TS67-0381

Document No.TS67-0381Revision - Date2006/01/27METALLIC TUBE FOR AUTOMOBILE PIPINGHAITECFRM-001DOCU TITLE METALLIC TUBE FORAUTOMOBILE PIPINGDOCUNOTS67-0381- Specificationrelease 2006/1/26 DariusTarngRev. No Description RevisedPageDate Rev.byApprove Review CheckPrepareDariusTarngFRM-002Contents1. Scope (3)2. Types (3)3. Finish (3)4. Manufacturing Method (4)5. Construction of Tube (4)6. Dimension of Tubes (5)7. Quality (5)8. Testing Method (11)9. Inspection (15)10. Designation (15)1. ScopeThis standard specifies the metallic tube for piping (hereinafter called “tube”) for use in automobile brake, fuel, lubricanting system, and so on. Fuel injection pipes forautomobiles are excluded.2. TypesTubes shall be classified into types with symbol and materials as shown in Table 1.TABLE 1Type Symbol Material Double Wall Steel Tubes TDWSingle Wall Steel Tubes TSWSPCC: JIS G 3141Copper Seamless Tubes C1201T C1201: JIS H 33003. Finish3.1 Symbols for types of surface treatment, which is applied to outer face of tubes (aftertube-forming), coating thickness, and so forth shall conform to Table 2.TABLE 2Treatment NoneLead-TinAlloy PlatingZinc Plating8μZinc Plating13μZinc Plating25μFluorocarbonResin CoatingSymbol N T Z8 Z13 Z25 F Remarks: Copper seamless tubes shall have no such symbol because no surface treatment is applied to them.3.2 Types of Chromate Treatment Applied after ZincPlating on Outer Face of Tubes(1) Chromate Treatment (light yellow and bright)Chromate treatment shall always be applied after zinc plating (z8, z13, z25).(2) Olive Chromate Treatment (olive color)Olive chromate treatment shall be applied after zinc plating.This treatment shall always be applied to pipes to be subject to fluorocarbonresin coating unless other treatments are specified.)1(Note (1): When applying the chromate treatment (light blue and bright) to pipes to be subject to fluorocarbon resin coating, “c” shall follow the symbol of zincplating.Example: Z13CF(3) Type and symbol surface treatment on the inner face of tubes shall conform toTable 3. K3 (copper plating 3μmin), however, shall apply only to single wallsteel tubs (TSW).TABLE 3Copper PlatingTreatment3μmin 8μminSymbol K3 K8Remarks: The thickness of copper plating on the inner face is intended for that after tube-forming.4. Manufacturing Method(1) Apply copper plating to both faces of the material shown in Table 1. Make it into adouble wall form and apply copper brazing in a reducing atmosphere furnace toobtain the double wall steel tube.(2) Apply copper plating to both faces of the material shown in Table 1 or one face tobe inner surface. Then apply resistance welding to obtain the single wall steel tube.(3) The copper seamless tube shall be produced in accordance with JIS H 3300.5. Construction of TubeExamples of construction of double wall steel tubes, which have been subjected to surface treatment, are shown in Figs. 1 and 2.FIG. 1 FIG. 2Remarks: Fluorocarbon resin coating shall be applied always after zinc plating (olive chromate treatment) or lead-tin alloy plating.6. Dimension of TubesNominal diameter and dimension of tubes shall be as specified in Table 4.TABLE 4Unit: mmWall ThicknessOuter DiameterStandard DimensionNominal DiameterStandardDimensionAllowance Double Wall Steel Tube Single WallSteel TubeCopperSeamless TubeAllowance 3.17 3.17 0.7 0.7 0.8 4.76 4.76 0.7 0.7 0.8 6.35 6.35 0.7 0.70.88 8 0.7 0.7 1 10 10 0.7 0.7 1 12 12－ 0.9 112.7 12.7 － 0.9 1 15 15 1116 16 － 1 1 18 18 － 1 1 20 20 － － 1 22 22±0.1－－1±0.1Remarks: The end form of tubes shall conform to TS68-0022 (End Form of Metallic Tubesfor Automobile Piping) 7. Quality7.1 General Requirements(1) Tubes shall be substantially straight with their ends at right angles to tube axis. (2) Tubes shall have a smooth finish on the inside and outside surfaces and shall be free from detrimental defects such as flaws, cracks, oxidized scales, and so forth that might affect manufacturing, assembling, and handling processes. (3) The appearance of tubes, after subjected to surface treatment, shall be free from defects such as white rust, poor coating film, and so on.