Você está na página 1de 13

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 1 of 13

Approval

Electronic: PDM Flow

Documentation Type:

Title:

process:

PDTD - Product

Prepared:

EREAL

Deliverable:

IMPROVED FATIGUE RESISTANCE

Verified:

APJ / MCC

D09

STUD BOLTS

Approved:

EMIRODRIGUEZ / IRU

The present document, its content, its annexes and/or amendments (the “Document”) has been drawn up by GAMESA CORPORACIÓN TECNOLÓGICA, S.A. (“GAMESA”) for information purposes only, and contains private and confidential information regarding GAMESA and its subsidiaries (the “Company”), directed exclusively to its addressee. Therefore it must not be disclosed, published or distributed, partially or totally, without the prior written consent of GAMESA, and in any case expressly indicating the fact that GAMESA is the owner of all the intellectual property. All the content of the Document, whether it is texts, images, brands, trademarks, combination of colours or any other element, its structure and design, the selection and way of presenting the information, are protected by intellectual and industrial property rights owned by GAMESA, that the addressee of the Document must respect. In particular (notwithstanding the general confidentiality obligation), the addressee shall not reproduce (except for private use), copy, transform, distribute or publish to any other third party, any of the information, totally or partially.

INDEX

SCOPE

  • 1 ...............................................................................................................................

3

  • 2 .....................................................................................................................

REFERENCES

3

  • 3 DEFINITIONS AND ACRONYMS

............................................................................................

4

  • 4 GENERAL REQUIREMENTS

..................................................................................................

4

4.1

Qualification

........................................................................................................................

  • 4.2 Qualified Products, Product changes and Requalification

...........................................................

  • 4.3 Traceability ..........................................................................................................................

  • 4.4 Hazardous constituents

.........................................................................................................

4

4

4

5

  • 4.5 Written Communication .........................................................................................................

5

  • 5 TECHNICAL REQUIREMENTS

...............................................................................................

5

5.1

Geometry

............................................................................................................................

5

5.1.1

Dimensions

....................................................................................................................................

5

5.1.2

Threads

.........................................................................................................................................

5

  • 5.2 Surface Roughness

...............................................................................................................

5.3

Concentricity

........................................................................................................................

5.4

Materials

.............................................................................................................................

5

5

5

  • 5.4.1 Chemical Composition

....................................................................................................................

5

  • 5.4.2 Steel Making

..................................................................................................................................

5

  • 5.4.3 Heat treatment

..............................................................................................................................

6

  • 5.5 Mechanical and metallurgical properties

..................................................................................

  • 5.6 Surface treatment

................................................................................................................

6

6

  • 5.7 Non-destructive Inspection for surface discontinuities

...............................................................

7

  • 5.7.1 Visual Inspection report

.................................................................................................................

7

  • 5.7.2 Magnetic particle and liquid penetrant examination

.........................................................................

7

  • 5.8 Heat treatment

....................................................................................................................

7

6

5.9 Marking ...............................................................................................................................

8

TEST METHODS

.................................................................................................................

8

6.1

Tensile tests

........................................................................................................................

8

6.2

Impact

test ..........................................................................................................................

  • 6.3 Hardness test

......................................................................................................................

8

8

  • 6.4 Decarburization test

.............................................................................................................

8

  • 6.5 Metallographic test

...............................................................................................................

8

  • 6.6 Fatigue tests ........................................................................................................................

9

  • 6.6.1 Test fixtures

..................................................................................................................................

9

  • 6.6.2 Test procedure

  • 6.6.3 Test conditions

..............................................................................................................................

9

..............................................................................................................................

9

  • 6.6.4 Internally threaded component

....................................................................................................

10

  • 6.6.5 Determination of the Whöler curve (S/N curve)

............................................................................

10

  • 6.7 Tightening torque tests

.......................................................................................................

10

  • 7 APPROVAL PACKAGE (CAP) REQUIREMENTS

PART

..............................................................

