NAVISTAR MPAPS P-9511-2015 Arc Welding - Aluminum.pdf

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1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 1 of 7 NAVISTAR, INC. Material, Parts, and Process Specificatio

2、ns (MPAPS) NUMBER: MPAPS P-9511 Former Designation: TMS-9511 TITLE: Arc Welding - Aluminum CURRENT REV No.: 1510 DATE: Oct. 2015 WRITTEN/EDITED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: Rev. 0906 June 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specifi

3、cation may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior

4、 to use. Change Notice: New MPAPS format; editorial changes. 1.0 APPLICATION Aluminum cab frames and other welded aluminum assemblies. 2.0 SCOPE This specification covers the arc welding of structural members which are made from wrought or cast aluminum or aluminum alloy components. The aluminum all

5、oy can be either a nonheat-treatable (e.g., 5052) or heat-treatable (e.g., 6061) grade. It also pertains to fillet welds in tee or lap joints, bevel or flare-V groove welds, square groove welds, and plug or slot welds. The welds shall be made using a gas-metal arc process with a suitable shielding g

6、as such as argon, helium or a mixture of the two gases (MIG: Gas Metal-Arc or TIG: Gas Tungsten-Arc). These processes are to be used interchangeably unless otherwise specified. The location of joints to be welded shall be designated on the engineering drawing using the appropriate welding symbols (p

7、er AWS A2.4) and notes to indicate size, type, length and location. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise

8、 specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 AWS A5.10 CFR Title 29, Part 1910 AWS A2.4 NAVISTAR Manufacturing Std. MS-D-13 AWS D1.2 NA

9、VISTAR Engineering Design Std A-16 NAVISTAR MPAPS B-50 AWS D8.14 4.0 REQUIREMENTS Fabrication of welded aluminum structures of sheet or plate by means of fillet welds, square or bevel groove welds or plug and slot welds shall conform appropriately to the guidelines requirements and recommendations o

10、f AWS D1.2, clause 4, where applicable, in regards to the preparation of base metal, NUMBER: MPAPS P-9511 TITLE: Arc Welding - Aluminum REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers

11、 are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 2 of 7 assembly, technique, use of tack and temporary welds, weld termination, control of distortion and weld profiles. 4.1 Filler Metal Filler metal shall be selected on the basis of the base metals being joined,

12、 and it shall be determined from AWS A5.10 unless otherwise specified on the engineering drawing. 4.2 Weld Length Weld length shall be shown on the engineering drawing. Welds shall be acceptable if they are short according to the following table: TABLE 2 WELD LENGTH TOLERANCE Specified Length Tolera

13、nce cm In mm in 15 and Under 6 and Under 6 1/4 Over 15 Thru 30.5 Over 6 Thru 12 13 1/2 Over 30.5 Thru 61.0 Over 12 Thru 24 38 1 1/2 Over 61.0 Thru 122 Over 24 Thru 48 64 2 1/2 Over 122 Thru 244 Over 48 Thru 96 114 4 1/2 Over 244 Thru 488 Over 96 Thru 192 216 8 1/2 4.2.1 The effective weld length sha

14、ll not include skips, voids, undersize welds, off-location welds, or any other discontinuities defined under Quality. 4.3 Weld Location The lateral location of the weld in the joint shall be shown by the proper weld symbol. Where desired, this may be supplemented by cross hatching on the Engineering

15、 drawing or by a note in the tail of the weld symbol. Where a specified location is shown on the drawing, the starting point of a continuous weld shall be within the tolerance included in Table 3: TABLE 3 WELD LOCATION TOLERANCE Specified Length Tolerance cm In mm in 15 and Under 6 and Under 6 1/4 O

16、ver 15 Over 6 13 1/2 Intermittent 13 1/2 4.3.1 No welds shall be closer than 3 mm (1/8 in) from the edge or end of a joint. When it is required that a weld be hooked or boxed around a corner or end of a joint, it shall be indicated on the engineering drawing as a continuous weld and included in the

17、specified length. Hooked welds shall be a portion of a continuous weld or an individual portion of the weld and shall be free from pinholes, voids, and craters. “No Weld“ areas shall be specified on the engineering drawing using a specific note or dimension to define the minimum length of the area w

18、here no welding is permitted (or the maximum dimension where welding is excluded from a specified reference point). All welds shall be centered in the joint to ensure fusion between the two members being joined. Portions of the weld off-joint shall be considered as skips or voids. NUMBER: MPAPS P-95

19、11 TITLE: Arc Welding - Aluminum REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 3 of 7 4.4 Welde

20、d Joints Weld joints in 6xxx series alloys shall be beveled or spaced to permit excess filler alloy dilution. Groove welded joints shall conform to AWS D1.2 recommended joint patterns. The joint patterns can be modified upon prior written approval from Materials Engineering. 4.5 Weld Size 4.5.1 Fill

21、et Weld Size Weld leg length shall be shown on the engineering drawing, and it shall be the minimum length permitted. The leg length shall be equal to the thickness of the thinnest stock being welded or 3 mm (0.12 in), whichever is greater, unless otherwise indicated on the engineering drawing. When

22、 a gap is present, the leg length on the gap side shall be increased by the amount of the gap. See Figure 1. Figure 1 Weld Leg Length L = 3.0 mm (1/8 in) minimum L1 = 3.0 mm (1/8 in) + Gap Minimum or 1.00t, whichever is greater or 1.00t + gap, whichever is greater 4.5.2 Fillet Weld Throat Depth Unle

23、ss otherwise specified, a minimum throat depth shall be maintained throughout the length of the weld. The minimum throat depth shall be (1) no gap: 60% of the specified leg length or (2) gap: 60% of the total of the limit for convexity shall not be required, but all other requirements shall be met.

