___________________________________________________________________________________________________________________

ISSUED BY NUMBER

H.B. McLean ENGINEERING 827

R.A. Schwarze FIRST ISSUED
TEST INSTRUCTIONS
APPROVED BY
April 30, 1986
R.E. Blough ELECTRO-MOTIVE SUPERSEDES

LaGrange, Illinois

SUBJECT Metallurgical Requirements for the Qualification of Castings for General

Usage
AFFECTS MODELS

PART NOS AFFECTED

REF. DRAWINGS

1. Scope:

This Engineering Test Instruction (ETI) covers the metallurgical aspects of qualifying
castings for general usage in production or service applications. It concerns the
testing of initial samples of production castings submitted in compliance with EMD
SPAP (Supplier Product Approval Process). Prototype castings shall also be tested
per this ETI. Acceptable standards may be modified by the product engineer during
the prototype phase.

This document is intended to supplement the existing requirements contained in

Engineering drawings, in EMS and other Engineering specifications or in society
specifications referenced therein, by defining testing procedures and establishing
requirements not directly covered in these sources.

REV DATE RFC PAGES AFFECTED CHANGED BY APPROVED BY

B 1-29-2007 D702912 Complete Retype C. Gursky B.L. Braglia
EMD 677-E WORD:ETI0827.doc

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2. Applicable Conditions:

2.1 It is the supplier's responsibility to submit sample castings and supporting

documentation unless otherwise authorized by the EMD Product Engineering
and Materials Engineering Departments whenever any of the following
conditions occur:

a) Release of new part.

b) Change in casting source for existing part.
c) Transfer of tooling to new plant location.
d) Castings to be produced at more than one of the supplier's plant
locations. Samples from each location are required.
e) Significant change in prints or specifications.
f) Significant change in foundry processes which may cause non-
conformance to specifications.
g) New tooling.

2.2 Notification - In regard to the above conditions it is necessary that all affected
parties be notified and informed of requirements in advance of the intended
action. To this end the following responsibilities are assigned:

Supplier - The castings supplier shall inform EMD Supply Chain Management
of any supplier initiated changes which may require re-qualification (see items
c, d, f and g).

EMD Supply Chain Management - shall inform Materials Engineering of any

proposed changes by a supplier or of any proposed change of castings source
(item b). Subsequently, after review by the product design engineer and
castings metallurgist, Supply Chain Management shall provide the supplier
with all pertinent specifications and confirm to the supplier the need to provide
samples and testing to this ETI.

In the case of new parts (item a) or changes initiated by EMD (item e), Supply
Chain Management shall provide the supplier with all pertinent specifications
and inform him of the need to provide samples and testing to this ETI.

Materials Engineering - When notified by Supply Chain Management of an

intended change (see above) the castings metallurgist shall inform the
appropriate product engineer. The castings metallurgist shall then assist the
product engineer in reviewing the radiographic requirements of the casting
(see below) and in evaluating the feasibility of the proposed change, including
possible questions about the need for re-qualification.

In the case of new parts or EMD initiated changes in existing parts, the
castings metallurgist shall again assist the product engineer as described in
the paragraph above.

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Product Engineering - The product engineer shall inform the castings

metallurgist of any new parts or EMD initiated changes in existing parts. Then
with the aid of the castings metallurgist the product engineer shall determine
the radiographic requirements of the casting (see below) and evaluate any
questions about the need for qualification or re-qualification. The product
engineer shall also be responsible for including radiographic requirements on
the engineering drawing when necessary. Finally the product engineer shall
inform Supply Chain Management of the need for requalification when
necessary.

In the case of changes proposed by a supplier or a proposed source change

by Supply Chain Management, Materials Engineering is to notify the product
engineer of the intended action. Thereafter the product engineer shall have all
of the responsibilities described in the previous paragraph.

2.3 Setting Radiographic Requirements:

The product engineer has primary responsibility for evaluating castings for
critical areas that may require more stringent radiographic requirements than
are indicated in this ETI (see Section 5.5). The EMD castings metallurgist is to
assist in such evaluations. If a casting is judged to need more stringent
requirements, then these must be explicitly indicated on the engineering
drawing. In such cases the product engineer is to issue the necessary
instructions to Product Design, whether for new parts or as a revision to
existing parts, and also notify the Materials Engineer of the requirements. The
Materials Engineer shall evaluate the specified requirements for completeness
as well as subsequently review the finished drawing.

The results of the evaluation of radiographic requirements and the need, if

any, of more stringent requirements are to be transmitted to the supplier via
Supply Chain Management before sample castings are made and tested. If
there is insufficient time to produce finished drawings, sketches or marked up
prints can be used to convey the necessary information.

