架中。2.如果支架用在铸造线上，它们必须有热量。3.如果使用支架，机器操作员必须能够读取温度输出。如果保温炉中的金属温度超出规定范围，必须建立警报以指示超出公差条件。4.铸造机的保温炉必须能够将金属提取点的金属温度控制在+/-5℃以内，除非客户同意更宽的范围。5.允许在装有熔炉或钢包的铸造机中合金化，但必须尽量减少，以防止夹杂物等缺陷。保温炉通过热电偶及报警系统控制温度，当低于或超过规定值时，就会自动报警。Pass4.0Cast In PlaceInsert现浇插入J4.1Insert Source插入源☆1. The customer Product Engineering must approve the source for cast in place inserts.2. The insert source must implement Full Compliance with the applicable template Process Tablebefore PPAP. For example, a ductile iron bearing cap in a bedplate, the casting source mustimplement Full Compliance with the Ductile Iron Casting Process Table before PPAP.1、顾客产品工Do not apply不适用程必须批准的源代码在插入的地方。2、插入源必须实现完全Conform to 符合适用的模板在PPAP流程表。例如，球墨铸铁轴承盖在台板，铸造源必须实现完全Conform to 符合球墨铸铁铸造工艺表在PPAP。1. Cast-in-place inserts must be pre-heated immediately prior to pouring metal into the die.2. The cast-in-place inserts must be completely dry. The volatiles content on the inserts must beaudited, measured, and recorded.3. The cast-in-place inserts must be properly stored (maintained clean and dry).1、场铸插入之前必须立即预浇注金属到模具。2、场铸插入必须完全干燥。插入的挥发物含量必须审核，测量和记录。3、场铸插入必须妥善保存(保持清洁和干燥)。J4.2Insert ProcessControl插入过程控制Do not apply不适用J4.3Insert Audit插入审核☆1. There must be a regular audit to section the castings to inspect the bonding of the cast in placeinsert with the aluminum. Audit results must be documented.2. Depending on customer design requirements, dye penetrant inspection may be required onDo not applymachined castings to inspect for cracks (or contact separation) around the inserts. Audit results不适用must be documented.1、必须有一个定期审核部分铸件检查焊接的地方插入铝。审计结果必须记录。2。根据顾客的设计要求，可能需要着色渗透检验对机加工铸件检查插入裂缝(或接触分离)。审计结果必须记录。ConformFilters may be required by customer to be used in all molds. 顾客可能要求所有的铸型使用过滤网。to 符合The inverted mold does not require a strainer翻转铸型不需要过滤网5.0J5.1Pouring浇注Filter 过滤网PassJ5.2Auto Pouring自动浇注1. If stationary auto pouring holders are used, they must have heat.2. Stationary auto pouring holders must be capable of controlling metal temperature at the metalextraction point to +/-10C.3. If stationary auto holders or tilting auto ladles are used, they should have an infraredConformmeasurement sensor to check the temperature of the metal stream for each mold poured. TheManual pouringto 符合device should alarm if the temperature is out of range. 1、如果使用固定式自动浇包，浇包必须加热手动浇注。2、固定式自动浇包必须能够控制金属液温度，金属液温度波动必须在±10℃之内。3、如果使用固定式自动浇包或倾斜式自动浇包，应该有红外线测量传感器测量倒入每个铸型内的金属液温度。如果温度超出控制范围，此装置能够立即报警。Automatic pouring of molten metal into the mold is required. Manual pouring is not allowedunless otherwise approved by customer.1. Manual pouring into a tilt-pour basin is allowed.Conform2. Dip wells should be covered when the holding furnace is not in use.to 符合3. Metal ladles should be on heat at their home position.1、金属液最好采用自动浇注方式浇注铸型。如果顾客同意，手工浇注也可以。2、当保温炉不在使用状态时，应盖上升降盖。3、金属浇包应在静止位置加热。PassJ5.3Metal Pouring金属浇注The heat preservation furnace has a lift cover for heatpreservation保温炉有升降盖保温PassJ5.4Batch PourSystem间歇式浇注Metal Quality金属质量Immersion temperature audit from each ladle or pour box to confirm that all molds were pouredConformwithin specified temperature range. 对浇包或浇注杯用浸入式温度Conform to 符合温度范围to 符合计检查，已确保所有的铸型的液体浇注温度都在规定的温度范围内。