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CORPORATE PRODUCT & PROCESS SPECIFICATION

1.0 SCOPE

This specification covers heat-treated aluminum alloy sand and permanent mold castings. Alloy
and temper designations are in accordance with ANSI H35.1 and H35.1M. Quality requirements
are covered by 1E2850.

2.0 APPLICATION

This specification is intended to apply to high strength structural aluminum castings with
complex configurations susceptible to high (examples: brake saver stator, complex gear
housings). Unless otherwise noted on the detail drawing, castings will be made to a Grade C
quality level with a Class 3 inspection frequency requirement. This specification may also be
used to procure other Classes and Grades of Aluminum Association 356.0 aluminum alloy
castings. Design Control shall establish the grade and class for each casting design per
1E2850 and note the Grade and Class required for the application in the body of the detail
drawing. Sections of a casting may be of varying quality grades depending on the stresses
applied to that portion of a casting. Particular attention should be given to areas that contain, or
w ill eventually contain, stress risers after machining (such as sharp internal corners, holes or
notches). The heat-treated condition required shall be as shown on the detail drawing.

3.0 QUALIFYING SPECIFICATIONS

1E0015 Numerical Code

1E0466 Salvage of Aluminum Castings
1E0552 Test Specimens - Metallic Materials
1E0576 Foundry Instructions
1E2272 Solution Treat - Precipitation Harden Metals
1E2278 Precipitation Harden
1E2349 Materials Application - Alternate
1E2850 Quality Requirements - Aluminum Alloy Sand and Permanent Mold Castings
ASTM E29 Practice for Using Significant Digits in Test Data to Determine Conformance with
Specifications

4.0 COMPOSITION (%) (SIMILAR TO ALUMINUM ASSOCIATION 356.0)

4.1 Chemical composition of the castings shall conform to the following percentages by weight
determined by wet chemical methods in accordance with ASTM E34, or by spectrochemical
methods.

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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Silicon 6.5 - 7.5 Titanium 0.25 MAX

Iron* 0.6 MAX Lead 0.05 MAX
Copper 0.25 MAX Other Elements (Each) 0.05 MAX
Manganese* 0.35 MAX Total Other Elements** 0.15 MAX
Magnesium 0.20 - 0.45 Aluminum Remainder
Zinc 0.35 MAX

Note*: If iron exceeds 0.45, manganese content shall not be less than one-half iron content.
Note**: Lead content is included in this total.

4.2 Test results may be rounded in accordance with the “rounding off” method of ASTM E29.

5.0 MECHANICAL PROPERTY REQUIREMENTS

5.1 The inspection Class specified by Engineering Design Control establishes the test
method(s) used to control mechanical property requirements during production.

5.2 Requirements for Tensile Specimens Sectioned from Casting (Classes 1 Through 4)

5.2.1 Tensile Specimens Sectioned from Selected Area - When specific test specimen
location(s) are identified on the detail drawing, the mechanical property requirements in Figure 1
shall apply to the heat-treated castings.

Tensile Yield Strength Elongation Typical* Hardness

Type of
Condition Strength (0.2 % Offset) In 50 mm 500 Kg Load, 10 mm
Casting
MIN, MPa MIN, MPa MIN, % Ball, BHN
Sand T51 160 110 1.0 60
T6 205 140 3.0 70
T7 215 200 1.0 75
T71 170 125 3.0 60
Permanent T51 170 124 1.0 70
Mold T6 228 152 3.0 80
T71 170 145 3.0 65
Figure 1

Note*: For Caterpillar Inc. guidance only.

5.2.2 Tensile Specimens Sectioned from Any Area - When specific test specimen
location(s) are not identified on the detail drawing, the mechanical property requirements in
Figure 2 shall apply to the heat-treated castings.

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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Tensile Yield Strength Elongation in

Type of Heat
Strength MIN, (0.2 % Offset) MIN, 50 mm MIN,
Casting Treatment
MPa MPa %*
Sand T51 138 97 1.0
T6 186 124 3.0
T7 200 165 1.0
T71 152 110 3.0
Permanent T51 159 110 1.0
Mold T6 207 138 3.0
T71 172 124 3.0
Figure 2

Note*: Elongation of 1.0% requires that yielding be visible on stress strain curve. Accuracy
of the elongation test procedure is not capable of detecting values of 1% or less.

5.3 Integrally-Cast and Separately-Cast Tensile Specimens (Classes 3 and 4)

5.3.1 Class 3 Castings - The tensile properties of either integrally or separately cast test
specimens may be used to control mechanical property requirements during production.

5.3.1.1 The mechanical properties of the castings must meet the requirements of Figure 1 if
the detail drawing requires “Tensile Specimens Sectioned from Selected Area(s)”.

