Mercedes-Benz DBL 4023

Company Standard Date published: 2012-08

Supersedes: DBL 4023: 2012-03

Total no. of pages: 7
Person in charge: Karl-Heinz Mayer
Plant 010; Dept.: PWT/VWO
Date of translation: 2012-12 Phone: 0049-711-17-57459

Free-Cutting Steel

Foreword

This DBL describes the supply specifications for parts and components manufactured from free-
cutting steel.

Changes
In comparison with edition 2012-03, the following changes have been made:

- Product versions .10 to .24 introduced for materials in accordance with DIN EN 10277-3
- Updating of normative references

NOTE: This translation is for information purposes only.

The German version shall prevail above all others.

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Contents
1 Scope......................................................................................................................................................2
2 Normative references .............................................................................................................................3
3 Terms and definitions .............................................................................................................................3
4 General requirements .............................................................................................................................3
5 Abbreviated material designation for documentation .............................................................................3
6 General properties of the materials, raw materials and supply condition ..............................................3
7 Technical data ........................................................................................................................................4
7.1 Chemical composition ........................................................................................................................4
7.2 Strength ..............................................................................................................................................4
8 Tests .......................................................................................................................................................5
9 Deliveries ................................................................................................................................................6
10 Marking ...............................................................................................................................................6
11 Packaging ...........................................................................................................................................6
Annex A (informative) Overview of product versions with status NFN ...........................................................7

Table 1 Product versions, overview

Product version Material designation Material Application examples

number
.01 ETG88 Drive shafts, armature shafts, through-
shafts
.02 ETG100 See ETG 88
.03 HSX110 Tensioning nuts, e.g. common rail
.04 HSX130 Injector holders
.05 HSX Z12 High-strength pump shafts
.10 11SMn30 1.0715 Shafts, union nuts
.11 11SMnPb30 1.0718 Shafts, union nuts
.12 10S20 1.0721 Shafts, union nuts
.13 10SPb20 1.0722 Shafts, union nuts
.14 15SMn13 1.0725 Shafts, union nuts
.15 35S20 1.0726 Shafts, union nuts
.16 35SPb20 1.0756 Shafts, union nuts
.17 36SMn14 1.0764 Shafts, union nuts
.18 36SMnPb14 1.0765 Shafts, union nuts
.19 38SMn28 1.0760 Shafts, union nuts
.20 38SMnPb28 1.0761 Shafts, union nuts
.21 44SMn28 1.0762 Shafts, union nuts
.22 44SMnPb28 1.0763 Shafts, union nuts
.23 46S20 1.0727 Shafts, union nuts
.24 46SPb20 1.0757 Shafts, union nuts

1 Scope
Parts conforming to this Supply Specification are intensively machined turned parts; materials conform-
ing to this Supply Specification are semi-finished products for such turned parts.

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2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments) applies.

DIN EN 10277-3 Bright Steel Products – Technical Delivery Conditions – Part 3: Free-Cutting
Steels
DIN EN 10278 Dimensions and Tolerances of Bright Steel Products
DIN EN 10204 Metallic Products – Types of Inspection Documents
ISO 18265 Metallic Materials – Conversion of Hardness Values
DBL 8585 General Requirements – Environmental Protection, Hazardous Substances,
Dangerous Goods – Negative Substance List
MBN 10300 Standard Designation of Materials for Technical Documentation
MBN 10456 Surface Crack Testing

3 Terms and definitions

Oe: Oerstedt (unit of magnetic field strength)

4 General requirements
For safety requirements, homologation (in particular, exhaust emissions) and quality, the existing statu-
tory requirements and laws shall be complied with. In addition, the relevant requirements of the Daimler
Group apply.

All materials, procedures, processes, components, and systems shall conform to the current regulatory
(governmental) requirements regarding regulated substances and recyclability. The Negative Substance
List DBL 8585 shall be observed.