(4) The height of welding beads on the single wall steel tube shall conform to the follows:TABLE 5Unit: mmHeight of Outer Bead Height of Inner BeadOuter Dia of TubeAllowance Outer Dia of Tube Allowance Up to 4.76 +0.04 0 Up to 10 (t=0.7) +0.1 0 6.35 +0.05 0 12 to 12.7 (t=0.9) +0.2 0 8 and Over+0.1 015 and Over (t=1.0)+0.3 07.2 Detailed Requirements(1) Double wall steel tubes without inner face copper plating (K8) shall conform to the requirements in Table 6. Test shall be conducted in accordance with 8.1. (2) Single wall steel tubes without inner face copper plating (K8) shall conform to the requirements in Table 7. Test shall be conducted in accordance with 8.1. (3) Double wall steel tubes with inner face copper plating (K8) applied shall conform to the requirements in Table 8. Test shall be conducted in accordance with 8.1 and 8.2.(4) Single wall steel tubes with inner face copper plating (K8) applied shall conform to the requirements in Table 9. Test shall be conducted in accordance with 8.1 and 8.2.(5) Copper seamless tubes shall conform to JIS H 3300.(6) Double wall and single wall steel tubes with fluorocarbon resin coating applied shall conform to the requirements in Table 10. Test shall be conducted in accordance with 8.1.TAPLE 8[Requirements for Double Wall Steel Tubes with Inner Face Copper Plating (K8) Applied](4)TDW-N-K8－ TDW-Z8-K8TDW-Z13-K8TDW-Z25-K8 Test MethodsType Copper plating I n n e r F a c ec o a t i n gFilm Thickness8μ8.1.9I n n e r F a c e C o r r o s i o n R e s i s t a n c eRed RustFormation LimitArea of red rust formation after 24 hr shall be 2.5 % max. 8.2.1Note (4): Requirements other than Table 8 shall conform to Table 6.TABLE 9[Requirements for Single Wall Steel Tubes with Inner Face Copper Plating (K8) Applied](5)TSE-N-K8－ TSW-Z8-K8TDW-Z13-K8TDW-Z25-K8 Test MethodsType Copper plating I n n e r F a c ec o a t i n gFilm Thickness8μ8.1.9I n n e r F a c e C o r r o s i o n R e s i s t a n c eRed RustFormation LimitArea of red rust formation after 24 hr shall be 2.5 % max. 8.2.1Note (5): Requirements other than Table 9 shall conform to Table 7.TABLE 10[Requirements for Double and Single Wall Steel Tubes with Fluorocarbon Resin CoatingApplied] (8)Item RequirementsTestMethodsCoating Hardness No scratch with pencil HB. 8.1.2Coating Thickness 8μmin. Average: 20μmin. 8.1.9Corrosion Resistance White rust (6) shall not be formed within 240 hr: nored rust within 3000 hr.8.1.10Adhesion No crack or peeling of coating 8.1.12Weather-OmeterTest No blister, peeling, discoloration, etc, after exposure to sunshine Weather-Ometer for 300 hr.8.1.13Chipping Resistance After subjected to 3 cycles of chipping test by gravelometer, expose to salt spray test for 240 hr.No red rust formed.8.1. 14Chemical Resistance Immerse in chemicals. Upon removal, coating shallbe free from softening, crack, swell, and other defects. (7)8.1.15Heat Resistance Coating shall be free from discoloration, blister,crack, etc.8.1.16Heat Cycle Test Coating shall be free from crack, blister, peeling, distortion, etc.8.1.17Note:(6) White rust and blister of coating shall be 5 places max wit6hin 120 hr.(7) Coating defects such as pinhole, etc shall be out of evaluation.(8) Requirements other than specified in Table 10 shall conform to Tables 6, 7, 8 and9.8. Testing Method8.1 Test Methods for Double and Single Wall Steel Tubes without Inner Face CopperPlating (Table 11)(2) Bend tube with radius shown in Table belowthrough angle 90°and find flattening rate(2) Drive a conical jig with a 1/10 slope into theend of the specimen to expand the outsidediameter by 20% and inspect for flaw, andcrack.8.1.5 Expanding Test(1) Use test specimens100 mm long.(2) Cut the specimenalong lines distant90°each from theweld line in thedirection of tube axisand unroll it into aflat plate. Then,inspect the weldzone for crack,peeling, and otherdetrimental defects.8.1.6 Flat-BendingTest (1) Use test specimens100mm long.(2) Insert the specimenbetween two platesand compress ituntil it becomes flatwith opposinginside surfacebrought in contactwith each other.Bend the specimenin the direction oftube axis throughangle 90° aroundthe mandrel whosediameter is threetimes the thicknessof the tube.Re-flatten andinspect for flawsand cracks.100 mm long.