Standard Specification for Carbon Steel Wire for Wire Rope 1

Transcription

1 Designation: A Standard Specification for Carbon Steel Wire for Wire Rope 1 This standard is issued under the fixed designation A 1007; the nuber iediately following the designation indicates the year of original adoption or, in the case of revision, the year of last revision. A nuber in parentheses indicates the year of last reapproval. A superscript epsilon (e) indicates an editorial change since the last revision or reapproval. 1. Scope* 1.1 This specification covers uncoated and four classes of round, etallic coated, cold-drawn, carbon steel wire for wire rope in five strength levels. This specification specifies: Diensional tolerances, Mechanical characteristics, Cheical coposition requireents, Coating requireents (if applicable), and Packaging requireents. 1.2 The values stated for etric equivalents are provided for inforational purposes only. 2. Referenced Docuents 2.1 This specification incorporates, by dated or undated reference, provisions fro other publications. These norative references are cited at their appropriate place in the text and the publications are listed. For dated references, subsequent aendents to or revisions of any of these publications apply to this specification only when incorporated in it by aendent or revision. For undated references, the latest edition of the publication referred to would apply. 2.2 ASTM Standards: 2 A 90/A 90M Test Method for Weight [Mass] of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings A 510 Specification for General Requireents for Wire Rods and Coarse Round Wire, Carbon Steel A 938 Test Method for Torsion Testing of Wire B 6 Specification for Zinc B 750 Specification for GALFAN (Zinc-5 % Aluinu- Mischetal) Alloy in Ingot For for Hot-Dip Coatings E 8 Test Methods for Tension Testing of Metallic Materials IEEE/ASTM-SI-10 Standard for Use of the International Syste of Units (SI): The Modern Metric Syste 2.3 ISO/EN Standards: 3 1 This specification is under the jurisdiction of ASTM Coittee A01 on Steel, Stainless Steel and Related Alloys and is the direct responsibility of Subcoittee A01.03 on Steel Rod and Wire. Current edition approved Sept. 1, Published Septeber Originally approved in Last previous edition approved in 2002 as A For referenced ASTM standards, visit the ASTM website, or contact ASTM Custoer Service at service@ast.org. For Annual Book of ASTM Standards volue inforation, refer to the standard s Docuent Suary page on the ASTM website. 3 Available fro Aerican National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036, EN Steel Wire and Wire Products Steel Wire for Wire Rope 2.4 Industry Standard: API 9A Specification for Wire Rope Industry References: 5 AIME/ISS Carbon Steel, Wire and Rods AIAG Priary Metals Identification Tag Application Non-Referenced Industry Applicable Standard: ISO Std Drawn Wire for General Purpose Non-Alloy Steel Wire Ropes 3 3. Terinology 3.1 Definitions: actual diaeter the arithetic ean of the iniu and axiu diaeter easureents in one location on the wire breaking force level (Levels 1,2,3,4 or 5) a wire strength based on the iniu load carrying capability of a designated wire drawn-galvanized a zinc coating that is applied to the wire prior to the final cold drawing operation by either an electro-deposition or hot-galvanizing process drawn-zn5 Al-MM a zinc-aluinu alloy (ischetal) coating that is applied to the wire prior to the final cold drawing operation by a olten coating process final-coated Zn5 Al-MM a zinc-aluinu alloy (isch-etal) coating that is applied to the wire after the final cold drawing operation by a olten coating process final-galvanized a zinc coating that is applied to the wire after the final cold drawing operation by either an electro-deposition or hot-galvanizing process noinal diaeter the diaeter of the wire expressed in inches (illietres) and specified by the user to designate the wire size. It is the basis for the deterination of the values of all characteristics of the wire for acceptance purposes ovality the arithetic difference between the axiu diaeter and the iniu diaeter in one location on the wire; it shall not be greater than half the tolerance specified in the respective tables referred to in the following parts of this specification. 4 Available fro Aerican Petroleu Institute (API), 1220 L. St., NW, Washington, DC , 5 Available fro Autootive Industry Action Group (AIAG), Lahser Rd., Suite 200, Southfield, MI 48033, *A Suary of Changes section appears at the end of this standard. Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA , United States. 1