5 Abbreviated material designation for documentation

e.g. Steel ETG 88 + DBL 4023.01
e.g. Steel EN 10277-3 36SMnPb14 -1.0765 +DBL4023.xx

6 General properties of the materials, raw materials and supply condition

6.1 Materials

In accordance with EN 10277-3 (with the exception of 1.0736 (11SMn37) and 1.0737 (11SMnPb37))
and ETG 88 and ETG 100, HSX 110, HSX 130 and HSX Z12 (for chemical-physical data, refer to Sec-
tions 7.1 and 7.2)
These special materials manufactured by a special drawing process (WK) may only be used following
consultation with Process and Materials Engineering (PWT) or the Materials Testing Department of the
receiving plant.

Particular attention shall be paid to the following points:

- The maximum possible melt charges shall be produced and processed in the interest of uniformity
of supplies.

- Compliance with the requirements for the parts shall be ensured by selecting suitable feed stock
surfaces and by performing adequate tests for core defects.

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6.2 Supply condition

Ready-to-install parts: conforming to drawing and order specifications

Semi-finished products

The surface of the bars supplied shall not display any closed lap, scale or cracks. Any drawing scores
present are only permitted on material in accordance with DIN EN 10278 h11 and shall be within the di-
mensional tolerance. Minor compressions resulting from sawing or shearing are permitted up to a maxi-
mum length of half the bar diameter and shall not impair the insertion of the bars into the automatic pro-
cessing machines.

6.3 Dimensions and tolerances / Form of supply

6.3.1 As-supplied shape

Ready-to-install parts as well as bars, sections and tubes as semi-finished products.

6.3.2 Dimensions and tolerances

Ready-to-install parts conforming to drawing and order specifications.

Bars and sections in fixed lengths in accordance with order.

The tolerances specified in DIN EN 10278 and the information contained in the order shall apply. The
bars shall be sufficiently straight to ensure proper running in automatic processing.

7 Technical data

7.1 Chemical composition

ETG88/ ETG100 HSX110 HSX130/ HSX Z12

Carbon 0,42 – 0,48 0,38 – 0,40 0,16 – 0,20
Manganese 1,35 – 1,65 1,30 – 1,45 1,55 – 1,65
Silicon 0,10 – 0,30 0,70 – 0,80 1,15 – 1,25
Phosphorus < 0,040 < 0,040 < 0,040
Sulfur 0,24 – 0,35 0,025 – 0,040 0,12 – 0,17
Chromium - max. 0,15 1,15 – 1,25
Molybdenum - max. 0,040 0,30 – 0,35
Others - V 0,08 - 0,12 -
Ti max. 0,015
The steels shall be cast fully killed.
Aluminum additive is permitted.

7.2 Strength

7.2.1 Strength values

Material Dimensions Tensile Yield Elongation Notch im- Hardness

Thickness mm strength stress at rupture A5 pact energy HB
from to N/mm² N/mm² % min. Av in J at
RT
ETG88 5 120 800 - 950 > 685 7 approx. 15 235 – 285
ETG100 8 70 960 - 1100 > 865 6 approx. 10 280 – 330
HSX110 17 45 1050 - 1200 > 950 8 approx. 15 305 – 360
HSX130 17 50 1250 - 1400 > 1200 6 approx. 20 365 - 420
HSX Z12 18 50 950 - 1150 > 800 12 approx. 40 280 - 340

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7.2.2 Transverse strain

For steels 10S20 ( 1.0721 ), 10SPb20 ( 1.0722 ), 11SMn30 ( 1.0715 ) and 11SMnPb30 ( 1.0718 ) –
all in accordance with DIN EN 10277-3 - a transverse strain of at least 5 % shall be ensured in the
expansion test (refer to Section below) in treatment conditions turned, +CA and +CN.
The test result is the mean value of three tests of which none shall provide a value of less than 3%.

For grades 11SMn30, 11SMnPb30 and 10S20, an average transverse toughness value of 3 % with a
minimum value of 2 % shall be achieved also in cold-worked condition within the dimension range of
16 mm to 100 mm.