(2) Insert the specimen between two plates and compress it until the distancebetween the plates becomes three times the wall thickness of the tube.Inspect for flaw and crack.The tube shall be compressed with its welding location square to the direction of compression.8.1.8 Non-Destructive Flaw Detection Test No abnormality shall be detected on the tube when it is subjected to eddy current test, supersonic flaw detection test (JIS Z 2344) orequivalent.The particulars of tests shall conform to theagreement with the Quality Control Department.8.1.9 Thickness Test The minimum thickness shall be measured by means of a microscope or thickness gauge. Measurement shall be made at three places more than 500 mm distant from each other.8.1.10 Corrosion Test Conduct test in accordance with 5.1 “Salt Spray Test” in JASO M 104-73 (7320).8.1.11 Pressure Resistance Test Inspect the specimen for leakage and otherdefects when it is subjected to the specifiedhydraulic pressure for 5 minutes.8.1.12 Adhesion Test Inspect coating for peeling after bending test(8.1.3) and Flaring Test (8.1.4) 8.1.13 Weather-Ometer Test Expose to a sunshine Weather-Ometer.Inspect for change in coating.8.1.14 Chipping Resistance Test Conduct test in accordance with 5.1 “Salt SprayTest” and 5.4 “Chipping Test by Gravel Impact”in JASO M 104-73 (7320)Apply only tofluorocarbon resin coating.8.1.15 Chemical Resistance Test Immerse in the following chemicals for specified hours and inspect for change in coating. Testchemicals shall be at room temperature. (1) 1/10 sulfuric acid solution for 8 hr. (2) Commercial gasoline for 48 hr. (3) Commercial brake fluid for 48 hr.8.1.16 Heat Resistance Test Conduct heat resistance test at 150℃ for 24 hr.8.1.17 Heat Cycle Test Conduct test in accordance with 5.5 “HeatCycle Test” in JASO M 104-73 (7320). Rum 4 cycles.8.2 Test Methods (8)for Double and Single Wall Steel Tubes with Inner Face CopperPlating Applier (Table 12)TABLE 12Test ItemDouble Wall Steel TubeSingle Wall Steel TubeSingle Wall SteelTubeRemarks8.2.1 Inner Face Corrosion Test Conduct test in accordance with JIS Z 2371 “Salt Spray Test”. Test specimens and theirsetting method shall conform to the follows: (1) Shape of Test SpecimenCut a tube in half with its seam placed in the middle of the test specimen. Its length shall be as follows:Remarks: The double wall steel tube is shownabove. The single wall steel tube shall be prepared in the similar way.(2) Cleaning and Sealing of Test SpecimenClean the test specimen and perfectlyremove cutting chips and other grit and dust. Then seal all the cut sections. (3) Setting Test SpecimenThe test specimen shall be set slantingly with its inside facing upward as shown below.(4) SamplingTest specimens shall be cut from finished products in current use.Note (8): The test method other than “Inner Face Corrosion Test” shall conform to 8.1 (Table 11).9. InspectionConduct the tests required in paragraph 8 of this standard depending upon types of the tubes on every lot of samples specified by the agreement with the InspectionDepartment of MMC. The lot shall conform to all items of testing.All tubes shall pass the inspection in accordance with either pressure resistance test or nondestructive flaw detection test. When otherwise made agreement with the Quality Control Department of MMC, the requirement shall conform to the agreement.10. Designation(1) General DesignationTubes shall be designated by symbols of tube types, surface treatment, platingthickness, and so on (Tables 1, 2, and 3) with nominal diameters as follows:Example 1. Double wall steel tube, nominal dia 6.35, zinc plating 8μ(chromatetreatment) only on outer face.TDW-Z8-6.35Example 2. Double wall steel tube, nominal dia 10, zinc plating 13μ(chromatetreatment) on outer face, copper plating 8μon inner face.TDW-Z13-K8-10Example 3. Double wall steel tube, nominal dia 10, fluorocarbon resin coating.TDW-Z25F-10(2) Designation on DrawingWhen designating tubes on drawing, symbols of tube types, surface treatment,plating thickness, and so on shall be entered in “material column”, and nominal dia and wall thickness of tubes shall be entered in “dimension column” or the drawing.。