10

  • 7.1 Serial production requirements

............................................................................................

10

  • 7.1.1 Responsibility

..............................................................................................................................

  • 7.1.2 Inspection and test report

............................................................................................................

10

10

  • 8 SERIAL PRODUCTION REQUIREMENTS

..............................................................................

13

9

ANNEXES

.........................................................................................................................

13

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 2 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 

RECORD OF CHANGES

Rev.

Date

Author

Description

0

10/05/09

APJ

24/03/13

  • 1 EREAL

Initial Version

Definitions reviewed Table 2 updated according to reviewed definitions

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 3 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 
  • 1 SCOPE

This specification specifies the characteristics, technical and acceptance requirements for improved fatigue resistance stud bolts and is applicable to all parts when called in design and manufacturing drawings.

During manufacturing process validation documentation shall be given in a CAP (Component Approval Package).

Once First Article Validation has been completed, then reduced inspection level shall be applied (less documentation shall be required), provided manufacturing process is within its limits.

  • 2 REFERENCES

Number

Title

ISO 898-1

Mechanical properties of fasteners made of carbon steel and alloy steel.

EN 10002-1

Tensile testing of metallic materials. Part 1: Method of test at ambient temperature

EN 10045-1

Charpy impact test on metallic materials. Test method (V and U notches)

ISO 6506

Metallic materials- Hardness test-Brinell test.

ISO 6507-1

Metallic material -Hardness test-Vickers test- Part 1: Test Method

DIN 969

Axial load fatigue testing of threaded fasteners

ISO 10683

Fasteners-Non-electrolytically applied zinc flake coating.

ISO 6157-1

Fasteners: Surface discontinuities. Part 1: Bolts, screws and studs for general requirements

EN 10204

Metallic materials. Types of inspection documents

ISO 724

ISO general- purpose metric screw threads- Basic dimensions

ISO 68-1

ISO general purpose screw threads-Basic profile_Part 1: Metric screw threads

GPR91001

General bolting

GTS73001

Tightening torque test specification

PBE-1-016-R01

 

ISO 4287

Chemical Products, Substances in Articles and Dangerous Goods Assessment Geometrical Product Specification-Surface Texture: Profile method- Terms , definitions and Surface Texture parameters

ISO 9227

Corrosion tests in artificial atmospheres- Salt spray tests

ASTM E340.

Test method for macroetching metals and alloys

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 4 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 
  • 3 DEFINITIONS AND ACRONYMS

Manufacturing lot: Quantity of fasteners including product grade, property class, size and shank diameter, regardless its length, manufactured from bar, rod, from a single cast, processed through the same or similar steps at the same time or over a continuous time period through the same heat treatment and/or coating process.

Therefore, this definition is applicable to all those part numbers

  • a) manufactured to GPR90001

  • b) made of quenched and tempered steel property class 10.9 in accordance with ISO 898-1

  • c) having triangular M36 thread according to ISO 68-1

  • d) with coarse pitch thread

  • e) having thread tolerances as per ISO 965-1

  • f) with the same nominal shank diameter

  • g) with tolerances according to ISO 4759-1, Product grade A

  • h) regardless its length

Manufacturing batch: Quantity of fasteners with the same part number from the same manufacturing lot processed together at one time.

Therefore, this definition is applicable to each one of the part numbers that conform a manufacturing lot.

Inspection lot: quantity of fasteners from a single manufacturing batch inspected at one time which completely defines the fastener.

Acceptance quality level, AQL: quality level in a sampling plan corresponding to a high probability of acceptance.

Acceptance number, Ac; Maximum number of nonconformities of the same characteristic in any given sample which, when exceeded, causes the lot to be rejected.

Sampling plan: a plan according to which one or more samples are taken in order to obtain information and possibly to reach a decision.

