Pre-Tech Review

ATLAS Project
6091762 – Pipe Air

PoV : Karthik.Cr [12-Feb-2021]

Energy & Transportation

Purchasing - SDE
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Product Details
Casting Wt Facility
# Part Number EC Level Part Description Material EAU Model Component 3D CAD Image (Reference)
(Kg) Impacted
109/ 2021
1 6091762 0 Pipe Air Aluminum 354 / 2022 1.988 5016 KG12
354 / 2023
Part Envelope : 170 X 203 [H X D]
Foundry Process Compatible
GDC (Permanent Mold)
Supplier Sourcing Scope
•Agree before Technical
SDC review signoff

Casting Machining Packing •Agree before Technical

SPC review signoff

PPAP
• Level 3
Plan
Souring Approach : T1RP
Supplier prepares Get ready for "Pilot
Share Requirements process Build" activity Customer Validation
with supplier documentation to including the Conduct "Pilot Build" + formal approval of
including all SC & understand risk purchase and + create the the PPAP and then
Quality History before purchasing validation of the production PPAP ship part after
production tooling production tooling approval.

GW GW GW GW GW GW

1 2 3 4 5 6

Date # Date # Date # Date # Date # Date #

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 Casting EMS (Engineering & Manufacturing Statement)
(1) Chemical Composition In Accordance to 1E1540F (EN 1706 AC42000)
Applicable IE Spec
1E1540F - Cast material manufacturer’s
standard - aluminium casting.
1E5236-Quality requirements - aluminium
alloy sand and permanent mold castings
1E5167A-Intellectual property intended use.
1E4552-Packaging, preservation treatment
and lubrication of components.
(2) Mechanical Properties
Note : Refer EN 1706 AC4C Clause 7 Table 3 T6 solution heat treated and fully artificially aged) 1E4386-Pipes with bead ends for hoses.

Alloy Group Alloy Designation Heat Tensile Yield Elongation Brinell's 1E4246D-Restriction of hazardous substances
Treatment Strength Strength % Hardness 1E2966B - Identification key characteristics.
Numerical Chemical Symbol (Mpa) (Mpa)
1E2722A - Drawing - pro – engineer.
Al Si7 Mg EN AC -42000 EN AC – AL Si7 Mg T6 260 Min 220 Min 1 Min 90 Min 1E2650-Threads - millimeter size screw

Tensile test as per EN 1706 AC4C Clause 7.2 & 7.3.3(Test Piece taken from Casting) shall be carried out in accordance with EN 10002-1.
1E2500B - Cleanliness finished engine
components.
Hardness tests as per EN 1706 AC4C Clause 7.4 shall be carried out in accordance with EN ISO 6506-1 on porosity free areas of castings or on the portion of a test piece
that has not been stressed. 1E0507M - Identification - part number.
Test specimens are removed from castings. [Note : Engineering & AMT agreement required for Specimen location] 1E0198P Letters and trademarks corporate.
(3) Microstructure : SDAS requirements and guidelines to be jointly agreed with CATERPILLAR team 1E0013Y - Confidentiality drawing security
Perform Microstructure analysis in accordance to 1E0576A Clause 5.4.3.1 [Location to be agreed jointly B/w Supplier – Design Engineer – AMT.] classification
1E0012A - Interpretation geometric tolerance
(4) Soundness Requirements : Radiography acceptance level/std [to be agreed jointly B/w Supplier – Design Engineer – AMT.]
Inspection practices to abide with 1E0576A Clause 5.4.2.

(5) Heat Treatment : T6 solution heat treated and fully artificially aged in accordance to EN 1706 AC4C.

