© ISO 2016 Diesel engines — Steel tubes for high pressure fuel injection pipes — Part 1 Requirements for seamless cold drawn single wall tubes Moteurs diesels — Tubes en acier pour lignes d’injection[.]
INTERNATIONAL STANDARD ISO 8535-1 Sixth edition 2016-11-15 Diesel engines — Steel tubes for highpressure fuel injection pipes — Part 1: Requirements for seamless colddrawn single-wall tubes Moteurs diesels — Tubes en acier pour lignes d’injection de combustible haute pression — Partie 1: Exigences pour les tubes monoparoi sans soudure étirés froid Reference number ISO 8535-1:2016(E) I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n © ISO 2016 ISO 8535-1:2016(E) COPYRIGHT PROTECTED DOCUMENT © ISO 2016, Published in Switzerland All rights reserved Unless otherwise specified, no part o f this publication may be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on the internet or an intranet, without prior written permission Permission can be requested from either ISO at the address below or ISO’s member body in the country o f the requester ISO copyright o ffice Ch de Blandonnet • CP 401 CH-1214 Vernier, Geneva, Switzerland Tel +41 22 749 01 11 Fax +41 22 749 09 47 copyright@iso.org www.iso.org ii I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 8535-1:2016(E) Contents Page Foreword iv Scope Normative references Terms and definitions Dimensions and tolerances 4.1 Diameters 4.2 Length Material processing 5.1 Steel manufacturing process 5.2 Manufacturing of tubes f 5.3.1 General f f f 5.5 Minimum mechanical properties of tubes 5.6 Cleanliness 5.7 Straightness 5.8 Corrosion resistance Testing 6.1 General 6.2 Scope of tests 6.3 Dimension tests 6.5 Bending test 6.6 Cold upsetting of tubes f 6.8 Inside pressure test 6.9 Retesting 7 Designation Identification and marking Packing Annex A (informative) Theoretical maximum pressure for inside pressure testing Bibliography 10 S ur ace quality M inimum quality ins ide s ur ace (b o re grade S ) 3 H igher quality ins ide s ur ace (b o re grades O, P, Q, R) S ur ace finis h 6.4 M echanical- p ro p erty tes ts 6.7 S ur ace quality tes t 6.1 Tes t certificate © ISO 2016 – All rights reserved I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n iii ISO 8535-1:2016(E) Foreword I SO (the I nternational O rganiz ation for Standardiz ation) is a worldwide federation of national s tandards bodies (ISO member bodies) The work o f preparing International Standards is normally carried out through ISO technical committees Each member body interested in a subject for which a technical committee has b een es tablished has the right to b e represented on that committee I nternational organi zation s , governmental and non- governmental, in liaison with I SO, al so take p ar t in the work ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters o f elec trotechnical s tandardi z ation T he procedures used to develop this cument and those intended for its fur ther maintenance are describ ed in the I SO/I E C D irec tives , Par t I n p ar ticu lar the different approval criteria needed for the di fferent types o f ISO documents should be noted This document was dra fted in accordance with the editorial ru les of the I SO/I E C D irec tives , Par t (see www iso org/direc tives) Attention is drawn to the possibility that some o f the elements o f this document may be the subject o f patent rights ISO shall not be held responsible for identi fying any or all such patent rights Details o f any patent rights identified during the development o f the document will be in the Introduction and/or on the I SO l is t of p atent declarations received (see www iso org/p atents) Any trade name used in this document is in formation given for the convenience o f users and does not cons titute an endors ement For an explanation on the meaning o f ISO specific terms and expressions related to formity assessment, as well as information about I SO ’s adherence to the World Trade O rganization ( WTO) principles in the Technical B arriers to Trade (TB T ) see the following URL: www.iso.org/iso/foreword html T he comm ittee res p ons ible for this cument is Propulsion, powertrain, and powertrain fluids I SO/ TC 22 , Road vehicles, Sub committee SC 4, This sixth edition cancels and replaces the fi fth edition (ISO 8535-1:2011), which has been technically revised with the fol lowing changes: — ins ide diameter s i zes , mm and , mm have b een added to Table ; — code and co de have b een added to Table A lis t of p ar ts in the I SO 5 series can b e found on the I SO web s ite NOTE The first part o f the general title, “Diesel engines ”, is used for Part ignition engines ” i s s ti l l u s ed but wi l l b e replaced at the next revi s ion iv I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n only while for Part 2, “Compression- INTERNATIONAL STANDARD ISO 8535-1:2016(E) Diesel