The transverse strain requirement of > 3% in the expansion test shall be fulfilled by steels ETG 88 to
25 mm, ETG 100 to 20 mm, HSX 110 to 45 mm, HSX Z12 to 50 mm and HSX 130 to 20 mm.
In the case of dimensions above these values, these requirements are not fulfilled by ETG 88, ETG
100 and HSX 130. Transverse strain values of less than 2% will be reached.

7.3 Expansion test

The expansion test for determining transverse strain shall be conducted on crack-free test pieces with
a height of 0,5 D (diameter or width across flats of the products). The hole diameter shall be 0,6 D.
Widen the specimens with a well-oiled cone 1 : 100 whereby the test speed shall correspond to the
tensile testing speed. The specified values shall be reached without the test piece breaking.

7.4 Microstructure

Manganese sulfides shall be distributed uniformly. The shape, size and distribution of nonmetallic in-
clusions (in particular manganese sulfide MnS) and the primary segregation shall not impair the heat
treatment results and further processing of the components. Required grain size KG 5 and finer.

8 Tests
8.1 Hardness test

Compliance with the strength values according to 4.2.1 shall be verified by means of hardness testing
on a lot and random sample basis. For tolerance fields, refer to EN 10277-3 and Table 7.2.1, hard-
ness conversion in accordance with ISO 18265, Tab A1.

8.2 Transverse toughness test

The transverse toughness test shall be conducted for each melt charge by means of the expansion
test according to 7.3. If drawing conditions within a melt charge vary significantly, the test shall be
conducted subdivided according to drawing lots.

8.3 Crack testing

Ready-to-install parts: shall be technically free of cracks in accordance with MBN 10456.

Semi-finished products:
"Crack test quality" means the use of 100% crack-tested semi-finished material. The semi-finished
material shall be technically crack free in accordance with MBN 10456. The residual magnetism in
the tested semi-finished products or the tested parts shall not exceed 400 A/m corresponding to 5 0e
at the pole ends.

8.4 Ultrasonic testing of semi-finished products

In order to ensure freedom from core defects, ultrasonic testing shall be carried out as standard with
adequate test severity and counterchecking by means of reference and practical samples.

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8.5 Test for mixed-up material in semi-finished product

Before delivery a suitable inspection for mixed-up materials shall be performed to ensure that no in-
correct steel grades are included in the delivery.

9 Deliveries
In particular, the results of the tests on the blanks shall be documented in a test report before delivery.
In accordance with the agreements with the Materials Testing Department of the receiving plant, this test
report 3.1 in accordance with DIN EN 10204 shall accompany the delivery or be submitted on request.
The test report shall indicate the following information:

a) Supplying plant
b) Melting and casting process as well as batch number of the supplied material
c) Tests carried out in accordance with Section 4
d) Results of any tests agreed separately with the Materials Testing Department of the receiving plant.

10 Marking
In addition, in the case of semi-finished products, all bars of dia. 40 mm or more shall be stamped with the
material designation, batch number and manufacturer's symbol or identified by means of a label. No
stamp shall be affixed to the jackets of the bars. For smaller dimensions, the appropriately bundled bars
shall be provided with a suitably marked tag. The bars shall not be marked with paint.

11 Packaging
In addition, in the case of semi-finished products, each delivery within certain dimensions should be from a
single melt wherever possible. The admissible bundle weights differ depending on the plant and unloading
point and are therefore stipulated on the order. The bars shall be packaged in such a way that they lie
flush on one side. On one side, at least, the bars shall be cut to length in accordance with the contour.

The bundles shall be packaged so that any shifting of the bars in the bundle during transport is avoided.

Any undersized lengths shall be packed separately. Admissible lengths and volumes shall be agreed with
the Materials Testing Department of the receiving plant.

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Annex A (informative)
Overview of product versions with status NFN
Product version Material designation Application examples
DBL 4023.00 e.g. Steel EN 10277 – 1.0718 (11SMnPb 30)+C+
DBL4023.10

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