Niobium titanium alloy bars and rods
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- Mu2e Solenoid Niobium Titanium Alloy Bars and Rods Specification Spec : ES-464091
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| ES-464091
Mu2e Solenoid Niobium Titanium Alloy Bars and Rods Specification Spec #: ES-464091 July 16, 2012
1.0 SCOPE This specification establishes the minimum requirements for the finished product of Niobium alloy bar and rod containing Titanium as specified herein. This material will be used in the manufacture of superconducting wire for use in the cables for the Mu2e solenoid magnets at Fermilab. Final acceptance of the material will be subject to the requirements of this specification at the time of final processing. 1.1 Definitions Lot: A lot is defined as all material of a single process and casting, heat treated (if applicable) in the same charge in a batch-type furnace. 2.0 APPLICABLE DOCUMENTS 2.1 Applicability The following documents of the issue in effect on the date of invitation for bids or request for proposal form a part of this specification to the extent specified herein. 2.1.1 Government Documents a) NBS Handbook 91; Experimental Statistics 2.1.2 Industry and Society Documents a) ANSI B46-1; Surface Texture b) ASTM A-388; Ultrasonic Testing and Inspection of Heavy Steel Forgings. c) ASTM E-8; Tension Testing of Metallic Materials d) ASTM E-29; Recommended Practices for Indicating Which Places of Figures are to be Considered Significant in Specified Limiting Values. e) ASTM E-92; Test for Vickers Hardness of Metallic Materials. f) ASTM E-112; Standard Methods for Estimating the Average Grain Size of Metals. g) ASTM E-94; Standard Recommended Practice for Radiographic Testing. h) ASTM E-165; Standard Practice for Liquid Penetrant Inspection Method i) ASTM B884-05; Standard Specification for Niobium-Titanium Alloy Billets, Bar, and Rod for Superconducting Applications 2.2 Source of Documents Any difficulty in obtaining the applicable documents should be referred to the Fermilab Subcontract Administrator. 2.3 Precedence In the event of conflict between the requirements of this specification and the above applicable documents, this specification shall take precedence. Any such conflict shall be brought to the attention of the Fermilab Subcontract Administrator. 3. REQUIREMENTS 3.1 Material Properties
The material shall meet the specifications listed in 2.1.2i. 3.1.1 Size
3.1.2 Product Composition 3.1.2.1 Casting - The elemental composition of the as cast alloy shall be chemically determined and shall be as follows: Ti 47 wt%, + 1 wt% % by Weight Maximum Oxygen .1000 Hydrogen .0035 Carbon .0200 Iron .0200 Tantalum .2500 Nitrogen .0150 Nickel .0100 Silicon .0100 Copper .0100 Aluminum .0100 Chromium .0060 Niobium 53 wt%, + 1 wt%
3.1.2.2 Partially Forged or As-Forged Condition Material held at an intermediate size shall meet the compositional requirements of the as-cast state. 3.1.2.3 Finished Product Chemical analysis of each lot shall be performed for the interstitial elements and shall conform to the following limits: % by Weight Maximum Oxygen .1000 Hydrogen .0045 Carbon .0200 Nitrogen .0150
3.1.5 Internal Structure 3.1.5.1 Inclusions The finished product shall be free of inclusions as follows: Finished Product Size Inclusion Size Limit 16 mm (0.625 inch) diameter or less No inclusions in excess of 0.36 mm (0.014 inch) (equivalent diameter) as determined by 100% ultrasonic inspection. > 16 mm (0.625 inch) diameter No inclusions or voids in excess of 3% of the product diameter or 2.5 mm (0.096 inch) (equivalent diameter), whichever is smaller. 3.1.5.2 Grain Size The grain size of the finished product shall be determined at two locations 90° apart using the applicable provisions of 2.1.2f. The grain size shall be determined in the outer 25% of the radial dimension and shall be as follows: Nominal Diameter, mm(inch) Grain Size 12 to 51 (0.50 to 2.0) No. 4.5 or finer ( 75 m) 52 to 115 (2.1 to 4.5) No. 2.5 or finer ( 150 m) 116 to 152 (4.6 to 6.0) No. 1.5 or finer ( 210 m) greater than 152 (6.0) No. 1.0 or finer ( 250 m) 3.2 Manufacture 3.2.1 Manufacturing Plan A manufacturing plan shall be established by the vendor, defined by flow chart, diagram, or narrative; and shall be submitted to the Fermilab Subcontract Administrator for review and approval. Where proprietary processes are applied, such processes may be protected by a non-disclosure agreement between Fermilab and the manufacturer. After production start, any changes to the approved manufacturing plan must be brought to the attention of the Fermilab Subcontract Administrator. No changes shall be implemented without written authorization through the Fermilab Subcontract Administrator. 