PROCUREMENT

SPECIFICATION
IRON CASTINGS 9.50250
normazione Page: 1/12
Date: January 2000

---
PURPOSE

CFO
This Procurement Specification covers classification, drawing callouts, tests, test methods and defect
allowances for machined or unmachined iron castings

Code
---
Ch.
5
Edition
This Procurement Specification consist of 12 pages and 1 annex.

Change Date Description

--- July ’86 Edition 3 --- Editorial changes §§ 6, 7 and 8 revised. Class of importance of
visual inspection (was “Critical”) for Service Class 1 changed in
§ 9 together with class of importance of marking for all service
classes. Annexes 51 added. (AS)
--- July ’94 Edition 4 --- Editorial changes. §§ 4.4 (Weight check ), 4.19 (Radiographic
inspection) and 9 (Classification of characteristics) revised.
Inspection Form, Annexes 51 cancelled. Specifications Data

THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

Sheet, Annex 1 added. (DA)

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

--- Jan. ’00 Edition 5 --- § 4.5 “Visual inspection”, § 4.5.1 “Acceptance standard”

THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

modified and editorial changes carried out. (DA)
CONFIDENTIAL

ANY HARD COPY IN YOUR POSSESSION SHOULD BE CONSIDERED NOT UP---TO---DATE. SEE RELEVANT WEB SITE FOR UP---TO---DATE DOCUMENT

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 2
9.50250 Change

| § ‘‘A’’ : TEST EQUIPMENT

Test equipment is indicated in the Standards listed under references (§ B).

| § ‘‘B’’ : REFERENCES

|9.01102 | Quality of supplies.CFO

|9.01102/01 | Supply inspection requirement. CFO

|9.01103 | Product quality and conformity certificate. CFO

|01368 | Symbols and requirements for materials and processes. TFO

|01370/03 | Surface texture –Surface roughness. TFO

|50106 | Test for metals – Brinell hardness test. TFO

|50108 | General purpose tests – Rockwell hardness test. TMD

|50113 | Tension testing – General purpose tests. TMD

|50145 | Case depth measurement for ferrous metal parts. TMD

|50161 | Nondestructive testing – Radiographic inspection – Flaw classification --- Drawing

callouts – Methods – Equipment – Personnel. TMD

|50210 | Sampling and preparation of metallographic specimens for ferrous metals. TMD

|50258 | Iron and steel castings --- Separately cast tensile test specimens. TMD

|50259 | Ultrasonic inspection of cast iron spheroidization. TMD

|50260 | Microscopic examination of ferrous materials – Classification of graphite in cast iron.

TMD

|0.00013 | Date of manufacture marking. NPR

|0.00024/01 | Magnetic particle inspection --- Equipment, products, methods and test procedures.
NPR
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

|9.57103 | Liquid nitrided cases. CMD

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

|E 192 ASTM| Reference radiographs of investment steel castings for aerospace applications.
THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

| § ‘‘C’’ : ANNEXES

| 1 | Specifications Data Sheet.

CONFIDENTIAL

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 3
Change 9.50250

1
GENERAL

1.1
Scope
This Procurement Specification covers classification, drawing callouts, tests, test methods and defected
allowances for machined or unmachined iron castings.

1.2
Application
This Procurement Specification applies to all castings for motor vehicles unless otherwise specified on
drawings, relevant standards, Test Data Sheet or purchase agreements.

2
CLASSIFICATION
Casting are divided into the following service classes in accordance with P.S. 9.01102:

--- Castings whose malfunction or premature deteriora-

Service Class 1
tion could constitute hazard

--- Castings involving high replacement costs whose

Service Class 2 malfunction or premature deterioration could impair
serviceability

Service Class 3 --- All other castings

3
DRAWING CALLOUT

3.1

THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

Mandatory requirements

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

3.1.1
Procurement Specification 9.50250 – Service Class 1, 2 or 3. THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

3.1.2
Material designation and condition and number of applicable Procurement Specification.
CONFIDENTIAL

3.1.3
Marking details (raised, embossed, etc.).

3.2
Other requirements (where applicable)

3.2.1
Heat and/or surface treatments and number of applicable Standards.

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 4
9.50250 Change

3.2.2
Coating and applicable Standard.

3.2.3
Areas to be traded and or protected identified as per Std. 01368.

3.2.4
Identification of critical areas. If not indicated on drawing, all surface hardened areas, fillets, grooves and
areas with abrupt geometrical changes are to be considered critical.