Charging raw materials or scrap into the auto pouring holders or ladles and running productionConformout of them at the same time is prohibited. 在生产运行的同时，由于缺料向自to 符合动浇注包或浇包加原材料和废料是严格禁止的。Do not pour the remaining liquid aluminum or rawmaterials into the holding furnace.严禁将剩余的铝液或原料倒入正在生产保温炉内。PassJ5.5PassJ5.6Alloying 合金Alloying into the auto pouring holders or ladles is allowed, but must be minimized in order toIn strict accordance with the ratio of new and oldConformprevent defects such as inclusions. 合金浸入自动浇注包内是允许的，为防止例如夹杂物的缺陷，合金加materials (alloy) feeding meltingto 符合入必须是最小量。严格按新料与旧料（合金)比例加料熔化Ladles must be free of skull (aluminum oxide film) before entering the dip well. Visual inspectionConformcriteria should be defined and posted in the work area. 在进入倾斜井前浇包内必须无渣壳（氧化铝to 符合膜）。应规定目视的检查规范并在工作区域张贴。The ladle and gate must be cleaned of aluminum oxidefilm.浇瓢和浇道口处必须将氧化铝膜清理干净。PassJ5.7LadleCleanliness浇包清理Ladle Design浇包设计PassJ5.8ConformBest practice for Ladle design uses a dam (hole in the back) to hold back the dross. 最好的做法是为The ladle is provided with a dam to hold back scum.to 符合浇包设计一个堤坝（后面有孔）挡住浮渣。浇包有挡浮渣的堤坝设置。When pressure pour dosing furnaces are used, an inert gas or dry air may be used to pressurize theCastings of different sizes are selected according toConformchamber. If air is used, the dew point must be less than -40º C, preferably below -80º C. 当使用压力casting size.to 符合浇注定量包时，密封压力室内可使用惰性气体或干燥气体。如果使用空气，露点必须低于-40℃，最好为-80根据铸件大小选用不同大小的浇包。℃。ConformLaunders from dosing furnaces must be designed and maintained such that metal does notto 符合buildup in them. 对定量浇注包，必须保证溜槽的设计不会造成金属液的堆积。Conform to符合要求PassJ5.9DosingFurnace 定量包PassJ5.10Launders 溜槽PassJ5.11Oxide Control氧化物控制1. Metal quality must be tested for oxide content. As a minimum verification PoDFA (Porous DiskFilter Analysis), or other analysis approved by customer.Conform2. Dip wells must be frequently skimmed to minimize the dross accumulation. 1、必须测试金属液的to 符合氧化物含量。最起码验证PoDFA（透水板薄膜分析的结果），或者顾客批准的其他分析方法。2、倾斜井必须被经常进行清理，除去浮渣，使浮渣减少到最低量。It is recommended that equipment computer programs or mechanical limits for pouring and cycleConformtimes are protected from non-authorized changes so that only authorized personnel can changeto 符合the program or settings. 为防止对浇注和循环周期的非授权更改，建议设备计算机程序或机械限制设置，只有授权的人员才可以修改程序或设置。Cast machine should have real time closed loop monitoring which is either tied into theextractor/robot control or creates an alarm when key parameters are beyond control limits.ConformCastings that are outside the control limits must be marked and later scraped. 铸造机应具备对铸件to 符合取出/机器手控制，或关键参数失去控制时能够报警的实时闭环监控系统。上述超出控制范围状态时的铸件必须被标识，能够分离出来进行附加的验证。J5.12MachineSettings 设备设置The scale control of the surface of the heatpreservation furnace is mainly to remove the scale ofthe surface by iron scraping tools. It is stipulated thatevery 3-5 castings must be scraped once. 保温炉表面的氧化皮控制主要通过铁扒工具去除表面的氧化皮，规定每浇注3-5个铸件必须扒一次。The surface pouring machine and the deaerator of theheat preservation furnace have keys to lock the controlcabinet to control the modification parameters of thestaff. 浇注机和除气机都有匙钥锁住控制柜，控制员工修改参数。The castings in question must be stored separatelybefore they can be put into the qualified basket.对问题的铸件必须单独存放，经验收合格才能放入合格的筐内。