ARMY 12479550 REV A-2006 Ground Combat Vehicle Welding Code - Steel.pdf

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1、19207-12479550 Revision A Page 1 of 165 Revisions LTR Description Date (YY-MM-DD) Approved - Initial Release Direct ERR FOM U6466 01-12-07 T. A. Higgins A Direct ERR FOM U8332 Incorporated ADCN 157519 03-04-30 T. A. HigginsAcknowledgment Design Activity U.S. Army Tank-Automotive and Armaments Comman

2、d Warren, Michigan 48397-6000 This code is based on commercial and military specifications; primarily ANSI/AWS B2.1, ANSI/AWS D1.1, MIL-STD 1941 and MIL-STD 1261. This document was prepared by a team from United Defense, L.P., Ground Systems Division (UDLP) and the U.S. Armys Tank-Automotive Armamen

3、t Research, Development and Engineering Center (TARDEC). Design Approval TARDEC/UDLP Weld Team Ground Combat Vehicle Welding Code - Steel Drawn Date Drawing Approval Size Cage Code Richard J. Rush 01/12/06 Tom Altobelli A 19207 12479550 Provided by IHSNot for ResaleNo reproduction or networking perm

4、itted without license from IHS-,-,-19207-12479550 Revision A Page 2 of 165 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 p

5、hrase that 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

6、 jumped 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-,-,-19207-12479550 Revision A Page 3 of 165 Preface Introduction This document follows th

7、e AWS format, and is based on current practice in the manufacture of ground combat vehicles. 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 en

8、gineers using the latest in finite element analysis. This code is divided into seven sections and five appendices. Revisions This code and all revisions will be electronically maintained. Signed original copy of document located at AMSTA-TR-E/ART. Recommendations for change must be submitted in writ

9、ing to U.S. Army Tank-Automotive and Armament Research, Development and Engineering Center (TARDEC), Attention AMSTA-TR-E/MEPS. Consensus of the standing Weld Team is required for revisions to this code. Specification Cross Reference A table is included on page 4 to provide a cross- reference betwee

10、n this code and military standards and specifications (active and cancelled). 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 Claude

11、Braafladt - UDLP Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12479550 Revision A Page 4 of 165 Table P.1 Cross Reference Table Topic Applicable References Stud Welding MIL-STD-1261, Classes 1, 2 and 3 Non Critical Welds AWS D1.1 Statically

12、Loaded Welds MIL-STD-1261, Class 1 MIL-STD-248 Critical Welds MIL-STD-1261, Class 2 AWS D1.1 Cyclically Loaded Welds MIL-STD-1941, Attachments to Armor MIL-STD-1185, Attachments to Armor MIL-STD-1261, Class 3 MIL-STD-2219, classes A it is appropriate for use in fabrication of ballistic and non-balli

13、stic primary structures, supporting structures and appurtenances. When conformance to the code is stipulated in contract documents, all provisions of this code shall be complied with, except for those provisions that contract documents specifically exempt. The following is a summary of the code sect

14、ions and appendices: 1. General Requirements This section contains basic information on the scope and limitations of the code. 2. Design of Welded Connections This section has been omitted. Responsibility for this section resides with the design agency. 3. Prequalification This section contains the

15、requirements for exempting a non-armor Welding Procedure Specification (WPS) from the qualification requirements of this code. 4. Qualification This section contains the qualification requirements for non-armor WPSs and welding personnel (welders, welding operators and tack welders). 5. Fabrication

16、This section contains the requirements for the preparation, assembly and workmanship of welded steel structures. 6. Inspection This section contains criteria for the qualifications and responsibilities of inspectors, acceptance criteria for production welds, and standard procedures for performing vi

17、sual inspection and NDT (nondestructive testing) 7. Stud Welding This section contains the requirement for the welding of studs. Appendices Appendix A Code-Approved Base Materials. This appendix contains tables that cross-reference and group the base and filler material qualification requirements. W

18、ithin the type/grade grouping, other materials not specifically listed, may also be used with this document with Engineering approval. Appendix B Welding of Armor Steel. This appendix contains the welding, testing, procedure qualification, and performance qualification requirements of armor steel. A