5.3.1.2 The mechanical properties of the castings must meet the requirements of Figure 2 if
the detail drawing requires requires “Tensile Specimens from Any Area”.

5.3.2 Integrally Cast Tensile Specimens - Shall be obtained from prolongation(s) on the
heat-treated castings and tested in accordance with ASTM E8. The prolongation(s) should be
designed to obtain the same solidification rate as the section(s) of the casting they represent.
For specific test specimen locations the prolongations will represent the solidification rates of the
specified test location. When test specimen locations are not identified the prolongations will
represent the thickest and thinnest sections of the casting.

5.3.2.1 For specific test specimen location(s) shown on the detail drawing, the mechanical
properties of the integrally cast tensile specimens machined from prolongation(s) on the
castings must meet the requirements of Figure 1. During the Advanced Product Quality
Planning (APQP) process, specimens machined from both prolongations and castings will be
tensile tested to demonstrate that both sets of tensile specimens have statistically the same
mechanical properties. These data will be reviewed and approved by Metallurgical or Technical
Materials Engineer of Affected Plant(s) in consultation with Engineering Design Control.

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.

DATE CHG NO NUMBER

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5.3.2.2 When specific test specimen locations are not shown on the detail drawing, the
mechanical properties of the integrally cast tensile specimens machined from prolongation(s) on
the castings must meet the requirements of Figure 2. During the APQP process, specimens
machined from both prolongations and castings will be tensile tested to demonstrate that both
sets of tensile specimens have statistically the same mechanical properties. These data will be
reviewed and approved by Metallurgical or Technical Materials Engineer of Affected Plant(s) in
consultation with Engineering Design Control.

5.3.3 Separately Cast Tensile Specimens - This test method is allowed only when the
receiving facility verifies that the mechanical properties of separately cast test specimens are
representative of the mechanical properties of the casting. The foundry’s sampling plan must be
documented and approved by Metallurgical or Technical Materials Engineer of Affected Plant(s)
in consultation with Engineering Design Control. This will be accomplished as part of the APQP.
The separately cast test specimens shall be produced from the same melt as the castings they
represent, using the same mold type, and heat-treated with the castings they represent and
must meet the requirements of Figure 1.

5.3.4 For Class 4 castings, by the tensile properties of either integrally cast or separately cast
test specimens may be used to control mechanical property requirements during production.
A correlation with mechanical property data of specimens removed from castings is not
required. Note, the properties measured for separately cast specimen properties will not reflect
the actual strength of the castings. Actual strength properties of the casting will expectedly be
75% of the values measured for heat-treated separately cast test specimens.

5.3.4.1 Integrally-cast tensile specimens shall be obtained from prolongation(s) on the heat-
treated castings and tested in accordance with ASTM E8. The prolongation(s) should be
designed to obtain the same solidification rate as the section of the casting they represent.
Their minimum properties shall satisfy the requirements specified in Figure 2.

5.3.4.2 Separately cast tensile specimens shall be produced from the same melt using the
same mold type, and heat-treated with the castings. The specimens shall be tested in
accordance with ASTM E8 and the properties shall satisfy the minimum requirements specified
in Figure 1.

6.0 SAMPLING AND TESTING

6.1 Tests for composition and mechanical properties are acceptance tests and shall be
performed on each melt or lot as applicable. Methods of analysis, test, and inspection shall
conform to ASTM or other specific standards.

6.2 Chemical Analysis Specimens - Chemical analysis specimens shall be cast from each
melt and shall be of any suitable size and shape.

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.

DATE CHG NO NUMBER

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CORPORATE PRODUCT & PROCESS SPECIFICATION

6.3 Tensile Specimens from Heat Treated Castings - The supplier shall determine a test
plan that will assure all castings will meet the mechanical property requirements of this
specification. This data shall be available for audit or made available to Caterpillar when
requested.

6.3.1 Unless otherwise specified on the part number drawing, tensile test specimens shall be
selected as specified in Figure 3 and machined from areas designated. Specimens shall be
taken as near the surface of the casting as possible with the centerline of the specimen between
the casting surface and a point half way between the surface and the part center (between mid-
radius and surface of a round section). All tensile specimens will be heat treated with the
casting lot they represent.

Nominal Gage
1E0552 Section
Diameter
Test Specimen Thickness (mm)
(mm)
X – 11A* 6.35 12.5 – 25
X – 11B 6.25 19 – 38
X–5 6.25 19 – 38
X–1 12.5 38 and Over
Figure 3

Note*: May be used in sections less than 12.5 mm thick. Evidence of ductility for sections less
than 12.5 mm shall be determined from stress-strain curve. Full diameter of grip ends not
required. Where necessary (section thickness to thin), sheet type tensile specimens per ASTM
E8 may be used.