Limiting quality (LQ 10 ): in a sampling plan, the quality limit which corresponds to a specified 10% probability of acceptance.

  • 4 GENERAL REQUIREMENTS

    • 4.1 QUALIFICATION

The material covered by this specification shall be a product which has been tested and comply with the characteristics specified herein.

  • 4.2 QUALIFIED PRODUCTS, PRODUCT CHANGES AND REQUALIFICATION

No deviation from approved method of manufacture is permitted without prior written approval from Gamesa Materials & Processes Engineering. Any change by the manufacturer may be cause for requalification. A change is defined as, but not limited to: material specification or manufacturing process changes, or supply changes product and/or manufacture location.

  • 4.3 TRACEABILITY

Material for re-testing and specimens tested in CAP and serial production must be stored for 2 years. Part Approval and Serial production documents must be kept for 20 years.

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 5 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 
  • 4.4 HAZARDOUS CONSTITUENTS

As a general rule, in accordance PBE-1-016-R01, any substance prohibited by the Environmental Management System of GAMESA, regardless it is covered or not by International codes must not be used in any manufacturing process of the parts covered by this specification.

  • 4.5 WRITTEN COMMUNICATION

All communication in regard to this specification shall be made in accordance with GSQM.

  • 5 TECHNICAL REQUIREMENTS

    • 5.1 GEOMETRY

      • 5.1.1 Dimensions

The dimensions shall conform to the applicable part drawing. Dimensions apply before coating.

  • 5.1.2 Threads

Bars used for stud bolts manufacturing shall be turned and straightened before rolling process.

Threads shall be fully formed by any single cold rolling process subsequent to heat treatment.

The tolerance at the thread shall be in accordance with the applicable part drawing.

  • 5.2 SURFACE ROUGHNESS

The surface roughness of the fasteners shall be in accordance with the requirements of the applicable drawing.

  • 5.3 CONCENTRICITY

The concentricity of the stud shank shall be within the values specified in the applicable drawing.

  • 5.4 MATERIALS

Property class of fastener shall be 10.9 in accordance with ISO 898-1.

Fasteners shall be manufactured in alloy steel quenched and tempered in accordance with ISO 898-1.

The steel shall be selected on a hardenability basis so a minimum of 90% martensite exists in the core after oil quenching.

  • 5.4.1 Chemical Composition

Chemical composition shall be assessed in accordance with relevant EN or ISO standard and shall be documented from the original steelmaker.

  • 5.4.2 Steel Making

Steel melting procedure shall be electric arc furnace or oxygen converter, ladle refined, fine grain practices and deoxided with aluminium. Steel shall be protected from reoxidation during all casting or teeming operations.

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 6 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 

Melting process shall be certified including general aspects of the manufacturing process, in inspection and test certificate. Certificates must include the name of steel maker, melting procedure/process. Raw material certificate must meet formalistic requirements of EN 10204-3.1.

  • 5.4.3 Heat treatment

Fasteners shall be heat treated by quenching in oil from above the transformation temperature. If heat treatment is performed by a subcontractor, the heat treated material shall be returned to manufacturer for testing.

  • 5.5 MECHANICAL AND METALLURGICAL PROPERTIES

Mechanical properties of the material in the final condition (quenched and tempered) shall be reported per lot and shall be in agreement with Table 1.

Table 1: Mechanical properties of fasteners

Test

Section

Direction 2)

Characteristic

Acceptance

requirements

     

Tensile strength, MPa

 

Tensile test 1) 2) acc to EN

6.1

L

Yield stress, σ 0.2% , MPa, min

ISO 898-1

10002-1

Elongation, %, min

   

Reduction of area, %,min

 

Impact 4) acc to EN 10045-1

6.2

L

ISO-V notch, J,

30 (Ind.28)

at -20ºC, min

Hardness Brinell test (HB) at mid radius or surface hardness acc to ISO 6506

6.3

-

HB 10/3000

ISO 898-1

Surface hardness, HV0.3 acc

6.3

L

Maximum surface hardness,

390

to ISO 6507-1

HV0.3

       

Studs shall show no traces of surface

Decarburization acc to ISO 898-1, mm

6.4

L

Partial and complete decarburization/decarburization

carburization or decarburization on the shank and

thread.

