GMN7152 2002

ENGINEERING
STANDARDS
Material Specification
Metals

GMN7152

Specification and Verification of
Tensile and Fatigue Properties in Cast Components

Copyright October 2001 General Motors Corporation All Rights Reserved
October 2001 Originating Department: North American Engineering Standards, Records and Documentation Page 1 of 16

1 Scope
1.1 Description. This specification provides pro-
cedures for (1) specifying tensile and fatigue prop-
erties at designated control locations for aluminum
and cast iron parts and (2) verifying that these
properties exist as specified. Control locations
may be in the part, from co-cast appendages, or
from separately cast specimens. This specification
may be used in drawings, CTS, VTS, statements
of requirements, BOM/BOP/BOD, or other docu-
ments.
1.1.1 This specification may also be used to pro-
vide requirements for properties other than tensile
and fatigue.
1.1.2 Except for Class 1 lot control, procedures
specified herein are intended to audit capability of
meeting mechanical property requirements.
1.2 Limitations
1.2.1 This specification neither requires nor pro-
motes the usage of mechanical property specifica-
tions. Further, this specification should not be
used if mechanical property control is not needed.
1.2.2 This specification does not designate particu-
lar property levels or control locations. These are
to be chosen based upon the needs of the part and
the availability of an adequate volume of material
from which to prepare a test specimen.
1.2.3 This specification specifically applies to prop-
erties measured in designated control locations for
parts during manufacturing. Once parts have been
subjected to environments known to affect me-
chanical properties, including normal use,
degradation of properties does not constitute an
out-of-specification condition.
1.2.4 This specification does not supplant specifi-
cations that define a given material and grades by
minimum mechanical properties. Further, proper-
ties specified for parts should not be derived solely
from such specifications for material.
1.2.5 Warranty Disclaimer. Data submitted under
this specification does not constitute any express
or implied warranty, including without limitation any
warranty of merchantability or fitness for a particu-
lar purpose.
1.2.6 General Disclaimer. Use of this specification
does not imply that the designated control location
represents any other region of the part.
1.2.7 Adherence to this specification does not ab-
solve Supplier of the responsibility to provide ac-
ceptable product.
2 References
Note: Only the latest approved standards are ap-
plicable unless otherwise specified.
2.1 Normative
ASTM B557M ASTM E8M
ASTM E21 ASTM E83
ASTM E466 ASTM E1012
ISO/IEC Guide 25 ISO/IEC Standard 17025
ISO 6892 QS 9000
2.2 GM
GP-11 GP-12
GMW3001 GMW3059
2.3 Additional
DCT-4627 (Delphi specification)
3 Requirements
3.1 Responsibilities
3.1.1 Supplier shall:
3.1.1.1 Quote parts against this specification with
an expectation that, based on experience with
similar castings and processes, mechanical prop-
erty requirements will be met.
3.1.1.2 Bear all costs required to comply with re-
quirements in this specification, including manufac-
turing additional parts required for testing. Costs
are not to be separately rebilled to Customer.
3.1.1.3 Obtain written agreement from Customer
on any deviation from requirements in this specifi-
cation.
GMN7152 GM ENGINEERING STANDARDS

Page 2 of 16 October 2001

3.1.1.4 Provide qualified personnel to manage all
operations obtaining, reporting and reacting to
property data. This includes casting sufficient
parts to provide required test specimens and ex-
pediting long lead-time items such as fatigue test-
ing.
3.1.1.5 Develop a process control plan containing
procedures to satisfy requirements in this specifi-
cation and a PFMEA showing response to insuffi-
cient specified requirements.
3.1.1.6 Keep records on test data and statistical
calculations available for inspection by Customer,
and submit complete reports at required reporting
periods.
3.1.1.7 Notify Customer when mechanical test
results or statistical calculations fall below speci-
fied requirements.
3.1.2 Customer shall:
3.1.2.1 Specify property levels for which a docu-
mented need exists, and within the capability of the
design of the part and the casting process chosen.
3.1.2.2 Establish lines of communication with Sup-
plier on data reporting and notification. The default
contact person for Customer is the Design-
Responsible Engineer.
3.1.2.3 Designate sufficiently large control loca-
tions to meet minimum sample size requirements.
3.2 Classes
3.2.1 One of four Classes in Table 1 is to be speci-
fied.
3.2.2 Class 1 requires tensile testing prior to re-
lease of individual lots plus statistical analysis of
tensile and fatigue data to audit process capability.
3.2.3 Class 2 omits lot control, but requires statisti-
cal analysis of tensile and fatigue data to audit
process capability.
3.2.4 Class 3 requires statistical analysis to audit
tensile property capability in production, omitting
both lot control and fatigue studies.
3.2.5 Class 4 requires that tensile property data be
submitted at PPAP, but no process auditing in
production. Class 4 is particularly applicable to
parts where component-level testing is to be used
to audit material integrity.
3.3 Reporting Periods
3.3.1 Tables 2A-2D list required actions by report-
ing period properties to be measured, sampling
frequency, sample count, and responses to results.
Table 1: Mechanical Property Control Classes
Class Definition Examples*
1
For rigorous control of ten-
sile and related properties,
including fatigue.
Chassis
components
2
For control of tensile and
related properties, including
fatigue, but without contain-
ment.
Aluminum
bedplates
3
For control of tensile and
related properties, excluding
fatigue and containment.
Aluminum
engine blocks
and heads
4
Where supplier qualification
is needed, but long term
property monitoring is not
(may apply if component-
level QC is done).
Miscellaneous
*Note: Application of this specification and its classes is not
limited to the examples cited.
3.3.2 Prototype. Mechanical property tests are to
be performed at prototype to establish capability of
process and design in preparation for PPAP.
- Lot control testing is required for all Class 1
parts.
- Tensile and fatigue studies shall be made with
material, tooling and process representative of
production.
- Compliance with property specifications is not
required at prototype except for Class 1 tensile
testing for lot control.
- By agreement from Customer, previously estab-
lished data from similar parts in production may
be submitted to comply with prototype testing
requirements.
3.3.3 PPAP. Testing listed in Tables 2A-2D applies
to the initial PPAP submission. Mechanical
properties are not required to be documented in
subsequent PPAP submissions for replicate
tooling. However:
- Following significant process change Customer
has discretion to require additional PPAP sub-
missions of mechanical property data.
- All specifications must be met for PPAP submis-
sions.
3.3.4 GP-12. Initial production data is sampled at a
greater rate than in later production.
3.3.5 Regular Production. In production, a small
number of samples are to be taken on a weekly
basis (lot-by-lot for Class 1) and reported semi-
annually.
GM ENGINEERING STANDARDS GMN7152