2 A uncoated wire the surface of a wire furnished with a residual lube fil as a result of cold-drawing said wire. 4. Ordering Inforation 4.1 It is the responsibility of the purchaser to specify all requireents that are necessary for aterial ordered under this specification. Such requireents shall include, but are not liited to the following: Quantity (ass), Nae of aterial (drawn steel wire for wire rope), Wire type (uncoated, drawn- or final-galvanized/zn5 Al- coated), Wire diaeter, Wire strength grade (Level 1 through 5), Packaging (Section 15), Cast or heat analysis; if requested, Certification or test report; if requested, and ASTM designation and date of issue. 5. Materials and Manufacture 5.1 The base etal rod used in the anufacture of rope wire shall be rolled fro good coercial quality steel. The steel ay be either ingot cast or strand cast. 5.2 A sufficient discard shall be ade to ensure freedo fro detriental piping and undue segregation. 5.3 The wire shall be cold-drawn to produce the desired properties. 5.4 The wire shall be furnished in one of five types, as specified: Uncoated, Drawn-galvanized, Final-galvanized, Drawn Zn5/Al-MM, and Final coated Zn5/Al-MM. 5.5 Uncoated, drawn-galvanized and drawn-zn5 Al-MM wire can be furnished in Levels 1 through 5. Final-galvanized and final-coated Zn5 Al-MM wire is usually furnished in Levels 1 through The ethod utilized in the production of either drawnor final-galvanized wire types ay be by an electro-deposition or hot-dip galvanizing process at the option of the producer The slab zinc used in galvanized zinc coatings shall be as specified in Specification B The ethod utilized in the production of Zn5 Al-MM wire types ay be either a continuous hot-dip alloy coating or two step coating where the first coating is zinc followed by a final bath having an aluinu content up to 7.2 % to prevent depletion of the aluinu content of the bath The bath etal used in continuous hot-dip Zn-5 Al-MM alloy coating shall eet the cheical coposition liits specified in Specification B Cheical Coposition 6.1 Upon agreeent with the purchaser, the wire anufacturer shall apply a steel of suitable cheical coposition that will satisfy the properties of the aterial ordered. 6.2 A quantitative analysis of each cast or heat shall be ade by the steel producer or his representative to deterine the percentage of the eleents specified. The analysis shall be ade fro a test saple preferably taken during the pouring of the cast or heat. The cheical coposition thus deterined shall be reported, if required, to the purchaser or his representative. 6.3 An analysis ay be ade by the purchaser fro the finished wire. The cheical coposition thus deterined as to the eleents required shall confor to the product analysis requireents specified in Table 3 of Specification A 510 or as agreed upon between the purchaser and the anufacturer. 7. Wire Diaeter 7.1 The wire shall be easured using a icroeter with an iniu accuracy of in. (0.002 ) for all diaeters. 7.2 All diaeter values easured in one location along the wire shall be within the tolerance liits given in Table 1 for uncoated and drawn-galvanized or drawn-zn5 Al-MM rope wire or Table 2 for final-galvanized or final-coated Zn5 Al-MM rope wire. 8. Tensile Properties 8.1 Tensile Test Procedure: Standard Testing Method The tensile test shall be carried out in accordance with Test Methods E8. The distance between the grips of the testing achine shall not be less than 8 in. (203 ). The speed of the ovable head of the testing achine, under no load, shall not exceed 1 in./in (0.4 /s). Any specien breaking within 1 in. (25.4 ) of the jaws ay be disregarded and a retest perfored Alternate Testing Method The tensile test shall be carried out in accordance with Test Methods E8. The loading rate ay be greater than that specified, depending on the nuber of tests to be carried out for the batch inspection. However, it shall not exceed the rate corresponding to a 25 % elongation between anchorages in 1 in. The iniu distance between the claping jaws of the test achine is 4 in. (100 ). In the event of a dispute, the tensile test shall be TABLE 1 Wire Diaeter Tolerances Uncoated and Drawn-Galvanized or Zn5 Al-MM Rope Wire Diaeter Range, in. Diaeter Range, Tolerance, in. Tolerance, Minus Plus Minus Plus to incl to 0.64 incl Over to incl. Over 0.64 to 1.50 incl Over to incl. Over 1.50 to 2.36 incl Over to incl. Over 2.36 to 3.61 incl Over to incl. Over 3.61 to 5.08 incl Over to.250 incl. Over 5.08 to 6.35 incl

