CORPORATE ENGINEERING TEST PROCEDURE

Global Standards
TITLE: Exhaust Fatigue Life Estimation CETP: 09.00-C-301
Supersedes: None 200610 Page 1 of 7

1.0 INTRODUCTION
This test procedure provides the methodology necessary to verify exhaust system robustness to
program specific exhaust system structural durability requirements necessary to meet the
Vehicle Durability Verification Tests. This document may be used for all vehicles.
DESCRIPTION - This subsystem test verifies exhaust system robustness to structural
durability test track events representing the customer Real World User Profile (RWUP). The
purpose of this test methodology is to support the GPDS process by replacing the need for
structural and attribute prototype vehicles and provides for high reliability confidence while
going into M1 prototype vehicle sign-off. Exhaust system product verification is successful
demonstrated by meeting acceptance requirements contained within this document and
reliability targets cascaded from platform vehicle targets. Unless otherwise stated, exhaust
components subjected to this test are intended to meet product in-service useful life of 150,000
miles of vehicle structural durability.
This test procedure compares stress/strain exhaust system values measured on vehicle when
subjected to program specified local market requirements RWUP track surface to stress/strain
life curves of pertinent exhaust system component/locations. The stress/strain life curves are
corrected to account for safety factors (required due to variability of test measurements and
material/manufacture properties) and thermal effects. The stress/strain damage measured on
vehicle is then compared to component capability, as inferred from the stress/strain life curves.
1.1 COMMONALITY. This is a CONTROL TEST and can be used to qualify vehicles or
Components throughout the world. The test may be conducted at any location having the
necessary equipment and facilities. Proposed revisions to this procedure must be submitted per
FAP03-179. All Ford Motor Company Exhaust System Suppliers and other Ford Motor
Company approved sources may use this procedure to validate exhaust systems. All equipment
and facilities must meet ISO-9000 requirements prior conducting exhaust systems tests.
1.2 This procedure is a living document and will be updated as necessary.
1.3 DEFINITIONS
1.3.1 Hot-End Exhaust System - All components and hardware attached from the manifold pierce
points (including all flanges, gaskets, and fasteners) to the outlet of the last underbody catalytic
converter or other emission control device such as diesel particulate filters (including the outlet
pipe, and shields attached to the catalyst). Includes all pipes, HEGO and CMS bosses, exhaust
side heat shields, brackets, fasteners, and flex-decouplers and the manifold, when integral to the
catalyst (Often referred to as a "Mani-Cat").

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 CORPORATE ENGINEERING TEST PROCEDURE
Global Standards
TITLE: Exhaust Fatigue Life Estimation CETP: 09.00-C-301
Supersedes: None 200610 Page 2 of 7

1.3.2 Cold-End Exhaust System - All components from the outlet of the catalytic converter (s)
(including the attaching joint and fastener hardware, excluding the catalyst outlet pipe) to the
tailpipe outlet (including all exhaust components: resonators, pipes, mufflers, brackets, hanger
rods and brackets, exhaust side heat shields, flex-decouplers, and fasteners).
1.3.3 Complete Exhaust System - Is defined as both Hot-End and Cold-End Exhaust Systems,
including any attached ornamental tailpipe tip treatments.
1.3.4 Powertrain - Including, but not limited to, engine and transmission.
1.3.5 Exhaust Support System – The Support system that is welded or clamped to the exhaust system
piping or tuning chambers that are used to attach the exhaust system to the vehicle body by use
of an exhaust isolator, and the support system that is attached to the body side of the vehicle by
means of threaded fasteners or weldments.
1.3.6 Muffler Inlet/Outlet Pipes – The region of the exhaust system where the exhaust piping either
enters (Inlet) or exits (Outlet) the muffler, resonator, or other tuning device.
1.3.7 Catalyst Inlet/Outlet Pipes – The region of the exhaust system where the exhaust piping either
enters (Inlet) or exits (Outlet) the catalytic converter.
1.3.8 Endurance Limit (Fatigue Limit) – The maximum reversed load (or stress) that may be repeated
an indefinite number of times without causing failure.
1.3.9 Other terms as specified in ASTM Standard E 1823 – 96, Standard Terminology Relating to
Fatigue and Fracture Testing
1.3.10 Life = 1 – (Cumulative Damage) {Remaining life expressed as a fraction of original life}
1.4 ACRONYMS
ASD – Auto Spectral Density.
CETP – Corporate Engineering Test Procedure.
GPDS - Global Product Development System.
FRF – Frequency response function.
RWUP – Real World User Profile.
RLDA – Road Load Data Acquisition.
KLT – Key Life Test.
SDS - System Design Specification.

