Caterpillar specification 1E2679_Chg05_24-Mar-2009

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CORPORATE PRODUCT & PROCESS SPECIFICATION 1.0 SCOPE This specification covers general requirements for steel castings. Unless otherwise specified, these requirements apply when 1E2679 is specified in the individual material specification. 2.0 GRAIN SIZE Fine grain metallurgical practice is required (per ASTM E112: G.S. = 5 or finer). 3.0 COMPOSITION AND HARDENABILITY 3.1 Composition 3.1.1 Composition of castings must be within the limits of the individual material specifications, and may be further restricted by hardenability (DI or Jominy) limits when such requirements are included. 3.1.2 Suppliers must submit in writing to the Metallurgical Division of the receiving Caterpillar Inc. Plant the expected finished casting analysis (or any changes thereto). Sample compositions with a mean or aim chemistry that corresponds to the aim DI are included as examples in some of the material specifications. 3.1.3 Castings utilized in Caterpillar Inc. products must not contain levels of radioactivity above background radiation levels. Suppliers should ensure the castings are not contaminated by inspection of incoming charge materials, etc., to prevent contamination. 3.1.4 Arc furnace melted heats must be refined by an oxygen blow down of the melt by the amount shown in Figure 1. Unless otherwise negotiated and agreed upon with the receiving facility’s Metallurgical Division, castings are to be poured with only (1) furnace heat. Alloy Type Carbon Reduction Low Alloy (1E0003 & 1E0627 ) 0.20% MIN High Alloy 0.30% MIN Figure 1 - Carbon Reduction Oxygen Treatment 3.1.5 Certain elements may be present in steel that are not specified or required. Unless otherwise specified, these incidental elements shall not exceed the values in Figure 2.

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CORPORATE PRODUCT & PROCESS SPECIFICATION

Element MAX Allowable Nickel 0.30 Wt % Chromium 0.20 Wt % Molybdenum 0.08 Wt % Copper 0.35 Wt % Lead 0.02 Wt % Tin 0.03 Wt % Vanadium 0.030 Wt % Figure 2 - Incidental Element Limits 3.2 Hardenability 3.2.1 When DI (ideal diameter) hardenability limits are specified, they must be determined as follows: 3.2.1.1 DI must be calculated per the method described in the 1E0024B, Section 17. (This method is also useful when used in reverse, i.e., knowing the hardenability required, it is possible to work out the various combinations of chemical composition that will produce the required DI.) 3.2.1.2 The successful use of this procedure is dependent on an accurate and complete chemical analysis. The analysis must include the following elements: carbon, manganese, silicon, nickel, chromium, molybdenum, copper, vanadium, and zirconium. 3.2.2 When Jominy end-quench hardenability limits are specified, the following practice is required: 3.2.2.1 A Jominy end-quench test is required on bars from each ladle or batch treatment of steel. 3.2.2.2 Jominy end-quench tests must be performed according to ASTM A255. As cast test bars may be used in lieu of machined test bars when correlation between the two types of test bar results has been established. 3.2.2.3 When boron is used as a hardenability intensifier, analysis for boron, zirconium and titanium is recommended as an indication of the boron effectiveness.

THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION 4.0 HEAT TREATMENT 4.1 Unless otherwise specified by the material specification, all castings must be normalized or normalized and tempered by the supplier for grain refinement and attainment of mechanical property requirements. 4.2 Final heat treatment (e.g., 1E0106), as specified on the part number drawing, must be provided by the foundry when shown on the purchase order. 4.3 Unless otherwise specified in specific part number requirements, the following table is a requirement for steel castings with 1E0106 Direct Harden Heat Treatment. Parts must be water (oil and polymer unacceptable) quenched and achieve the following as-quenched minimum hardness. The requirements are for parts with section size of 102 mm and less. For parts with section sizes greater than 102 mm and having 1E0106 on the print, consult strategic sourcing SDE, plant metallurgist and supplier quality. Material Grade 1E0002 1E0602 1E0626 1E0627 1E0977 1E1123 1E1132 1E1144 1E1257 1E1787 1E2808

Minimum Hardness (Brinell Diameter) 2.8 2.8 3.2 3.4 3.4 3.2 2.8 3.2 3.3 2.8 3.0 Figure 3

5.0 MECHANICAL PROPERTY TESTING 5.1 Mechanical property requirements must be determined on specimens removed from castings in the annealed, normalized, or normalized and tempered condition as applicable.

THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION 5.2 Tensile Test Specimens 5.2.1 Unless otherwise specified on the part number drawing, 1E0552-X1 and -X2 tensile specimens must be used to determine mechanical properties. 1E0552-X1 and -X2 are the only specimens for which rejection for low mechanical properties is permitted. Mechanical properties determined on other tensile test specimens (see Figure 4) may be used for information only. Specimens must be taken as near the surface of the casting as possible, locating the centerline of the specimen between the surface and centerline of the casting section (see Figure 5). Using cast test bars is an acceptable method for determining mechanical properties provided the casting section size is less than the test specimen diameter and the test bar and the casting have similar cooling rates. In the event that this is done, tensile and yield strength requirements in the individual material specification must be multiplied by 110% for new tensile and yield requirements for the cast test bars. 5.2.2 Test specimens may be located on the centerline of a casting section when the section does not exceed two times the test specimen gauge diameter. However, the minimum elongation and reduction of area values do not apply when the centerline of the casting is included in the test specimen gauge diameter. 5.2.3 Test specimens exhibiting low elongation must be examined macroscopically for porosity or shrinkage in the test gauge section. If such defects are present, the specimen may not be used as a basis for rejection on low mechanical properties. However, such defects must be judged on the basis of their effect on part appearance and function. 5.2.4 Elongation determined from 1E0552-X1, -X2 and -X5 specimens must be based on 50 mm and 25 mm gauge lengths, respectively. Elongation determined on all other specimens must be based on their specified gauge length.

THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION

Test Specimen Casting Section Test Thickness Specimen Nominal Gauge Diameter X1 12.83 mm 38.0 mm and Larger X2 12.83 mm 38.0 mm and Larger X5 6.35 mm 19.0 – 38.0 mm X10B 4.63 mm 19.0 – 38.0 mm X10C 6.40 mm 25.0 – 38.0 mm X11A 4.53 mm 13.5 – 38.0 mm X11B 6.40 mm 19.0 – 38.0 mm Figure 4 - Tensile Test Specimens

Figure 5 - Location of Specimen 5.3 Hardness Testing - Hardness tests must be performed on a surface which has been ground to a depth sufficient to avoid surface irregularities. 5.4 Charpy Impact Test Specimen - Where a Charpy requirement is included, the Charpy impact test specimen must be 1E0552-W9 Type A. The specimens must be taken from as near the casting surface as possible and must not include the centerline of the casting section thickness. The notch must be machined in the side adjacent to the casting surface. 5.5 Test procedures for tension testing, hardness testing, and charpy impact testing must conform to ASTM E8, ASTM E10, and ASTM E23, respectively. THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION 6.0 SURFACE CARBON CONTROL 6.1 Decarburization restricted as follows: Maximum Affected Depth (MAD), mm =

[0.50 + (.020 Times the Maximum Section Thickness in mm)].

6.2 No surface carburization permitted. However, for components in dozer and ripper assemblies assigned Design Control Codes J221, J222, J223, J224, the surface carbon of weldable steel castings may exceed the specification up to a maximum of 0.40% combined total of base carbon and additional surface carbon to a maximum surface depth of 1.5 mm. If any surface carburization is present, preheating of weldable steels will be applied in accordance with the requirements of the producing facility’s Weld Engineering Department. 7.0 QUALITY REQUIREMENTS 7.1 Additional quality requirements apply if 1E2075 and/or 1E4032 appear on the part number drawing. Requirements in 1E2075 and/or 1E4032 supersede any contradictory requirements in this specification if 1E2075 and/or 1E4032 appear on the part number drawing. 7.2 Conformance Records of Castings - The supplier must, upon request by Caterpillar, furnish records showing conformance of castings to the requirements of this specification. 7.3 Casting Surface - The casting surface, on visual examination, must be free from adhering sand, scale, cracks, and hot tears. Superficial surface irregularities may be removed by grinding providing the ground section remains within the allowable dimensional tolerances, and is finished in a workmanlike manner. 7.4 Casting Defects 7.4.1 Requirements for Internal Soundness are as follows: Discontinuity Type Gas Sand Shrink Type 1 (Linear) Type 2 (Dendritic) Type 3 (Spongy) Type 4* (Feathery)