3 A TABLE 2 Wire Diaeter Tolerances Final-Galvanized or Final-Coated Zn5 Al-MM Rope Wire Diaeter Range, in. Diaeter Range, Tolerance, in. Tolerance, Minus Plus Minus Plus to incl to 1.55 incl Over to incl. Over 1.55 to 2.01 incl Over to incl. Over 2.01 to 2.34 incl Over to incl. Over 2.34 to 2.62 incl Over to incl. Over 2.62 to 3.02 incl Over to incl. Over 3.02 to 3.61 incl Over to incl. Over 3.61 to 4.75 incl Over Over carried out strictly in accordance with Test Methods E 8,in particular with regard to the loading rate The iniu breaking forces are specified in Table 3 of this specification, for wire grade Levels 1 through 5. The range in breaking force for a given grade level is based on the calculated iniu tensile strength requireent (psi). While no axiu values are shown for breaking force, rope wire is generally produced to a tensile strength range of psi. The resultant iniu breaking force of either uncoated, drawn-galvanized, and drawn-zn5 Al-MM wires of various levels shall eet or exceed the values shown in Table 3. The resultant iniu breaking force for final-galvanized or final-coated Zn5 Al-MM wire is obtained by reducing the value stated for its level in Table 3 for uncoated wire by 10 %. TABLE 3 Miniu Breaking Forces Wire Diaeter Miniu Torsional Values (Nuber of Twists in 8 in.) Miniu Breaking Force A in. Level 1 Level 2 Level 3 Level 4 Level 5 Level 1 Level 2 Level 3 Level 4 Level 5 lbf N lbf N lbf N lbf N lbf N

4 TABLE 3 A Continued Wire Diaeter Miniu Torsional Values (Nuber of Twists in 8 in.) Miniu Breaking Force A in. Level 1 Level 2 Level 3 Level 4 Level 5 Level 1 Level 2 Level 3 Level 4 Level 5 lbf N lbf N lbf N lbf N lbf N

5 TABLE 3 A Continued Wire Diaeter Miniu Torsional Values (Nuber of Twists in 8 in.) Miniu Breaking Force A in. Level 1 Level 2 Level 3 Level 4 Level 5 Level 1 Level 2 Level 3 Level 4 Level 5 lbf N lbf N lbf N lbf N lbf N

6 TABLE 3 Continued Wire Diaeter Miniu Torsional Values (Nuber of Twists in 8 in.) Miniu Breaking Force A in. Level 1 Level 2 Level 3 Level 4 Level 5 Level 1 Level 2 Level 3 Level 4 Level 5 lbf N lbf N lbf N lbf N lbf N A 1 lbf = N. A Torsional Properties 9.1 Torsion Test The torsion test shall be conducted in accordance with Test Method A 938 with the following odifications. The standard distance between the jaws of the testing achine is in. ( ). In order to save tie during tests, the distance between the jaws of the testing achine ay be shortened to as sall as 100 wire diaeters (less than 8 in. (203 )). One end of the wire is to be rotated with respect to the other end at a unifor speed, not to exceed sixty 360 (6.28 rad) revolutions per inute, until breakage occurs. The achine ust be equipped with an autoatic counter to record the nuber of revolutions (twists) causing breakage. One jaw shall be fixed axially and the other jaw ovable axially and arranged for applying tension weights to 6