October 2001 Page 3 of 16

Table 2A: Test Requirements for Class 1 Table 2B: Test Requirements for Class 2
Reporting
Period
Property
Sample Count/
Sampling
Frequency
Data
Interpretation
& Required
Actions

Reporting
Period
Property
Sample Count/
Sampling
Frequency
Data
Interpretation
& Required
Actions
UTS, YS
& % EL
Greater of 1
sample/10 pcs,
or 1 sample/lot.
One 15-sample
tensile study.

UTS, YS
& % EL
1 sample/25
pcs.
One 15-sample
tensile study
GP-11
Prototype
(Note 1-2)

Fatigue
Strength
One 30-sample
Fatigue/SC
study
Tensile lot
control mins.
must be met.
Report fatigue
data to Cus-
tomer.

GP-11
Prototype
(Note 1-2)

Fatigue
Strength
One 30-sample
Fatigue/SC
study
Report data to
Customer
UTS, YS
& % EL
One 30-sample
tensile property
study

UTS, YS
& % EL
One 30-sample
tensile property
study PPAP
(Note 3)
Fatigue
Strength
One 30-sample
Fatigue/OP
study
PPAP
submissions
must meet
both min. and
statistical
specs.

PPAP
(Note 3)
Fatigue
Strength
One 30-sample
fatigue strength
study
PPAP
submissions
must meet
both min. and
statistical
specs.
UTS, YS
& % EL
Greater of 1
sample/500
pcs, or
2 samples/lot

UTS, YS
& % EL
Greater of 1
sample/1000
pcs, or
2 samples/wk
GP-12
Fatigue
Strength
Fatigue/OP: 4
samples/mo

GP-12
Fatigue
Strength
4 samples /mo
UTS, YS
& % EL
Greater of 1
sample/1000
pcs, or
1 sample/lot

UTS, YS
& % EL
Greater of 1
sample/5000
pcs, or
1 sample /wk
Regular
Production
Fatigue
Strength
Fatigue/OP:
2 samples/mo
Semi-annual
reporting.

Tensile lot
control mins.
Must be met.
If statistical
specs are not
met monthly,
initiate
notification
procedure

Regular
Production
Fatigue
Strength
Fatigue/SC:
2 samples /mo
Semi-annual
reporting.

If statistical
specs are not
met monthly,
initiate
notification
procedure
Notes:
1. Parts sampled for tensile and fatigue studies are to be made with tooling and process representative of production.
2. By agreement from Customer, for prototype: (a) multiple specimens may be taken from the designated control location in the same
part, (b) data available from similar parts already in production may be used to establish prototype capability.
3. Initial PPAP only. In tooling undergoing PPAP, the 30 samples should be distributed among each available cavity.
3.4 Test Methods
3.4.1 Coding for each property is listed in Table 3
along with standards covering permissible test
methods.
3.4.1.1 Requirements in this specification take
precedence over Normative and Additional stan-
dards referenced herein.
3.4.2 Elongation
3.4.2.1 Where specified minimum elongation is
3.0%, elongation shall be determined by the
extensometer method per ASTM B557M with an
extensometer of ASTM E83, Class B2 or better.
(see also Appendix A: Definitions.)
3.4.2.2 Where specified minimum elongation
> 3.0%, the gage mark method may be used, pro-
vided:
- Suppliers laboratory demonstrates acceptable
correlation between results of the extensometer
and gage mark methods, per Appendix B.
- Each operator is qualified for each reporting
period.
- A spring-loaded fixture (e.g. per ASTM B557M)
is used to clamp the specimen halves together
prior to measuring the gage length after test.
3.4.2.3 Gage length for elongation measurement
shall not be changed after PPAP.


Table 2C: Test Requirements for Class 3 Table 2D: Test Requirements for Class 4
Reporting
Period
Property
Sample Count/
Sampling
Frequency
Data
Interpretation
& Required
Actions

Reporting
Period
Property
Sample Count/
Sampling
Frequency
Data
Interpretation
& Required
Actions
GP-11
Prototype
(Note 1-2)

UTS, YS
& % EL
One 15-sample
tensile property
study
Report data to
Customer

GP-11
Prototype
(Note 1-2)

UTS, YS
& % EL
One 15-sample
tensile property
study
Report data to
Customer
PPAP
(Note 3)
UTS, YS
& % EL
One 30-sample
tensile property
study
PPAP
submissions
must meet
both min. and
statistical
specs.