engines — Steel tubes for high-pressure fuel injection pipes — Part 1: Requirements for seamless cold-drawn single-wall tubes Scope T h i s c u ment s p e ci fie s d i men s ion s and re qui rements for h igh-pre s s u re fuel fuel for s e am le s s cold- d rawn s i ngle -wa l l s te el tub e s i nj e c tion pip e s u s e d on d ie s el (compre s s ion-ign ition) engi ne s (cl as s ) a nd for i nj e c tion pu mp te s ti ng (cla s s 1) This document applies to diesel (compression-ignition) engines Normative references T he fol lowi ng c u ments are re ferre d to i n the tex t i n s uch a way th at s ome or a l l o f thei r content s titute s re qu i rements o f th i s c u ment For date d re ference s , on ly the e d ition cite d app l ie s For u ndate d re ference s , the late s t e d ition o f the re ference d c ument (i nclud i ng a ny amend ments) appl ie s ISO 6507-1, Metallic materials — Vickers hardness test — Part 1: Test method ISO 6892-1, Metallic materials — Tensile testing — Part 1: Method of test at room temperature ISO 12345, Diesel engines — Cleanliness assessment of fuel injection equipment Terms and definitions No term s and defi nition s a re l i s te d i n th i s c u ment ISO and IEC maintain terminological databases for use in standardization at the following addresses: — IEC Electropedia: available at http://www.electropedia.org/ — ISO Online browsing platform: available at http://www.iso.org/obp Dimensions and tolerances 4.1 Diameters Recommended inside and outside diameters are given in Table between supplier and customer Tolerances on inside and outside diameters shall be as follows a) Inside diameter, d d f ≤ m m: ± , m m ± , 02 m m d for O ther s i z e s may b e u s e d b y agre ement or cla s s cla s s (the s e tolera nce s are i n accordance with I S O ) > m m: ± ,10 m m © ISO 2016 – All rights reserved I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 85 -1 : 01 6(E) NOTE Classes and are explained in Clause b) Outside diameter, D D < m m: ± , m m D ≥ m m: ± ,10 m m for classes and c) T he ma xi mu m va lue o f the concentricity o f the tub e outs ide d ia me ter relative to the i n s ide d i ame ter shall be proportional to the wall thickness, as shown in Figure Figure — Concentricity of the tube outside diameter 4.2 Length L eng th a nd tolerance s on leng th s l l b e b y agre ement b e twe en s uppl ier and c u s tomer 5 Material processing Steel manufacturing process T he tub e s sh a l l b e manu fac tu re d from u na l loye d qua l ity s te el or an e qu iva lent qua l ity s te el pro duce d by a s te el-ma ki ng pro ce s s th at en s ure s a ver y homo gene ou s s truc tu re I f re que s te d b y the c u s tomer, the s uppl ier s l l s tate the me tho d o f ma nu fac ture and the de oxidation process used Manufacturing of tubes T he fi na l re duc tion(s) o f the tub e s l l b e properties I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n fol lowe d b y he at tre atment to ach ieve the s p e ci fie d me cha nic a l ISO 85 -1 : 01 6(E) Table — Recommended inside and outside diameters I n s ide d iameter (d ) mm 1,5 1,7 1,9 2,12 2,36 2,65 3,5 3,75 4,25 4,75 5,3 6,7 7,5 8,5 9,5 10,6 11,8 a Preferred O uts ide d i ameter 4,5 (D ) mm 6,35 10 12 15 19 24 30 1,12 1,25 1,4 1,6 1,8 2,24 Size combinations to be used appear in shaded cells 2,5 2,8 3,15 3,6 4,5 5,6 6,3 7,1 10 11,2 12,5 NOTE The diameter sizes have been established with the ratio of outside to inside diameter within the range of to Based on ISO a © ISO 2016 – All rights reserved I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 85 -1 : 01 6(E) 5 Surface quality General The outside and inside sur faces o f finished tubes shall be free from scale, rust, grooves, laps, laminations, deep pits or other injurious de fects Minimum quality inside surface (bore grade S) The inside o f tubes o f bore grade S shall be finished to ensure a smooth bore o f accurate size with no more than five imper fections (fissures, crevices, etc.) over 0,08 mm to 0,13 mm (maximum) deep, per tube cross-section, using ×50 magnification for examination (see Table ) 3 Higher quality inside surface (bore grades O, P, Q, R) I f closer control over the depth o f imper fections is required, bore grades O, P, Q or R, assessed under the magnification indicated (see Table ) may be specified in the tube designation (see C lause 6) Table — Bore grades Code Magnification Permitted imperfections S As i n ×50 A maximum o f five imper fections over 0,05 mm to 0,08 mm R ×10 (ma ximum) de ep A maximum o f five imper fections over 0,02 mm to 0,05 mm Q ×10 (ma ximum) de ep A maximum o f five imper fections over 0,01 mm to 0,02 mm P ×2 0 (ma xi mum) deep O Al l i mp erfec tions equa l to or les s than , 01 m m deep ×500 5.4 Surface finish The outside sur face o f the tube may be coated on delivery by metal plating or