6.3.2 Test specimens with macro (gross) porosity in the test gage section shall not be used for
determining the mechanical properties. However, such porosity shall be judged based on its
effect on part appearance and function.

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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6.4 Integrally Cast Tensile Specimens - Prolongation(s) of the casting shall be designed to
provide integrally cast tensile specimens. Caterpillar Design Control is encouraged to consult
with the casting supplier to assure that the properties of the integrally cast tensile specimen(s)
are representative of critical sections (those which would normally be audited by use of Selected
Area Tensile Test Specimens Cut from Castings). Unless otherwise specified on the part
number drawing, the specimens shall have the dimensions of the standard 12.8 mm gage
diameter specimen described in 1E0552-X1, or conform to ASTM B557M with 12.70 mm
diameter at the reduced parallel gage section. If casting, core print or gating geometry
precludes the use of a standard test specimen as a prolongation, substitute specimen sizes may
be used that can be cast or machined to those allowed by ASTM B557.

6.5 Separately Cast Tensile Specimens - Test specimens shall be cast in the same mold
type used for the casting. If the metal used for castings is given any treatment, such as de-
gassing, grain refining, modification or cooling and reheating, the metal for the specimens will be
a portion of the metal so treated and, during such treatment, will be heated to the same
maximum temperature and held for approximately the same time as the molten metal for the
castings. The temperature of the metal during pouring of the specimens will not be lower than
that used during pouring of the castings. For sand molds, chills are not permitted on test
specimen cavity except on the end faces of the specimen. The test section of the tension test
specimen shall be cast to size in accordance with the dimensions shown in ASTM B26 and
B108 and not machined prior to test. The grip ends may be machined to adapt them in such a
manner as to ensure axial loading.

7.0 HEAT TREATMENT

7.1 Castings heat-treated to a T6, T7 or T71 condition shall be solution treated and water
quenched per 1E2272 and precipitation hardened per 1E2278. Heat treatment times and
temperatures shall be as shown in Figure 4.

Solution Solution Precipitation Precipitation

Type of Heat
Temp, Time, Harden Harden Time,
Casting Treatment
°C ±5 Hrs Temp, °C ±5 Hrs
Sand T51 -- -- 227 7-9
T6 538 12 154 2-3
T7 538 12 204 2-4
T71 538 12 246 2-4
Permanent T51 -- -- 227 7-9
Mold T6 538 8 154 2-3
T71 538 10 218 2-4
Figure 4

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: The exact time for precipitation hardening is influenced by foundry variables and may be
adjusted to obtain the properties specified in Article 5.0.

8.0 FOUNDRY PRACTICE

8.1 The best commercial practice including melt treatment for removal of oxides and other
entrained non-metallics, the reduction of dissolved hydrogen concentration, grain refinement
and/or modification of Si eutectic morphology shall be employed consistent with the production
of sound castings meeting the quality requirements of 1E2850, Grade C, Class 3, or the grade
and class specified on the engineering drawing. The castings shall be properly gated and
adequately risered to produce sound, leak proof castings. Chills shall be employed when
necessary to maintain soundness in heavy sections. The use of chaplets should be avoided
whenever possible. Aluminum chaplets are permitted when necessary. Steel chaplets can be
used only with written permission of the engineering department of the procuring facility or when
indicated on the detail drawing. Copper and copper alloy chaplets are prohibited.

8.1.1 For sand castings, melt modification to attain a Class 3 or better Si morphology as
described by the American Foundry Society “Microstructural Control in Hypoeutectic Aluminum-
Silicon Alloys” Chart is required. Either strontium or sodium may be used to accomplish
modification of the microstructure.

8.1.2 When the sand casting process is used to make “prove design” components that in
production will be made via the permanent mold casting process, melt modification to attain a
Class 4 (see Figure 6) or better Si morphology as described by the American Foundry Society
“Microstructural Control in Hypoeutectic Aluminum-Silicon Alloys” Chart is required. Chills will
be employed as necessary to maintain soundness in heavy sections.

8.2 Castings shall be produced in lots from metal conforming to Article 4.0. Metal melted from
previously analyzed ingot may be poured into castings. Furnace or ladle additions of grain-
refining elements or alloys are permissible. Molten metal taken from alloying furnaces, with or
without additions of foundry operating scrap (gates, sprues, risers and rejected castings), shall
not be poured into castings unless first converted to ingot, analyzed and re-melted or unless the
composition of a sample taken after the last addition to the melt conforms to Article 4.0.