PPAP
(Note 3)
UTS, YS
& % EL
One 30-sample
tensile property
study
PPAP
submissions
must meet
both min. and
statistical
specs.
GP-12
UTS, YS
& % EL
Greater of 1
sample/1000
pcs, or
2 samples/wk
GP-12
UTS, YS
& % EL
NA
Regular
Production
UTS, YS
& % EL
Greater of 1
sample/5000
pcs, or
1 sample/wk
Semi-annual
reporting.

If specs are
not met
monthly, initi-
ate notification
procedure

Regular
Production
UTS, YS
& % EL
NA
Not required
Notes:
1. Parts sampled for tensile and fatigue studies are to be made with tooling and process representative of production.
2. By agreement from Customer, for prototype: (a) multiple specimens may be taken from the designated control location in the same
part, (b) data available from similar parts already in production may be used to establish prototype capability.
3. Initial PPAP only. In tooling undergoing PPAP, the 30 samples should be distributed among each available cavity.

3.4.2.4 Deviations from these requirements must
be approved by Customer.
3.4.3 Fatigue Strength (Classes 1 and 2)
3.4.3.1 Fatigue strength should be specified at 1E7
cycles and under load ratio R=-1 (fully-reversed
loading). Alternative conditions may be specified
at discretion of Customer.
3.4.3.2 Conduct fatigue tests under uniaxial, sinu-
soidal loading. Procedures for staircase (Fa-
tigue/SC) and overstress probe (Fatigue/OP) test-
ing are listed in Appendices C and D.
3.4.3.3 For Class 1, prototype-level fatigue
strength is to be determined by the staircase
method (Fatigue/SC).
3.4.4 Other Mechanical Properties. This specifi-
cation may be used to establish requirements for
mechanical properties other than tensile and fa-
tigue per the following requirements:
- The property name must be noted in the material
specification callout along with a reference to a
national or international test standard. Any op-
tions allowed by the test standard, including
specimen geometry, must be noted under Ex-
ceptions.
- For properties other than tensile and fatigue,
only Class 3 or 4 may be specified.
- A separate callout may be used to designate a
Class that is different from other mechanical
property requirements.
- Testing and reporting requirements are to follow
those for tensile testing in the specified Class,
see Tables 2C and 2D.
3.5 Statistical Basis. Three (3) statistical meth-
ods that may be used to quantify requirements are
listed in Table 4.
3.5.1 Minimum (Min) requires that all tensile test
results be greater than the specified property level,
except those subject to retest and replacement
testing per 3.8. Min is used as follows:
- For Class 1, specifying a lot control minimum for
each tensile property listed.
- For all Classes, specifying minimum tensile
elongation.


Table 3: Properties for Specification, Codes
and Test Methods
Property Code Method
Applicable
Standards
Ultimate
Tensile
Strength
UTS
Yield
Strength
(Note 1)
YS
% Elongation
(Note 2) % EL
Tensile
Test
ASTM E8M
ASTM B557M
ISO 6892
Fatigue/
SC
Staircase
test
GMN7152, Ap-
pendix C
ASTM E466
Fatigue
Strength
(Note 3)
Fatigue/
OP
Overstress
probe test
(Note 4)
GMN7152, Ap-
pendix D
ASTM E466
Elevated
Temperature
Tests
(Note 5)
NA
General
procedure
ASTM E21
Notes:
1. Use 0.2% offset method.
2. See text for requirements for determining elongation.
3. Must specify desired fatigue strength and cycle count.
4. The overstress probe test results in a stress-time percent
parameter, see Appendix D.
5. Follow procedures in ASTM E21 for elevated temperature
testing where applicable.
Table 4: Choices for Statistical Basis
Statistical
Basis
Code Class Requirements
Minimum Min 1 - 4
Test results shall
be equal or exceed
listed value, except
those subject to
retest or replace-
ment
Mean 3
Sigma
3 Sigma 2 - 4
Weibull B1 B1 1
Must be calculated
with at least
30 samples. Cus-
tomer must be
notified if the calcu-
lated value does
not meet the part
spec.
3.5.2 Mean minus 3 sigma (3 Sigma) is the result
of a calculation from a body of data. This statisti-
cal basis is used as follows:
- For Class 2, specifying required fatigue strength.
- For Classes 2-4, specifying required UTS and
YS.
3.5.3 Weibull B1 is the result of a calculation from
a body of data. It is used as follows:
- To specify required statistical minimums for UTS
and YS in Class 1.
- To specify the statistical minimum for the re-
quired 100% STP result from the Overstress
Probe Test in Class 1. A complete explanation
of this test is given in Appendix D.
3.6 Frequency of Testing and Data Analysis
3.6.1 Samples may be accumulated and tested in
intervals not exceeding a calendar month, except
as follows:
- Timing shall be respected for GP-11, PPAP, and
GP-12 data reporting periods.
- For Class 1, tensile properties shall be deter-
mined on a lot-by-lot basis, prior to shipment.
3.6.2 Statistical property data ( 3 Sigma and B1)
shall be recalculated and compared to the specifi-
cation at least monthly using a minimum of 30 test
results for each required property.
3.6.2.1 If more than 30 results are available, use
all data accumulated during the reporting period.
3.6.2.2 If less than 30 tests have been executed in
a reporting period, augment the sample count to
30 with the latest results from the previous period
with the following exception:
- Data from prototype and any PPAP submission
shall be calculated separately.
3.6.2.3 Fatigue data obtained during production
will often span more than one reporting period.
When this occurs add the results of the monthly
fatigue tests to the body of data. If more than 30
test results have accumulated, omit the oldest
data.
3.7 Acceptability of Properties, Lot Control
3.7.1 Class 1. Tensile properties are to be used for
lot control. Statistical properties (B1) for tensile
and fatigue are to be used to monitor process ca-
pability.
3.7.1.1 Tensile testing is required prior to shipment
of each lot. If specified lot control minimums are
not met, subject to retest or replacement testing,
the lot shall be rejected or reworked.
3.7.1.2 Statistical properties for tensile and fatigue
are to be monitored. If statistical property require-
ments are not met, Customer is to be notified;
parts are not to be segregated or recalled except
by discretion of Customer.


