GMW16037

WORLDWIDE ENGINEERING STANDARDS

Test Procedure Materials

GMW16037

Test Method to Quantify Cleanliness of Powertrain Components

1 Scope Note: Nothing in this standard applicable laws and regulations.

supersedes

Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. This Purpose. This document outlines a method for determining the weight (and size, if specified) of foreign material (residual dirt) retained in or on any component after final washing and just prior to engine or transmission assembly. 1.2 Foreword. This method may be used to quantify foreign material present in components, sub-assemblies and assemblies; and may be used after pre-machining operations prior to shipment to the final machining location. 1.3 Applicability. The method involves washing engine and transmission components deemed necessary with a specified wash fluid, collecting the rinse wash fluid, filtering solid materials from it and determining the weight (and size, if specified) of solids present.

3.2.1 Nylon filter membranes, 10 micron (maximum), shall be used except where local test procedures require the use of 44 micron (maximum) and 10 micron (maximum) nylon filters in series. 3.2.2 Paper filter elements may also be used at those locations where this procedure is used to monitor grease content of plant wash system coolant. 3.2.3 A 3.2.3 A 5 micron filter (or equivalent) shall be used for filtering wash fluid that is recycled to a reservoir. 3.2.4 Acceptable Appendix A.

wash

fluids

are

listed

in

3.3 Test Vehicle/Test Piece. Components, subassemblies and assemblies shall be obtained from the production process at the point of their inclusion into the assembly (if washed at the plant) or as shipped from a supplier (if shipped directly to the assembly line). Components may also be obtained from the production line at the final washer exit in order to monitor and control washer effectiveness. 3.4 Test Time. Not applicable.

2 References

3.5 Test Required Information. Not applicable.

Note: Only the latest approved standards are applicable unless otherwise specified.

3.6 Personnel/Skills. Per local requirements.

2.1 External Standards/Specifications.

4 Procedure

None

4.1 Preparation. Prior to sediment evaluation, test samples must not be rinsed, wiped, or cleaned in any way other than what is typical for the production process. Lot numbers or other pertinent shipment information should be recorded for samples to be tested. Protect samples from airborne debris during transport to the sediment test equipment and avoid rough handling.

2.2 GM Standards/Specifications. None

3 Resources 3.1 Facilities. While no specific facility requirements are defined herein, it is preferred that the test procedure is carried out in an enclosed room or laboratory separate from the plant environment. This will protect the equipment and minimize the possibility of introducing foreign material to the components. 3.2 Equipment. A list of equipment and materials which may be necessary and useful in evaluating components for sediment levels is shown in Appendix A.

4.2 Conditions. 4.2.1 Environmental Conditions. 4.2.1.1 When evaluating transmission assemblies, torque converters shall be checked separately, exterior surfaces shall not be rinsed as part of the procedure. Local procedures shall dictate whether or not to remove valves from bores.

© Copyright 2009 General Motors Corporation All Rights Reserved

July 2009

Originating Department: North American Engineering Standards

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GMW16037

GM WORLDWIDE ENGINEERING STANDARDS

4.2.1.2 Test frequency and sample size should be determined by local plant procedures. Sample size must be sufficient to allow for statistical control of production processes and establishment of control limits. Reduced sampling is possible based on statistical data showing process capability. 4.2.1.3 Reintroduction of test samples into the production process must occur before the final wash. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.3 Instructions. 4.3.1 Prepare Test Equipment and Materials. 4.3.1.1 Oven dry the required number of filters for 30 to 35 minutes at 50 to 55°C. Allow filters to cool for 15 to 20 minutes in a desiccator prior to use. Times and temperatures may be adjusted to meet current plant practices and production schedules. 4.3.1.2 Ascertain the weight of filters to four decimal places by means of an analytical balance and record the value in milligrams (mg). 4.3.1.3 Rinse collection sink/tray before and after each test with a sufficient quantity of wash fluid to purge the system of any foreign material. Collect the fluid in a beaker and visually examine the sediment for unusual particles or amounts. Equipment and materials should be protected from environmental contamination when not in use. 4.3.1.4 Monthly wash fluid cleanliness check (for sites that recycle fluid). Collect at least 1 L of wash fluid in a clean beaker and note the volume used. Filter the fluid with vacuum assist through a pre-dried and pre-weighed 10 micron (maximum) filter. Remove filter from the funnel and expose to drying cycle (4.3.5.1). Determine amount of residue collected by subtracting original filter weight from weight of filter plus (+) residue. If amount of residue exceeds 0.50 mg/L, wash fluid must be replaced with new. Wash fluid must be replaced annually regardless of test results. 4.3.2 Measurement of Test Sample. Prepare the required number of filters per 4.3.1.1 and 4.3.1.2. 4.3.2.1 Place component to be evaluated in the clean collection tray/washing cabinet and rinse surfaces of interest with wash fluid. Rinse device should be a handheld spray gun with 70 kPa (0.7 bar) minimum nozzle pressure. Appendix A lists equipment part numbers currently in use at some plants. Other equipment may be acceptable as long as a nozzle pressure of 70 kPa (0.7 bar) is maintained throughout the rinsing operation. Effort

