JASO M101 Metal Pipes for Automobile Tubing

1.  Scope

This standard specifies the metal pipes for tubing mainly used for brakes, fuel and lubrication of automobiles (hereinafter referred to as the “pipes”).
Remarks:

The applicable standards for this standards are shown below.
JIS G3141 Cold rolled carbon steel sheets and strip
JIS G3445 Carbon steel tubes for machine structural purposes
JIS G 3472 Electric resistance welded carbon steel tubes for automobile structural purposes
JIS H 3300 Copper and copper alloy  seamless pipes and tubes
JIS Z 2241 Method of tensile test for metallic materials
JIS Z2244 Method of vickers hardness test
JIS Z2251 Method of micro hardness test for vickers and knoop hardness
JASO M 104 Testing method for automobile brake tube

2. Classification

2.1 Type of pipe
The pipes shall be classified into the following 4 groups:

Table 1 Pipes for automobile tubing

TypeCodeExample of application
Brazed double wall low carbon steel tubingTDWTubing mainly for brakes
Welded low carbon steel tubingTSWTubing mainly for fuel and lubircation
Carbon steel tubes for machine structural purposesSTKM 11JTubing for cooling etc.
Copper and copper alloy seamless pipes and tubesC1201 or C1220Tubing mainly for air brakes

2.2 Classification of surface treatment
The pipes shall be classified as tabulated below, according to the types of surface treatment:

Table 2  Surface Treatment

Type
Without surface treatmentDipped tin-lead alloy coatingElectrolytic zinc coatingOrganic film on electrolytic zinc coating
8μm13μm25μm8μm13μm25μm
Brazed double wall low carbon steel tubingTDW-N-T-Z8-Z13-Z25-Z8-OC-Z13-OC-Z25-OC
Welded low carbon steel tubingTSW-N-T-Z8-Z13-Z25-Z8-OC-Z13-OC-Z25-OC
Carbon steel tubes for machine structural purposesSTKM 11J-N-T-Z8-Z13-Z25
Copper and copper alloy seamless pipes and tubesC1201 or C1220

3. Quality

3.1 Appearance
Both inside and outside of the finished tubing shall be smooth and free from cracks, flaws or rusts.

3.2 Chemical composition
Chemical composition of the tubing shall be pursuant to JIS G3141, JIS G3445, JIS G 3472, and JIS H 3300.

3.3 Mechanical property
Mechanical property of the pipes shall be pursuant to Table 3.

Table 3 Mechanical Property

Type Code Tensile strength MPa Yield point MPa Elongation % Hardness HV Bending expansion, flat bending
Brazed double wall low carbon steel tubing
TDWNot less than 294Not less than 176Not less than 25Not more than HV150Wall of the tubing shall be free from flaws or cracks after the tests pursuant to Table 10 are conducted
Welded low carbon steel tubingTSW
Carbon steel tubes for machine structural purposesSTKM 11JNot less than 294Not less than 30
Copper and copper alloy seamless pipes and tubesC1201 or C1220Not less than 206Not less than 40

3.4 Surface Treatment

(1) Thickness of surface treatment shall be pursuant to Table 4 and Table 5.

Table 4 Thickness of inside surface treatment

 Type CodeThickness of inside surface treatment
 Brazed double wall low carbon steel tubing TDW As is copper-coated for fusion process
  Welded low carbon steel tubing TSW Copper coating not less than 3μm
  Carbon steel tubes for machine structural purposes STKM 11J –
 Copper and copper alloy seamless pipes and tubes  C1201 or C1220 –

Table 5 Thickness of outside surface treatment

 TypeThickness of outside surface treatment
 Dipped tin-lead alloy coatingElectrolytic zinc coatingOrganic film on electrolytic zinc coating
 Z8Z13Z25Z8-OCZ13-OCZ25-OC
Brazed double wall low carton steel tubingAverage 6μm, minimum 3μmNot less than 8μmNot less than 13μmNot less than 25μmZinc coating not less than 8μmZinc coating not less than 13μmZinc coating not less than 25μm
Organic film average 20μm minimum 10μm
Welded low carbon steel tubing Zinc coating not less than 8μm Zinc coating not less than 13μm Zinc coating not less than 25μm
Organic film average 20μm minimum 10μm
Carbon steel tubes for machine structural purpose –
Copper and copper alloy seamless pipes and tubesNo treatment shall be required

(2) Corrosion resistance

The test shall be conducted pursuant to corrosion test specified in Table 10 and shall meet requirements in Table 6.