3.7.1.3 Classes 2, 3, and 4. Properties (including
both minimum and statistical) are to be monitored.
If property requirements are not met, Customer is
to be notified; parts are not to be segregated or
recalled except by discretion of Customer.
3.8 Retests and Replacement Tests
1
3.8.1 When a test result fails to meet a specified
minimum, retesting may be permitted per 3.8.3. If
a discrepancy occurs with a test, a replacement
test may be permitted per 3.8.4.
3.8.1.1 A complete explanation of retests and re-
placement tests shall be summarized in each peri-
odic report.
3.8.2 Excluded Data. Statistical calculations may
exclude results subject to retest or replacement.
3.8.3 Retests. If one or more specimens fail to
conform to specified minimum (Min) property lev-
els, retests will be permitted under the following
conditions:
- Retesting for each specimen that failed, at least
two additional specimens from the same desig-
nated control location in either the original part (if
sufficient material remains), or from other parts
from the same lot.
- For Class 1, if any retest fails, the lot is subject
to rejection or rework.
- For Class 2-4, if any retest fails, Customer is to
be notified per procedures herein.
3.8.3.3 Limitation. Retesting of otherwise valid
tests, for the purpose of inflating results of statisti-
cal calculations, is prohibited.
3.8.4 Replacement Tests. A test specimen may
be discarded and a replacement specimen se-
lected from the same lot of material in any of the
following situations:
- The specimen was poorly machined.
- The test procedure was incorrect or the test
equipment malfunctioned.
- Either the fracture or necking occurred outside
the gage length, and the elongation was below
the specified value.
- If the specimen failed at a discontinuity that is
not present in parts that pass quality control pro-
cedures in the process control plan.

1
Requirements for retests and replacement tests herein
are based on those from ASTM B557M.
3.8.4.1 For separately cast test specimens, pre-
existing cracks exhibited in the fracture are
grounds for selecting replacement test specimens.
3.8.4.2 For test specimens excised from parts,
however, discontinuities revealed in the fracture
that are indicative of inferior material, such as
cracks, ruptures, flakes, and porosity, are not rea-
sons for a replacement test.
2
3.9 Designated Control Location
3.9.1 Data submitted under this specification shall
be derived from specimens excised from a desig-
nated control location noted on the part print.
3.9.1.1 Class 1. A general area may be desig-
nated where specified properties are to be met.
Supplier is responsible for specified properties
throughout the designated area.
3.9.1.2 Classes 2, 3, and 4. A region in the part
for extraction of mechanical test specimens should
be precisely specified, allowing for sample size
and machining stock.
3.9.2 More than one control location may be des-
ignated for a part, each having different property
requirements.
3.9.3 The control location is not limited to the part
itself. Co-cast or separately cast specimens may
be designated under the following condition:
- Separately cast specimens must be processed
concurrently with associated lots.
3.9.4 The control location is to be processed by the
same foundry and post-casting practices (e.g.,
shakeout time, heat treatment) that affect me-
chanical properties throughout the part or the re-
gion of the part it represents. Exceptions agree-
able to Customer shall be noted on the part print
under Exceptions.
3.9.5 Mechanical properties are to be determined
per Tables 2A-2D for each control location speci-
fied.
3.10 Specimen Requirements
3.10.1 Specimen geometry is specified in the stan-
dards listed in Table 3. The minimum diameter or
thickness of test specimens is to be 6 mm.

2
Note

that this specification is intended to audit material
properties in parts (not material per se), as affected by
part design and casting parameters.


3.10.1.1 Tensile Specimens
- Round bars are recommended. Flat bars may
be used in thin sections with approval from Cus-
tomer.
- Gage length to diameter ratio may be either 4:1
or 5:1.
3.10.1.2 Fatigue Specimens. Round bars having
straight (cylindrical) gage length nominally 2 x
diameter are recommended.
3.10.2 Specimen geometry, including gage length,
shall not be changed after PPAP without agree-
ment by Customer.
3.10.3 Parts scrapped for reasons that do not af-
fect mechanical properties may be used to furnish
test specimens, provided this is documented on
the test report.
3.10.4 For aluminum parts in the F or T4 tempers,
or after any other thermal processing known to
produce an unstable structure, samples should be
tested within two weeks after production. How-
ever, storage time under refrigeration (<0C) does
not count toward elapsed time. Any variation from
this requirement shall be noted on the test report.
3.11 Data Report Requirements. Mechanical
property data determined per 3.6 shall be summa-
rized and reported to Customer semi-annually.
Required elements for complete report are as fol-
lows:
- Summary of mechanical test results in a format
after the form in Appendix E, including notice of
any scrap parts used and why they were
scrapped, and summarized explanations for re-
tests and replacement tests.
- Tabular or graphical listing of results of individual
tests in chronological order.
- A record of machining and testing sources, with
specimen sizes noted (plus drawing if non-
standard).
- A statement summarizing any deviations and
exceptions agreed to by Customer.
- Process control plan containing procedures to
satisfy requirements in this specification and
PFMEA showing response to insufficient proper-
ties.
- If applicable, current reporting period results of
correlation study made between gage mark ver-
sus extensometer measurement of % EL.
3.12 Notification Procedure
3.12.1 Customer is to be notified immediately if
results of mechanical tests or statistical data fail to
meet the specification for parts that have been
shipped or where shipment is pending. However:
- Notification is not required if retests or replace-
ment tests per 3.8 are successful.
- Notification is not necessary for parts that are
scrapped or otherwise rejected.
3.12.2 After initial notification a report should be
assembled including:
- Test data or statistical data that fail to meet the
specification, along with historical data from pe-
riods when the specification was successfully
met.
- Documentation of the number of parts affected,
the time period they were produced and identify-
ing markings to that effect.
- Reaction plan including increased sampling and
root-cause investigation.
3.13 Lab Certification. All testing to generate
data against this specification shall be performed
in laboratories accredited to either ISO/IEC Stan-
dard 17025 (successor to ISO/IEC Guide
25:1990), QS 9000, or one of their successors.
3.14 Deviations and Exceptions
3.14.1 Deviations and exceptions to requirements
stated herein are permissible if explicitly agreed to
in writing by Customer.
3.14.2 Deviations and exceptions may be noted, at
the discretion of Customer, on the part specifica-
tion per Figure 1 and Section 7.
4 Manufacturing Process
Not applicable
5 Rules and Regulations
5.1 Rules and Regulations for Material Specifi-
cations. All materials supplied to this specification
must comply with the requirements of GMW3001,
Rules and Regulations for Material Specifica-
tions.
5.2 Restricted and Reportable Substances for
Parts. All materials supplied to this specification
must comply with the requirements of GMW3059,
Restricted and Reportable Substances for
Parts.