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 Casting EMS (Engineering & Manufacturing Statement)
CTQ (Critical to Quality) Notes :
1. Part is produced in Permanent mould (Chilled Gravity Die cAst Only) compliance to 1E1540F (EN 1706 AC42000) with T6 heat treatment process.
2. Part to Qualify Pressures test requirements SWP – 0160 class 3A . Avoid Porosity/pin/gas holes by Maintaining Clean meatal(De-Gassing) chemistry & temperature(Pouring).
3. Traceability markings, Compliance to 1E0198P [to be included with Part No; Version Code; Change Level; Date & Supplier Code] location as specified in the print - marking,
Letter Size, jointly agreed with Engineering.
4. Dimensional validation – white light scan for Tools, Cores & Castings to be performed against 3CAD with datum fit alignment method. [As Cast + Machined part validation]
5. Surface finish(As-cast) of the casting is critical - Casting must be smooth, free from parting Line & Fettling marks throughout distance as specified in print “Note-D” as 1E4386.
6. Wall thickens of the casting is maintained 6 mm [BSC] and 5 mm Min.
7. Datum X; Y & Z are established by target datums on rough castings.
8. Optional to use Shot blasting post T6 heat treatment process to remove scaling if any.
9. Shall Perform/complete Mould flow simulation before final tool cut.
10. Arrive on QTP(Quality test plan) for Material properties verification.
11. Porosity acceptance level class 4 Type-“D” per 1E5236 and Type-”C” for port spotface.
12. Impregnation process acceptance to be jointly agreed with Caterpillar team(in accordance to 1E spec)
13. Compliance with RoHS/REACH requirements.
Key Facilities Required:
❑ Establish a closed loop process/system to monitor and control, casting Cooling time Vs ejection and completion of T6 Heat treat cycle.
❑ Heat treat process – Part should be facilitated with appropriate locator/bin/basket during loading in HT furnace to avoid distortion during HT process.
❑ T6 Heat treatment Furnace with Time & Temperature controller integrated to thermocouple.
❑ Targeting fixture and templates for profile measurement.
Mold flow White light Chemical Mechanical T6
Test X-Ray Microstructure
Simulation scan Composition properties Heat Treatment
Internal/ Internal/ Internal/
Location Internal Internal Internal Internal
External External External

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 Machining EMS (Engineering & Manufacturing Statement)
Applicable IE Spec
1E1540F - Cast material manufacturer’s
standard - aluminium casting.
1E5167-Intellectual property intended use.
1E4552-Packaging, preservation treatment
and lubrication of components.
1E4386-Pipes with bead ends for hoses.
1E4246D-Restriction of hazardous
substances
1E2966B - Identification key characteristics.
CTQ (Critical to Quality) Notes : 1E2722A - Drawing - pro – engineer.
1. Casting is Made from Part No 6091757. Machining features are added to the part. 1E2500B - Cleanliness engine components.
2. Datum “X” is generated from target datums and Datums “X” is used to generate Datum Y & Z. 1E0507M - Identification - part number.
3. Datum X Face – Dimension at Pipe with bead end is critical for Fit & Function. 1E0198P Letters and trademarks corporate.
4. Centre Line of the pipe is taken into consideration during machining minimize the casting off-set. 1E0013 - Confidentiality drawing security
5. Side connection pipes tip dimensions as specified in the Detail-B of the print critical and should be free from fettling defects. classification
6. Mounting Boss positional tolerance 1mm is maintained to facilitate fit & function. 1E0012 - Interpretation geometric tolerance
7. Boss as shown in Section A-A is Machined - Drill + Tap Dia 6mm Depth 15mm; M6. 1E2850-Quality requirements - aluminium
8. Bellows/Tube fitment end dimensions (Radius; Fillets & Angle) is critical in terms of fit and function. alloy sand and permanent mold castings
9. Part to Qualify Pressures test requirements, Maximum permissible air leakage rate 12cm3 /Min @30Kpa. Requires verification before packing.1E2122 - Surface texture.
10. Coordinated distance, vital for fitment. Shall require EoL (End of Line) Functional Gauge with fixed datums asper drawing. 1E0576A-Foundry instructions.
11. Cleanliness -1E2500B to be compliance, shall required a washing process and Millipore verification.
1E2712-Port dimensions - metric straight
thread o-ring

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 Painting [If applicable]
❑ Paint Color, Source and grade and performance requirements to be agreed with Engineering and Buyer.

Packaging
❑ Finished part surface should be free from rust and dust, Rust oil Application shall require.
❑ Grade and type to be jointly agreed with Caterpillar Packaging and Manufacturing engineering.
❑ Finished part should be protected to avoid dents and damages on the machined surface, shall require a comprehensive packaging. Same to be agreed with Caterpillar Packaging and
Manufacturing engineering

Inspection & Testing Facilities

Note : Gauges (Variable) to meet 1/10th of the tolerance and qualify GRR requirements.

Dimensions EoL Surface Profile Millipore

Test Leak Tester Impregnation
CMM Inspection Finish projector test
Internal
Machining Internal Internal Internal Internal Internal Internal
(If applicable)
Key Facilities:
❑ EoL functional gauge/fixture for positional tolerance measurement.
❑ Template Gauges for profile measurement.
❑ Washing machine to meet Millipore requirement in accordance to 1E2500B as listed in the below table.

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 Thank you!

Any Questions?

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