galvanizing, or may be s ubm itted to a chemical s urface treatment (see Table ) T he ins ide s urface of the tub e shal l remain unco ated Table — Sur face finish on delivery Code Application remarks O utside s urface condition May have additional finish at Not specified (at manu facturer’s choice) manu fac turer ’s choice Outside sur face as-processed, without any additional finish Tubes annealed or normalized in a controlled atmosphere may be discoloured, but shall be free from C ond ition preferre d for fur ther s urface pro ces s i ng lo o s e s ca le When m i ni mum corro s ion res i s t- m i ni mum and an add itiona l colourles s ch romati ng a ance i s re qui red No t recom mended Zinc electroplated with a coating layer thickness o f µm minimum and an additional yellow chromating a Zinc electroplated with a coating layer thickness o f µm a for u s e with light a lcohol-b as ed fuel s s uch a s methanol (4, , , 7, 8) (Res er ved for fur ther applic ation ) — As specified subject to agreement — C h romati ng a s des crib ed i n I S O and I S O 452 I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 85 -1 : 01 6(E) 5 Minimum mechanical properties of tubes The tubes shall comply with one o f the classes o f mechanical properties (codes to 4) as listed in Table Table — Mechanical properties Code NOTE M inimum M inimum M inimum tensile s trength proof s trength elongation N/mm2 N/mm % 30 23 22 15 10 Rm 310 360 490 600 750 850 Rp0,2 205 220 355 430 670 770 A5 M a ximum hardnes s HV 115 150 194 280 310 340 The mechanical properties apply when the tube is tested in accordance with ISO 6507-1 and ISO 6892-1 Cleanliness The bore shall be clean and free from any contamination or coating which would impair the processing and serviceability o f the tubes When speci fying a cleanliness requirement for the inside o f the tubes, ISO 12345 shall be used Straightness Unless otherwise agreed between supplier and customer, the tubes shall be straight within a maximum error of in 400, with no localized deformation Corrosion resistance The outside and inside surfaces shall be protected against corrosion for transportation and storage in closed areas A permanent coating may be used on the outside sur face when agreed between supplier and customer Any temporary coating used shall not be injurious to the injection and combustion systems o f the engine and shall be removable with diesel fuel 6.1 Testing General Unless otherwise agreed between supplier and customer, tests shall be carried out in accordance with 6.2 to 6.8 6.2 Scope of tests Tubes shall be tested by lots o f the same dimensions, steel type, heat treatment and sur face finish Tubes from each heat of steel shall be tested irrespective of lot For the test in 6.4, a test inspector shall select one tube from each lot, and for the test in 6.6, three tubes The tests in 6.3, 6.7.1 and 6.8 shall be performed on all selected tubes For the test in 6.7.3, the lot size, the number of samples and the acceptance limit shall be agreed upon between supplier and customer © ISO 2016 – All rights reserved I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 8535-1:2016(E) 6.3 Dimension tests The tube dimensions shall comply with the dimensions and tolerances indicated in C lause 6.4 Mechanical-property tests The tubes shall comply with the specifications given in Table T he tes ts shal l b e made in accordance with I SO 65 07-1 and I SO 92 -1 Tens ile s trength, pro of s trength, elongation and hardnes s shal l b e meas ured 6.5 Bending test T he tub e shal l withs tand cold b ending through 18 ° over a ro d of the s ame diameter as the tub e outs ide diameter, without showing other than outside superficial cracks 6.6 Cold upsetting of tubes T his tes t shal l b e carried out on tub es of outs ide diameter mm and b elow A length of tub e twice the outs ide diameter (2 D) shal l b e cap able of b eing compres sed to a length D without showing cracks of dep ths exceeding ,1 mm The test shall be made between two plane and parallel plates in a suitable fixture 6.7 Surface quality test 6.7.1 A visual check shall be made to ensure that tubes satis fy the requirements in 6.7.2 I f mutually agreed between supplier and customer, the visual inspection may be replaced by a non-destructive test p rocedure 6.7.3 I f proo f o f a specified de fect depth in the bore is required, an inspection by attributes, with an agreed acceptable quality level (AQL) shall be set when ordering; the test shall be made on metallographic cross-sections o f the tube with the minimum magnification specified in Table 6.7.4 Surface coatings on tubes with plated or otherwise treated surfaces shall satis fy tests on these coatings when required Such tests shall be agreed b etween supp lier and customer 6.8 Inside pressure test Tub es shal l b e cap able of withs tanding appropriate ins ide pres s