should be made to ensure that all foreign material and loose debris is removed from the component and the collection tray/washing cabinet by flushing the tray with excess fluid and wiping it with a non-metallic squeegee. Collect all sediment from the tray in a beaker and mark the beaker for identification. 4.3.2.2 Engine components with internal oil and/or coolant passages (i.e., engine blocks) shall be rinsed according to work instructions such that sediment levels are established for each type of passage. Water passages must be rinsed first. 4.3.2.2.1 To ensure all sediment is removed from internal passageways of components such as cylinder blocks and heads, pressurized air shall be used. Pressure shall be 210 kPa (2.1 bar) and orifice size shall be 2.0 mm (0.080 in). 4.3.2.3 Burrs resulting from machining operations, casting processes, etc., which remain firmly attached after rinsing and air blowout shall be noted but shall not be included in the total sediment weight. Appropriate equipment (mirrors, lights, bore scopes) shall be used to inspect internal passageways for loose chips not removed by the rinse or air blowout. In such cases, proper actions shall be taken to improve the cleanliness process. 4.3.2.4 Any plant specific procedures regarding rinsing sequence, burr reporting, etc., must be the same site-to-site for similar components. 4.3.3 Place dried and weighed filters in the filtration funnel. 4.3.4 Pour the collected wash fluid through the filter plus (+) funnel using a vacuum assist. Rinse the collection chamber/beaker thoroughly and transfer the wash fluid to the funnel for filtering. 4.3.5 Carefully remove the filter from funnel and expose to the following drying cycle. 4.3.5.1 Filters must be dried 30 to 35 minutes at 50 to 55 C. Times and temperatures may be adjusted to meet current plant practices and production schedules as long as there is evidence that filter weight has stabilized for that cycle. 4.3.6 After drying, the filters shall be placed in a desiccator to cool for 15 to 20 minutes. Debris samples must be properly identified. 4.3.7 Weigh dried filter plus (+) sediment and record weight. 4.3.8 Return washed parts to departments from which they were taken unless surface condition has been degraded or component has been disassembled during sediment testing. Transmission seals and clutch plates must be scrapped.


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GMW16037

5 Data

6 Safety

5.1 Calculations. Determine total sediment weight by subtracting filter weight (4.3.1.2) from weight of filter plus (+) sediment (4.3.7). When two filters are used (3.2.1), weights should be reported for each filter size.

This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

5.2 Interpretation of Results. If something unusual is observed on the contaminated filters (high weights, large particles, etc.), examination of the filters under a light microscope is recommended. Should part specifications include a maximum allowable particle size, measure the sediment particles using a calibrated grid. Note the size (longest dimension in microns) of the largest particle and record on datasheet. 5.3 Test Documentation.

7 Notes 7.1 Glossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. SPC

Statistical Process Control

8 Coding System

5.3.1 Transfer engine data to Statistical Process Control (SPC) charts and plot the data, where applicable. Transmission data should be recorded on suitable quality charts.

This standard shall be referenced documents, drawings, etc., as follows:

5.3.2 Notify Production Department Supervisor of any out-of-control points or otherwise undesirable conditions.

9 Release and Revisions

in

other

Test to GMW16037

9.1 Release. This standard originated in August 2008, replacing GMN6752. It was first approved by GM Powertrain in June 2009. It was first published in July 2009.


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GMW16037


Appendix A A1 Laboratory Equipment Some specific equipment that has proven useful in testing is listed below. Other fluids and other brands/models of equipment may be used as long as the test procedure is not compromised. A1.1 Drying oven with thermometer. A1.2 Desiccator. A1.3 Magnet.

A1.17 Wash Fluids – TechSolv 331 or 336; Chemcentral SC142; Betz Permatreat 435 (4% solution); Citrikleen 3SR166 (1:10 in water); Odorless mineral spirits (Trans only); Naptha. A1.18 Nylon filter membranes – Great Lakes Filters Part Number(as) 325-041-8000 (engines) and 321-041-8000 (transmissions). Phone No.1-800521-8565. A1.19 Stereomicroscope.

A2 Transmission System

A1.4 Analytical balance. A1.5 Brushes. A1.6 Vacuum pump, manifold, and trap. A1.7 Squeegee.

Solvent

Handling

A2.1 Sanborn paint tank and sprayer (#011-0798 (pressurized container).

A1.8 Drum pump.

A2.2 Whatman Gamma - 12 high performance inline filter unit.

A1.9 Stainless rinse collection sink (washable, drainable).

A2.3 Whatman filter tube 12-10 (VWR #28205349).

A1.10 Side-arm flask, filter funnel, beakers, wash bottles.

A2.4 Whatman filter tube 12-80 (VWR #28205280).

A1.11 Sediment wash cart.

A2.5 Millipore 25 mm Filter-Jet solvent dispenser.

A1.12 Air line and hose. A1.13 Nalgene vacuum manifold – Catalog No. 345-0001.

A3 Transmission System

A1.14 Jabsco drum pump – Model #16520-3350 (to be used with air pressure of 3500 kPa (50 psi)).

A3.1 Kewaunee Scientific 1.22 m (4 ft) airflow supreme hood.

A1.15 Spraying Systems Co. GunJet – Model #3139430 (source: Industrial Hose and Hydraulics, Ltd., 905-688-1243).

A3.2 Gelman Sciences parabolic filter 4230.

A1.16 Vacuum pump – Gast 0211 Series, oiless (pump to be set at 381 mm (15 in) of Hg); or Piab, Inc.

Vacuum

Filtration

A3.3 Funnel with Essig fitting. A3.4 Gelman Sciences support screen 4235, Serial No. 14770-00. A3.5 Bottle, 18.9 L (5 gal). A3.6 Hazardous waste collection drum.


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GMW16037

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