19、ppendix C Forms. This appendix contains applicable forms for procedure qualification, performance qualification, and armor welding data sheets. Appendix D Illustrations Weld Positions, Test Specimens and Test Fixtures. This appendix contains illustrations displaying dimensional information related t

20、o test specimens and fixtures. Appendix E Prequalified Joint Details and Joint Preparations. This appendix contains the Prequalified WPS limitations. 1.1.1 Application This code is intended to be used for the following: materials listed in Appendix A or other materials approved by Engineering as ref

21、erenced in 1.1 Appendix A. steel materials qualified using procedures established in: ASME Boiler and Pressure Vessel Code AWS Codes API Standards Canadian Welding Bureau codes Note: All procedures qualified using the above listed standards and codes require UDLP review and approval. welding of armo

22、r steel. Any special requirements specified in Appendix B, “Welding of Armor Steel” supersedes any conflicting requirements found elsewhere in this document. 1.1.2 Limitations This code is not intended to be used for pressure vessels or pressure piping. 1.2 Approval All reference to a need for appro

23、val by the procuring activity or customer shall mean approval by the Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12479550 Revision A Page 17 of 165 Government, or the duly designated person who acts for and on behalf of the Government in al

24、l matters within the scope of this code. In addition, where contractor approvals shall be required, the term contractor shall refer to the prime contractor 1.3 Definitions The welding terms used in this code shall be interpreted in accordance with the definitions given in the latest edition of ANSI/

25、AWS A3.0, Standard Welding Terms and Definitions. Modified PQR A PQR that has been developed from existing procedures qualified in accordance with a military standard or specification and grandfathered into an AWS PQR format. Modified WPS A WPS that has been created from a modified PQR(s) developed

26、from an existing workmanship sample in accordance with a military standard or specification. Skewed T-Joint T-joint with a dihedral angle equal to or greater than 60 degrees. All T-joints less than 60 degrees shall be considered to be groove welds. 1.4 Welding Symbols Welding symbols shall be those

27、shown in the latest edition of ANSI/AWS A2.4, Symbols for Welding, Brazing, and Nondestructive Examination. Special conditions shall be fully explained by added notes or details. 1.5 Equipment Calibration The manufacturer is required to develop and maintain a welding equipment calibration program. T

28、his program shall consist of, as a minimum, an annual comparison check of the machine output with instrumentation calibrated using standards traceable to the National Institute of Standards and Technology (NIST). The standard may be a load bank, voltmeter/ammeter, clamp-on meter, etc. Machine output

29、 for amperage and voltage must be within 10% of full scale. Proper documentation and evidence of the implementation must be maintained and is subject to random audit. Location for calibration shall be as follows: GMAW/SAW/FCAW At wire feeder GTAW/SMAW At power supply All other processes As close as

30、practical to the welding process 1.6 Safety Precautions Safety precautions shall conform to the latest edition of ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society. Note: This code may involve hazardous materials, operations, and equipment. The c

31、ode does not purport to address all of the safety problems associated with its use. It is the responsibility of the user to establish appropriate safety and health practices. The user should determine the applicability of any regulatory limitations prior to use. 1.7 Standard Units of Measurement Val

32、ues in this code will normally be stated in U.S. customary units. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12479550 Revision A Page 18 of 165 2 Design of Welded Connections 2.1 Intended Use This document does not address the design of we

33、lded connections. The responsibility for the design and designation of weld criticality is a function of the appropriate design agency. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12479550 Revision A Page 19 of 165 This page intentionally b

34、lank Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12479550 Revision A Page 20 of 165 3 Prequalification of WPSs 3.1 Scope Prequalification of WPSs (Welding Procedure Specifications) shall be defined as exemption from the WPS qualification te

35、sting required in section 4. All prequalified WPSs shall be documented using the form found in Appendix C or an alternate form provided the same variables are addressed. In order for a WPS to be prequalified, conformance with all of the applicable provisions of section 3 shall be required. WPSs that