24、Part configuration shall remain functional, and no overlap shall be permitted. See Figure 2. Figure 2 Weld Throat Throat = 0.60 L Throat = 0.60 (L + Gap) t t No Gap Gap t t L L L1 T T L t t No Gap L L Throat Gap Throat L T T NUMBER: MPAPS P-9511 TITLE: Arc Welding - Aluminum REVISION: 1510 This docu

25、ment is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 4 of 7 4.5.3 Flare Bevel and Flare V Groove Welds Effective weld size sha

26、ll be 3 mm (1/8 in) minimum or 100% of the thinnest stock being welded, whichever is greater. Minimum effective weld size shall be shown on the engineering drawing and shall be determined as shown in Figure 3. Figure 3 Weld Size Note: It is necessary to deviate from the AWS definition to adequately

27、define the size of flare-groove welds. 5.4 Plug or Slot Weld A weld made through a hole in one member of a tee or lap joint joining that member to the other. Walls of the hole may or may not be parallel. The hole shall be completely filled with filler metal. A fillet welded hole or a spot weld shall

28、 not be construed as meeting this specification. See Figure 4. Figure 4 Plug or Slot Weld A A Effective Weld Size = A A A NUMBER: MPAPS P-9511 TITLE: Arc Welding - Aluminum REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Cor

29、porate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 5 of 7 4.7 Fusion Fusion is the joining of two metals where coalescence or metallurgical bonding of one material to the other takes place. 4.7.1 Fillet Welds All welds shall ha

30、ve 100% minimum fusion for the total specified leg length of the weld. 4.7.2 Flare V and Flare Bevel Groove Welds All welds shall have 100% minimum fusion of the groove face for the specified weld size. See Figure 5. Figure 5 - Minimum Fusion , Groove Welds 4.7.3 Plug or Slot Welds Welds shall have

31、100% minimum fusion of side walls and entire bottom surface of hole. B B B B Effective Groove Face = B B B B B Incomplete Fusion NUMBER: MPAPS P-9511 TITLE: Arc Welding - Aluminum REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission f

32、rom Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 6 of 7 5.0 QUALITY 5.1 INSPECTION REQUIREMENTS Visual examination of fillet and square groove weld surfaces involving plate and pipe shall be performed on test specimens

33、 in accordance with this specification, clauses 3.6 and 5, Figure 4.2 and Table 5.3(Visual Inspection Acceptance Criteria) per AWS D1.2/1.2M:2014, Visual examination of Sheet T-joint fillets welds, lap joint fillet welds, Flare Bevel and V Groove welds, plug welds and slot welds shall be performed i

34、n accordance with this specification and AWS D8.14/8.14M. 6.0 QUALIFICATION Engineering qualification of sources is required in advance of production shipments. Suppliers shall submit samples for approval of weld assemblies to the Navistar Supplier Quality. Samples shall be accompanied by test data

35、certifying that all requirements of the specification have been met. Upon approval, master samples denoting the minimum level of acceptable appearance quality shall be developed and retained by the supplier and the quality department of each using NAVISTAR facility. 6.1 General Suppliers, including

36、NAVISTAR plants, shall have the responsibility to notify the Product Quality Manager at the using plant in advance and in writing of any permanent change in the welding process such as rods, fixtures and processes. The changes shall be approved in writing by NAVISTAR before the change enters product

37、ion. The weld quality of all parts manufactured to this specification shall be equivalent in every respect to the initial samples approved. Members to be welded, filler metal, and shielding gas shall be free from contamination or soil which will affect the quality of the weld deposit. 6.2 Quality Co

38、ntrol Plan A Quality Control Plan for products supplied to the requirements of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features

39、 for management by statistical process control.* * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Design Standard A-16 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requirements All supplier

40、s to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certif

41、ication with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. NUMBER: MPAPS P-9511 TITLE: Arc Welding - Aluminum REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission f

42、rom Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 7 of 7 7.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approve

43、d by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Pu

44、rchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request fo

45、r change. 7.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of provid

46、ing all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. 8.0 SHIPPING AND HANDLING Shipping and identification shall be in accordance with NAVISTAR Manufacturing Standard MS-D-13.

47、 Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. 9.0 DESIGNATION ON DRAWINGS Aluminum assembly drawings requiring welding should reference this specification, along with or instead of AWS D1.2 (UG stamp #S76); in a note on the drawing to ensur

48、e weld quality. The following are examples of acceptable notes: “Welds must meet requirements of MPAPS P-9511” “All welds will conform to Navistar MPAPS P-9511 (latest revision) and any/all references to AWS D1.2 (or its successors).” 10.0 TECHNICAL INFORMATION For further information related to the

49、 technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: htt