7 A wire under test. Tests in which breakage occurs within 1 8 in. (3.18 ) of the jaw ay be disregarded. 9.2 Torsional Response Values The iniu nuber of twists for bright (uncoated) or drawn galvanized wire of the grades and sizes listed in Table 3 shall be the nuber of 360 (6.28 rad) revolutions in an 8-in. (203 ) length that the wire ust withstand before breakage occurs. When the distance between the jaws of the testing achine is different than 8 in. (203-), as peritted by 9.1, the iniu nuber of twists shall be adjusted in direct proportion to the change in jaw spacing as deterined by the following forula: T A 5 ~T L 3 L D! L L (1) T A = iniu nuber of twists for the adjusted spacing, T L = iniu nuber of twists for 8 in. (203 ) jaw spacing for size and grade. L D = distance between testing achine jaws for adjusted spacing, inches (). L L = 8 in. (203 ). Torsion testing of final-galvanized or final coated Zn5 Al-MM rope wire is not required but can be produced to the torsional requireents of Table 3 for uncoated rope wire, subject to the following reduced values. Wire over in. Wire in. Wire in. 30 % of Table 3 iniu 40 % of Table 3 iniu 50 % of Table 3 iniu 9.3 Torsion Test Loading During the torsion test, load as shown in Table 4 shall be applied to the wire being tested. 10. Wrap Testing 10.1 All etallic coated wire produced to this specification ust eet a wrap test as a easure of steel ductility. The wrapping ay be done by any hand or power device that will coil the wire in a closely wound helix about a andrel equal to twice the noinal diaeter of the aterial being tested for six coplete turns without wire fracture All etallic coated wire produced to this specification ust eet a wrap test as a easure of coating adherence. The wrapping ay be done by any hand or power device that will coil the wire in a closed helix about a andrel for six coplete turns without the coating of the wire flaking or cracking. The andrel diaeter for drawn coatings (either galvanized or ischetal) is as listed in Table 5. The andrel for finalgalvanized wire and final-coated ZN5/AL-MM is as listed in Table Metallic Coatings for Rope Wire 11.1 Drawn-galvanized and drawn-zn5 Al-MM rope wire shall be ade having a tightly adherent, unifor, and continuous coating. The iniu weight of zinc or zinc-alloy coating tested in accordance with Specification A 90/A 90M shall be as specified in Table 5. The andrel diaeter shall be as specified in Table Final-galvanized and final-coated Zn5 Al-MM rope wire shall be ade having a tightly adherent, unifor and continuous coating. The iniu weight of zinc or zinc-alloy coating tested in accordance with Specification A 90/A 90M TABLE 4 Applied Load for Torsion Testing Applied Load Diaeter of Wire Pounds Force (lbf) Newtons (N) Inches Miniu Maxiu Miniu Maxiu Up to Up to Over to Over 0.25 to Over to Over 0.41 to Over to Over 0.51 to Over to Over 0.76 to Over to Over 1.02 to Over to Over 1.28 to Over to Over 1.53 to Over to Over 1.79 to Over to Over 2.04 to Over to Over 2.30 to Over to Over 2.55 to Over to Over 2.80 to Over to Over 3.06 to Over to Over 3.31 to Over to Over 3.57 to Over to Over 3.82 to Over to Over 4.07 to Over to Over 4.33 to Over to Over 4.58 to Over to Over 4.84 to Over to Over 5.09 to Over to Over 5.34 to Over to Over 5.60 to Over to Over 5.85 to Over to Over 6.10 to