36、 do not conform to the requirements of section 3 may be qualified by tests in conformance with section 4. The use of a prequalified joint shall not exempt the contractor from using sound engineering judgment in determining the suitability of application of these joints to a welded assembly or connec

37、tion. Welders, welding operators and tack welders that use prequalified WPSs shall be qualified in conformance with section 4, Part C or those codes/standards listed in 1.1.1. 3.2 Welding Processes 3.2.1 Prequalified Processes Shielded metal arc welding (SMAW), submerged arc welding (SAW), gas metal

38、 arc welding (GMAW) (except GMAW-S, short circuiting transfer and GMAW-P, pulse mode), and flux cored arc welding (FCAW) WPSs which conform to all of the provisions of section 3 shall be deemed as prequalified and are therefore approved for use without performing WPS qualification tests for the proc

39、ess. 3.2.2 Other Welding Processes. Other welding processes not covered by 3.2.1 may be used, provided the WPSs are qualified by applicable tests as prescribed in section 4. In conjunction with the tests, the WPSs and limitation of essential variables applicable to the specific welding process shall

40、 be established by the contractor developing the WPS. The range of essential variables shall be based on documented evidence of experience with the process but may not exceed the limits specified in section 4. Any change in essential variables outside the range so established shall require requalifi

41、cation. 3.3 Base Metal/Filler Metal Combinations Only base metals and filler metals listed in Table 3.1 and Appendix A Table M1 (Group 1,2,3) may be used in prequalified WPSs. Reference engineering drawings to determine the filler metal strength requirements to match or undermatch base metal strengt

42、h. 3.4 Minimum Preheat and Interpass Temperature Requirements The preheat and interpass temperature shall be sufficient to prevent cracking. Table 3.2 shall be used to determine the minimum preheat and interpass temperatures. For all materials not listed in Table 3.2, preheat and interpass temperatu

43、res shall be established on a PQR and documented on a WPS. Preheat and interpass temperature limitations for armor steels are indicated in Appendix B. 3.4.1 Base Metal/Thickness Combination The minimum preheat or interpass temperature applied to a joint composed of base metals with different minimum

44、 preheats from Table 3.2 (based on category and thickness) shall be the highest of these temperatures. 3.4.2 Alternate SAW Preheat and Interpass Temperatures Preheat and interpass temperatures for parallel or multiple electrode SAW shall be selected in conformance with Table 3.2. For single-pass gro

45、ove and fillet welds or combinations of base metals, preheat/interpass temperatures may be established which are sufficient to reduce the hardness in the heat-affected zones of the base metal to less than 215 Brinell hardness number for steel having a minimum specified tensile strength not exceeding

46、 60,000 psi, and 265 Brinell hardness number for steel having a minimum specified tensile strength greater than 60 000, but not exceeding 70,000 psi. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-19207-12479550 Revision A Page 21 of 165 Table 3.1 P

47、requalified Base Metal-Filler Metal Combinations for Matching Strength (see 3.3) G Steel Specification Requirements Filler Metal Requirements r o Min.Yield Point/ Tensile Min. Yield Point/ Tensile Strength u Strength Range Electrode Strength Range p Steel Specification1,2ksi ksi Specification3,6ksi

48、ksi ASTM A36436 58-80 ASTM A53 Grade B 35 60 min ASTM A106 Grade B 35 60 min SMAW ASTM A131 Grades A, B, CS, D, DS, E 34 58-71 AWS A5.1 or A5.57ASTM A139 Grade B 35 60 min E60XX 50 62 min ASTM A381 Grade Y35 35 60 min E70XX 60 72 min ASTM A500 Grade A 33 45 min E70XX-X 57 70 min Grade B 42 58 min ASTM A501 36 58 min SAW ASTM A516 Grade 55 30 55-75 AWS A5.17 or A5.237Grade 60 32 60-80 F6XX-EXXX 48 60-80 ASTM A524 Grade I 35 60-85 F7XX-EXXX or 58 70-95 Grade II 30 55-80 F7XX-EXX-XX I ASTM A529 42 60-85 ASTM A570 Grade 30 30 49 min GMAW Grade 33 33 52 min AWS