ARMY MIL-HDBK-730-1986 MATERIALS JOINING《连接材料》.pdf

1、MIL-HDBK-730L(MR-) 31 JANUARY 1986 SUPERSEDES MIL-HDBK-66 1 JULY 1968 MIL-HDBK-68 1 AUGUST q971 O MILITARY STANDARDIZATION HANDBOOK on MATERCALS JOINING THIS DOCUMENT CONTAINS 381 PAGES. h: AMSC NO. : NIA OlSTRlBUTlON STATEMENT A: Approved for public. release, distribution is unlimited. - - -. . .“

2、“ : .i* . “. - . c - L . -. “ “ “ . . . .r_ - _._ - . j “_ . -. THJM Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-DEPARTMENT OF DEFENSE WASHINGTON, D.C. 20402 MATERIALS JOINING 1. This military handbook is approved for use by the Materials Tech

3、nology Laboratory, Department of the Army, and is available for use by all Departments and Agencies of the Department of Defense. 2. This handbook supersedes MIL-HDBK-56 “Arc Welding“ and MIL-HDBK-58 “Thermal Joining of Betals-Processes other than Arc Welding“, 3. Beneficial comments (recommendation

4、s, additions, deletions) and any pertimnt data which may be of use in improving this document should be addressed to: Director, Materials Technology Laboratory, Arsenal St., Attn: SLCMT-lISR-ES, Watertown, MA 02172-2719, by using the self-addressed Standardization Document Improvement Proposal (DD F

5、orm 1426) appearing at the end of this document or by letter. Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-The purpose of this handbook is to provide Department of Defense engineering and quality assurance personnel with the basic principles an

6、d general knowledge of materiais joining processes. This handbook is the end product of a revisional study conducted on DoD Handbook H56, “ARC WELDING“ dated 1 July 1968 and MIL-HDBK-58, “THERMAL JOINING OF METALS PROCESSES OTHER THAN ARC WELDING“ dated 1 August 1971. Appreciation is expressed to th

7、e following organization for permission to use copyrighted material; American Welding Society, American Society for Metals, Lincoln Electric Company, Hobart Brothers Company, and Brooks/Cole Engineering Division. The new handbook entitled “Military Standardization Handbook on Materials Joining“, MIL

8、-HDBK-730(MR), reflects the most current state-of-the-art in the field of materials joining and its related processes. It follows that the new handbook contains new knowledge, technologies and philosophies not found in its predecessors. This new handbook was prepared under Contract No. DAAG-46-82-C-

9、0091 by the Franklin Research Center, Philadelphia, Pennsylvania 19103, and in conjunction with, the US Army Materials Technology Laboratory, Watertown, Massachusetts, 02172. Comments on this handbook are invited and should be addressed to: a The Director US Army Materials Technology Laboratory Wate

10、rtown, Mass. 02172-0001 ATTN SLCMT-MRS-ES iii Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-730 TH M 9999970 OOlllSOO 3 m MIL-HDBK-73O(MR) CONTENTS Section 1 . THEORY OF MATERIALS JOINING 1.1 Welding. Brazing and Soldering of Metals 1.2

11、 Weldbonding 1*3 Adhesives . 1 . 4 Weldability of Plastics I . 5 Classification of Welding Processes 1.6 Heat 1.7 Electric Arc Welding 1.8 PowerSources . 1.8.1 Polyphase Working . 1.8.2 Transformer 1.8.3 Bectification . 1.8.4 Polarity 1.8.5 Arc Initiation . 1.8.6 Duty Cycle . le9 WeldPosition 1.10 M

12、etalSransfer 1.10.1 Short-circuiting transfer mode . 1.10.2 Globular transfer mode . lelO. 3 Spray transfer mode l.10,4 Pulsed-spray tranafer mode . 1.11 Shielding Gases 1.11.1 Ar.on . 1.11.2 H61iUm . 1.11.3 Argon-Hydrogen . 1.11.4 Argon-Oxygen . 1.11,5 Argon-Carbon Dioxide . 1.11.6 Cr;rbon Dioxide