Metallographic test

6.5

T

Minimum tempered martensite

90%

in the core

Fatigue tests acc to ISO

6.6

Full size

Stress amplitude at 5 10 6 for a

60MPa

3800

survival probability of 50%

Note 1: Tensile tests of full size studs shall be desirable. Note 2:

  • - L: Direction of maximum grain flow or principal deformation parallel to the longitudinal axis of the round.

  • - T: Circumferential direction or tangential direction.

  • 5.6 SURFACE TREATMENT

Surface finish shall be based on zinc flake coatings and shall be specified in applicable drawing. Acceptance requirements for coating are covered by ISO 10683.

The coating process shall not adversely influence the mechanical and physical properties of the stud bolts.

The protection treatment shall fulfil the different tests indicated below:

-Neutral salt spray resistance acc to ISO 9227: 960h without red corrosion -Adhesion test according to ISO 10683

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 7 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 
  • 5.7 NON-DESTRUCTIVE INSPECTION FOR SURFACE DISCONTINUITIES

Fasteners selected for inspection shall be randomly selected from the manufacturing batch in the quantities specified in Table 3.

  • 5.7.1 Visual Inspection report

Fasteners shall be examined visually for burst, cracks, laps, flakes, seams, and any other defect that could affect its quality.

Cracks:

Cracks of any depth, any length, or in any locations are not permitted.

Discontinuities in the thread (seams, laps and surface irregularities):

-No discontinuities in the root thread are acceptable, over the full height of the flank loaded during tightening nor over the area of the flank not loaded during tightening inside the thread flank diameter.

Laps and seams not permissible Major Dia Pitch Dia Flank not loaded during tightening
Laps and seams not
permissible
Major Dia
Pitch Dia
Flank not loaded
during tightening

Non premissible laps, seams, surface irreg.

-No discontinuities in the shank diameter to thread transition are acceptable.

-On the top of the threads, and on the flank which is not loaded during the tightening in the area outside the thread flank diameter, the discontinuities shall not exceed 25% of height of truncated thread.

Surface Laps irregularities Major Dia Pitch Dia Minor Dia. Flank not loaded during tightening
Surface
Laps
irregularities
Major Dia
Pitch Dia
Minor Dia.
Flank not loaded
during tightening

Premissible laps, surface irreg.

Maximum depth of permissible discontinuities normal to the surface shall be 0,5mm.

-No discontinuities in the shank for reduced shank studs are acceptable.

  • 5.7.2 Magnetic particle and liquid penetrant examination

Bolts shall be examined by magnetic particle inspection or liquid penetrant examination for discontinuities in accordance with ASTM E1444 and ASTM E1417.

In case of doubt or disagreement on the nature of depth of defects, the final decision shall be taken after micrographic examination according to ASTM E340.

  • 5.8 HEAT TREATMENT

Heat treatments shall be reported according to EN 10204-3.1.

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 8 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 
  • 5.9 MARKING

Studs shall be marked in accordance with the applicable drawing. Marking of supplier and lot number is mandatory.

  • 6 TEST METHODS

    • 6.1 TENSILE TESTS

Full size tests shall preferably be tested full size and shall conform to the requirements in Table 1. When fasteners cannot be tested full size, tests shall be conducted using tests specimens machined from the stud bolts. Specimens shall be machined concentric with the axis of the stud in accordance with ISO 898-1.

  • 6.2 IMPACT TEST

The impact test shall be carried out in accordance with EN 10045-1.

