saej844v004

SURFACEVEHICLESTANDARD(R)NonmetallicAirBrakeSystemTubingSAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright©2004SAEInternationalAllrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanada)Tel:724-776-4970(outsideUSA)Fax:724-776-0790Email:custsvc@sae.orgSAEWEBADDRESS:http://www.sae.orgIssued1963-06Revised2004-11SupersedingJ844JUN1998®J844REV.NOV20041.Scope1ThisSAEStandardcoverstheminimumrequirementsfornonmetallictubingasmanufacturedforuseinairbrakesystems.Non-reinforcedproductsaredesignatedtypeAandreinforcedproducts,typeB.Itisnotintendedtocovertubingforanyportionofthesystemwhichoperatesbelow–40°C,above+93°C,aboveamaximumworkinggagepressureof1.0MPa,orinanareasubjecttoattackbybatteryacid.Thistubingisintendedforuseinthebrakesystemforconnections,whichmaintainabasicallyfixedrelationshipbetweencomponentsduringvehicleoperation.Coiledtubeassembliesrequiredforthoseinstallationswhereflexingoccursarecoveredbythisdocument,SAEJ1131,andSAEJ2494-3totheextentofsettingminimumrequirementsontheessentiallystraighttubeandtubefittingconnectionswhichareusedintheconstructionofsuchassemblies2.1.1GeneralRequirementsTesttemperatureshalluse±3°Casthetesttolerancerange.Alltesttimesareminimumunlessotherwisespecified.Dryairshallbeaminimumof–50°Cdewpoint.Tubingshallbecutsquareat90degrees±7degrees.Preconditionalltestsamplesat0.7MPa±0.1MPafor30swithoutleakage.Newsamplesshallbeusedforalltests.2.References2.1ApplicablePublicationsThefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.Unlessotherwisespecified,thelatestissueofSAEpublicationsshallapply.1.SeeSAEJ1149forMetallicAirBrakeSystemTubingandPipe.2.Federalregulationscoveringdesignedrequirementsandacceptedapplicationsforcoiledtubeassembliesaresetforthin49CFR393.45.ConformancetoSAEJ844doesnotimplycompliancewithFederalregulationsforairbraketubing.Sizes3.97mmandbelowmaynotmeet49CFR571.106requirementsforairbrakesystems.SAEJ844RevisedNOV2004-2-2.1.1SAEPUBLICATIONSAvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001.SAEJ246—SphericalandFlangedSleeve(Compression)TubeFittingsSAEJ1131—PerformanceRequirementsforSAEJ844NonmetallicTubingandFittingAssembliesUsedinAutomotiveAirBrakeSystemsSAEJ1149—MetallicAirBrakeSystemTubingandPipeSAEJ2494-1—Push-To-ConnectTubeFittingsforUseinthePipingofVehicularAirBrakeSAEJ2494-2—DimensionalSpecificationsforNon-MetallicBodyPush-to-ConnectFittingsUsedonaVehicularAirBrakeSystemSAEJ2494-3—PerformanceRequirementsforSAEJ844Non-MetallicAirBrakeTubingandPushtoConnectFittingAssembliesUsedinVehicularAirBrakeSystems2.1.2ASTMPUBLICATIONSAvailablefromASTM,100BarrHarborDrive,WestConshohocken,PA19428-2959.ASTMD4329—PracticeforOperatingLight-andWater-ExposureApparatus(FluorescentUV-CondensationType)forExposureofPlasticsASTMG53—RecommendedPracticeforOperatingLight-andWater-ExposureApparatus(FluorescentU-CondensationType)forExposureofNonmetallicMaterials2.1.3FEDERALREGULATIONSAvailablefromTheSuperintendentofDocuments,U.S.GovernmentPrintingOffice,Washington,DC20402.49CFR393.45—BrakeTubingandHoseAdequacy49CFR571.106—BrakeHoses3.InstallationandAssemblyRecommendations3.1EndFittingsEndfittingsaretobeassembledtothetubinginaccordancewiththefittingmanufacturer’srecommendations.ThefittingmaybeofthedesignshowninSAEJ246,SAEJ2494-1,SAEJ2494-2,oranyotherdesignsuitableforusewithnonmetallicairbraketubing.PerformancetestrequirementsfornonmetallicairbrakeassembliesarecoveredinSAEJ1131andSAEJ2494-33.2NoncoiledTubingNoncoiledtubingshouldnotbeusedinflexingapplicationssuchasframetoaxle.SAEJ844RevisedNOV2004-3-3.3SupportandRoutingWheninstalledinavehiclethistubingshallberoutedandsupportedsoasto:a.Eliminatechafing,abrasion,kinking,orothermechanicaldamageb.Minimizefatigueconditionsc.Beprotectedagainstroadhazardsbyinstallationinaprotectedlocationorbyprovidingadequateshieldingatvulnerableareasd.Nottobeexposedtotemperatures,internalorexternal,over+93°Corbelow–40°Ce.Nottobeexposedtoattackbybatteryacidf.Avoidexcessivesag4.IdentificationAirbraketubingshallbelabeledinacontrastingcolorwiththelegendrepeatedevery380mmorlessalongtheentirelengthoftubinginlegibleblockcapitalletters.Thefollowingminimuminformation,intheorderlisted,isrequired.Additionalinformationand/oranotherlaylinemaybeadded,ifnecessary.a.Airbrakeb.SAEJ844c.Type,AorBd.Nominal,tubingOD(refertoTable1,NominalTubeSizeOD)e.Tubingmanufacturer’sidentification5.ManufactureThetubingshallbemanufacturedtocomplywiththerequirementsoutlinedinthisdocument.6.ConstructionTypeAtubingshallconsistofasinglewallextrusionof100%virginnylon(polyamide)containingadditiveswhichprovideheatandlightresistance.TypeBtubingshallconsistofacoreextrusionof100%virginnylon(polyamide)containingadditives,whichprovideheatresistance.Thiscoreshallbereinforcedwithpolyesterbraidorequivalent,andcoveredwithaprotectivejacketof100%virginnylon(polyamide)containingadditiveswhichprovideheatandlightresistance.Theprotectivecoveringshallbebondedtothecorethroughtheintersticesofthebraid.Theinnercoreandouterjacketshallbeofcontrastingcolors.7.DimensionsandTolerancesThetubingshallconformtodimensionsshowninTable1underallconditionsofmoisture.Conformancewiththisrequirementshallbedeterminedonsampleswhichhavebeensubjectedto110°Cfor4hinacirculatingairoven,andonseparatesampleswhichhavebeenimmersedinboilingwaterfor2h.Dimensionaltestsshallbemadeaftersampleshavebeenreturnedtoroomtemperaturefor0.5hto3h.SAEJ844RevisedNOV2004-4-TABLE1—DIMENSIONSANDTOLERANCESTypeofTubingNominalTubingSizeODTubingBasicODmmOutsideDiameterTolerancemmInsideDiameterBasicmmWallThicknessBasicmmWallThicknessTolerancesmmA1/8in3.18±0.082.020.58±0.08A5/32in4mm4.00±0.082.380.81±0.08A3/16in4.75±0.082.970.89±0.08A6mm6.00±0.084.001.00±0.08A1/4in6.35±0.084.351.00±0.08A5/16in8mm8.00±0.106.001.00±0.10B3/8in9.53±0.106.391.57±0.10B10mm10.00±0.137.001.50±0.10B12mm12.00±0.139.001.50±0.10B1/2in12.70±0.139.561.57±0.10B5/8in15.88±0.1311.202.34±0.13B16mm16.00±0.1312.002.00±0.13B3/4in19mm19.05±0.1314.372.34±