Document Text Contents
Page 1
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
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Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
Subject:Subject: Manufacturing and Testing Specification for Ductile Iron Gears
Scope:Scope: Manufacturing procedures, process control, and properties of these castings
must fall within guidelines of ASTM A536 with the additional requirements
outlined below. If the supplier has reasons to suggest alternate specifications for
improved manufacturing procedures or improved casting performance it is
incumbent on the supplier to contact the appropriate FFEM representative and
design engineer.
Reference(s):Reference(s): Vendor shall verify that all documents listed below are available before
commencing manufacture. As a minimum, the gear casting shall satisfy the
requirements of the following engineering documents:
AGMA/ANSI 2004-B89 Gear Materials and Heat Treatment Manual
ED 40.736.007 Hardness Testing of Gears
ASTM A609 Std. Practice for Ultrasonic Examination of Castings
ASTM E125 Reference P hotographs f or M agnetic P article
Indications
ASTM E1030 Std. Method for Radiographic Examination
ASTM E709 Std. Guide for Magnetic Particle Examination
ASTM A802 Std. Practice for Steel Casting, Surface Finish
ASTM A536 Std. Spec. For Ductile Iron Castings
Gear Assembly Drawings
Gear Detail Drawings
Separate Parts List (SPL)
CONTENTSCONTENTS
1.0 INTRODUCTION
2.0 INSTRUCTIONS
3.0 MANUFACTURING
4.0 MATERIALS
5.0 CHEMICAL ANALYSIS
6.0 HEAT TREATMENT
7.0 MECHANICAL PROPERTIES AND TESTING
8.0 ULTRASONIC TESTING
9.0 MAGNETIC PARTICLE INSPECTION
10.0 VISUAL SURFACE INSPECTION
Page 2
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
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Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
11.0 VENDOR TEST REPORT REQUIREMENTS
Page 20
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
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Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
Magnetic Particle Test Areas
Figure 4. Flange Mounted, Y-Section Zone 2
Page 21
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
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Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
Magnetic Particle Test Areas
Page 39
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
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of 34
Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
10.0 10.0 VISUVISUAL AL SURSURFAFACE CE INSPINSPECTECTIONION
10.110.1 The visual inspection method is based on ASTM A802/A802M-89.
10.2 10.2 AccAccepteptancance e CriCriterteriaia
Surface Feature Level
A. Surface Texture 3
B. Non-metallic Inclusions 2
C. Gas Porosity 2
D. Fusion Discontinuities 1
E. Expansion Discontinuities 3
F. Inserts 1
G. Thermal Cut Surfaces N/A
H. Mechanically Prepared Surfaces 3
J. Weld Surfaces N/A
11.0 11.0 VENDOR VENDOR TEST TEST REPORREPORT T REQUIRREQUIREMENTSEMENTS
11.111.1 Report of as-cast surface conditions in accordance with ASTM A-802.
11.211.2 Report all non-conformances to this specification for FFEM review and
disposition.
11.311.3 Vendor must supply the following certified documents:
11.3.111.3.1 Mechanical test report including:
Tensile Strength (PSI) or (MPa)
Yield Point (PSI) or (Mpa)
Elongation in 2" (%)
Brinell Hardness Number (BHN)
Page 40
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
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Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
11.3.211.3.2 Chemical analysis report of all elements based on a cast-on coupon
sample.
11.3.311.3.3 Magnetic particle testing report clearly stating that casting conforms to this
ED 40.736.000
11.3.411.3.4 Ultrasonic testing report clearly stating that casting conforms to this ED
40.736.000
11.3.511.3.5 Heat treatment records, (furnace and attached thermocouples charts) of all
heat treatment procedures to which casting has been subjected.
11.3.611.3.6 All documents to show: P.O. Number
Contract Number
Drawing Number
Vendor Serial Number
11.411.4 It is expected that the vendor will follow all other procedures, examinations and
tests that are normally carried out in accordance with sound manufacturing and
industry practice.