8 A TABLE 5 Weight of Coating-Mandrel Diaeter Drawn-Galvanized or Drawn Zn5 Al-MM Rope Wire in. Diaeter of Wire Adherence Test Miniu Weight of Coating Mandrel Diaeter A oz/ft 2 kg/ to to D to to D to to D to to D to to D A Where: D = noinal diaeter of wire being tested. TABLE 6 Weight of Coating-Mandrel Diaeter Final-Galvanized or Final Coated Zn5 Al-MM Rope Wire in. Diaeter of Wire Adherence Test Miniu Weight of Coating Mandrel Diaeter A oz/ft 2 kg/ to to D to to D to to D to to D to to D to to D and larger 4.90 and larger 3D A Where: D = noinal diaeter of wire being tested. shall be as specified in Table 6. The andrel diaeter shall be as specified in Table Workanship, Finish and Appearance 12.1 The surface of the wire shall be free fro rust and excessive scale. The wire surface shall be sooth and free fro detriental discontinuities such as seas, pits, and die arks Each coil or spool of wire shall be one continuous length properly coiled and firly tied. 13. Sapling 13.1 Material testing shall be carried out by the supplier in accordance with a ethod approved by the purchaser. The nuber of test speciens taken fro the end of a given package vary with the quality control procedures and the facilities of each anufacturer, but is generally not less than 10 % of the coils produced The purchaser ay elect to have incoing acceptance testing perfored. To ensure representative sapling, the saples shall be taken at rando fro the coil or spool ends. 14. Retesting 14.1 If non-coplying results are obtained, the purchaser ay reject the entire lot, reclassify the aterial or perfor further testing to establish aterial acceptability. This additional testing shall be based solely on the non-coplying characteristic. 15. Package Marking 15.1 The coil or spool ass, diensions, and protective covering shall be agreed upon between the anufacturer and purchaser The wire size, purchaser order nuber, ASTM specification nuber, heat nuber and anufacturer identification shall be on a tag securely attached to each package Bar coding of each package is acceptable as a suppleentary identification ethod on the wire identification tag. If bar coding is used, the coding shall be consistent with the AIAG Standard 02.00, Priary Metals Identification Tag Application. 16. Keywords 16.1 etallic coated; rope; wire APPENDIXES (Nonandatory Inforation) X1. IMPERIAL (ENGLISH) WIRE MATERIALS (IN ACCORDANCE WITH CRITERIA SET FORTH IN EN ) X1.1 Definitions of Ters Relating to Sapling and Acceptance: X1.1.1 batch a defined quantity of wire of the sae diaeter, the sae grade, and the sae finish presented for inspection and anufactured in conditions assued to be identical and unifor. X1.1.2 unit (wire package) A variable or fixed quantity supplied in a: X coil of a single length or ass of wire, or X bobbin (reel) A single length or ass of wire wound on a reel, spool or bobbin, or X flat coil (spooless core) A single length or ass of wire wound on a cardboard center dru, or X other wire packaging as agreed between supplier and purchaser. X1.1.3 base unit for sapling ( 1 ) a ass expressed in pounds (lb) conventionally with a value equal to 100d, where d is the diaeter of the wire expressed in inches. X1.1.4 size of batch (N): nuber given by the following forula: (X1.1) 3 1 = batch ass, tons, and 1 = base unit ass, lb. Knowing that conventionally: d d = noinal wire diaeter, in., (X1.2) 8