0.138.MechanicalPropertiesThetubingshallconformtothemechanicalpropertiesshowninTable2,whentestedaccordingtothemethodsoutlinedinthisdocument.TABLE2—MECHANICALPROPERTIESTypeofTubingNominalTubingSizeODMinimumBurstPressureat24°CMPaTestBendRadius(1)mmMaximumStiffnessNA1/8in6.99.44.4A5/32in4mm8.312.74.4A3/16in8.319.14.4A6mm8.325.48.9A1/4in8.325.48.9A5/16in8mm6.932.027.0B3/8in9.738.136.0B10mm8.238.136.0B12mm6.945.090.0B1/2in6.650.889.0B5/8in6.263.5222.0B16mm6.070.0225.0B3/4in19mm5.576.2356.01.Fortestpurposeonly.9.PerformanceRequirementsThetubingshallsatisfactorilymeetthefollowingperformancetests.SectionsoftheseperformancetestsshallbeconductedasInspectionTeststobeperformedoneachlotoftubing,andwherealotisdefinedas“theoutputofoneproductionshiftofonesizeandcoloroftubing.”SAEJ844RevisedNOV2004-5-InspectionTestsareasfollows:Section9.1LeakTestSection9.9RoomTemperatureBurstTestSection9.10ColdTemperatureImpactSection9.11Adhesion9.1LeakTestThetubingmanufacturershallsubjecteachcontinuouslengthoftubingtotestatagagepressureof1.4MPato1.8MPawithanappropriategasforaperiodoftime(minimum30s)sufficienttodeterminethepresenceofanyleaks.Defectivesectionsshallbecutoffandscrapped.Theremainingtubingshallberecoupledatthepointswheredefectivesectionswereremovedandagainsubjectedtothe1.4MPato1.8MPapressuretest.Theprocedureshallberepeateduntilallsectionsoftubingdesignatedfordistributiontousershavesuccessfullywithstoodthetest.9.2MoistureAbsorptionExposesampleoftubingfor24hinacirculatingairovenat110°C.Removefromoven,weighimmediatelyandexposefor100hat100%relativehumidityand24°C.Within5minfromhumidityconditioning,wipesurfacemoisturefromboththeinteriorandexteriorsurfacesofthetubingandreweigh.Moistureabsorptionshallnotexceed2%byweight.9.3UltravioletResistancePlacesamplesoftubinginthesampleracksofaQ-PanelQUVtestapparatus*equippedwithPhillipsbulbs,typeUVA-340.Exposefor300hminimum.Ifthetestapparatusisequippedwitha“SolarEye,”thebulbsneednotberotatedandtheirradianceshouldbesetat0.85,howeverallbulbsshouldbediscardedafter4800hmaximum,oriftheyfallbelowthe0.85irradiancelevel,whicheveroccursfirst.Ifthetestapparatusisnotequippedwitha“SolarEye,”thebulbsmustberotatedevery400hmaximum,asrecommendedbythemanufacturerandASTMG53,thisprocedurewillresultindiscardinglampsafter1600hofuse.Controlthetemperatureoftheapparatusto45°C.Thespecimensaretobemountedonaplatesuchthattheplateisnogreaterthan51mmfromthelightbulbs.Theautomatichumiditycyclingmustbeturnedoff.RotatethespecimensaccordingtoASTMD4329exceptthetimeintervalshouldbeeach96hoursmaximuminsteadofweekly.MaintainandoperatetheQUVtesterinaccordancewiththemanufacturersinstructions.Immediatelyfollowingthisexposure,subjectthetubingtotheimpacttestshowninFigure1.Subjecttubingtoroomtemperatureburstasspecifiedin9.9.Tubingshallwithstandnolessthan80%oftheburstpressureshowninTable2.