PassPassJ5.13Control Limits控制限制Pass6.0Low Pressure Casting Process低压铸造过程J6.1ProcessProfileMonitoring过程监控概要1. Machine must have real time monitoring capability for chamber pressure, metal position in tube,cavity fill time, mold temperature, metal temperature, and cycle time.2. When applicable, flow monitoring transducers should be in place for cooling lines.3. Cast machine should have real time closed loop monitoring which is either tied into theDo not applyextractor/robot control or creates an alarm when key parameters are beyond control limits. 1、不适用设备必须有对燃烧室压力、金属在管道中位置、型腔填充时间、模具温度、金属温度和周期时间的实时监控能力；2、当适用时，流量监测传感器应安装在冷却管线适合位置；3、铸造机应具备对提取装置/机械控制或关键参数无法控制时报警的实时闭环监控能力。1. A coarse filter may be used in the top of the fill tube.2. A fine filter may be used in the bottom of the fill tube.3. All fill tubes should be made of solid ceramic material. If the holding furnace is stationary, thebottom end of the fill tube should be inside a fine filter chamber submerged in the molten metal.1、在填充管道顶端可能使用粗过滤器。2、在填充管道底端可能使用精过滤器。3、所有填充管道应由固体陶瓷材料制造。如果保温炉是静止的，填充管的底端应有精滤腔淹没在熔融金属内。J6.2Fill Tube BestPractices填充管的最佳实践Do not apply不适用J6.3Low PressureCover Gas低压覆盖气体Metal Quality金属质量Inert gases are preferred. If dry air is used the dew point must be less than -40º C, preferably belowDo not apply-80º C. 低压覆盖气体最好使用惰性气体。如果使用干燥空气，露点温度必须低于-40℃，最好低于-80℃。不适用Chemistry and density samples must be taken from the low pressure holding furnace.化学和密度采样必须从低压保温炉中采集。Do not apply不适用J6.4J6.5Metal Quality金属质量1. If the holding furnace is stationary, pouring blocks with filters should be used when filling theholder.2. The holding furnace should be skimmed off after every fill of the furnace.1、如果保温炉是静止的，浇注填充时必须带有滤网。2、每次向保温炉内添加金属液都应进行撇渣。The software for the fill/pressure profile should have an infinite number of channels available forprocess options.填充速度/压力曲线的软件应有无限个频道可供选择应用。Do not apply不适用J6.67.0ProcessControl过程控制Do not apply不适用Post Processing and Heat Treating后加工和热处理J7.1Riser Removal去除冒口J7.2Trimming清理There are two methods for removing the riser:hammering and cutting. The hammering position isRiser removal must not damage casting. When riser removal requires a cutting operation, it shouldspecified on the pouring system and the riser. If theConformbe done with an accurate cutting process such as CNC, robot, or saw, which accurately locates thehammer cannot be struck, the riser can be removed byto 符合casting. 去除冒口必须不可以造成铸件损伤。当冒口去除需要切割操作时，它应由精确切割过程完成。例如cutting 去除方法有锤击和切割两加工中心（CNC）、机器人或锯割，应精确地定位铸件。种，锤击位置规定在浇注系统和冒口上，不能锤击的通过切割去除浇冒口1. All parts must be cooled to a defined temperature prior to fixturing for riser removal andtrimming.Conform2. Trimming operations must allow the part to be properly fixtured to prevent damage. AutomatedConform toto 符合part handling systems are preferred. 1、所有零件在夹紧前已进行冒口移除或符合要求清理，必须被冷却到规定温度。2、清理操作必须确保零件被适当夹紧，避免损坏铸件。最好使用自动控制系统处理铸件。Heat treating must be before machining and may be in-house or outsourced. Heat treating mustConformbe in compliance with CQI-9: Special Process: Heat Treat System Assessment (HTSA), published byto 符合AIAG. 必须在加工前进行热处理，可在厂内进行热处理，也可以外包。热处理必须Conform to 符合由AIAG发布的《CQI-9特殊过程：热处理系统评审》要求。