ENGINEERING MATERIAL SPECIFICATION

DIE CAST ALUMINUM – GENERAL PURPOSE WSS-M2A171-A1

DIE CAST ALUMINUM – MEDIUM DUTY APPLICATIONS WSS-M2A171-A2

1. SCOPE

The materials defined by these specifications are die cast aluminum alloys for general purpose and
medium duty applications.

2. APPLICATION

WSS-M2A171-A1 is used to specify die cast components where attributes such as pressure tightness
are the main requirement, such as water pump housings.

WSS-M2A171-A2 is used to specify die cast components where a minimum set of mechanical
properties are required. These specifications are not intended to specify the material used for safety-
critical components.

3. REQUIREMENTS

3.1 APPROVED SOURCES

This specification does not use approved sources. Any reliable supplier meeting these
requirements may be used.

3.2 CHEMICAL COMPOSITION, % by Weight

(ASTM E34 / ASTM E607 / ASTM E1251)

Castings supplied to WSS-M2A171-A1 or -A2 shall be made of a grade chosen from the
following list of national standard grades. The chemical composition shall conform to the
requirements in the given standard. The grade chosen for a given application shall be listed for
reference on the PPAP documentation, and the supplier shall not change the chosen grade
without prior engineering approval (SREA).

Standard Grades
ASTM B85* UNS A03800, UNS A13800, UNS A03830, UNS A03840
EN 1706 AC46000, AC46200, AC46500
JIS H5302 ADC10, ADCZ10, ADC12, ADCZ12

In addition to the chemical composition requirements within the national standard, the following
conditions shall apply:

• A maximum magnesium content of 0.55% is allowed for both grades

• For castings supplied to WSS-M2A171-A2, iron, manganese and chromium are further
restricted (commonly known as the "sludge factor") such that (%Fe + (2x%Mn) +
(3x%Cr)) ≤ 2.00%

Date Action Revisions Rev. 2

2015 10 01 Revised See Summary of Revisions G. Weber, NA
2010 09 27 Revised G. Weber, NA
2009 06 24 Activated G. Weber, NA
Controlled document at www.MATS.ford.com Copyright © 2015, Ford Global Technologies, LLC Page 1 of 5
 ENGINEERING MATERIAL SPECIFICATION

WSS-M2A171-A1/A2

3.3 MECHANICAL PROPERTIES

A1 Castings supplied to WSS-M2A171-A1 are not required to meet a set of minimum

mechanical properties.

A2 Castings supplied to WSS-M2A171-A2 shall meet the following minimum mechanical

properties in the as-cast condition ('F' Temper):

Property Machined Bars Cast Bars

0.2% Offset Yield, MPa, min 140 150
Elongation, %, min 0.5 1.0

All test samples shall be machined from cast components. Location(s) and procedure
for obtaining test specimen shall be outlined in the component Engineering Specification
or on the Engineering Drawing/CAD file and shall form part of the agreed Control Plan.
Upon agreement between Ford and the supplier, separately cast test bars may be used
if the component dimensions or geometry prevent the machining of an adequately sized
test bar.

Upon agreement between Ford and the supplier, functional testing of the part may be
substituted for mechanical property testing. Such testing shall stress the part in critical
areas to insure that mechanical properties are sufficient for the design. Leak testing is
not acceptable as a functional test to assess mechanical properties. Details of the
agreed upon functional test shall be documented in the component Engineering
Specification or on the Engineering Drawing/CAD file, and Materials Engineering shall
review the test details prior to release.

3.4 HARDNESS
(ISO 6506/ASTM E10)

A1 Castings supplied to WSS-M2A171-A1 are not required to meet a specific hardness

range.

A2 80 HB minimum. Location(s) and procedure for testing hardness shall be outlined in the
component Engineering Specification or on the Engineering Drawing/CAD file and shall
form part of the agreed Control Plan.

3.5 INTERNAL SOUNDNESS AND ACCEPTANCE CRITERIA

(ASTM E505)

When specified in the component Engineering Specification or on the Engineering Drawing/CAD

file, castings shall be checked for internal soundness (for example, shrinkage, porosity and other
internal defects) by x-ray inspection. Castings shall display soundness of ASTM E505 Level 3 or
better throughout the casting. In locations on the casting designated as High Impact Areas,
soundness of ASTM E505 Level 2 or better is required. Locations designated as High Impact
Areas shall be specified in the component Engineering Specification or on the Engineering
Drawing/CAD file. Frequency of testing shall form part of the agreed Control Plan.

Alternate methods of evaluating internal soundness may be utilized, upon agreement between
Ford Design Engineering, Ford Materials Engineering, Ford STA and the supplier. Acceptance
criteria and frequency of testing shall form part of the agreed Control Plan.

3.6 CONTROL OF CASTING MANUFACTURING PROCESS

Ford Global Manufacturing Standard W-CMS defines a minimum set of required process
controls for various casting processes. All castings supplied to WSS-M2A171-A1 or -A2 shall
meet the requirements of W-CMS.

Copyright © 2015, Ford Global Technologies, LLC Page 2 of 5

 ENGINEERING MATERIAL SPECIFICATION

WSS-M2A171-A1/A2

4. GENERAL INFORMATION

The information given below is provided for clarification and assistance in meeting the requirements of
these specifications. Contact gmfs@ford.com for questions concerning Engineering Material
Specifications.

4.1 CHEMICAL COMPOSITION

At the latest release of this specification, the chemical composition requirements of the national
standard grades referenced in this specification were as follows. Single figures are maximum
unless otherwise specified.