3.2.2 Statistical Process Control The Vendor shall institute a program of Statistical Process Control (SPC) as appropriate to the manufacturing process. Actual SPC elements, control limits, and methods shall be determined and documented as part of the Vendor's Quality Plan. Norms will be established using mutually agreed upon, recent data. All data outside of a 3 range from the norm will be subject to a review arranged by the Fermilab Subcontract Administrator, even when data meets the limits set within this specification. 3.2.3 Control of Manufacturing Machines and Methods The machines and equipment used to process all superconductor made to this specification shall be identified for Fermilab and documented as part of the vendor's Quality Plan. No changes to machines, methods or processes shall be permitted without prior written approval through the Fermilab Subcontract Administrator. 3.2.4 Fabrication Annealing specifications will be specified by the superconductor manufacturers. This will be supplied with the final dimensional requirements. 3.2.5 Cleanliness 3.2.5.1 Partially Forged or As-Forged Condition Cleanliness Requirements shall not be applied to material held at an intermediate size, but will be applied upon subsequent final processing. 3.2.5.2 In Process Precautions shall be taken during manufacture to ensure removal of substances deleterious to the use of the finished product for the intended application. Cleaning shall be performed following each nondestructive examination. 3.2.5.3 Finished Products Materials shall be examined with the unaided eye, corrected for 20/20 vision, under an illumination of at least 1000 lux. The presence of contamination (i.e., grease, oil, dirt, lubricants) is cause for rejection. 4.0 QUALITY ASSURANCE 4.1 Quality Assurance Plan
4.2 Responsibility The vendor shall be responsible for the performance of all tests and inspections required prior to submission to the buyer of any of the products for acceptance. The performance of such tests and inspections does not limit the right of the buyer to conduct tests and inspections to verify conformance to all requirements of this specification. Such buyer testing and inspection shall be confined to the scope of requirements defined in this specification or approved variations thereof. 4.3 Inspection and Test Fermilab’s Technical Representative and Subcontract Administrator reserve the right to witness manufacturing steps, tests and inspections established under the vendor’s quality assurance program to demonstrate compliance with this specification. 4.3.1 Nondestructive Testing Requirements - All finished products shall be examined nondestructively in accordance with the following requirements and shall comply with the specified acceptance criteria. 4.3.1.1 Ultrasonic examination - Each finished bar or rod shall be examined during processing as follows: a. All bars and rods 12 mm (0.50 inch) diameter or larger shall be examined with ultrasonic test equipment calibrated with a flat bottom hole standard. Discontinuities producing indications with amplitude equal to or greater than that produced in the reference hole shall be cause for rejection. b. Longitudinal wave examination shall be performed in accordance with the applicable requirements of 2.1.2b or equivalent. In addition, all bars and rods shall be examined with ultrasonic test equipment calibrated with a flat bottom hole standard in accordance with the provision listed below. Level 0 applies for all sizes. Discontinuities producing indications with an amplitude equal to or greater than that produced in the reference hole shall be cause for rejection. Section thickness is defined as the thickness of the material in the direction of propagation of the ultrasonic wave. Section Thickness L-0 mm (inch) under 51 mm (2.0") .36 (.014) 51 to 102 mm(2.0" to 4.0") 1.6 (.064) 103 to 205 mm (4.1" to 8.0") 2.4 (.096) over 205 mm (8.0") 3.2 (.127) Depth of holes shall be as follows: (1) 25% of the material thickness for 2 inch thickness or less; (b) the greater of 12 mm (0.50 inch) or 10% of the material thickness for material thickness greater than 50 mm (2 inches). c. Circumferential angle-beam examination: Each finished bar or rod shall be examined by circumferential angle-beam examination. This examination shall be performed by relating the angle-beam ultrasonic inspection procedures described in 2.1.2b, or equivalent, to solid bars or rods. For bars and rods, the ultrasonic equipment shall be calibrated using a standard containing the following diameter hole