6 Approved Sources
Not applicable
7 Coding System
7.1 This material specification shall be referenced
in drawings, CTS, VTS, statements of require-
ments, BOM/BOP/BOD, or other documents in the
format given in Figure 1.
8 Release and Revisions
8.1 Release. This material specification was origi-
nated in March 2001 and was approved by the
GMNA Casting Specialist Team in August 2001. It
was first published in December 2001.

Figure 1. Coding system to be used on drawings or other documents (choose one)
Mechanical properties per GMN7152 Class 1: Mechanical properties per GMN7152 Class 2:
UTS: ___ MPa B1, ___ MPa Min UTS: ___ MPa 3Sigma
YS: ___ MPa B1, ___ MPa Min YS: ___ MPa 3Sigma
%EL: ___ % Min %EL: ___ % Min
Fatigue/OP: ___ MPa, 100% STP B1 Fatigue/SC: ___ MPa 3Sigma
Test conditions: ___C, 1E7 cycles, R = 1 Test conditions: ___C, 1E7 cycles, R = 1
Control location: _______________________ Control location: _______________________
Exceptions: _______________________ Exceptions: _______________________

Mechanical properties per GMN7152 Class 3: Mechanical properties per GMN7152 Class 4:
UTS: ___ MPa 3Sigma UTS: ___ MPa 3Sigma
YS: ___ MPa 3Sigma YS: ___ MPa 3Sigma
%EL: ___ % Min %EL: ___ % Min
Test conditions: ___C Test conditions: ___C
Control location: _______________________ Control location: _______________________
Exceptions: _______________________ Exceptions: _______________________
Notes:
1. Replace blanks by specific part requirements (property value, test temperature, control location, exceptions).
2. Class 1: Include a specified minimum for lot control of tensile properties.
The statistical basis for Fatigue/OP refers to results of STP calculations, per Appendix D.
3. CUSTOMER may designate alternative fatigue cycles-to-failure and load ratio (R).
4. It is not mandatory to use all properties listed. Omit any not specified.
5. Properties other than tensile and fatigue may be specified. Use Class 3 or 4, write out the property name plus required prop-
erty level, and detail test method under Exceptions.



Appendix A: Definitions
3 Sigma: A statistic calculated as mean minus
three times the standard deviation. Coded as 3
Sigma.
Co-cast: Pertaining to material appended to a
casting that will be removed for the purpose of
providing a test specimen.
Customer: The organization responsible for
specifying and receiving production or service
parts from Supplier.
Deviation and Exception: Any alteration to re-
quirements herein.
Elongation: Mechanical property describing ten-
sile ductility at break. This specification follows
ASTM E557M which defines elongation as plastic
elongation at fracture, excluding the elastic portion
of the total elongation at break. Note that elastic
elongation at fracture is equal to 100% x [stress at
fracture]/[elastic modulus].
Extensometer Method: This refers to the calcula-
tion of percent tensile elongation from the stress
vs. strain results of a tensile test.
Gage Mark Method: This refers to calculation of
percent tensile elongation from the increase in the
distance between gage marks applied to a speci-
men prior to test.
Lot: A group of parts processed together repre-
senting a short series of casting heats and a single
heat treatment batch or, in the case of continuous
furnaces, a group of racks or baskets quenched
together.
Minimum Specification: Requires individual test
results to be greater than or equal to a specified
value. Coded as Min.
Overstress Probe Fatigue Test: A fatigue testing
strategy that results in a stress time percent (STP)
parameter representing cumulative cycles suc-
cessfully tested in a series of increasing stress
amplitudes. See Appendix D. Coded as Fa-
tigue/OP.
Particular Property Level: A specification listing
predetermined values to be applied to a particular
part or family of parts.
PFMEA: Process Failure Mode Effects Analysis,
whereby likely scenarios of failures in the process
are investigated.
Recall: Logistical process whereby selected parts
are segregated from parts already delivered to a
customer and physically removed. (Here customer
may be downstream from the entity referred to
herein as Customer.)
Root-Cause Investigation: Actions taken to di-
agnose an out-of-specification condition.
Segregate: Physical separation of one series of
parts from others.
Staircase Fatigue Test: A fatigue testing strategy
that results in estimates for mean and standard
deviation of the fatigue strength. See Appendix C.
Coded as Fatigue/SC.
Statistical Specification: A specification requir-
ing calculated statistics based on a plurality of
individual test results.
Supplier: Providers of production or service parts
to Customer.
Temper: In ferrous alloys, an intermediate-
temperature heat treatment applied after harden-
ing. In cast non-ferrous alloys, a series of heat
treatments (a special case is the F temper for as-
cast or as-fabricated).
Thermal History: Time exposure of the part to
temperatures, both intentional and unintentional,
during processing and use.
Unstable Structure: A condition whereby the
microstructure of a part is subject to change due to
exposure to thermal conditions in its intended envi-
ronment.
Weibull B1: A statistical specification based on
the Weibull distribution representing a property
value that 99% of test results would exceed.
Coded as B1.