3.2.5

Identification of tensile specimen location using symbol .

3.2.6
Identification of hardness measurement point.

3.2.7
Permissible defect levels for tests as per §§ 4.5, 4.18, 4.19 of this Procurement Specification, should they
differ from those normally specified.

3.2.8
Air or hydraulic leakage tests (Class 1 and 2 castings only), unless otherwise specified, shall be carried
out on machined castings.
Test data and acceptance conditions shall be shown on drawing of appropriate Standards.

4
REQUIREMENTS FOR CASTINGS

4.1
Dimensions and tolerances
Dimension shall be checked against drawings and or applicable Standards; contours, fillets and internal
dimension not measurable on whole castings shall be checked after sectioning component.
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES
WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

4.2
THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

Surface roughness
As per drawing or applicable Standards.

4.3
CONFIDENTIAL

Hand grinding roughness

Ra 16 as per Std. 01370/03.

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 5
Change 9.50250

4.4
Weight check
As per drawing.
Minimum weigh specified on drawing shall be determined on the basis of the results of experimental
tests on components submitted for release approval.
For front and rear suspension control arms and front hub carriers, minimum weigh specified on drawing
shall be checked again after 50,000 molds have been produced from the same pattern.
For this purpose castings shall be subjected to the bench impact test used for product release.

4.5
Visual inspections
Castings shall be submitted for inspections after deburring and cleaning.
Inspection shall be carried out under a minimum luminous intensity of 100 lux.

4.5.1
Acceptance standards
--- Unmachined surfaces: Shall be smooth without breakage, cracks or any other defect which could
jeopardize component serviceability and or subsequent machining.
Surface discontinuity at minimum distance 10 mm to each other typical for
castings as allowed according to Table 1 (H).

TABLE 1

DIMENSION OF ALLOWED DEFECTS

Casting thickness
Service Class
< 10 10 to 20 > 20

1 ± 0.5 mm ± 0.8 mm ± 1 mm

2 and 3 ± 0.8 mm ± 1 mm ± 1.5 mm

THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

(H) Parts subjected to specific P.S. or drawing are excluded.

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

--- Machined surfaces: Defects such as blowholes shrinkage cavities, rarefactions, porousness, in-
clusions having the same dimensions expected for raw surfaces provided THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

they are in one for 200 mm2 of machined surface. Castings thickness shall
be considered the minimum section value before mechanical processing.

4.6
CONFIDENTIAL

Markings
Unless otherwise specified and whenever possible, marking shall be as per drawing readly legible, posi-
tioned so as not to be removable by subsequent machining and shall consist of:
--- Producer’s trademark;
--- Drawing number of part;
--- Heat number or date of manufacture (method A, B or C (as per Std. 0.00013). For Service Class 1
and 2 castings only.

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 6
9.50250 Change

4.7
Coatings
Coatings where applied shall comply with Standards referenced on drawing.

4.8
Chemical analysis
As per Standard referenced on drawing.

4.9
Micrographic inspection

4.9.1
Carry out test as directed in Standards 50210 and 50260. Structure shall comply with requirements for
the specified condition indicated in Material Standards referenced on drawing.

4.10
Spheroidization check (spheroidal graphic cast iron only)
Spheroidization check shall be performed using the fast micrographic method specimens taken from
heat (materials produced through ladle inoculation only).
Where component geometry permits, check shall be performed using the ultrasonic methods per Std.
50529.
During qualification, spheroidizidal shall be checked through micrographic inspection (see § 4.9).