Heat treatment conforms to the requirements of THEQI-9 Special Process: Review of Heat TreatmentSystems published by AIAG热处理符合由AIAG发布的《CQI-9特殊过程：热处理系统评审》要求PassPassJ7.3Heat Treat热处理★PassJ7.4Heat Treat热处理Heat Treat 热处理Heat Treat 热处理Any liquid quench must have automatic temperature control and agitation. Equipment must beConformThe furnace temperature is within ±5℃capable to control quenching medium to within ± 5º C. Preferably over 80C. 任何液体淬火介质必须to 符合炉温在±5℃以内实现自动温度控制和搅动。设备必须能控制淬火介质在±5℃以内。最好超过80℃。ConformCold water not to be introduced to the quench tank while parts are being quenched.当零件进行淬to 符合火时，不允许淬火槽使用冷水。ConformThe delay from solution heat treat into a quenchant must not exceed 30 seconds.在淬火剂中的延停to 符合时间必须不低于30秒。The water temperature is controlled at 60-100 ℃控制水温在60℃-100℃Conform to符合PassJ7.5J7.68.0PassPassInspection and Testing检验和试验RetainedMaterial orCleanlinessRequirement样品保留及清理要求J8.1Equipment must be available onsite to properly administer retained material inspection perThere are sample racks in the quality control room toConformcustomer requirements.现场必须有适当的设备用于管理检验样件保留品并Conform to 符合每个顾客要求keep samples, and there are limited samples on siteto 符合。品保室有样品架保存样品，在现场有限度样品PassJ8.2DimensionalInspection 尺寸检验☆J8.3WallThickness产品壁厚☆1. As a minimum, the casting plant shall have a programmable Coordinate Measuring Machine(CMM) on site. The CMM must be run in an automatic mode. Where possible, the application ofpoint cloud/laser scanning inspection technology is preferred. When used in combination withpoint cloud scanning technology, the CMM is considered the “gage of record” for dimensionalmeasurements because of precision associated with the points measured.2. The casting plant shall maintain a CMM hit point map/drawing showing all CMM hit points thatare agreed upon between the casting plant and the customer. (Point Cloud Inspection/laserscanning can be used in place of CMM inspection if agreed upon with customer ProductEngineering).3. The CMM program must include checking the flatness of each individual rawcasting datum surface if the datum pad is intended to be a flat surface. Preferably less than0.250mm.4. Point cloud/laser scanning inspection must use the part-design datum construction to align themeasurement data. Unless otherwise specified by the customer, \"best-fit\" data alignment is notallowed.5. The casting plant is responsible for comparing the scan with the 3D Math Model. In all cases theConformPoint Cloud/laser scan must be aligned to the math model using the X-Y-Z raw casting datumto 符合surfaces. Results must be shared with customer Product Engineering and the responsible APQPQuality Engineer.6. Point Cloud/laser scanning Inspection is recommended for prototype parts and PPAP parts asdefined by the customer specific requirements. The scanning may be out-sourced. 1、作为最低要求，铸造厂在现场应有可编程的三坐标测量仪器（CMM），CMM必须在自动模式下运行。如果可能，最好使用图像激光扫描检查技术的应用程序。当与图像扫描技术结合使用时，CMM被认为是尺寸测量的“有记录的测量仪”因为测量精度与所测量的点相关。2、铸造厂应持有一份全坐标测量接触点示意图/图纸，图纸展示所有铸造厂与顾客协商确定的测量点（如果顾客的产品工程部门部门同意，图像扫描/激光扫描可以代替CMM的检测）。3、CMM检测程序必须包括毛坯铸件每个单独定位基准面的平面度检查。如果铸件平面上设置了定位基准凸点，高度最好不要超过0.250mm。4、图像/激光扫描的检验必须根据零件设计数据图纸来对照测量数据。除非顾客另有规定，不允许使用“最合适”的数据做依据。5、铸造厂负责图像扫描与3D数字模型进行对比。在任何情况下，图像/激光扫描与数字模型使用的X-Y-Z毛坯铸件基准面应保持一致。比对结果必须通报顾客的产品工程部门部门和负责APQP的质量工程师。6、对原型样件和顾客特别要求的用于生产批准的样件，推荐进行图像/激光扫描检验。