Appendix B: Correlation Study for Per-
centage Elongation Between Exten-
someter and Gage Mark Method
B1 Scope. This section describes (1) a procedure
for correlating results of extensometer and gage
mark methods for measuring tensile elongation,
and (2) whether the difference between the two
methods is acceptably small.
B2 Description. Percentage elongation is most
accurately measured by an extensometer. The
gage mark method tends to yield a larger result,
0.5 - 2% (absolute) greater than that of the exten-
someter method. The extensometer should con-
form to ASTM E83, Class B2 or better.
B3 Test Procedure. The following correlation
study shall be conducted whenever any supplier
adopts the gage mark method of elongation meas-
urement.
B3.1 Pretest. Prior to testing the original gage
length must be marked and measured.
B3.1.1 Use a fine mark or scriber line to identify
each end of the original gage length. Do not use
notches or center punches, which can result in
premature fracture. In order to render the fine
scribe line more easily visible, a dye bluing film
may be applied to the test piece before marking.
B3.1.2 For the correlation study, the extensometer
gage length must be equal to the original scribed
gage length. The original gage length should be
measured to an accuracy of 0.05 mm by each
operator to be qualified.
B3.2 Extensometer Method
B3.2.1 Place the extensometer on the specimen,
with its knife-edges at the gage marks. Leave the
extensometer on the specimen during the tensile
test until the specimen fractures. Follow similar
procedures for non-contact extensometers.
B3.2.2 The total elongation at fracture consists of
elastic elongation plus plastic elongation. It is
necessary to subtract the elastic elongation from
the total elongation to obtain the percent elonga-
tion (which is the value measured by the gage
mark method). Use the following formula:
|
.
|
\
|
=
modulus elastic
stress breaking
100% n %elongatio total EL %

B3.2.3 In addition, examine the load vs. extension
curve. If the gage slips during testing, the data
must be discarded and a replacement test per-
formed.
B3.2.4 Report elongation by the extensometer
method to the nearest 0.1%.
B3.3 Gage Mark Method
B3.3.1 The same specimen from the extensometer
method is to be used for the correlation study. To
reduce bias, the operator should not have prior
knowledge of the elongation value reported by the
extensometer method.
B3.3.2 Each operator should have individually
measured the gage length of each specimen be-
fore testing. Each operator should repeat this for
the final gage length.
B3.3.3 When measuring the final gage length spe-
cial precautions must be taken to ensure proper
contact between the broken halves of the test
specimen.
- First, remove any partially torn fragments that
might influence the final measurement from the
broken ends of the specimen.
- Place the halves in a fixture that holds them
together with an axial force applied by means of
a spring-loaded screw. The force should be suf-
ficient to hold the pieces together firmly without
crushing the fracture surface.
B3.3.4 Measure the final gage length to the near-
est 0.05 mm. To improve accuracy in measure-
ment, a measuring microscope or other suitable
instrument should be used. Report the gage mark
elongation to the nearest 0.1%.
B3.4 Correlation Study
- Use ten specimens
- For manual elongation measurement, all opera-
tors seeking qualification are to individually
measure each specimen before and after test.
- Calculate gage mark elongation for each combi-
nation of specimen and operator.
- For each sample record the differences between
the extensometer result and elongation results
from each of the operators, heretofore known as
the Differences.
- Calculate mean and standard deviation of Differ-
ences for each operator and for the combination
of all operators.
B4 Report
B4.1 Summarize data from the correlation study.
B4.2 Acceptability standard
- Mean of Differences less than 1.0% for each
operator.


- Standard deviation of Differences must be less
than 0.40% for each operator and for all opera-
tors.
B4.2.1 If the above two tests are not met, then the
gage mark method may not be used to measure
elongation except by express agreement from
Customer.
B5 Limitations. This procedure must be repeated
using recently tested specimens for each data
reporting period, whenever new mechanical testing
operators are added, and whenever the mechani-
cal testing system is recalibrated.


Appendix C: Procedure for Staircase
Testing for Fatigue Strength
(Fatigue/SC)
C1 Scope. This section describes how to conduct
a load-controlled staircase fatigue test and how to
analyze the results.
C2 Description. The load-controlled staircase
fatigue (SC) test is a convenient algorithm for es-
timating mean and standard deviation of fatigue
strength at a given number of cycles-to-failure.
While convenient and easily understandable, the
test suffers the following disadvantages: (1) it is
insensitive to bimodal distributions of stress ampli-
tude vs. life
1
and (2) it can be time consuming.
C3 Recommended Sample Size. Thirty-five (35)
samples (30 for test, 5 for setup)
C4 Recommended Test Equipment
(1) Servo-hydraulic, uniaxial test machine,
equipped to control and measure loads to
within 1.0% in the range needed for the mate-
rial tested and the test frequency used, and
also to stop the test when the specimen
breaks
2
.
(2) Gripping mechanism to hold specimen, aligned
per ASTM E1012. Collet grips are recom-
mended as they align more reliably and re-
quire smaller specimen ends.
(3) Heating device capable of heating entire gage
section of specimen to targeted temperature
3C with a maximum temperature gradient of
5C across the specimen. Measures must be
taken to overcome the tendency for grips to act
as heat sinks.
C5 Test Conditions. Use a fully reversed (R = -1),
sinusoidal waveform in load control unless other-
wise specified.
C6 Test Procedure
C6.1 Unless otherwise noted, procedures shall
follow ASTM E466.