4.11
Hardness

4.11.1
Unless otherwise specified on drawing, hardness shall be checked as directed in Std. 50106 after grind-
ing off sufficient material from surface in areas where casting serviceability will not be impaired. As a rule,
on ! 6 mm thickness shall be checked with 7350 N load with 5 mm dia sphere, while on > 6 mm thick-
ness, hardness shall be measured with 29400 N load and 10 mm dia sphere.
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

4.11.2
WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

Check that results comply with requirements of Standard referenced on drawing.

THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

4.12
Core hardness

4.12.1
CONFIDENTIAL

Core hardness shall be determined as directed in Std. 50106 in cases where measurement point is spe-
cified on drawing and for surface hardened parts.

4.12.2
Results shall comply with requirements of Standard referenced on drawing.

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 7
Change 9.50250

4.13
Case hardness (surface hardened castings only)

4.13.1
Carry out test as directed in Std. 50108.

4.13.2
Check that results comply with requirements of Standards referenced on drawing.

4.14
Case position and contour (surface hardened castings only)

4.14.1
Case position shall be checked by etching surface of area concerned with 30% Nital in water.
Case contour shall be checked by sectioning area concerned along two representative perpendicular
planes and etching sectioned surfaces with 30% Nital in water.
Position and contour shall comply with drawing requirements.

4.15
Case depth (surface hardened castings only)

4.15.1
Carry out test as directed in Std. 50145 for induction hardened and/or chill hardened cases, and as per
Procurement Specification 9.57103 for liquid nitrided cases.

4.15.2
Check that results comply with drawing requirements.

4.16
Tensile properties of cut specimens

4.16.1

THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

Carry out test as directed in Std. 50113 on specimens cut from locations indicated on drawing and/or

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

agreed upon with Supplier on order.
THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION
4.16.2
Check that results comply with requirements of Standard referenced on drawing.

4.17
CONFIDENTIAL

Tensile properties of separately cast specimens

4.17.1
Carry out test as directed in Std. 50258. Number of specimens submitted for each lot shall be agreed
upon on order.

4.17.2
Check that results comply with requirements of Standard referenced on drawing.

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 8
9.50250 Change

4.18
Magnetic particle inspection

4.18.1
Carry out test as directed in Process Std. 0.00024/01.

4.18.1.1
Acceptance standards
As indicated on drawing or as shown in Table 2 where drawing requirements are not specified.

TABLE 2

ACCEPTANCE STANDARDS FOR MAGNETIC PARTICLE INSPECTION

Condition Defects Service Class 1 Service Class 2 Service Class 3

As---cast All types Not allowed --- Repairs as per § 5.4 allowed

Defects of lenght ! 3
mm allowed provided
Not allowed in critical
that they are not ali-
Grinding areas. For other areas
Not allowed gned and that distance
cracks see requirements for
between two indication
Service Class 3
is twice the lenght of
the larger indication
Machined
Other cracks Not allowed

Shrinkage Not allowed in critical

Allowed if defects do
Sponginess areas. For other areas
Not allowed not jeopardize part ser-
Blowholes see requirements fo
viceability
Porosity Service Class 3

4.19
Radiographic inspection
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES
WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

4.19.1
THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

Carry out test as directed in Std. 50161.

4.19.1.1
Acceptance standards
CONFIDENTIAL

As indicated on drawing or as shown in Table 3 where drawing requirements are not specified.

TABLE 3

ACCEPTANCE STANDARDS FOR RADIOGRAPHIC INSPECTION ¡

Service Class 1 Service Class 2 Service Class 3

Critical areas Other areas Critical areas Other areas Critical areas Other areas

Level A Level C Level B Level D Level C Level E

¡ Levels are identify by reference radiographs in ASTM E 192 (see Table 4).