The impact specimens shall be taken lengthwise, located as close to the surface of the stud or screw as

possible. The non-notched side of the test piece shall be located near the surface of the stud bolt. The longitudinal axis of the notch shall be perpendicular to the principal rolling direction.

  • 6.3 HARDNESS TEST

For qualification, product hardness test shall be conducted at mid-radius and radius position, one diameter back from the end of a transverse section in accordance with ISO 898-1. Three readings shall be taken approximately 120º to one another on the same plane.

For routine inspection, product hardness may be determined on the end after removal of any coating and after suitable preparation of the test piece.

Surface hardness shall be conducted on the shank at 0.1mm depth after removal of any coating and after suitable preparation of the tests piece. Surface hardness shall not be more than 30 Vickers points above the measured core hardness on the product when readings of both surface and core are carried out at HV0.3. Maximum surface hardness on shank shall be 390HV.

  • 6.4 DECARBURIZATION TEST

Carburization and decarburization on the surface of the shank and threads shall be determined by microexamination in accordance with ISO 898-1. Hardness measurement method only is applicable on the shank.

  • 6.5 METALLOGRAPHIC TEST

A metallographic examination on a longitudinal section through the thread axis shall be done in order to analyse the thread fibre structure. The specimen shall be etched in a 3-5% Nital and examined optically at 50 to 200X magnification. The fibre structure in the threads shall be continuous and follow the thread contour with the maximum density at the bottom of the root radius as indicated in the following picture.

Confidentiality: 2 / SUPPLIER INFORMATION Code: GPR90001-en Rev: 1 GAMESA PART REQUIREMENTS Date: 29/03/13 Pg. 8

A metallographic examination on the transversal section shall be made in order to analyse de microstructure in the core of the stud. A 90% of tempered martensite shall be required.

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 9 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 
  • 6.6 FATIGUE TESTS

    • 6.6.1 Test fixtures

The test fixtures shall be in accordance with DIN 969.

  • 6.6.2 Test procedure

For qualification, a S/N curve shall be performed with at least 4 levels and 2 specimens per level, in order to cover the range from 10 4 to 10 6 and to determine the inclined part of the S/N curve. 6 more specimens shall be used to define the fatigue strength at 5 10 6 cycles through the staircase method, Figure 1, in accordance with the combined test method in DIN 969.

Confidentiality: 2 / SUPPLIER INFORMATION Code: GPR90001-en Rev: 1 GAMESA PART REQUIREMENTS Date: 29/03/13 Pg. 9

Figure 1: Combined test method with 14 specimens

  • 6.6.3 Test conditions

At least 14 specimens shall be required.

The test shall be continued until the test piece fails, or until 5 10 6 cycles has been exceeded.

Tests shall be carried out with constant mean stress equal to

σ

m

=

0.70

×R

p

0.2 min

Where:

R p0.2 is the minimum stress at 0.2% non proportional elongation in accordance with ISO 898-1.

For failures in the threads, the calculation of the tensile strength shall be based on the nominal stress area A s .

A s

=

π

d

2

d 3
d
3

4

2

Being;

d 2 Basic pitch diameter of thread (see ISO 724)

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 10 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 

d 3 Nominal minor diameter of thread d 3 =d 1 -H/6 d 1 Basic minor diameter of thread (see ISO 724) H is the height of the fundamental triangle of the thread (see ISO 68-1) For failures in the shank, the calculation of the tensile strength shall be based on the shank diameter.

Survival criterion: The definition of failure is complete separation of the fastener into two parts

Test temperature: Room temperature. The initial set value for intervals of the test stress amplitude in the inclined part shall be

σ

aI

=10MPa. This value can be modified as a function of test results

Difference in levels of stress amplitude in the transition range modified as a function of test results.

σ

aII

=5MPa. This value

can

be

  • 6.6.4 Internally threaded component

For fatigue testing of these fasteners, the appropriate size, property class and improved perpendicularity (0.15) of nuts in accordance with ISO 4032 or ITH nuts shall be used.