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
%p
n{1
}
of 34
Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
Subject:Subject: Manufacturing and Testing Specification for Ductile Iron Gears
Scope:Scope: Manufacturing procedures, process control, and properties of these castings
must fall within guidelines of ASTM A536 with the additional requirements
outlined below. If the supplier has reasons to suggest alternate specifications for
improved manufacturing procedures or improved casting performance it is
incumbent on the supplier to contact the appropriate FFEM representative and
design engineer.
Reference(s):Reference(s): Vendor shall verify that all documents listed below are available before
commencing manufacture. As a minimum, the gear casting shall satisfy the
requirements of the following engineering documents:
AGMA/ANSI 2004-B89 Gear Materials and Heat Treatment Manual
ED 40.736.007 Hardness Testing of Gears
ASTM A609 Std. Practice for Ultrasonic Examination of Castings
ASTM E125 Reference P hotographs f or M agnetic P article
Indications
ASTM E1030 Std. Method for Radiographic Examination
ASTM E709 Std. Guide for Magnetic Particle Examination
ASTM A802 Std. Practice for Steel Casting, Surface Finish
ASTM A536 Std. Spec. For Ductile Iron Castings
Gear Assembly Drawings
Gear Detail Drawings
Separate Parts List (SPL)
CONTENTSCONTENTS
1.0 INTRODUCTION
2.0 INSTRUCTIONS
3.0 MANUFACTURING
4.0 MATERIALS
5.0 CHEMICAL ANALYSIS
6.0 HEAT TREATMENT
7.0 MECHANICAL PROPERTIES AND TESTING
8.0 ULTRASONIC TESTING
9.0 MAGNETIC PARTICLE INSPECTION
10.0 VISUAL SURFACE INSPECTION
Page 2
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
%p
n{1
}
of 34
Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
11.0 VENDOR TEST REPORT REQUIREMENTS
Page 20
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
%p
n{1
}
of 34
Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
Magnetic Particle Test Areas
Figure 4. Flange Mounted, Y-Section Zone 2
Page 21
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
%p
n{1
}
of 34
Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
Magnetic Particle Test Areas
Page 39
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
%p
n{1
}
of 34
Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
10.0 10.0 VISUVISUAL AL SURSURFAFACE CE INSPINSPECTECTIONION
10.110.1 The visual inspection method is based on ASTM A802/A802M-89.
10.2 10.2 AccAccepteptancance e CriCriterteriaia
Surface Feature Level
A. Surface Texture 3
B. Non-metallic Inclusions 2
C. Gas Porosity 2
D. Fusion Discontinuities 1
E. Expansion Discontinuities 3
F. Inserts 1
G. Thermal Cut Surfaces N/A
H. Mechanically Prepared Surfaces 3
J. Weld Surfaces N/A
11.0 11.0 VENDOR VENDOR TEST TEST REPORREPORT T REQUIRREQUIREMENTSEMENTS
11.111.1 Report of as-cast surface conditions in accordance with ASTM A-802.
11.211.2 Report all non-conformances to this specification for FFEM review and
disposition.
11.311.3 Vendor must supply the following certified documents:
11.3.111.3.1 Mechanical test report including:
Tensile Strength (PSI) or (MPa)
Yield Point (PSI) or (Mpa)
Elongation in 2" (%)
Brinell Hardness Number (BHN)
Page 40
Engineering DocumentationEngineering Documentation
Inspection and Quality Control Procedures
Issued by: I. Botto Department: 736
Level III Number: 40.736.000 Revision: 4 Page:
%p
n{1
}
of 34
Printing Date - 19 Oct 2006 Copy Not Automatically Updated FFE Minerals USA Inc
11.3.211.3.2 Chemical analysis report of all elements based on a cast-on coupon
sample.
11.3.311.3.3 Magnetic particle testing report clearly stating that casting conforms to this
ED 40.736.000
11.3.411.3.4 Ultrasonic testing report clearly stating that casting conforms to this ED
40.736.000
11.3.511.3.5 Heat treatment records, (furnace and attached thermocouples charts) of all
heat treatment procedures to which casting has been subjected.
11.3.611.3.6 All documents to show: P.O. Number
Contract Number
Drawing Number
Vendor Serial Number
11.411.4 It is expected that the vendor will follow all other procedures, examinations and
tests that are normally carried out in accordance with sound manufacturing and
industry practice.
