ARMY 12472301 REV A-2008 Ground Combat Vehicle Welding Code - Aluminum.pdf

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1、19207-12472301 Revision A Page 1 of 123 Revisions LTR Description Date(YY-MM-DD) Approved - Initial Release Direct ERR FOM U5152 01-08-08 T. A. Higgins A Direct ERR FOM U8332 Incorporated ADCN 157518 03-04-30 T. A. HigginsAcknowledgment Design Activity U.S. Army Tank-Automotive and Armaments Command

2、 Warren, Michigan 48397-6000 This code is based on commercial and military specifications; primarily ANSI/AWS B2.1, ANSI/AWS D1.2, MIL-STD 1946 and MIL-STD 372. This document was prepared by a team from United Defense, L.P., Ground Systems Division (UDLP) and the U.S. Armys Tank-Automotive Armament

3、Research, Development and Engineering Center (TARDEC). Design Approval T. A. Higgins Ground Combat Vehicle Welding Code - Aluminum Drawn Date Drawing Approval Size Cage Code Richard J. Rush 01/03/08 Tom Altobelli A 19207 12472301 Provided by IHSNot for ResaleNo reproduction or networking permitted w

4、ithout license from IHS-,-,-19207-12472301 Revision A Page 2 of 123 IMPORTANT This document contains “hot links” that will allow quick searches and access to information. The mouse pointer is a “grabber hand” in this document. It changes to a pointing finger whenever you scan over a word or phrase t

5、hat is linked to text, a figure, or a table somewhere else in this document. Notice, as you scan over a page the pointer will change back and forth between the grabber hand and the pointing finger. Click the mouse to move to the linked site. In addition, the hot links are blue. After you have jumped

6、 to a linked site, you easily return to the location you clicked from by clicking on the double return arrows Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page 3 of 123 Preface Format This document follows the AWS format,

7、 and is based on the current practice in the manufacture of ground combat vehicles. Therefore, the section that normally would be included to establish design standards has been eliminated from this code. This follows the practice within this industry of having design performed by structural design

8、engineers using the latest in finite element analysis techniques. This code has been divided into 9 sections (sections 1 through 10, with section 2, normally applied to design, eliminated) that can be grouped into the following areas related to welding manufacture: General welding procedural require

9、ments for the qualification of welding processes and weld joint geometries. Specific requirements for qualifying welders for various welding processes. Specific requirements for welds in four different categories: Stud Welding Non-Critical Welding Critical Welding (Except Ballistic Structures) Balli

10、stic Welding Generally, the requirements for welds in the latter three categories can be related to the prior military specifications, as follows: Quality standards of Section 8, related to welding of attachments, is based upon MIL-STD-372, Class B. Quality standards of Section 9, related to welding

11、 of primary nonballistic structures, is based upon MIL-STD-372, Class A. Quality standards of Section 10, related to welding of structures subject to ballistic attack, is based upon MIL-STD-1946. For simplicity, this document can be divided into separate working sections. Sections 7 through 10 descr

12、ibe the requirements for specific weld categories and should be used to control welding of these individual categories. They should be used in conjunction with Section 6 which establishes basic quality procedures. Sections 1 through 5, excluding the nonexistent Section 2, establish the general workm

13、anship and technique requirements for all aluminum welding. It also establishes the qualification of procedures and of welders. These sections produce the framework for good welding performance in any facility fabricating components for our countrys defense. They must be followed for the establishme

14、nt of an acceptable facility with welders capable of performing the welding needed for this fabrication. Specification Cross Reference A table is included on page 4 to provide a cross- reference between this code and military standards and specifications (active and cancelled). Revisions This code a

15、nd all revisions will be electronically maintained. Signed original copy of document located at AMSTA-TR-E. Recommendations for change must be submitted in writing to U.S. Army Tank-Automotive and Armament Research, Development and Engineering Center (TARDEC), Attention AMSTA-TR-E/MEPS. Consensus of

16、 the standing Weld Team is required for revisions to this code. TARDEC/UDLP Weld Team Charter Members Michael W. Davis UDLP Steven W. Taylor UDLP Richard J. Rush UDLP David Berridge UDLP Marvin Kohn - UDLP Terry A. Higgins TARDEC Joe B. Regmont TARDEC Lucien A. Vita TACOM/ARDEC Provided by IHSNot fo

17、r ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page 4 of 123 Table P.1 WELD SPECIFICATION CROSS REFERENCE MATRIX Previous Specification Ground Combat Vehicle Weld Code MIL-STD-370 Grade A (SP) Section 10 (Other requirements as specified) Grade

18、A Section 10 Grade B Section 9 Grade C Section 8 MIL-STD-372 Class A Section 9 Class B Section 8 MIL-STD-1946 Armor to Armor Section 10 Attachments to Armor Section 8 MIL-STD-2219 All Classes Section 9 MIL-W-45205 Class A Section 9 Class B Section 8 MIL-W-45206 Armor to Armor Section 10 Attachments

19、to Armor Section 8 MIL-STD-45211 Stud Welding Section 7 ANSI/AWS D1.2 (Nontubular) Statically Loaded Section 8 Dynamically Loaded Section 9 ANSI/AWS D1.2 (Tubular) Tubular Section 9 ANSI/AWS D1.2 No Designation Section 9 Drawing 12309000 Level 1A Section 9 Level 1C Section 10 Level 2A Section 8 Leve

20、l 2C Section 10 Level 3B Section 8 Level 3C Section 8 Level 4B Section 8 (Other requirements as specified) Level 4C Section 8 (Other requirements as specified) Level 4D Section 7 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision

21、 A Page 5 of 123 TABLE OF CONTENTS Preface.3 List of Tables9 List of Figures.11 1 GENERAL PROVISIONS . 13 1.1 Scope 13 1.2 Approval .13 1.3 Materials.13 1.4 Welding Processes.16 1.5 Equipment Calibration16 1.6 Definitions.16 1.7 Welding Symbols16 1.8 Safety Precautions .17 1.9 Standard Units of Meas

22、urement 17 3 WORKMANSHIP 19 3.1 General.19 3.2 Preparation of Base Material19 3.3 Assembly21 3.4 Control of Distortion and Shrinkage .22 3.5 Weld Profiles 22 3.6 Rework/Repairs23 3.7 Cleaning of Completed Welds24 4 TECHNIQUE . 25 Part A General Requirements For Gas Metal Arc, Gas Tungsten Arc, Plasm

23、a Arc (Variable Polarity) Welding 25 4.1 Material Requirements .25 4.2 Welding Processes.25 4.3 Shielding Gases .25 4.4 Preheat Requirements .25 4.5 Interpass Temperature Requirements .25 4.6 Arc Strikes 25 4.7 Cleaning Prior to Welding .25 4.8 Weld Termination .25 4.9 Backing to Prevent Melting Thr

24、ough26 4.10 Peening 26 4.11 Thermal Stress-Relief Treatment.26 Part B Gas Metal Arc Welding .26 4.12 General.26 4.13 Restrictions on Gas Metal Arc Welding With Single Electrode26 Part C General Requirements Gas Tungsten Arc Welding .27 4.14 General.27 4.15 Tungsten Electrodes 27 4.16 Restrictions on

25、 Gas Tungsten Arc Welding .28 Part D Plasma Arc Welding 28 4.17 General.28 4.18 Tungsten Electrodes 28 4.19 Restrictions on Variable Polarity Plasma Arc Welding 28 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page 6 of 12

26、3 Contents 5 QUALIFICATIONS OF PROCEDURES AND PERSONNEL . 29 Part A General Requirements.29 5.1 General 29 5.2 Qualification of Welding Procedures29 5.3 Qualification of Welders, Welding Operators, and Tack Welders29 5.4 Qualification Responsibility 29 5.5 Records 29 5.6 Position of Test Welds29 Par