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 CORPORATE ENGINEERING TEST PROCEDURE
Global Standards
TITLE: Exhaust Fatigue Life Estimation CETP: 09.00-C-301
Supersedes: None 200610 Page 3 of 7

1.5 LIMITATIONS
1.5.1 Certain vehicle road events are not covered in this simulation:
1.5.1.1 Exhaust system body or ground contact.
1.5.1.2 Sustained lateral loading (vehicle cornering events below 1.0 Hz).
1.5.1.3 Sustained longitudinal loading (vehicle braking events below 1.0 Hz).
1.5.1.4 Corrosion-fatigue interactions.
1.5.1.5 Powertrain durability events:
1.5.1.6 Inherent engine unbalance > 50 Hz.
1.5.1.7 Sustained high temperature creep fatigue, and creep-plastic fatigue interactions.
1.6 ACCCEPTANCE CRITERIA
Predicted life of exhaust system component (number of cycles to failure) less then required for
component life, when compared to stress/strain life curve, after adjusting for safety factors and
correction factors.
1.7 Reference Modeling / Analysis Procedure
Refer to: www.dearborn2.ford.com/caedevpp/csc/Handbook
1.8 RECORD RETENTION
Supplier specific per Quality Operating System QS-9000
1.9 All applicable safety guidelines and procedures must be followed.

2.0 SOFTWARE/COMPUTER HARDWARE REQUIREMENTS

2.1 Computer Hardware and Software Requirements
Sufficient to conduct fatigue analysis such as "FLASH", "LIFE", "FLAP", or any other suitable
software.
2.2 Other Requirements
2.2.1 Hardware Testing Support
None required.

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 CORPORATE ENGINEERING TEST PROCEDURE
Global Standards
TITLE: Exhaust Fatigue Life Estimation CETP: 09.00-C-301
Supersedes: None 200610 Page 4 of 7

3.0 DATA REQUIREMENTS

3.1 Input Data Type
3.1.1 Load data (Road Load Data Acquisition CETP 09.00-R-100, Exhaust System Road Load Data
Acquisition), adjusted with a stress safety factor (recommended value of 2.0) and converted to
a rain flow analysis per SAE Standard J2623, Standard Rainflow File Format.
Recommended Safety Factor is (1.30) * (1.5) = 1.95 (Rounded to 2.00)
• 1.3 - Variation in Road Load Data
• 1.5 - Historical Possible Increase in Road Loads from Early Prototype to 1PP build phase.
3.1.2 Stress/Strain (or load/life) Life Curves from region of interest. Stress Life curves for the
regions of interest are to be generated using CETP 09.00-E-309, Development of Endurance
Strength Charts for Exhaust System Components (Force Controlled Constant Amplitude) or
any other method if concurred by the requesting engineer.
Ref: http://wwwdev.dearborn4.ford.com/exhaust/rv/?
3.1.3 Temperature profile of exhaust system, in regions of interest, during the program approved
durability events per CETP 09.00-R-101, or other temperature factor as concurred by the
requesting engineer.
3.1.4 Stress/Strain Life (or load/life) Curves (referenced in paragraph 3.1.2) are to be adjusted to the
operating temperature of the exhaust system during the program approved durability and engine
resonance events. The Stress/Strain Life Curve temperature compensation is to be
accomplished by decreasing the stress/strain by an amount corresponding to the same
percentage change in the ultimate stress. Chart attached.
Ultimate Tensile Strength (UTS) chart provided by AK Steel-July, 2006.