drilled to a depth of 12 mm (0.50 inch) into the end of the standard parallel to the axis and a distance one-fourth of the diameter from the axis: Standard Hole Rod Diameter Diameter 16 mm (0.625") and less .36 mm (.014") Greater than 16 mm (0.625") 3% of product diameter or 25 mm (0.96") whichever is smaller. The ultrasonic equipment shall also be calibrated for all bars using standards containing a notch which has the following depth and is no longer than 0.25 inch cut parallel to the longitudinal axis: Rod Diameter Notch Depth, Inch 12 to 50 mm (0.50 to 2.0) 1% of product diameter Ultrasonic examination can be performed on finished product less than 12 mm (0.50 inch) diameter. Discontinuities producing indications with amplitude equal to or greater than that produced in the reference or notch shall be cause for rejection. 4.3.1.2 Liquid Penetrant Examination Liquid penetrant examination of the surfaces of any finished bar or rod that do not pass a visual inspection shall be performed in accordance with 2.1.2h. The following indications are unacceptable: a. Any cracks. b. Any linear indications. c. Rounded indications with dimensions exceeding 0.8 mm (0.03 inch (rounded indications separated by 1.5 mm (0.06 inch) or less edge to edge shall be evaluated as a single indication). d. Rounded indications separated by less than the larger of 4 times the piece thickness or 12 mm (0.50 inch). 4.3.1.3 Procedures All nondestructive examination procedures shall be established by the vendor and submitted to the Fermilab Subcontract Administrator for approval, 30 days prior to use. 4.3.2 Destructive Testing Destructive sampling plans to verify the applicable requirements of this specification for finished material shall be submitted by the supplier to the Fermilab Subcontract Administrator for approval, 30 days prior to use. 4.3.2.1 Casting Composition The average elemental composition of each casting shall be established based on representative sampling. 4.3.2.2 Finished Product Chemical Composition The average elemental composition of each lot shall be established based on representative sampling. 4.3.2.3 Analytical Chemistry Procedures The procedures for analyzing composition of the product shall be in accordance with standards considered industrially acceptable for the specified alloys and shall be submitted to the Fermilab Subcontract Administrator for information. 4.3.2.4 Grade Certification The grade certification shall be determined by the radiographic testing procedures specified in 2.1.2g. 4.3.2.5 Hardness The hardness requirements of this specification shall be demonstrated by a sampling plan which verifies the requirements to a 90-90 confidence level in accordance with the provisions of 2.1.2e. Previously approved and experimentally verified plans are acceptable. 4.3.2.6 Grain Size The grain size requirements of this specification shall be established by a sampling plan which verifies the requirements to a 90-90 confidence level in accordance with the provisions of 2.1.2f. Previously approved and experimentally verified plans are acceptable. 4.4 Magnet Component Database The vendor shall submit to the Fermilab Subcontract Administrator, for each shipment of material, all documents requested in this specification (including the results of all tests required in 4.3). A mechanism for electronic transfer between the vendor and Fermilab may be established through contacting the Fermilab Subcontract Administrator. 4.4.1 A contact photograph of the product radiograph shall be supplied as grade certification. High resolution radiograph analysis shall be in accordance with 2.1.2g or equivalent. 4.5 Documentation of compliance Documentation shall be submitted to the Fermilab Subcontract Administrator that proves that all final products and all fabrication and inspection procedures were in compliance with this specification. Fermilab reserves the right to reject any material not conforming to the requirements of this specification. 5.0 PREPARATION FOR STORAGE OR DELIVERY 5.1 Packaging In preparation for either storage or delivery, the finished bars or rods shall be packaged in such a manner as to maintain cleanliness and prevent damage during ordinary handling during storage or shipment. Bars or rods shall be segregated as to lot number, and each package shall include the following information: Name of material; heat or casting number; lot number; and size. 5.2 Marking for Shipment Each bundle or packing box shall be legibly and conspicuously marked with the information furnished by the buyer. July 16, 2012 Yüklə 60,47 Kb. Dostları ilə paylaş:
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