Table 6 Corrosion Resistance

 Type and code of coating Criteria
 Time elapsed till formation of white corrosion product (hr)Time elapsed till form rust (red rust) (hr)
 Electrolytic zinc coatingZ8 72 192
 Z13  72 288
 Z25  72 480
 Dipped tin-lead alloy coatingTIron rust (red rust) shall appear 5 spots or less per 50 cm2 in 24 hours.
Organic film on electrolytic zinc coatingZ8-OC2000
Z13-OC2500
Z25-OC3000

(3) Performance of organic film

Performance of organic film shall be pursuant to Table 6 and shall meet requirements in Table 7, after the tests pursuant to Table 10 are conducted as occasion demands.

Table 7 Performance of organic film

Test Items Criteria
 Bending testNo flaking, cracking, and wrinkles shall occur.
 Chipping testNo conspicuous flaking and cracking shall occur.
 Heat cycle testNo blisters and flaking shall occur.
 Warm water testNo blisters, flaking, cracking, and dissolution shall occur.
 Fluid resistance testNo blisters, flaking, cracking , and dissolution shall occur.
Ozone resistance testNo flaking and cracking shall occur.

3.5 Guarantee pressure and burst pressure

The pipes shall be tested pursuant to Table 10 and shall resist the guarantee pressure specified in Table 8 without leaving injurious deformation.

Table 8 Guarantee pressure and burst pressure

TypeCodeNominal diameterGuarantee pressure MPaBurst pressure MPa
Brazed double wall low carbon steel tubingTDW<4.76

6 and 6.35

8

10

34.3

34.3

24.5

24.5

108

83.3

66.2

53.9

Welded low carbon steel tubingTSW<6.35

8-10

11-15

16-22.2

24.5

19.3

14.7

9.8

Carbon steel tubes for machine structural purposesSTKM 11J
Copper and copper alloy seamless pipes and tubes C1201 or C1220Pursuant to JIS H 3300

Table 9 Nominal diameter and dimension

Nominal diameterOutside diameterThicknessTolerance
Standard dimensionToleranceStandard dimension
Brazed double wall low carbon steel tubingWelded low carbon steel tubingCarbon steel tubes for machine structural purposesCopper and copper alloy seamless tubes
3.173.17+/-0.080.70.70.08+/-0.08
44 0.7 0.7
4.764.76 0.7 0.7 0.08
66 0.7 0.7
6.356.35 0.7 0.7 0.8 0.08
88+/-0.1 0.7 0.7 0.8 1.0 0.7 0.8 1.0 1.0 +/-0.1
99 1.0 1.0
1010 0.7 0.7 0.8 1.0 0.7 0.8 1.0 1.0
1111 0.8 1.0
1212 0.9 1.0  0.9 1.0 1.0
12.712.7  0.9 1.0  0.9 1.0 1.0
1414 1.0 1.0
1515 1.0 1.0 1.0
1616 1.0 1.0 1.2
1717 1.0  1.0 1.2
1818  1.0 1.2 1.0
1919  1.0 1.2
2020  1.0 1.2 1.0
2121  1.0 1.2
2222  1.0 1.2 1.0
22.222.2  1.0 1.2

Table 10 Test Method

ItemType
Brazed double wall low carbon steel tubingWelded low carbon steel tubingCarbon steel tubes for machine structural purposeCopper and copper alloy seamless pipes and tubes
Tensile testPursuant to JIS Z2241 (Method of Tensile Test for Metallic Materials).
Bending testExample if any flaws, cracks, or other defects occurred or not when the pipe was bent 360 degrees around a cylinder having the radius as specified below.