图像扫描检验可以外There must be regular audits to section raw castings for wall thickness verification; including anyhigh stress features in the FEA. If the supplier is responsible for any machining, there must beConformregular audits to section machined castings for wall thickness verification.必须有定期的审核，检查毛to 符合坯铸件剖面壁厚的变化。包括有限元分析时涉及到的高应力情况。如果供应商负责所有的机械加工，那么必须定期审核铸件机加工剖面的壁厚变化。1. There is a programmable CMM and only one 3Dscanner;2. Use process drawings for measurement;3. The CMM detection program includes the detectionof the blank locating datum;4) Conform to5. 3D scanning comparison;6. 3D scanning, no outsourcing1.有可编程的CMM，只有一台3D扫描仪；2.使用工艺图纸进行测量；3.CMM检测程序包括对毛坯定位基准面的检测；4. 符合；5.有3D扫描对比；6.有3D扫描，无外包PassOne piece is randomly selected for each shift to detectthe wall thickness每班随机1件，检测壁厚情况PassJ8.4InternalPassages 内部通道☆Supplier is responsible to acquire proper non-destructive inspection tools to evaluate for blockedAn endoscope device is available to inspect the cavityConformpassages. This may include boroscopes, endoscopes, probes, fiber optics, flow meters, or X-ray.供应for defects.to 符合商有责任获取专门的无损检测工具用以检查铸件隔断的通道。这些无损检测工具可能包括内孔表面检查仪、有内窥镜设备检查内腔缺陷。内窥镜、探针、光纤、流量表或X射线。PassJ8.5Dye PenetrantCheck andNaOH EtchCastings染色渗透检测和氢氧化钠腐蚀检测★1. There must be a regular audit to dye penetrant check (color check) or fluorescent penetrantinspection (FPI) entire casting or sections of castings specified by customer; including any highstress features in the FEA.2. There must be on-site capability to cut and NaOH etch castings for internal inspections. (NaOHConformis sodium hydroxide, also called caustic soda). 1、对染色渗透检测或者荧光渗透剂检测(FPI)必须进行to 符合常规审核。根据顾客的特定要求，或者检查整个铸件，或者检查铸件的断面，包括有限元分析（FEA）中识别出的高应力特征。2、必须能在现场进行切片和氢氧化钠腐蚀内部检测（氢氧化钠 sodium hydroxide，也称苛性钠（烧碱）caustic soda）。1. The supplier shall have a real time fluoroscopic/X-ray unit on-site.2. X-ray equipment must be capable of measuring the sensitivity and resolution so that the systemcan be proven to meet customer requirements defined by product design record.3. X-ray audits must include any high stress features in the FEA.Conform4. For some applications, automated defect recognition may be required.to 符合1、供应商在现场应有荧光检验/X光射线检测装置。2、X射线检测设备必须具有一定的测量敏感度和分辨率，以便能够证明测量结果Conform to 符合顾客产品设计记录规定的要求。3、X射线检测的评估必须包括有限元分析中识别出的高应力特性。4、某些应用，可能要求有缺陷自动识别装置。X-ray is used to detect the inner porosity有用X光检测内部气孔PassJ8.6X-rayX射线检测★1: The company has a fluorescence test/X-raydetection device2: X-ray testing equipment can meet the requirementsspecified in the customer's product design record3: There is assessment4: currently it is manual measurement consideringdefect automatic identification device1：公司有有荧光检验/X光射线检测装置2：X射线检测设备能满足顾客产品设计记录规定的要求3：有评估4：目前是手动测量考虑缺陷自动识别装置PassJ8.7 Repairs铸件返工★1. Customer must approve any salvage repair procedures. Casting repairs, such as welding, epoxy,Devcon, and impregnation, are not permitted, unless approved by customer Product Engineering.2. If repairs are allowed, repair method and procedures must be approved by Customer ProductEngineering.3. If straightening is allowed, a customer Product Engineering approved method is required,ConformBoth are approvednormally with a fixtured, automated process. Manual methods should not be used.1、对铸件进行抢to 符合都经过批准许可救性修补，必须得到顾客批准，不允许对铸件进行如焊接、环氧树脂、DevCon（得复康）和浸渗修补，除非得到顾客的产品工程部门部门的批准。2、如果顾客批准铸件修补，那么修复的方法和程序必须得到顾客的产品工程部门部门批准。3、如果顾客批准对铸件矫形，其方法需要得到顾客的产品工程部门部门批准，通常使用夹具、自动化方法矫形。