A03800 A13800 A03830 A03840 AC46000 AC46200

Si 7.5-9.5% 7.5-9.5% 9.5-11.5% 10.5-12.0% 8.0-11.0% 7.5-9.5%
Cu 3.0-4.0% 3.0-4.0% 2.0-3.0% 3.0-4.0% 2.0-4.0% 2.0-3.5%
Mg 0.10% 0.10% 0.10% 0.10% 0.05-0.55% 0.05-0.55%
Zn 3.0% 3.0% 3.0% 3.0% 1.2% 1.2%
Fe 2.0% 1.3% 1.3% 1.3% 1.3% 0.8%
Mn 0.50% 0.50% 0.50% 0.50% 0.55% 0.15-0.65%
Ni 0.50% 0.50% 0.30% 0.50% 0.55% 0.35%
Sn 0.35% 0.35% 0.15% 0.35% 0.25% 0.15%
Ti --- --- --- --- 0.25% 0.25%
Pb --- --- --- --- 0.25% 0.25%
Cr --- --- --- --- 0.15% ---
Others (each) --- --- --- --- 0.05% 0.05%
Others (total) 0.50% 0.50% 0.50% 0.50% 0.25% 0.25%

AC46500 ADC10 ADCZ10 ADC12 ADCZ12

Si 8.0-11.0% 7.5-9.5% 7.5-9.5% 9.6-12.0% 9.6-12.0%
Cu 2.0-4.0% 2.0-4.0% 2.0-4.0% 1.5-3.5% 1.5-3.5%
Mg 0.05-0.55% 0.30% 0.30% 0.30% 0.30%
Zn 3.0% 1.0% 3.0% 1.0% 3.0%
Fe 1.3% 1.3% 1.3% 1.3% 1.3%
Mn 0.55% 0.50% 0.50% 0.50% 0.50%
Ni 0.55% 0.50% 0.50% 0.50% 0.50%
Sn 0.25% 0.20% 0.20% 0.20% 0.20%
Ti 0.25% 0.30% 0.30% 0.30% 0.30%
Pb 0.35% 0.20% 0.20% 0.20% 0.20%
Cr 0.15% --- --- --- ---
Others (each) 0.05% --- --- --- ---
Others (total) 0.25% --- --- --- ---

Copyright © 2015, Ford Global Technologies, LLC Page 3 of 5

 ENGINEERING MATERIAL SPECIFICATION

WSS-M2A171-A1/A2

4.2 INFORMATIVE MATERIAL PROPERTIES (TYPICAL)

The following material properties are provided for information only and are not required to be
measured or verified prior to or during component production.

Parameter
Hardness, HB 80 – 110
Ultimate Tensile Strength, MPa (as-cast bars) 320
Ultimate Tensile Strength, MPa (bars machined from casting) 230
Compressive Yield Strength, MPa 140
Shear Strength, MPa 200
Fatigue Endurance Limit, MPa 60
Elastic Modulus, GPa 71
Poisson’s Ratio 0.33
Density, g/cc 2.7
o o
Coefficient of Linear Thermal Expansion, 20-100 C, µm/m/ C 21.1
o o
Coefficient of Linear Thermal Expansion, 20-200 C, µm/m/ C 21.8
o
Thermal Conductivity, W/m/ C 100
o
Specific Heat, J/kg/ C 960
o
Melting Range, C 515 – 595

4.3 RECYCLING CODE

When required, the recycling code listed on the part drawing and displayed on the part, as per
Ford Engineering CAD and Drafting Standard E-4, shall be <AlSi9Cu3(Zn)(Fe)>.

4.4 APPROVAL OF MATERIALS

Suppliers desiring approval of their materials shall first obtain an expression of interest from
Purchasing, Design or Product Development, and Materials Engineering. The supplier shall
submit a completed copy of their laboratory test reports, signed by a qualified and authorized
representative of the test facility, demonstrating full compliance with all the requirements of
the Material Specification. Tested material samples must be available for review upon request
and kept for a minimum of one year. Upon request, the supplier will review the associated
quality control documents (Process Failure Mode and Effects Analysis, Control Plans,
Certification testing) with Ford.

4.5 SUPPLIER'S ONGOING RESPONSIBILITY

All materials must be equivalent in all characteristics to the material upon which approval was
originally granted.

Prior to making any changes to the material originally approved, whether or not such changes
affect the material's ability to meet the specification requirements, the supplier shall notify the
affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering
activities of the proposed changes (with reasons) by submission of a completed Suppliers
Request for Engineering Approval, SREA.

For parts and components using Ford Engineering Material Specifications, all samples tested
to the specifications for Design Verification (DV), Production Verification (PV) and Production
Part Approval Process (PPAP) sign off must be kept until Job 1.

4.6 RESTRICTED SUBSTANCE MANAGEMENT STANDARD

Copyright © 2015, Ford Global Technologies, LLC Page 4 of 5

 ENGINEERING MATERIAL SPECIFICATION

WSS-M2A171-A1/A2

Substance restrictions imposed by regulations or Company direction applies to the materials

addressed by this document. The restrictions are identified in the Restricted Substance
Management Standard WSS-M99P9999-A1 which is updated yearly. It is the supplier’s
responsibility to comply with this standard on a continuing basis through IMDS and or GMAP
reporting.

5. SUMMARY OF REVISIONS

2015 10 01
Section 3.3 (A2) – Added functional testing as an alternative to tensile testing

2010 09 27
Section 3.2 (A1) – Removed sludge factor requirement
Section 3.2 (A2) – Added A03800 grade and changed sludge factor requirement from 1.80%
Section 3.3 (A2) – Eliminated requirement for ultimate tensile strength and changed elongation from
1.0% (machined) and 2.5% (cast)
Section 4.2 – Added typical hardness range and ultimate tensile strength
Section 4.3 – Added recycling code
Section 3.2 – Simplified this section
Section 4.2 – Corrected CLTE and TC values

Copyright © 2015, Ford Global Technologies, LLC Page 5 of 5