1
A bimodal distribution of stress amplitude versus life
may occur in the presence of two equally likely crack
initiation mechanisms exhibiting different probability
functions for stress amplitude vs. cycles to failure.
2
It is particularly advantageous if the ends of the speci-
men are not crushed together after the specimen breaks.
An unmarred fracture surface can reveal important in-
formation about fracture mechanisms.
C6.2 A series of tests are run during which the
stress amplitude for each test depends on the
stress amplitude of the preceding test, and
whether the preceding test resulted in a failure
(complete separation) or a runout. The cycles-to-
failure should already be noted on the part specifi-
cation. A common number is 10
7
cycles, which
permits testing at the rate of about one sample/day
at 120 Hz.
C6.3 Choose step size: The step size should be
approximately the fatigue strength standard devia-
tion. Since this is rarely known in advance, make
the choice based on previous experience. Take
into account that a step size too small results in
poor estimation of the mean, and one too large,
poor estimation of standard deviation. A step size
of 5 10% of anticipated fatigue strength is com-
monly chosen.
C6.4 Choose the initial stress amplitude. This
should be three standard deviations (-20 MPa for
aluminum) above the part print minimum.
C6.5 Begin preliminary testing using an inflated
step size. This economizes on specimens while
searching for the first turnaround (individual test
that breaks a succession of failures or runouts).
An initial step size of 1.5 2 times the final step
size is common for preliminary tests.
C6.6 At the first turnaround, record the stress am-
plitude as the first data point, adjust the step size,
and test 29 additional samples. Samples from
runouts are not to be reused.
C6.7 After each individual test, mark the position of
the specimen while it is still in the test machine,
remove the specimen, and then record both the
clock position of the crack initiation point and
where the sample broke along its length. Crack
initiation at a preferential clock position or failure
outside the gage length may indicate load column
misalignment.
C6.8 Whenever any sample has broken in the
shoulder, disregard the result and retest. (This
indicates a misalignment of the load column or
excessive grip pressure.)
C7 Calculations
C7.1 Refer to the example in Figure C1 and Table
C1. Compute the mean and standard deviation of
fatigue strength using the lesser (in number) of the
runout or failure results.


C7.2 Use the following formulas
1
:
(
+ = b
n
iN
d
o
S mean strength Fatigue
i

Fatigue strength standard deviation = 1.62d(C + 0.029)
( )
2
2
i i
2
n
iN N i n
C

=
(C 0.30 for valid standard deviation)
Where: S
o
= lowest stress level
d = step size
N
i
= number of runouts or failures (which-
ever is lower) at each stress level i
i = 0 for lowest stress level, 1 for next
highest, etc.
n = total number of runouts or failures
b = + for runouts and for failures
C = convergence factor
C7.3 The example test began using a setup step
size of 7 MPa. After the first turnaround, the step
size was decreased to 3.5 MPa and a total of 30
specimens were tested. Relevant data are enu-
merated in Table C1.
C7.3.1 Results
Fatigue strength mean =
55.0 + 3.5(22/14 ) = 58.75 MPa
Convergence factor (C) =
[14(46) (22)
2
]/(14)
2
= 0.82 (OK)
Standard deviation =
1.62(3.5)(1.05 + 0.029) = 4.79 MPa
C7.4 If C < 0.3, a valid standard deviation cannot
be calculated. This occurs when the step size is
large enough that the test oscillates between fail-
ures at one stress amplitude and runouts at an-
other.
C7.4.1 If this occurs an acceptable estimate for
standard deviation is as follows:
Where: C < 0.30:
Fatigue strength standard deviation = 0.75 (step size)

1
Reference W. J. Dixon, A.M. Mood, J. Am. Statist.
Assoc., vol. 43, p. 109 (1948).
Figure C1: Test Record for a Staircase Test
UTS01211(06/01)
48.0
51.5
55.0
58.5
62.0
65.5
69.0
72.5
76.0
79.5
83.0
-5 0 5 10 15 20 25 30
Initial stress increment: 7MPa (3 set-up tests)
Stress increment: 3.5 MPa
Mean Fatigue Strength: 58.75 MPa
Standard Deviation: 4.79 MPa
Convergence Factor: 0.82
Failures
Runouts
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
,

M
P
a
Test Number

Table C1: Calculations for Staircase Data
Stress i N
i
iN
i
i
2
N
i
65.5 3 2 6 18
62.0 2 6 12 24
58.5 1 4 4 4
55.0 0 2 0 0
Failures N= 14 iN
I
= 22 i
2
N
I
= 46
C8 Production Procedure. To determine the
fatigue strength during production for Class 2, use
the following procedure:
C8.1 Initially, four samples per month will be avail-
able (GP-12 sampling rate).
C8.2 Start at an initial stress amplitude equal to the
previously determined average fatigue strength.
C8.3 Do not calculate results for the first month.
Notify Customer if all four test results are failures.
C8.4 Make the first calculation of average, stan-
dard deviation and 3 Sigma the second month
after eight total tests have been run.
C8.5 Continue to recalculate average, standard
deviation, and 3 Sigma each month, adding addi-
tional test results per the required sampling plan.
C8.6 After 30 test results are available, replace the
earliest results with the newest results and con-
tinue thereafter to perform calculations based on
the latest 30 samples.
C8.7 Track individual test results, plus calculations
of average, standard deviation, and 3 Sigma val-
ues on a run chart.