8.2.1 A melt is defined as the metal withdrawn from a batch-furnace charge of 900 kg or less,
as melted for pouring castings, or when permitted by purchaser, a melt shall be 1800 kg or less
of metal withdrawn from one continuous furnace in not more than eight consecutive hours.

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

8.2.2 A lot is defined as all castings poured from a single melt in not more than eight con-
secutive hours and, if applicable, solution and precipitation heat treated in a single heat treat
batch.

9.0 QUALITY REQUIREMENTS

9.1 The finished castings shall be sound, uniform in quality, condition and composition and free
from blowholes, cracks, shrink, and other injurious defects detrimental to their intended
application. Castings that show injurious defects, revealed by machining operations subsequent
to acceptance, are not acceptable

9.2 Castings must meet both chemical analysis limits and mechanical property requirements.

10.0 SURFACE POROSITY REQUIREMENTS

The quality of the castings made to this specification will permit the attainment of the General
Surface Porosity Criteria and, if specified, the Critical Machined Surface Porosity noted on the
engineering drawing as defined in 1E2850, Paragraph 5.5.

11.0 QUALITY ASSURANCE PROVISIONS

11.1 Responsibility for Inspection - The casting supplier shall supply all samples for
supplier’s tests and shall be responsible for performing all required tests. Upon request by
Caterpillar, the supplier shall furnish records showing conformance of the castings to the
requirements of this specification. Caterpillar reserves the right to sample and to perform any
confirmatory testing deemed necessary to ensure that the castings conform to the requirements
of this specification.

11.2 Approval

11.2.1 The supplier shall assure that sample castings made from new or reworked molds meet
the dimensional and configurational requirements of the engineering drawing, and the
mechaniccal properties and quality requirements of this specification.

11.2.2 Supplier shall establish, for production of castings of each part number, parameters for
the process control factors that will produce acceptable castings. These parameters, which
constitute the approved casting procedure, will be used for making all production castings. If it
is necessary to make any significant change in parameters for the process control factors,
supplier shall submit for re-approval a statement of the proposed changes in processing and,
when requested, test specimens, sample castings or both. Production castings incorporating
the revised operations shall not be shipped prior to receipt of approval.

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

12.0 SALVAGE AND REPAIR OF CASTINGS

No casting repair is permitted without prior approval. Structurally sound castings having minor
defects may be repaired in accordance with the provisions outlined in 1E0466 only when
specifically authorized by the Caterpillar Design Control. Repaired castings shall be identified
as required in 1E0466. Repaired castings, which meet the requirements of the intended
application, may be accepted only on deviation. It is not the intent of this specification that
salvage measures be used in lieu of good foundry practice. Continued requests for salvage
may be denied unless the supplier has shown that the best foundry practice is employed.

13.0 ALTERNATE MATERIALS

Appropriately heat-treated EN 1706 AC-42000 (EN 1706 AC-Al Si7Mg) qualifies as a Type B
alternate material and may be used to fulfill the requirements of this specification when
economically competitive. Approval and documentation procedures of 1E2349 apply.
Chemistry of any alternate materials must meet lead requirements of Paragraph 4.1.

14.0 SIMILAR SPECIFICATIONS

14.1 This specification is similar to the following designations in Figure 7.

Sand Permanent
National Standard Alloy No. Condition Casting Mold Casting
Aluminum Association Alloy 356 T51, T6, T7, T71 X X
SAE 323 T51, T6, T71 X X
ASTM Designation B26 356.0 T6, T71 X
ASTM Designation B108 356.0 T6 X
EN 1706 AC-42000 T51, T6, T7 X X
(Al Si7Mg)
Figure 5 - Similar Specifications

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15.0 SUBSIDIARY SPECIFICATIONS (FOR CATERPILLAR REFERENCE ONLY)

15.1 At the time of release of 1E1047, Change 05, the following subsidiary versions of 1E1047
were in use by Caterpillar Facilities outside of the United States.

Caterpillar Materials Routiers S.A. (Albaret) “V” Version

Caterpillar Belgium S.A. (Gosselies) “V” Version
Caterpillar France S.A. (Grenoble) “V” Version
Caterpillar Brazil Ltd. (Piracicaba) “G” Version
Shin Caterpillar Mitsubishi Ltd. (Sagami) “X” Version
Shin Caterpillar Mitsubishi (Akashi) “X” Version
Figure 6

15.1 Subsidiary versions may be changed, released or canceled without a change to this
version of 1E1047. The Engineering Data System (EDS) provides information on the status of
subsidiary version specifications and should be referenced for current information.

16.0 REFERENCES

Aluminum Association Alloy 356.0

ANSI H35.1, H35.1M
ASTM B26 Grade 356, B108 Grade 356, B557, B557M, E8, E34, E29
EN 1706 AC-42000

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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