  • 6.6.5 Determination of the Whöler curve (S/N curve)

The Wöhler curve (S/N curve) shall be determined for a survival probability of 50% and 97.7%.

  • 6.7 TIGHTENING TORQUE TESTS

If the preload is achieved by mechanical elongation no tightening torque tests shall be required.

If the preload is achieved by tightening torque tests shall be carried out in accordance with GTS73001

  • 7 PART APPROVAL PACKAGE (CAP) REQUIREMENTS

Qualification inspection and tests (requirements, methods and number of tests) are specified in Table 2. They shall be carried out on a single inspection lot selected by simple random sampling.

Stud bolts supplied must be approved by Gamesa Quality Department . prior to the delivery of parts for serial production. The parts shall comply as a minimum with the quality requirements specified herein.

Irrespective of the requirements of the present specification, the supplied material shall be free of any defects that might cause problem during manufacturing or decrease the design performance.

  • 7.1 SERIAL PRODUCTION REQUIREMENTS

Once manufacturing process has been validated in supplier by means of a CAP, a reduced inspection level shall be applied in which it shall be required the documentation in Table 2. They shall be carried out on each production/manufacturing batch. Studs from the batch or lot tested shall be selected by simple random sampling.

  • 7.1.1 Responsibility

Serial production inspections and tests shall be carried out by the manufacturer, or under his responsibility.

  • 7.1.2 Inspection and test report

A test report showing actual numerical values shall be provided

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 11 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 

Table 2: Test to be reported

Characteristic

 

Requirement

 

Inspection

test

Sample size

 

method

PAC

 

Serial

   

Chemical analysis or

   

certificate

 

of

Raw

material

According to 5.4

 

conformity issued by

1

per

1

per manufacturing

certificate

 

the manufacturer of the semi-finished product

manufacturing lot

lot

Steel Making

 

According to 5.4.2

 

Requirements

 

of

1

per manufacturing

1

per

manufacturing

EN 10204-3.1

 

lot

lot

Dimensions

 

According

 

to

 

Per manufacturing

Per manufacturing

applicable drawing

-

batch. If requested

batch. If requested

 
     

to

 

Per manufacturing

Per

manufacturing

Surface roughness

According

applicable drawing

As per ISO 4287

 

batch. See Tables 3 and 4

batch.

and 4

See

Tables

3

     

Corrosion test acc to ISO 9227

Per

manufacturing

Per manufactufing lot.

Surface treatment

According to 5.6

Adhesion Test acc to ISO 10683

 

lot.

If requested

Tensile test

 

According to 5.5

 

As per EN 10002-1

Per manufacturing lot. See Table 5

Per manufacturing lot. See Table 5

Charpy v-notch

 

According to 5.5

 

As per EN 10045-1

Per manufacturing lot. See Table 5

Per manufacturing lot. See Table 5

Hardness tests

 

According to 5.5

 

As per ISO 6506

 

Per manufacturing lot. SeeTable 5

Per manufacturing lot. SeeTable 5

 

The fibre structure in

     

the threads

shall

be

In those cases where

continuous and follow

Macrographic

 

raw material

is

the

thread

contour

quenched

and

Thread

structure

fibre

with

the

maximum

density at the bottom

of

the root

radius as

indicated in

the

examination

longitudinal

through

axis.

the

on

a

section

screw

1

per manufacturing

lot

tempered, this test is

not necessary. If not,

may be requested per manufacturing lot.

it

 

following figure.

     
   

Magnetic

particle

   

inspection as

per

ASTM E 1444

or

In

those

cases

liquid

penetrant

where raw material

examination

 

as

are peeled

and

per ASTM E1417.

polished

bars,

this

Discontinuities

(before coating)

 

Cracks shall be lead to rejection

In

or

case

of doubt

disagreement

1

per manufacturing

lot.