不允许使用手工方法进行铸件矫形。Pass9.0MaterialProperties材料特性PassIn the foundry workshop, there are special physical andThe supplier shall have a metallurgical lab located on-site with capabilities to analyze chemistries,chemical testing rooms and mechanical performancehardness, microstructure, area fraction porosity, dendritic arm spacing (DAS), silicon particle size,rooms to test the chemical composition, hardness,Conformand any other features specified by customer Product Engineering. 供应商在现场建立冶金实验室并有metallographic structure, mechanical properties andto 符合能力对化学、硬度、金相组织、密度、晶粒度、硅粒度和顾客的产品工程部门部门要求的其它特性进行分析density实验室在铸造车间现场，有专用检测的理化室和机。械性能室来检测化学成分、硬度、金相组织、机械性能、密度J9.1LaboratoryLocation实验室位置☆PassJ9.2MaterialPropertyTesting材料性能测试★Material property testing must be defined per customer design records. Mechanical propertiestesting must be available, preferably on site. Mechanical property testing must include ultimatetensile strength, yield strength, and percent elongation. Some customers may require yieldstrength to be measured by an extensometer attached to the specimen. If retest or replacement isCheck tensile strength, yield strength and elongationConformnecessary must be with agreement of the customer Product Engineering. Testing begins withof each batchto 符合prototypes and continues through regular production.材料性能测试必须根据顾客设计记录的规定进行每批一次，对抗拉强度、屈服强度、延伸率进行检验。机械性能检测必须有，最好能在现场进行。机械性能检测必须包括抗拉强度、屈服强度、延伸率。一些顾客可能要求使用延伸测试仪附上试样测量抗屈服强度。如果有必要重复测试或替换测试方法，必须征求顾客的产品工程部门部门同意。测试开始于原型样件并在整个常规生产过程中持续进行。The casting source must prepare test bars from a location approved by customer ProductEngineering. For example, these might be cut from a casting or from a separately cast bar.Mechanical properties are often required from test bars cut from actual castings in an areaConformdesignated on the engineering drawing or in the part quality document. The test bar location in theto 符合casting will be dimensioned from casting features.铸件供应商必须按照顾客的产品工程部门部门批准的位置准备检测试棒。例如：检测试棒可从铸件上切取或单独制作试棒。机械性能往往需要从铸件上，根据工程图纸或零件质量文件指定的区域切割检测试棒。从铸件上取的试棒，应根据铸件特点标出位置尺寸。1. Metallurgical examination is to be done by the supplier prior to any component testing to insuremicrostructure meets engineering drawing specifications.2. A metallograph image analyzer is preferred.3. Reference photographs must be readily available at the metallograph for all microstructurerequirements.Conform4. Microstructure audits must include any high stress features in the FEA.to 符合1、为了确保显微组织Conform to 符合工程图纸的要求，在进行零件任何检验测试前，供应商应完成化学成分检测。2、最好使用金相图像分析仪器。3、所有显微组织要求的参考照片在金相显微镜上必须是现成的金相图片。4、金相组织的审核必须考虑FEA分析中识别出的高应力特性。PassJ9.3MechanicalProperty机械性能★Mechanical performance sampling shall be testedaccording to inspection procedures and customerrequirements and shall be approved by customer.机械性能取样按检验规程和客户要求检测，都经客户批准。PassJ9.4Microstructure Analysis金相分析★1: Test according to customer standard2: Analyze with metallographic microscope3: Metallographic images displayed on the computercan be saved and extracted4: Sampling according to customer requirements ornational standards1：按客户标准检测2：用金相显微镜进行分析3：金相图片显示在电脑上可以保存和提取4：按客户要求或国标要求的部位取样PassJ9.5HardnessTesting 硬度测试★1. Standard test block;2. Visually visible on the standard block;3. The standard test block was 90HBW, and the1. Hardness testing is to be done per ASTM E10.deviation range was ±1.7%;Supplier site must have certified Master blocks for auditing the calibration of the hardness tester.4. Reduced;2. The Tolerance range for the Master block must be posted on the hardness tester.5. 