9 A it follows that: or: d d (X1.3) (X1.4) X1.1.5 saple for testing a sufficient length of wire for easureent of an individual characteristic. X1.1.6 sapling length a sufficient length of wire to produce the necessary saples for testing all characteristics. X1.1.7 sapling taking all necessary saples to supply inforation on the batch. X1.1.8 saple size, n nuber of saples for tests. X1.1.9 non-conforance result of a test not coplying with the requireents for a characteristic. X1.2 Definitions of Ters Relating to Sapling and Acceptance: X1.2.1 batch a defined quantity of wire of the sae diaeter, the sae grade, and the sae finish presented for inspection and anufactured in conditions assued to be identical and unifor. X1.2.2 unit (wire package) a variable or fixed quantity supplied in a: X coil of a single length or ass of wire, or X bobbin (reel) A single length or ass of wire wound on a reel, spool or bobbin, or X flat coil (spooless core) A single length or ass of wire wound on a cardboard center dru, or X other wire packaging as agreed between supplier and purchaser. X1.2.3 base unit for sapling ( 1 ) a ass expressed in (kilogras) conventionally with a value equal to 100d, where d is the diaeter of the wire expressed in (illietres). X1.2.4 size of batch (N) nuber given by the forula: = batch ass, tonnes, and 1 = base unit ass, kg. Knowing that conventionally: d d = noinal wire diaeter (), it follows that: d or: 10 3 (X1.5) d (X1.6) (X1.7) (X1.8) X1.2.5 saple for testing a sufficient length of wire for easureent of an individual characteristic. X1.2.6 sapling length a sufficient length of wire to produce the necessary saples for testing all characteristics. X1.2.7 sapling taking all necessary saples to supply inforation on the batch. X1.2.8 saple size, n nuber of saples for tests. X1.2.9 non-conforance result of a test not coplying with the requireents for a characteristic. X2. METRIC WIRE MATERIALS (IN ACCORDANCE WITH CRITERIA SET FORTH IN en ) X2.1 Definition of Ters Relating to Sapling and Acceptance: X2.1.1 batch a defined quantity of wire of the sae diaeter, the sae grade, and the sae finish presented for inspection and anufactured in conditions assued to be identical and unifor. X2.1.2 unit (wire package) a variable or fixed quanity supplied in a: X coil of a single length or ass of wire, or X bobbin (reel) a single length or ass of wire wound on a reel, spool or bobbin, or X flat coil (spooless core) a single length or ass of wire wound on a cardboard center dru, or X other wire packaging as agreed between supplier and purchaser. X2.1.3 base unit for sapling ( 1 ) a ass expressed in (kilogras) conventionally with a value equal to 100 d, where d is the diaeter of the wire expressed in (illietres). X2.1.4 size of batch (N): nuber given by the forula: (X2.1) 3 1 = batch ass, tonnes, and 1 = base unit ass, kg. Knowing that conventionally: d d = noinal wire diaeter,, it follows that: d or: 10 d (X2.2) (X2.3) (X2.4) X2.1.5 saple for testing a sufficient length of wire for easureent of an individual characteristic. X2.1.6 sapling length a sufficient length of wire to produce the necessary saples for testing all characteristics. X2.1.7 sapling taking all necessary saples to supply inforation on the batch. X2.1.8 saple size, n, nuber of saples for tests. 9

10 X2.1.9 non-conforance result of a test not coplying with the requireents for a characteristic. A SUMMARY OF CHANGES Coittee A01 has identified the location of selected changes to this standard since the last issue (A ) that ay ipact the use of this standard. (Approved Sept. 1, 2007.) (1) Corrected errors in Table 3. (2) Revised Table 4 to show ax/in values and etric values. ASTM International takes no position respecting the validity of any patent rights asserted in connection with any ite entioned in this standard. Users of this standard are expressly advised that deterination of the validity of any such patent rights, and the risk of infringeent of such rights, are entirely their own responsibility. This standard is subject to revision at any tie by the responsible technical coittee and ust be reviewed every five years and if not revised, either reapproved or withdrawn. Your coents are invited either for revision of this standard or for additional standards and should be addressed to ASTM International Headquarters. Your coents will receive careful consideration at a eeting of the responsible technical coittee, which you ay attend. If you feel that your coents have not received a fair hearing you should ake your views known to the ASTM Coittee on Standards, at the address shown below. This standard is copyrighted by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA , United States. Individual reprints (single or ultiple copies) of this standard ay be obtained by contacting ASTM at the above address or at (phone), (fax), or service@ast.org (e-ail); or through the ASTM website ( 10