See

Table

3

test is not necessary

provided

that

on

the

nature

of

and 4

 

surface

defects

 

depth of defects,

 

control is declared in

the

final

decision

the

raw

material

shall

be

taken

certificates provided

after micrographic

by

the

steel maker

examination.

 

and

approved

by

 

Gamesa.

If

not,

Discontinuities

in

     

refer to Table 3 and

the

shank

thread

ans

(seams,

In

5.7

accordance

with

ASTM E1444

ASTM E 1417

or

1

per manufacturing

lot.

See

Table

3

per manufacturing lot.

4

laps

and

surface

     

and 4

 

irregularities)

     

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 12 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 
 

In accordance with

     

Fatigue tests

5.5.

Studs

tested full size

shall

be

In

accordance

with DIN 969

1

per manufacturing

lot . 14 valid tests

-N/A

 

Studs shall show no traces of surface

     

Carburization and

decarburization

carburization

or

decarburization on the shank and thread.

In

with 6.4

accordance

1

per manufacturing

lot . SeeTable 5

Per manufacturing lot. SeeTable 5

Table 3: Classification of defects and acceptable quality levels

Category of defects

AQL

Characteristics

 

0.065%

Thread Shank diameter Thread-shank run-out Surface discontinuities

Major

 

Total length

Shank length

 

1%

Concentricity

Surface roughness

 

Coating

Finish visual

 

2.5%

 

Minor

4.0%

Straightness All other dimensions. Other dimensions

AQL: Acceptance quality limit: Maximum number of defects per hundred units

 

Table 4: Sampling plans for visual inspection and dimensional characteristics

   

Acceptance number (Ac) and limiting quality (LQ 10 ) in accordance with the

Batch Size

Sample size

 

acceptance quality limit (AQL)

 

AQL 0.065%

AQL 1.0%

AQL 2.5%

AQL 4.0%

   

Ac

LQ 10%

Ac

LQ 10%

Ac

LQ 10%

Ac

LQ 10%

50

100%

51 to 90

  • 13

 

0

16.2

1

26.8

91 to 150

  • 20

 

1

18.1

2

24.5

151

to 280

  • 32

 

2

15.8

3

19.7

281

to 500

  • 50

 

1

7.56

3

12.9

5

17.8

501 to 1200

  • 80

 

2

6.52

5

11.3

7

14.3

1201

to

125

3

5.27

7

9.24

10

12.1

3200

3201

to

200

0

1.14

5

4.59

10

7.60

14

9.81

10000

10001

to

315

3.71

14

6.33

21

8.84

35000

35001

to

500

10

3.06

21

5.60

150000

150001 to

800

1

0.485

14

2.51

500000

Use sampling plan above Use sampling plan below

 

For those manufacturers who carry out an inspection during the manufacturing process (inspection on a machine and or inspection between operations), the sampling plan for the final inspection shall be compiled in such a way that the overall inspection plan shall guarantee and equivalent quality limit. LQ 10 : The quality limit which correspond to a specified 10% probability acceptance

Confidentiality: 2 / SUPPLIER INFORMATION

Code: GPR90001-en Rev: 1
 

Code: GPR90001-en

Rev: 1

GAMESA PART REQUIREMENTS

Date: 29/03/13

Pg. 13 of 13

Title:

IMPROVED FATIGUE RESISTANCE STUD BOLTS

 

Table 5: Sampling plans for inspection of mechanical and metallurgical characteristics.

 

Sample size

 

Batch size

Non-destructive tests

Destructive tests

Acceptance number Ac

A

B

Less than 500

8

3

0

500

8

3

0

501 to 3200

13

5

0

3201 to 35000

20

5

0

35001

32

8

0

  • 8 SERIAL PRODUCTION REQUIREMENTS

Once manufacturing process has been validated in supplier by means of a CAP, reduced inspection level shall be applied in which it shall be required the documentation in Table 2.

  • 9 ANNEXES

N/A