3000g load, 10mm diameter head and 10-15s stop-3. The Tolerance range for the Master must not exceed +/- 3%.delay time are preferred; According to the sample size,4. The customer specified range for hardness must be reduced by the tolerance allowed on theselect the appropriate load and head;hardness Master block.6. If required by the customer, test at the designated5. Unless Product Engineering specifies otherwise, Brinell hardness test using a 500Kg load, 10 mmlocation as required; If the customer does not require,diameter indenter, and 30 second dwell time.the factory test procedures test;Conform6. Hardness to be measured at a specified location from customer Product Engineering.7. The hardness test is destructive test, and the test isto 符合7.If hardness readings are out of specification, all castings in the Lot shall be hardness tested withbeyond the specification. Heat treatment is carried outany out-of-specification castings rejected. 1、硬度测试按照ASTM E10标准完成。供应商现场必须有for this batch1.有标准试块；认可的标准校准块，用作审核硬度计的校准。2.在标准块上，目视可见；2、标准校样的误差范围必须贴在硬度计上。3.标准试块为90HBW，偏差范围为±1.7%；3、标准校样的误差范围不得超过±3%。4.已降低；4、依据标准校样的允许误差，顾客要求的产品硬度范围必须降低。5.优先使用3000g负载，10mm直径压头，10-15s的停延时5、除非产品工程部门另有规定，布氏硬度测试使用500Kg负载，10mm直径的压头，30s的停延时间。间；根据试样大小，选择合适的负载和压头；6、在顾客的产品工程部门部门指定的位置测试硬度。6.如果顾客有要求，按照要求在指定位置检测；如果顾客没7、如果硬度读数超出规定要求，此批所有铸件均应进行硬度测试，超出规范的铸件为不合格件。有要求，厂内检测规程检测；7.硬度检测为破坏性试验，检测超出规范，对本批次进行热处理，热处理后再次随机抽检硬度，且热处理不超过2次Pass10.0Leak Testing泄漏测试Pass1. Acceptable methods for testing are: air under water, pressure decay, mass flow.2. For applications where 100% verification is required it is preferred that pressure decay or massflow systems be used. Some customers may require 100% air under water.3. Leak rate specification must be defined on the product engineering document.4. It is preferred that the internal volumes for each cavity be leak tested separately.5. It is preferred castings be thoroughly dried before going to air decay leak test. An in-line driermay be needed.6. Some castings may also require 100% flow testing. If flow testing is required, this must beConformautomated equipment. Using round balls or probes is acceptable if customer Product Engineeringto 符合agrees. 1、泄漏测试可接受方法有：水下空气试验、压力降低试验、流量试验。2、要求100%泄漏验证的过程最好使用压力降低或流量系统试验方法。顾客可能要求100%的水下空气试验。3、泄漏率的规范必须在产品设计文件中定义。4、最好对每个空腔的内部容积分别进行泄漏试验。5、最好是铸件在做空气泄漏测试之前彻底干燥。可能需要配置在线烘干设备。6、一些铸件可能还需要100％的流量测试。如果要求流量测试，则必须是自动的设备。用圆球或探针是可以接受的，如果顾客的产品工程部同意。J10.1Leak TestRequirement泄漏检测要求★The company has leak detection equipment and thisability, according to customer requirements canchoose. However, rocker arm products do not requirethis test requirement. 公司有泄漏检测设备及此项能力，根据客户要求可选择。但摇臂产品不需要此项检测要求。PassJ10.2Water DunkCapability浸水能力☆It is preferred that the casting plant have a water dunk tank on site for determining the location ofleaks on air decay rejects. The water temperature must be at least 20 °C. 铸造厂最好再现场有浸水能力检测，以确定产品泄漏位置。检测水温必须至少保持在20℃。Have the ability to choose according to customerrequirements有此项能力根据客户要求可选择