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 9
Change 9.50250

TABLE 4

ACCEPTANCE STANDARDS FOR RADIOGRAPHIC INSPECTION

Level A Level B Level C Level D Level E

Defects © Radiographic thickness (mm)

<4 4"10 >10 <4 4"10 >10 <4 4"10 >10 <4 4"10 >10 <4 4"10 >10

Blowholes 1 2 3 4 5

Shrinkage cavities 1 2 3 4 5

Shrinkage spongi- Not

1 2 1 3 2 4 3 5 4
ness allowed

Dentritic shrinka-
1 2 3 4 4
ge

Filomentary shrin-
Not allowed 1 2 3 3
kage

Low density inclu-

1 2 4 3 5 4 6 5
sion

Cracks Not allowed

© Castings shall be rejected if two or more types of defect close to the maximun tolerance are present.

4.20
Air and/or hydraulic leakage test

4.20.1
Carry out test as directed in applicable standards.

THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

4.21

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

Supplementary tests

4.21.1 THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

Supplementary tests not contemplated by this Procurement Specification may be carried out upon re-
quest and agreement between the parties.
CONFIDENTIAL

5
PROCESS CYCLE REQUIREMENTS
5.1
Shakeout
Casting shall be allowed to cool in the mold.

5.2
Removal of rises, gating and runners
Methods used to remove risers, gating and runners shall not damage component.
Where removal is sufficiently difficult to require the use of machinery, operations shall be specified by
agreement between Purchase and Supplier.

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 10
9.50250 Change

5.3
Heat treatment
Heat treatment, when required, shall be carried out as directed on Material Standards or other applica-
ble specific Standards.
Compliance with the requirements indicated on said Standards for the material condition involved shall
be guaranteed unless otherwise specified on drawing.

5.4
Scarfing
Any unacceptable surface defects may be removed by filing, hand grinding or milling.
Repaired area shall then be blended so as not to leave sharp edges, after which tests described in §§
4.5, 4.18 and 4.19 shall be repeated.
Components shall be considered acceptable provided that:
--- Defect has been completely removed.
--- Dimensions of repaired area are within tolerances specified on drawing.

5.5
Repairs
Repairs by welding, partial sealing or impregnation are now allowed unless otherwise indicated on
drawing, applicable Standards or authorized engineering deviations, in which case repair method, test
procedures and acceptance standards shall be indicated.
Repair by welding of heat treated castings, where permitted, shall be carried out prior to heat treatment.

6
PRODUCT QUALIFICATION REQUIREMENTS
Subject component to the checks and tests specified in § 4.
Check that results meet requirement.

7
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

REQUIREMENTS FOR SUPPLY INSPECTION

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

(to be carried out by Plant Quality Acceptance Depts)

Supply inspection shall be carried out according to P.S. 9.01102/01 (Restricted Distribution).
THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

8
SUPPLIER REQUIREMENTS
CONFIDENTIAL

8.1
The Supplier(s) shall comply with the general requirements contained in P.S. 9.01102 “QUALITY OF
SUPPLIES”.

8.2
Product Qualification Supplies

8.2.1
The Supplier(s) shall submit the amount of product specified in the purchase order and attach the Qual-
ity and Conformity Certificate (see P.S. 9.01103); all characteristics specified on the attached “Specifica-
tions Data Sheet” relating to the specific type shall be checked.
“Non---conforming” supplies are not permissible.

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 11
Change 9.50250

8.3
Product Supplies

8.3.1
The supplied product shall conform with drawing and this Specification.
When establishing the manufacturing process to be adopted and severity of inspections, the Supplier
shall take into account the classes of importance that FIAT has assigned to each of the characteristics
to which requirements refer (See § 9).

NOTE: Checks may be performed on components which have been subjected to non ---destructive tests
(indicated with NM in § 9) during product qualification and supply inspection.
Components which have been subjected to destructive tests (M) may not be used for further tests
or inspections unless otherwise specified case by case.