*TheQ-PanelQUVAcceleratedWeatheringTesterisavailablefrom:TheQ-PanelCompany26200FirstStreetCleveland,OH44145(216)835-8700SAEJ844RevisedNOV2004-6-9.4ColdTemperatureFlexibilityExposesampleoftubingfor24hinacirculatingairovenat110°C.Removefromovenandwithin30minexposefor4hat–40°C.Alsoexposeamandrelat–40°Chavingadiameterequalto12timesthenominaldiameterofthetubing.(Inordertoobtainuniformtemperatures,thetubingandmandrelmaybesupportedbyanonmetallicsurfaceduringtheentireperiodoftest.)Immediatelyfollowingthisexposure,bendtubing180degreesoverthemandrel,accomplishingthebendingmotionwithinaperiodof4to8s.Thetubingshallshownoevidenceoffracture.9.5HeatAgingTwoseparateheatagingtestsshallbeconducted;eachphaseshallberunonseparatetubingsamples.Subjecttubingtoroomtemperaturebursttestasspecifiedin9.9.Tubingshallwithstand80%oftheburstpressureshowninTable2.9.5.1Phase1—Bendsamplesoftubing180degreesaroundamandrelhavingadiameterequivalenttotwicethetestbendradiusspecifiedinTable2.Whileinthisposition,exposetubingandmandrelfor72hinacirculatingairovenat110°C.Removefromovenandpermittubingtoreturnto24°Cwhilestillonthemandrel.Within30minafterstabilizationat24°C(75°F),returnthetubingtoastraightpositioninaminimumof4s,thenre-bend(againsttheset)180degreesaroundthemandrel,accomplishingthebendingmotionwithinaperiodof4to8s.9.5.2Phase2—Exposesamplesoftubingfor72hinacirculatingairovenat110°C.Removefromovenandpermittubingtoreturnto24°C.Within30minafterstabilizationat24°C,subjecttubingtotheimpacttestshowninFigure1.NOMINALTUBEO.D.HOLEDIADmm1/8in45/32in4mm4.83/16in5.546mm6.81/4in7.145/16in8mm8.83/8in10.310mm10.812mm12.81/2in13.495/8in16.6616mm16.83/4in19mm20.32SAEJ844RevisedNOV2004-7-FIGURE1—TYPICALNYLONTUBINGIMPACTAPPARATUSNOTE—ImpactapparatusmaybedrilledtoacceptanycombinationoftubesizeslistedinthechartImpactapparatusfallingmassshallbe0.454kg,withadiameterof31.75mm,anda15.88mmsphericalradiusoneachend.Themassfalls304.8mmfor3/8"tubing.SectionA-Ashowsthetypicalholelocationwithrespecttotheimpactarea.9.6ResistancetoZincChlorideBendtubingtothetestbendradiusshowninTable2.Whileinthisposition,immerseina50%(byweight)aqueoussolutionofzincchloridefor200hat24°C.Removefromsolution.Tubingshallshownoevidenceofcrackingontheoutsidediameter.SAEJ844RevisedNOV2004-8-NOTE—Fresh,anhydrouszincchlorideshouldbeusedtomakeupaconcentrationof50%(byweight)aqueoussolution(specificgravityof1.576oraBaumeratingof53degreesat16°C).9.7ResistancetoMethylAlcoholBendtubingtothetestbendradiusshowninTable2.Whileinthisposition,immersein95%methylalcoholfor200hat24°C.Removefromsolution.Tubingshallshownoevidenceofcracking.9.8StiffnessUsesamples280mmlong.Insertarodofsuitablesizeintothetubingtomaintainastraightpositionwithin3.2mm.Exposetubingandrodfor24hinacirculatingairovenat110°C.Removefromovenandpermittubingandrodtoreturnto24°C.Within30minafterstabilizationat24°C,removerodandsubjecttubingtostiffnesstestshowninFigure2.TubingshallrequirenomoreforcethanspecifiedinTable2todeflect51mm.9.9RoomTemperatureBurstTestTubingshallbestabilizedfor0.5to3.0hat24°CandtestedbyincreasingpressureataconstantratetoreachthespecifiedminimumburstpressureinTable2withinatimeperiodof3to15s.TubingthatburstsbelowthepressurespecifiedinTable2shallberejected.9.10ColdTemperatureImpactConditiontubingbyexposingonehalfthesamplesfor24hat110°Cinacirculatingairoven,andonehalfthesamplesinboilingwaterfor2h;thenexposeallthesamplesto–40°Cfor4h.Also,exposeimpacttestapparatus,showninFigure1,to–40°C.Whiletubingandapparatusareatthiscoldtemperature(approximately–40°C),subjecttubingtoimpactasspecified.Thetubingshallshownoevidenceofcracks.Afterimpacttesting,permittubingtoreturnto24°C.Within30minafterstabilizationat24°C,subjecttubingtoroomtemperaturebursttestasspecifiedin9.10.Tubingshallwithstandatleast80%oftheburstpressureshowninTable2.Samplesizeshallbe10specimensperlot.Intheeventofanyfailures,asecondsamplefromthesamelotconsistingof20specimensshallbetested.Ifanotherfailureoccurs,thelotshallberejected.9.11AdhesionTest9.11.1Thistestappliesonlytothereinforcedproducts,TypeB.9.11.2CONDITIONThistestshallbeconductedat24°Cambienttemperature.9.11.3PROCEDUREANDREQUIREMENTSCutastripoftubingintoa6.0mmwidehelicalcoilequalinlengthtofivetimesthecircumferenceofthetubing.Bendthehelicalcoilinreverseofcoilingsoastoexposethebraidgapbetweentheouterjacketandcoretubesection.Startbyworkingasharpknifebladeintothebraidgaptoinitiateseparation,andthenattempttoseparatetheouterjacketfromthecoretubeatthebraidinterstices.Thebondedsurface(excludingthebraidedarea)betweentheouterjacketandcoresectionshallbeinseparablefortheentiretestsamplelength.SAEJ844RevisedNOV2004-9-9.12HeatAgingAdhesionTest9.12.1PROCEDURESubjectsamplestoPhase1oftheheatagingtestprocedureper9.5.1.9.12.2REQUIREMENTSAftercompletionofthePhase1procedure,thetubingshallmeettherequirementsof9.11.9.13CollapseResistanceTestProcedure9.13.1GENERALAlltestsaretobeconductedatroomtemperature24°Cunlessotherwisespecified.SAEJ844RevisedNOV2004-10-FIGURE2—STIFFNESSTESTAPPARATUSSAEJ844RevisedNOV2004-11-9.13.2PREPARATIONOFTESTSAMPLESThreesamplesshallbepreparedfortesting.Thefreetubelengthofthesamplesshallbeasfollows:3.14x(minkinkradius)+10x(tubeOD)+2x(lengthofsupportingpin)9.13.3TESTPROCEDUREPlaceareferencemarkatthemiddleofeachsampleandmeasurethecrosssectiondiameter(MinorDiameter[unbent])atthispointandrecord.NOTE—SeeFigures3and4forlocationofminordiameters.FIGURE3—MINORDIAMETER(UNBENT)FIGURE4—MINORDIAMETER(BENT)SAEJ844RevisedNOV2004-12-9.13.4Carefullyinstallthesamplesonabendtestfixture(asshowninFigure5)ina180-degreebendcondition.Thetubeshallbebentinthedirectionofthenaturalcurvatureofthetube.Samplespreparedper9.13.2shallbebenttoaradiusequaltotheminimumkinkradiuscalledoutinTable3.FIGURE5—BENDTESTFIXTURESAEJ844RevisedNOV2004-13-TABLE3—MINIMUMKINKRADIUS(1)TypeofTubingNominalTubingSizeODMinimumKinkRadiimmA1/8in9.4A5/32in4mm12.7A3/16in19.1A6mm25.4A1/4in25.4A5/16in8mm38.1B3/8in38.1B10mm38.1B12mm56.3B1/2in63.5B5/8in76.2B16mm84.0B3/4in19mm88.91.Itshouldbenotedthatthesevaluesrepresentunsupportedkinkradiiwhichcanbeusedforinstallationpurposes.9.13.5Agesamplesontestfixtureat93°Cfor24h.Allowthesamplestocooltoroomtemperature.Whilethesamplesareonthetestfixture,measuretheminordiameter(bent).Collapseofgreaterthan20%isconsideredafailure(seeEquation1).100x[unbent]ODMinor[bent]ODMinor-[unbent]ODMinorCollapsePercent=(Eq.1)10.Notes10.1MarginalIndiciaThechangebar(l)locatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisionshavebeenmadetothepreviousissueofthereport.An(R)symboltotheleftofthedocumenttitleindicatesacompleterevisionofthereport.PREPAREDBYTHESAEAIRBRAKETUBINGANDTUBEFITTINGSSUBCOMMITTEEOFTHESAEFLUIDCONDUCTORSANDCONNECTORSTECHNICALCOMMITTEESAEJ844RevisedNOV2004RationaleThemodificationsmadetothedocumentsmeettheneedtoreducetheoverallnumberofSAEdocumentsbymergingSAEJ1394intoSAEJ844.ThemergeralsoaccomplishedtheconversionofSAEJ844toSIunitsandsimplificationoftheuseofthedocumentbytheadditionofageneralrequirementssection.RelationshipofSAEStandardtoISOStandardNotapplicable.ApplicationThisSAEStandardcoverstheminimumrequirementsfornonmetallictubingasmanufacturedforuseinairbrakesystems.Non-reinforcedproductsaredesignatedtypeAandreinforcedproductstypeB.Itisnotintendedtocovertubingforanyportionofthesystemwhichoperatesbelow–40°C,above+93°C,aboveamaximumworkinggagepressureof1.0MPa,orinanareasubjecttoattackbybatteryacid.Thistubingisintendedforuseinthebrakesystemforconnections,whichmaintainabasicallyfixedrelationshipbetweencomponentsduringvehicleoperation.CoiledtubeassembliesrequiredforthoseinstallationswhereflexingoccursarecoveredbythisdocumentandSAEJ1131andSAEJ2494-3totheextentofsettingminimumrequirementsontheessentiallystraighttubeandtubefittingconnectionswhichareusedintheconstructionofsuchassemblies.NOTE—Federalregulationscoveringdesignedrequirementsandacceptedapplicationsforcoiledtubeassembliesaresetforthin49CFR393.45.ConformancetoSAEJ844doesnotimplycompliancewithFederalregulationsforairbraketubing.Sizes4.0mmandbelowmaynotmeet49CFR571.106requirementsforairbrakesystems.ReferenceSectionSAEJ246—SphericalandFlangedSleeve(Compression)TubeFittingsSAEJ1131—PerformanceRequirementsforSAEJ844NonmetallicTubingandFittingAssembliesUsedinAutomotiveAirBrakeSystemsSAEJ1149—MetallicAirBrakeSystemTubingandPipeSAEJ2494-1—Push-To-ConnectTubeFittingsforUseinthePipingofVehicularAirBrakeSAEJ2494-2—DimensionalSpecificationsforNon-MetallicBodyPush-to-ConnectFittingsUsedonaVehicularAirBrakeSystemSAEJ2494-3—PerformanceRequirementsforSAEJ844Non-MetallicAirBrakeTubingandPushtoConnectFittingAssembliesUsedinVehicularAirBrakeSystemsASTMD4329—PracticeforOperatingLight-andWater-ExposureApparatus(FluorescentUV-CondensationType)forExposureofPlasticsSAEJ844RevisedNOV2004ASTMG53—RecommendedPracticeforOperatingLight-andWater-ExposureApparatus(FluorescentUV-CondensationType)forExposureofNonmetallicMaterials49CFR393.45—BrakeTubingandHoseAdequacy49CFR571.106—BrakeHosesDevelopedbytheSAEAirBrakeTubingandTubeFittingsSubcommitteeSponsoredbytheSAEFluidConductorsandConnectorsTechnicalCommittee