Nominal diameterRadius (D is outside diameter of pipe
8mm or smaller1.5D
Over 8mm2.5D
Expansion test(1) Length of test specimen shall be 100 mm.

(2) Examine if any flaws and cracks occurred or not when a conic tool with 1/10 taper was plugged into one end of the specimen and the specimen was expanded until the diameter of end face was increased by 20%.

 (1) Length of test specimen shall be 100 mm.

(2) Examine if any flaws and cracks occurred or not when a conic tool with angle of 60 degrees was plugged into one end of the specimen and the specimen was expanded until the diameter of end face was increased by 20%.

Pursuant to JIS H 3300
Developing test (1) Length of test specimen shall be 100 mm.

(2) Example if any injurious defects such as cracks and flaking occurred to the weld or not when the test specimen is split longitudinally at 90 degrees on each side of the weld and developed to form a flat plate.

Flattening and bending test(1) Length of test specimen shall be 100 mm.

(2) Examine if any flaws and cracks occurred or not when the specimen is held between parallel plates, which are pressed in such a manner as the inside of tube comes to a close contact to make the specimen flat, and the flat specimen is once bent 90 degrees to the direction of axis around a cylinder having a diameter of 3 times the wall thickness of the tube and then stretched straight.

Flattening Test(1) Length of test specimen shall be 100 mm.

(2) Examine if any flaws and cracks occurred or not when the specimen is held between parallel plates, which are pressed in such a manner as the distance between the plates comes to 3 times the wall thickness of the tube. When the plates are pressed, the weld of tube shall be placed at 90 degrees to the direction of applied force.

Pursuant to JIS H 3300
Guarantee pressure testExamine if any leak of other defects occurred or not when pipe is applied with specified hydraulic pressure and held for 5 minutes. –
Burst pressure testPursuant to 5.10 specified in JASO M104.
Surface treatment thickness testThe standard practice shall be microscopic test.
Corrosion resistance testPursuant to 5.6, Neutral salt water spray test, specified in JASO M104.
Film performance testPursuant to 5. (test method) specified in JASO M104.
Hardness testPursuant to JIS Z2244 or JIS Z2251

4. Method of manufacturing

4.1 Method of manufacturing the brazed double wall low carbon steel pipes

The brazed double wall low carbon steel pipes shall be made by copper-coating both surfaces of SPCC specified in JIS G3141, shaping them into the form of double wall tubing, and sealing the seams by copper brazing and fusion in a reduction furnace.

4.2 Method of manufacturing the welded low carbon steel pipes

The welded low carbon steel pipes shall be made by copper coating both surfaces or inner surface of SPCC specified in JIS G 3141, shaping them into a tubular form, and sealing the edges by electric resistance welding, however inside surface, may not be copper coated if mutually agreed upon by the purchaser and the manufacturer.

4.3 Method of manufacturing the carbon steel pipes for machine structural purposes

Manufacturing of carbon steel tubes for machine structural purposes shall be pursuant to JIS G 3445 and JIS G3472.

4.4 Method of the copper and copper alloy seamless pipe and tubes

Manufacture of copper and copper alloy seamless pipes and tubes shall be pursuant to JIS H3300.

5 Dimension of pipes

5.1 Nominal diameter and dimension of pipe

Nominal diameter and and dimension of pipe shall be pursuant to Table 9.

5.2 Shape of pipe end

Formed pipe end shall be pursuant to Attached Tables 1-8.

6. Test method

Test method shall be pursuant to Table 10.

7. Inspection

7.1 Inspection of appearance

Inspection results shall meet requirements specified in the above 3.1.

7.2 Inspection of mechanical properties

Inspection shall be conducted pursuant to the above 6 and the results shall meet requirements specified in the above 4.3.

7.3 Inspection of dimensions

Inspection results shall meet requirements specified in the above 5.

7.4 Inspection of surface treatment

Inspection shall be conducted by the above 6 and the results shall meet requirements specified in the above 3.4.

7.5 Inspection of guarantee pressure

Inspection results shall meet requirements specified in the above 6.

8. Designation of product

Designation of products shall be pursuant to the standard number, type of tubing, and type and nominal diameter of outside surface.

 

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