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3. Supplier Responsibilities:

3.1 The supplier shall meet the requirements of EMD SPAP as further defined in
this document.

3.2 Sample production castings are to be made to EMD drawings and specifications
from specified materials on regular production tooling with no operations included
which shall not be incorporated in regular production processing unless authorized
by the EMD Product Engineering and Materials Engineering Departments. Sample
prototype castings for Product Engineering may be produced on temporary tooling
as agreed upon with the responsible product engineer.

3.3 In addition to providing representative sample castings to EMD, the supplier is

responsible for performing or having performed, by a qualified laboratory, the
inspections and tests contained in this ETI and related specifications. Such
inspections and tests are to be fully documented as required herein and in
SPAP. All testing is to be done prior to the shipment of samples and the
resultant documentation is to accompany the actual castings. As the purpose
of providing samples and documentation is to demonstrate compliance to
specifications, it is expected that the supplier will not knowingly submit
samples and/or results that fail to comply.

3.4 No regular production or prototype castings may be shipped without completed

SPAP approvals from EMD.

4. General Requirements:

4.1 Specifications

The requirements contained in this ETI are specifically directed at the

qualification of initial production castings for general use. As such they
supplement and somewhat modify existing specification sources.

In the case of radiographic inspection, this document establishes requirements

not previously stated in EMD specifications. These are meant to reflect the
generally expected quality levels for castings intended for general use and do
not override more stringent requirements which may exist in specific instances.

Acceptance criteria are based on the requirements already existing in other

EMD specifications. Should any apparent conflict exist between requirements
stated in EMD specifications and referenced society specifications, the order
of precedence is 1) the engineering drawing, 2) the EMS specification and
other EMD Engineering specifications (AI, ETI, EDPS,...) and 3) other
referenced specifications (ASTM, SAE, AAR....).

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4.2 Multiple Cavity Molds

When castings are produced in multiple cavity molds, complete test work and
documentation are to be provided for each cavity.

4.3 Marked Prints

Certain test procedures require that specimen locations be indicated on a

marked up print. It is permissible to indicate all such information on a single
print provided that it is clearly legible.

4.4 Weld Repairs

Weld repairs are not permitted on castings submitted for initial qualification.

5. Specific Requirements:

5.1 Chemical Analysis

a. Chemical analysis is required for all casting qualifications.

b. Tests are to be performed by recognized industry methods and

standards suitable to the analyses required.

c. Samples for chemical analysis are to be taken from actual castings,

separate test bars, or other specimens poured at the same time as the
sample castings. The type and amount of sampling shall be sufficient
to determine the required elements.

d. Acceptance Criteria - The specified chemical composition requirements

contained in the EMS specification, engineering drawing or other
referenced specification are the basis for acceptance. Where chemical
composition is not specified, the analysis shall be reported for
reference.

e. Reporting - The supplier shall submit a test report listing the actual
amounts determined for each specified element, for each casting
tested.

5.2 Mechanical Properties

a. Tensile testing to determine mechanical properties is required

whenever specified by EMS specification, engineering drawing or other
referenced specification.

b. All preparation and testing is to be done according to the requirements

of the appropriate ASTM specification: A370, B557 or E8.

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5.2 Mechanical Properties - (Continued)

c. Test bars are to represent the material condition of the casting as

supplied to EMD. If heat treatment is required, samples from castings
are to be taken after heat treatment. Separately cast or attached test
bars are to be heat treated with the actual castings.

d. Standard size (0.505" diameter) test bars are to be obtained from

actual castings if at all possible. Unless a specific test bar location is
indicated on the engineering drawing or in the EMS specification, the
supplier may take the sample from anywhere on the casting.

If it is physically impossible to obtain a standard size test bar from the

casting the foundry may instead cast test coupons attached to the
casting or gating system or separately in keel blocks. Note that certain
EMS specifications contain provisions for waiving tensile test
requirements if a proper sample cannot be obtained. However, such
waivers are not allowed for qualification purposes.

A minimum of two test bars are required. If a test bar is machined

improperly or if flaws are revealed by machining or during test, that bar
may be discarded and another one substituted. Otherwise retests are
not permitted.

e. Acceptance Criteria

The minimum properties requirements contained in the EMS

specification, engineering drawing or other referenced specification are
the basis for acceptance. Both test bars are to meet the requirements.

f. Reporting

The supplier shall submit a test report containing the following

information for each casting tested:

1) Test bar size and test method standard used,

2) Material condition (as cast or method of heat treatment),
3) Test bar location - whether from a casting, keel block or attachment.
The location of a bar taken from a casting should be indicated on a
marked up engineering drawing.
4) The properties values obtained in the test.