9
CLASSIFICATION OF CHARACTERISTIC S

CLASS OF IMPORTANCE
(See P.S. 9.01102) TYPE OF
CHARACTERISTIC S ¡
Service Service Service TEST
Class 1 Class 2 Class 3
Dimension and tolerances As per P.S. 9.01102 if not otherwise specified NM
Surface roughness on dwg. NM
Hand grinding roughness Minor Minor Minor NM
Weight check Minor Minor Minor NM
©
Visual inspection I.C.Q. = 0 Major Minor NM
¢
Marking I.C.Q. = 0 NM
Coatings See Standard referenced on drawing

THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

Chemical analysis Major Minor Minor M

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

Micrographic inspection Major Minor Minor M
Inoculation in THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION
100 % Major Minor NM
Ultrasonic mold
method Inoculation in
Spheroidization Major Minor Minor NM
ladle
check
CONFIDENTIAL

Fast micro-
Inoculation in Start and end ladle unless otehrwise
graphic me- NM
ladle specified
thod
Hardness Major Major Minor NM
Core hardness Major Minor --- --- --- M
©
Case hardness I.C.Q. = 0 Major Minor NM
¢
Case position and contour Major Minor --- --- --- M
Case depth Major Major --- --- --- M

(Continued)

PUBLISHED BY SATIZ --- NORMAZIONE

 Page 12
9.50250 Change

CLASS OF IMPORTANCE
(See P.S. 9.01102) TYPE OF
CHARACTERISTIC S ¡
Service Service Service TEST
Class 1 Class 2 Class 3
R
Cut speci-
C i Rs Minor Minor Minor M
men
Tensile proper
proper- A
ties R
Separately
cast speci- Rs On agreed specimens NM
men
A
Magnetic particle inspection Minor Minor Minor NM
©
Radiographic inspection I.C.Q. = 0 Major Minor NM
¢
Air and/or hydraulic leakage test I.C.Q. = 0 I.C.Q. = 0 --- --- --- NM
¡ Class of importance for any other characteristics shall be indicated on drawing or applicable Standard.
© I.C.Q. = 0 Means that all supplied components shall be conforming (see P.S. 9.01102).
This may be achieved either by guaranteeing the stability and accuracy of the production process of
the production process or by increasing severity of inspection up to 100#.
If required by qualification departments, 100% inspection shall be specified on drawing.
¢ Supplier shall record results of this test on “Quality Certificate” for each lot.
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES
WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE
THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION
CONFIDENTIAL

PUBLISHED BY SATIZ --- NORMAZIONE

 9.50250
IRON CASTINGS
ANNEX 1
normazione Specifications Data Sheet Page: 1/1

---
CFO
REQUIREMENTS
CHARACTERISTICS TEST
CONDITIONS Service Service Service
Classe 1 Classe 2 Classe 3

Code
Dimension and tolerances § 4.1 § 4.1
Surface roughness § 4.2 § 4.2

---
Hand grinding roughness § 4.3 § 4.3

Ch.
Weight check § 4.4 § 4.4
Visual inspection --- --- § 4.5

5
Marking --- --- § 4.6

Edition
Coatings § 4.7 § 4.7
Chemical analysis § 4.8 § 4.8
Micrographic inspection § 4.9 § 4.9
Inoculation in
Ultrasonic mold
method Inoculation in
Spheroidization ladle § 4.10 § 4.10
check
Fast micro-
Inoculation in
graphic me-
ladle
thod
Hardness § 4.11 § 4.11
Core hardness § 4.12 § 4.12

THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES

Case hardness § 4.13 § 4.13

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE

Case position and contour § 4.14 § 4.14

THE ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION

Case depth § 4.15 § 4.15
R
Cut speci-
Rs § 4.16 § 4.16
men
A
CONFIDENTIAL

Tensile proper
proper-
ties R
Separately
cast speci- Rs § 4.17 § 4.17
men
A
Magnetic particle inspection § 4.18 § 4.18
Radiographic inspection § 4.19 § 4.19
Air and/or hydraulic leakage test § 4.20 §4.20

PUBLISHED BY SATIZ --- NORMAZIONE