Category A B

1E2679 Requirement (MAX) A3 B4

C C C C

CA4 CB4 CC4 CD4

Note*: ASTM E446 Only Note: ASTM E446: 0 - 2”, ASTM E186: 2 - 4.5”, ASTM E280: 4.5 - 12”

Figure 6 THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION

7.4.2 Radiographs for evaluating casting defects must be produced according to ASTM Standards E94 and E1742 (2-2T sensitivity). Additionally, castings that have surface connected (as-cast or machined surface) shrinkage are rejectable. The finished part must have no shrinkage, porosity, gas, or sand on machined surfaces (note: some parts are machined at assembly level and have the same requirement). It is recommended that sample and first production castings should have 1 level better soundness than the specification requirement because of foundry process variability and the normal probability distribution. Internal chills to the casting are prohibited. External chills, i.e., in the cores and in the mold, are permitted. 7.5 Magnetic Particle Inspection 7.5.1 Magnetic particle inspection (MPI) must conform to requirements of ASTM E709. Linear indications must be rated according to ASTM E125. 7.5.2 Magnetic particle inspection requirements apply to random defects only. Out-ofspecification repetitive defects must be eliminated through improved foundry practice (not continual welding). 7.5.3 Requirements for magnetic particle inspection are as follows: Casting Weight

≤ 225 kg > 225 kg

Maximum ASTM E125 Linear Indication Areas of Casting Areas of Casting Not to Be Machined to Be Machined and Machined Surfaces I -3abc I -2abc I -4abc (Random) I -3abc (Repetitive) Figure 7

7.5.4 Castings to be quench and tempered must have 1 level better than specification. Discontinuities upon quench and temper processing tend to grow in size by 1 level. For castings quench and tempered by the foundry, the ultimate quality criteria is the finished castings and the spec. For castings quench and tempered by Caterpillar, use the above process requirement. 7.5.5 Castings over 225 kg will require wet continuous overall magnetic particle inspection with a 100% frequency. Wet continuous overall is meant as magnetizing the part all at once and using a liquid suspension. Overall magnetization is covered in ASTM E709-01, Section 12.3.2.3, and includes the Head and Tailstock Contact Technique, the Clamps Technique, and the Multidirectional Magnetization Technique, among others (no prods or yokes). THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION

Note: This is not meant to exclude use of dry MPI with prods or yokes for small areas and welds. Additional dry mag-particle inspection of these areas is acceptable. Castings less than 225 kg will require 100% mag-particle inspection unless through attribute charts and continued auditing proves that the process does not require 100% inspection. 7.5.6 The supplier must record magnetic particle inspection data in attribute charts showing defect location, size, and frequency. This data must be used to eliminate gross/repetitive defects. 7.5.7 Parts must be de-magnetized with magnetization not exceeding 5 gauss. 7.6 Finished Castings - Finished castings or agreed upon specimens from finished castings, when loaded to fracture, must not exhibit rock candy, planar faceting, or any other similar type of fracture surface. 7.7 Testing Castings - Castings may be destructively or non-destructively tested by Caterpillar to ensure that the quality level of the currently approved sample casting is being maintained. 7.8 Test Methods - When agreed to by the Engineering Design Control and the appropriate personnel responsible for supplier quality for the receiving plant, equivalent national standard test methods may be used in lieu of the ASTM test methods required by 1E2679. 8.0 CASTING WELD REPAIR 8.1 General Requirements 8.1.1 Castings produced to this specification may be repaired by welding except: (1) in surface hardened areas which are identified by H, HH, or H1, H2, etc.; (2) in areas where the part number drawing specifically prohibits weld repair; (3) as stated in 1E2075 areas. Part (1) requires that no welding is allowed in areas that are flame hardened (1E0399), induction hardened (1E0288), or laser hardened (1E2801). 8.1.2 Authorization to weld repair castings in no sense obligates acceptance of such castings by Caterpillar should subsequent examination indicate that the repair welds were unsatisfactory.

THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION

8.1.3 All repair welding must conform to a Weld Procedure Sheet written by the supplier. The Weld Procedure Sheet must include: electrode, welding parameters, method of removing defects, preheat (if needed), finishing requirements, post heat treatment, etc. The current Weld Procedure Sheet must be made available upon request for audit by Caterpillar Inc. Caterpillar reserves the right to change weld procedures where required to assure quality of product. 8.1.4 The supplier is responsible for minimizing weld repair on castings made to this specification. When feasible, defects that occur at similar locations on successive casting lots of the same part number must be corrected. 8.1.5 Casting weld repair guidelines provided in this article apply only to suppliers in order to ensure uniformity of product delivered to Caterpillar Inc. repair welding of steel castings at Caterpillar Inc. plants or designated facilities must be according to procedures specified by the appropriate weld engineering group. Questions regarding location and extent of defects that are repairable should be resolved with engineering design control. 8.2 Welding Guidelines 8.2.1 Preparation 8.2.1.1 Defects must be completely removed prior to welding. 8.2.1.2 An acceptable weld repair preparation must include an approximately 90º angle at the root for good penetration and to minimize root defects. The remainder of the preparation must include sidewall angles consistent with good weld practice. Undercut or parallel sidewalls in weld repair preparations are not acceptable. 8.2.2 Electrode - The electrode used must be as specified in the individual material specification. 8.2.3 Preheat - Unless otherwise specified in the individual material specification, preheating of castings is discretionary.

THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION 8.2.4 Welding 8.2.4.1 Through section weld repair of thermal cracks or hot tears is permitted when both sides of the section are accessible, and the maximum length of the defect on either side of the section containing the defect does not exceed that specified in the individual material specification. The least accessible side must be welded first, the root back gouged from the opposite side, and then welded. Through section defects longer than those covered above may be weld repaired by this practice only if welds are subsequently radiographed to assure acceptable quality and the appropriate design control and receiving plant quality control groups are notified that such repairs have been made. Disposition of the radiographs depicting the repair welds must be according to the quality control group involved. 8.2.4.2 Through section weld repair of sand, foreign material or porosity type defects is permitted when both sides of the section are accessible. 8.2.4.3 When only one side of the section is readily accessible, weld repair is permitted to the extent that the back wall does not burn through. The minimum allowable back wall thickness is 5 mm. 8.2.4.4 Unless otherwise negotiated, all accessible chaplets in non-critical areas of the casting must be weld repaired to a minimum depth of 13 mm or 50% of the section thickness, whichever is less, see Figure 8.

Figure 8 - Examples of Chaplet Weld Repair in Non-1E2075 Areas THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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CORPORATE PRODUCT & PROCESS SPECIFICATION 8.2.4.5 All repair welds must be inspected to assure conformance to Paragraph 8.4.2. 8.2.4.6 Back-up strips, if used, must be completely removed after weld repair. 8.3 Post Weld Heat Treatment - As specified in the individual material specifications. 8.4 Finishing and Inspection 8.4.1 Castings must be repaired in a workmanlike manner and buffed or ground smooth to give good contour and appearance. 8.4.2 Weld repaired areas of a casting must be free of defects such as cracks, porosity, incomplete fusion, etc., and must conform to bulk casting quality requirements set out in Article 7.0. 9.0 CLEANING Unless otherwise specified on the part number drawing, all castings must be cleaned by the supplier in accordance with 1E0576 foundry instructions. 10.0 IDENTIFICATION Orders are to be filled with a minimum number of furnace heats. Unless otherwise negotiated and agreed to by Caterpillar castings must be individually identified according to 1E0576 foundry instructions. 11.0 REFERENCES Caterpillar Specifications ASTM

1E0002, 1E0003, 1E0024B, 1E0106, 1E0288, 1E0399, 1E0552, 1E0576, 1E0602, 1E0626, 1E0627, 1E0977, 1E1123, 1E1132, 1E1144, 1E1257, 1E1787, 1E2075, 1E2801, 1E2808, 1E4032 A255, A370, E8, E10, E23, E94, E112, E125, E1742, E186, E280, E446, E709

THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

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