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5.3 Hardness

a. Hardness testing is required whenever specified by EMS specification,

engineering drawing or other referenced specification.

b. All tests are to be conducted on properly prepared surfaces according

to ASTM standards A370, E10 (Brinell) or E18 (Rockwell).

c. The material condition at the time of test shall represent the casting as
supplied to EMD. Any required heat treatments are to be performed
before hardness testing.

d. Hardness tests are to be done on actual castings. A random pattern of

tests to represent the various areas of the casting is desirable. The
number of tests performed should be at least sufficient to represent the
range of significantly different section sizes contained in the casting.
Note that some EMS specifications and engineering drawings do
prescribe specific locations for hardness tests.

e. Acceptance Criteria

The specified hardness requirements contained in the EMS

specification, engineering drawing or other referenced specification are
the basis for acceptance.

f. Reporting

The supplier shall report the readings obtained for each casting tested.
A marked up copy of the engineering drawing indicating the locations
of the hardness tests performed is to be included.

5.4 Microstructure

a. Metallographic examination is required in all cases, even if not explicitly

required in specifications.

b. All samples are to be prepared in accordance with ASTM E3.

c. The material condition at the time of examination shall represent the

casting as supplied to EMD. Any required heat treatments are to be
performed before examination.

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5.4 Microstructure – (Continued)

d. The number of micro samples taken from a casting should be sufficient

to represent significant differences in section size. At least one micro
sample should contain the cast surface.

e. Acceptance Criteria

The purpose of examination is to verify that the casting microstructure

complies with the intended condition of the material. The actual
requirement may be specific, as in the case of graphite types in ductile
iron, or more general as expressed by terms such as "pearlitic" or
"normalized" or "solution treated and aged".

f. Reporting and Sample Submission:

The supplier shall submit either a brief written description or

representative photomicrograph of the structure observed in each
sample. If photomicrographs are submitted the magnification and
etchant used should be included. The location of all samples should
be indicated on a marked up engineering drawing.

5.5 Radiographic Examination

a. Radiographic examination is required in all cases.

b. Radiography shall be performed according to ASTM Standard E94.

c. The number of radiographs shall be sufficient to represent the entire

casting. In the case of multiple cavity molds a casting from each cavity
is to be entirely radiographed.

d. Acceptance Criteria

The following requirements are considered basic and shall apply

unless otherwise indicated on the engineering drawing.

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5.5 Radiographic Examination - (Continued)

d. Acceptance Criteria - (Continued)

1). Ferrous Materials

Radiographs are to be evaluated in comparison with ASTM

Reference Radiograph Standards E446, E689 and E802. The
following acceptance levels shall apply:

Maximum Allowable
ASTM Standard Category Level

E446 and A Gas Porosity 3

E689* B Inclusions 3
CA Shrinkage 3
CB Shrinkage 3
CC Shrinkage 3
CD Shrinkage 3

E802** ----- 2

No cracks, hot tears or unfused inserts are allowed.

* - For section sizes up to 2".

** - For gray iron only.

2). Aluminum

Radiographs are to be evaluated in comparison with ASTM

Reference Radiograph Standard E155. The following
acceptance levels shall apply:

Category Maximum Allowable Level ***

1/4" 3/4"

Gas holes 2 2
Gas porosity (round) 5 5
Gas porosity (elongated) 4 4
Shrinkage cavity 2 2
Shrinkage porosity or sponge 3 3
Foreign material (less dense) 2 3
Foreign material (more dense) 3 3

No cracks or hot tears allowed.

*** - Acceptance levels listed meet Quality Level III of Aluminum

Association Standard AA-CS-M5-85.

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5.5 Radiographic Examination - (Continued)

d. Acceptance Criteria - (Continued)

3). Copper

Radiographs are to be submitted for castings. No cracks, hot tears

or foreign material allowed. The product engineer may specify
acceptance criteria.

e. Reporting

The supplier shall submit a report for each casting radiographed which
lists the level achieved in the casting for each category listed above.
Furthermore, the supplier shall submit all radiographs (properly
identified) used in evaluating the castings.

6. Acceptance:

The acceptance criteria for specific tests are contained in the appropriate parts of
Section 5 of this document. However the EMD Materials Engineering Department
reserves the right to audit the reported results or perform any other additional tests it
deems necessary to verify the quality of the sample castings submitted. A final
disposition on metallurgical acceptability is to be made in writing by the EMD Materials
Engineering Department.

7. Regular Production:

The testing procedures and requirements for initial qualification of castings are of
necessity more extensive and stringent than those employed for ongoing production.
Therefore, after approval it is expected that the test methods and the frequency of
testing will follow more normal practices, suitable for regular production. This in no
way implies a lessening of the requirements contained in EMD specifications. Nor
does it imply any reduction in overall quality, for it is expected that the supplier will
maintain the practices used to produce the initial castings. It does mean that only
those requirements explicitly stated in EMS specifications, engineering drawings and
other referenced specifications will apply. Microscopic and/or radiographic testing will
in general not be required for regular production, though there may be specific
requirements in some cases. In the event that the quality of the castings falls off
significantly, the supplier will be required to requalify under the terms of this ETI.

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