27、t B Types of Tests, Test Methods and Acceptance Criteria35 5.7 Types and Purposes of Tests 35 5.8 Visual Examination.36 5.9 Tension Tests Groove Welds 36 5.10 Bend Tests Groove Welds Plate and Pipe .37 5.11 Soundness Tests Fillet Welds .43 5.12 Radiographic Examination .44 Part C Procedure Qualifica

28、tion46 5.13 General.46 5.14 Limits of Qualified Positions for Procedures 46 5.15 Preparation of Test Weldment Procedure Qualification 48 5.16 Limitation of Variables Procedure Qualification.48 5.17 Tests Procedure Qualification .50 5.18 Retests .55 Part D Performance Qualification55 5.19 General.55

29、5.20 Limits of Qualified Positions for Performance 55 5.21 Preparation of Test Weldments Performance Qualification 58 5.22 Limitation of Variables Welder Performance Qualification 60 5.23 Limitation of Variables Welding Operator Performance Qualification .60 5.24 Limitation of Variables Tack Welder

30、Performance Qualification .60 5.25 Tests Performance Qualification .62 5.26 Retests .63 5.27 Period of Effectiveness.63 6 INSPECTION 67 Part A General Requirements.67 6.1 General.67 6.2 Inspection of Materials .67 6.3 Inspection of Welding Procedure Qualification and Equipment.67 6.4 Inspection of W

31、elder, Welding Operator, and Tack Welder Qualifications68 6.5 Inspection of Work and Records68 6.6 Obligations of the Contractor .68 6.7 Nondestructive Testing .68 Part B Radiographic Inspection 69 6.8 General.69 6.9 Extent of Testing 69 6.10 Radiographic Procedures.69 6.11 Acceptability of Welds .7

32、3 6.12 Examination, Report, and Disposition of Radiographs 73 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page 7 of 123 Contents Part C Ultrasonic Testing of Groove Welds 73 6.13 General.73 7 STUD WELDING 75 Part A Gener

33、al Requirements.75 7.1 General75 Part B Arc Stud Welding .75 7.2 General Requirements .75 7.3 Material Requirements .75 7.4 Workmanship .75 7.5 Technique.76 7.6 Qualification Requirements 76 7.7 Operator and Pre-production Qualification .78 7.8 Acceptance Criteria Production Welds78 7.9 Mislocated S

34、tuds78 7.10 Repair of Misapplied Studs 78 Part C Capacitor Discharge Stud Welding79 7.11 General Requirements .79 7.12 Material Requirements .79 7.13 Workmanship .79 7.14 Technique.79 7.15 Qualification Requirements 79 7.16 Operator and Pre-production Qualification 81 7.17 Acceptance Criteria Produc

35、tion Welds81 7.18 Mislocated Studs81 7.19 Repair of Misapplied Studs 81 8 NON-CRITICAL WELDING 83 Part A General Requirements.83 8.1 Application83 8.2 Base Metal .83 8.3 Filler Metal84 Part B Workmanship .84 8.4 Dimensional Tolerances.84 8.5 Temporary Welds.84 8.6 Weld Termination .84 8.7 Quality of

36、 Welds .84 9 CRITICAL WELDING (Except Ballistic Structures). 87 Part A General Requirements.87 9.1 Application87 9.2 Base Metal .87 9.3 Filler Metal87 Part B Workmanship .88 9.4 Dimensional Tolerances.88 9.5 Temporary Welds.88 9.6 Weld Terminations .88 9.7 Quality of Welds .88 Provided by IHSNot for

37、 ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page 8 of 123 Contents 10 BALLISTIC WELDING . 91 Part A General Requirements.91 10.1 Application91 10.2 Base Metal .91 10.3 Filler Metal91 Part B Workmanship .91 10.4 Temporary Welds.91 10.5 Weld Te