Appendix D: Procedure for Overstress
Probe Testing for Fatigue Strength
(Fatigue/OP)
D1 Scope. This section describes how to conduct
load-controlled overstress probe testing and how
to analyze the results.
D2 Description. The overstress probe test results
in a calculated parameter consisting of cumulative
cycles at a succession of stress amplitudes, nor-
malized at the specified fatigue strength and cycle
count. While this test uses individual samples
efficiently, it suffers from the following disadvan-
tages:
(1) It does not determine the actual average fa-
tigue strength.
(2) It may be inappropriate for certain steels that
cyclically strain harden.
1

D3 Recommended Sample Size. 30 samples.
D4 Recommended Test Equipment
(1) Servo-hydraulic, uniaxial test machine
equipped to control and measure loads to
within 1.0% in the range needed for the mate-
rial tested and the test frequency used, and
also to stop the test when the specimen
breaks.
2

(2) Gripping mechanism to hold specimen, aligned
per ASTM E1012. Collect grips are recom-
mended as they align more reliably and re-
quire smaller specimen ends.
(3) Heating device capable of heating entire gage
section of specimen to targeted temperature
3C with a maximum temperature gradient of
5C across the specimen. Measures must be
taken to overcome the tendency for grips to act
as heat sinks.
D5 Load Conditions. Use a fully reversed (R =
-1), sinusoidal waveform in load control unless
otherwise specified.
D6 Test Procedure
D6.1 Unless otherwise noted, procedures shall
follow ASTM E466.

1
Progressive increases in stress amplitude can cause a
material that cyclically strain hardens to exhibit transient
increases in fatigue resistance.
2
It is particularly advantageous if the ends of the speci-
men are not crushed together after the specimen breads.
An unmarred fracture surface can reveal important in-
formation about fracture mechanisms.
D6.2 A series of samples are tested, each starting
at a stress amplitude equaling the specified fatigue
strength then retested in successive tests at higher
stress amplitudes increased in equal 10% incre-
ments. The test for each sample ends when it
fractures.
D6.3 The cycles-to-failure should already be noted
on the part specification. A common specification
is 10
7
cycles, which are accumulated in 23 h at
120 Hz.
D6.4 Test the first sample at a stress amplitude
equal to the specified fatigue strength and for the
specified number of cycles. If the sample does not
fail, increase the load by 10% and run the same
sample for an additional number of cycles equaling
10% of the original cycle count. Continue this until
failure, which is defined as complete separation
2
.
D6.5 Test the remaining samples following the
same procedure.
D6.6 Calculate for each sample:
STP = 100% [Cycle life]/[Specified cycle count]
Where: STP = stress time percent
Cycle life = cumulative cycles
Specified
cycle count
= number of cycles
specified
D6.7 In the following example, the specification
calls out a fatigue strength of 70 MPa at 10
7
cy-
cles.
D6.7.1 The record of one sample is enumerated in
Table D1 showing that it ran out (i.e., it did not fail)
after 10
7
cycles. It was then successively tested
for 10
6
cycles (10% of the specified cycle count) in
increasing stress amplitude increments of 7 MPa
(10% of the specified fatigue strength). The sam-
ple failed when it was tested at a stress amplitude
of 133 MPa. It accumulated 1.8 x 10
7
cycles.
D6.7.2 Hence, for this sample:
STP = 100% [1.8 x 10
7
]/[1.0 x 10
7
] = 180%
D6.8 Individual STP results for each sample are
then fitted to the Weibull distribution. Procedures
to do this may be found in any statistics textbook.
The statistical minimum (B1) of STP must be
greater than 100%.


Table D.1 Test Record for an Overstress
Probe Test
Stress Ampli-
tude
Cycles
Cumulative
Cycles
70 MPa 1 x 10
7
1.0 x 10
7
77 MPa 1 x 10
6
1.1 x 10
7

84 MPa 1 x 10
6
1.2 x 10
7

91 MPa 1 x 10
6
1.3 x 10
7

98 MPa 1 x 10
6
1.4 x 10
7

105 MPa 1 x 10
6
1.5 x 10
7

112 MPa 1 x 10
6
1.6 x 10
7

119 MPa 1 x 10
6
1.7 x 10
7

126 MPa 1 x 10
6
1.8 x 10
7

133 MPa failure

D7 Production Procedure. To determine the
STP during production of Class 1, use the follow-
ing procedure:
D7.1 Initially, four samples per month will be avail-
able (GP-12 sampling rate).
D7.2 Test the first four samples per procedures
herein.
D7.3 Do not calculate Weibull results the first
month. Notify Customer if any test result is below
100% STP.
D7.4 Make the first calculation of Weibull B1 the
second month after eight total tests have been run.
D7.5 Continue to recalculate the Weibull statistics
each month, adding additional test results per the
required sampling plan.
D7.6 After 30 test results are available, replace the
earliest results with the newest results and con-
tinue thereafter to perform calculations based on
the latest 30 samples.
D7.7 Track individual STP and calculated B1 val-
ues on a run chart.
D8 Remark. This procedure is derived from Del-
phi specification DCT-4627 on mechanical prop-
erty testing of cast aluminum steering knuckles.


Appendix E: Mechanical Test Data Report
UTS01212(06/01)
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GMN7152 2002

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