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 CORPORATE ENGINEERING TEST PROCEDURE
Global Standards
TITLE: Exhaust Fatigue Life Estimation CETP: 09.00-C-301
Supersedes: None 200610 Page 5 of 7

Ultimate Tensile Strength At Temperature

700
Lines Interpolated
600
409
Pressure (Kpa)

500
439
400 18CrCb
300 15CrCb
309
200
316/316L
100
0
0 200 400 600 800 1000
Temperature (C)

3.2 Output Data Type

Damage analysis of the component(s) of interest.

4.0 MODEL, ANALYSIS AND POST PROCESSING REQUIREMENTS

4.1 Data Processing
Vibration stress data for each test mode as acquired in CETP 09.00-R-100 (or other method as
concurred by the requesting engineer) is analyzed for frequency (Rainflow Order). Using S-N
data for each region of interest calculate the damage amount for all test modes (accounting for
temperature effects) corrected with the Smith Watson Topper mean stress correction method
using Miner's Rule or any other method as concurred by the requesting engineer.

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 CORPORATE ENGINEERING TEST PROCEDURE
Global Standards
TITLE: Exhaust Fatigue Life Estimation CETP: 09.00-C-301
Supersedes: None 200610 Page 6 of 7

5.0 SEQUENCE OF OPERATION

Road Load Data

From 09.00-R-100, Exhaust System Road Load Data Acquisition

Data Post Processing
and Validation

Rainflow Cycle Count

Fatigue Life Estimation (Miner's Law)

Apply Safety Factor

(2.0)

Smith Watson Topper Life > 20% Yes

Mean Stress (0.20)
Correction

Adjust S-N Curve for

Part Ok'd For Vehicle
Operating
No Durability
Temperature

Redesign Part and Re-

Run S-N Curves (If
Required)

6.0 GENERAL INSTRUCTIONS

6.1 Validation and Correlation Checks
Review the results against baseline result and /or test result, if available.
6.2 Lessons Learned
To capture improvements that are critical to overall procedure consistency and robustness,
forward lessons learned to the procedure owner.

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 CORPORATE ENGINEERING TEST PROCEDURE
Global Standards
TITLE: Exhaust Fatigue Life Estimation CETP: 09.00-C-301
Supersedes: None 200610 Page 7 of 7

7.0 PRESENTATION OF DATA

7.1 Data Presented
Stress plots (assign value not contour value), fatigue life table and frequency table, Percent Life
retained.

8.0 REFERENCES
8.1 Documents and Sources
8.1.1 FAP03-179, Developing Corporate Engineering Test Procedures.
8.1.2 NAT CAE Local Procedure- Exhaust System.
8.1.3 CETP 09.00-C-300, Exhaust System Durability CAE.
8.1.4 CETP 09.00-E-309, Development of Endurance Strength Charts for Exhaust System
Components (Force Controlled Constant Amplitude)
8.1.5 CETP 09.00-E-400, Exhaust System Structural Durability Key Life Test (KLT).
8.1.6 ASTM Standard E 468 – 90 Standard Practice for Presentation of Constant Amplitude
Fatigue Test Results for Metallic Materials.
8.1.7 SAE J2623, Standard Rainflow File Format.
8.1.8 CETP 09.00-R-100, Exhaust System-Road Load Data Acquisition.
8.1.9 CETP 09.00-R-101, Exhaust System-Thermal Mapping.
8.1.10 S-N Database, http://wwwdev.dearborn4.ford.com/exhaust/rv/?
8.2 Correlation / Confidence Data Sources
AK Steel properties charts.

9.0 RECORD OF REVISIONS

See metadata field "Review Note".

10.0 ATTACHMENT
None.

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