38、rminations .91 10.6 Ballistic Certification .91 10.7 Macro Specimens.93 10.8 Quality of Welds .93 10.9 Ballistic Shock Test Procedure 95 APPENDICES 99 APPENDIX A STANDARD FORMS. 101 APPENDIX B WELD TYPES 119 APPENDIX C - ALTERNATIVE RADIOGRAPHIC SAMPLING PLAN. 121 Provided by IHSNot for ResaleNo rep

39、roduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page 9 of 123 LIST OF TABLES Table P.1 Weld Specification Cross Reference Matrix.4 1.1 Aluminum Alloy Products Available for Structural Applications .14 1.2 Recommended Aluminum Alloy Filler Metals for Structura

40、l Welding of Various Aluminum Alloys15 3.1 Limit of Acceptability and Repair of Cut Edge Discontinuities in Plate 20 4.1 Typical Current Ranges for Tungsten Electrodes27 4.2 Typical Chemical Composition of Tungsten Electrodes 28 5.1 Tensile Strength of Welded Aluminum Alloys (GTAW or GMAW With No Po

41、stweld Heat Treatment)40 5.2 Procedure Qualification - Type and Position Limitations .50 5.3 Number and Type of Test Specimens and Range of Thickness Qualified Procedure Qualification; Complete Joint Penetration Groove Welds52 5.4 Number and Type of Test Specimens and Range of Thickness QualifiedPro

42、cedure Qualification; Partial Joint Penetration Groove Welds .54 5.5 Number and Type of Test Specimens and Range of Thickness Qualified Procedure Qualification Fillet Welds57 5.6 Welder Performance QualificationType of Weld and Position Limitations .58 5.7 Number and Type of Test Specimens and Range

43、 of Thickness Qualified Welder and Welding Operator Qualification 64 6.1 Penetrameter Requirements 70 7.1 Minimum Fillet Weld Size for Small Diameter Studs76 7.2 Minimum Required Torque Values and Tension Loads for Arc Stud Welding (F-22 Aluminum Alloy Studs) .77 7.3 Minimum Required Torque Values a

44、nd Tension Loads for Capacitor Discharge Stud Welding (F-22 Aluminum Alloy Studs) .80 9.1 Maximum Acceptable Porosity in Radiographs for Any 3 in. Length of Weld (Dynamically Loaded).89 10.1 Sample Inspection Frequency Table95 10.2 “Consecutives” Table for Random Positions95 10.3 Striking Velocity R

45、equirements for 5083 Aluminum Alloy Using the 75 mm Aluminum M1002A Plate Proofing Projectile 97 10.4 Striking Velocity Requirements for 7039 Aluminum Alloy Using the 75-mm Aluminum, M1002A Plate Proofing Projectile 97 10.5 Striking Velocity Requirements for 5083 Aluminum Alloy Using the 57-mm Alumi

46、num M1001A Plate Proofing Projectile 97 10.6 Striking Velocity Requirements for 7039 Aluminum Alloy Using the 57-MM Aluminum M1001A Plate Proofing Projectile 97 10.7 Striking Velocity Requirements for 2519 Alloy Aluminum Armor Weldments Using the 75-mm, M1002A Aluminum Plate Proofing Projectile97 Pr

47、ovided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page 10 of 123 This page left intentionally blank Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12472301 Revision A Page

48、 11 of 123 LIST OF FIGURES Figure 3.1 Edge Discontinuities in Cut Plate21 3.2 Maximum Allowable Root Opening.22 3.3 Acceptable and Unacceptable Weld Profiles23 5.1 Positions of Groove Welds30 5.2 Positions of Fillet Welds 31 5.3 Position of Test Plates for Groove Welds .32 5.4 Position of Test Plates for Pipe or Tubing for Groove Welds .33 5.5 Position of Test Plates for Fillet Welds34 5.6 Position for Test Pipes for Fillet Welds .35 5.7 Reduced Section Tension Specimens Plate and T