ure, which shal l b e agreed b etween ), without permanent internal de formation or burst This ability shall be confirmed by a hydraulic test Other non-destructive tests, such as electronic testing, may be s uppl ier and cus tomer (see Annex A used if agreed b etween s uppl ier and cus tomer 6.9 Retesting I f, after tes ting in accordance with 4, the selec ted tub e fai l s , two other tub es shal l b e taken from the same lot to repeat the test The same procedure shall apply to the test in E ach of the tub es taken shall meet the test requirements I f any tube fails to meet the test requirements, the whole lot is considered as rejected The supplier may submit a rejected lot for acceptance again in an improved condition, e.g by repeating the heat treatment I f, in this case, the tes t res u lts of and rejected I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n not fulfil the requirements, the whole lot shall be ISO 8535-1:2016(E) T e s t c e r t i f i c a t e A test certificate, i f required [see Clause 7, i)], shall be issued for each shipment, confirming that the tubes supplied meet the specifications o f this document For proo f, the records o f the continuous production inspections concerning the following tests may be used: a) b) c) d) e) f) g) dimensions in accordance with 6.3; mechanical properties in accordance with 6.4; bending test in accordance with 6.5; cold upsetting in accordance with 6.6; visual inspection in accordance with 6.7.1; metallographic test in accordance with 6.7.3; inside pressure test in accordance with 6.8 Other test certificates may be agreed upon between supplier and customer Designation A steel tube that meets the requirements of this document shall be designated as follows, in the order given: a) the word “Tube”; b) a reference to this document, i.e ISO 8535–1; c) tube type: a seamless cold-drawn single-wall steel tube is indicated by the letter “S”; d) size: the second and third characters identi fy the nominal inside and outside diameters, respectively, o f the tube, in millimetres; e) class: the fourth character determines the bore tolerance [see 4.1 a)]; f ) the fi fth character identifies the mechanical properties o f the tube in accordance with Table 4; g) the sixth character identifies the bore grade o f the tube in accordance with Table 2; h) the seventh character identifies the treatment o f the outside sur face o f the tube (see Table 3); i) at the end the o f the designation, the letter “Z” may be added to indicate that a certificate from the tube manu facturer is required for confirmation o f compliance with this document and additional delivery requirements, i f any (see ISO 404) EXAMPLE A tube conforming to this document shall be designated as shown below © ISO 2016 – All rights reserved I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 8535-1:2016(E) I d e n t i f i c a t i o n a n d m a r k i n g Tub e s sh a l l b e identi fie d b y u s e o f lab el s with the de s ignation i n accorda nce with marking is permissible if agreed between supplier and customer P a c k i n Clause Additional g Unless otherwise agreed upon between supplier and customer, the tubes shall be delivered in secure bundles, with tubes sealed at both ends I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 85 -1 : 01 6(E) Annex A (informative) Theoretical maximum pressure for inside pressure testing The theoretical maximum test pressure, deformation (see 5.8 p max , in kilopascals, for checking permanent internal ReH , ) i s given by the pro duc t o f the s tre s s co e ffic ient a nd the upp er yield s treng th , i n new ton s p er s quare m i l l i me tre, and i s b as e d on von M i s e s ’ yield criterion: p max = where 10 K2 − 1 + 3K4 × R eH D K= d where D d is the outside diameter, in millimetres; is the inside diameter, in millimetres © ISO 2016 – All rights reserved I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 85 -1 : 01 6(E) Bibliography [1] [2 ] [3 ] [4] [5 ] [6 ] [7 ] 10 Preferred numbers — Series of preferred numbers Steel and steel products — General technical delivery requirements Metallic and other inorganic coatings — Surface treatment, metallic and other inorganic coatings — Vocabulary Diesel engines — Fuel injection pumps — High-pressure pipes for testing Chromate conversion coatings on electroplated zinc and cadmium coatings Compression-ignition engines — Steel tubes for high-pressure fuel injection pipes — Part 2: Requirements for composite tubes Diesel engines — High-pressure fuel injection pipe assemblies — General requirements and dimensions ISO , I S O 4, ISO 2080, I SO 40 93 , I S O 45 , ISO 5 -2 , ISO 132 96, I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n ISO 8535-1:2016(E) ICS 43.060.40 Price based on 10 pages © ISO 2016 – All rights reserved I n tern ati o n al Org an i z ati o n fo r S tan d ard i z ati o n