13、. 1.11.7 Nitrogen. . 1,11.8 Gas Mixtures 5.12 Fluxes 1.13 Joint Design . 1.14 Welding Symbols 2. 15 Jigs. Fixtures. Positioners 1.16 Structure of Solids 1.16.1Metals 1.16.2 Polymers 1.16.3 Ceramics 1.16. 4 Composite Materials Page 1 3 5 6 10 11 12 13 14 17 17 1E 18 19 20 20 21 21 22 23 24 24 24 25 2

14、5 25 30 34 35 37 37 38 38 98 iv Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-CONTENTS . continued Section Page 1.17 Welding Metallurgy 38 1.17.1 Phase Transformations . 1.17.2 Heat Treatment 1.17.3 Effect of Alloying Elements. . 42 44 45 1.17.3

15、.1 Steel . 1.17.3.2 Aluminum and Magnesium 1.17.3.3 Copper and Nickel 1.17.3.4. Titanium . 45 47 47 48 2 . SHIELDEDMETAL-ARC WELDING 49 2.1 Process Description 2.2 .Covered Electrodes 2.3 Arc Blow 49 50 54 3 . GAS METAL-ARC WELDING . 59 Pulsed-Spray Welding . Narrow-Gap Welding GMA Spot Welding . 61

16、 . 62 63 67 4.1 4.2 4.3 Electrode Classification . Shielding Gas . Welding Variables . 72 75 75 5 . SUBMERGED-ARC WELDING . 78 6 . GAS TUNGSTEN-ARC WELDING . 91 6.1 6.2 6.3 6.5 6.6 6.7 6.8 6.4 Welding Current Electrodes Filler Metals. Shielding Gases . Flow Rate . Arc Initiation Arc Termination Base

17、 Metal Cleaning 91 94 95 96 96 97 98 98 99 7.1 Power Source 7.2 Arc Initiation - 102 102 V . 1 . Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-_ _ ML-HDBK-730 TH m 4999970 0041902 7 m MIL-HDBK-730(MR) CONTENTS . continued Section Page 9.3 Electr

18、odes 103 9.4 FillerMetals 103 7.5 Orifice and Shielding Gases . 104 7.6 Joint Design . 104 7.7 WeldBacking. 105 8. ELECTROGAS WELDING . 107 9.1 Fluxes 114 9.2 Electrode Composition 114 9.4 Metallurgical Considerations . 114 9.5 Applications . 116 9.5 Dilution . 114 11 . STUD ARC WELDING 125 11.1 Stu

19、d Arc Welding . 125 11.2 Capacltor-Discharge Stud Welding . 128 11.3 Quality Control . 131 12.1 Resistance Spot Welding . 133 12.2 Weld Spacing . 139 12.3 Quality Control . 140 12.4 Resistance Seam Welding . 140 12.5 Projection Welding 144 32.6 Flash Welding 145 12.7 Percussion Welding 147 12.8 Upse

20、t Welding 148 13 . THERMIT WELDING 150 13.1 Process . 151 14. ELECTRON-BEAM WELDING e o . o o . 0 4 e 154 14.1 High Vacuum EBW . 156 14*2 Soft Vacum EEW . 156 14.3 Nonvacuum EBW 158 vi Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-mm MIL-HDBK-73

21、0 TH 7777770 OOq1703 7 . a MIL-HDBK-730(MR) CONTENTS . continued Section 15 . LASER-BEAM WELDING . 16 . SOLID STATE WELDING . . 16.1 16.1.1 16.2 16.3 16.4 16.5 16.5.1 16.5.2 16.5.3 16.6 16.6.1 16.7 16.8 Cold Welding Process . Diffusion Welding Forge Welding Explosion Welding Friction Welding Process

22、 Characteristics Continuous-Drive FRW Procedure . Inertia-Drive Welding Procedure . Ultrasonic Welding . Procedure Hot Pressure Welding Electromagnetic Impact Welding . 17 . MAGNETICALLY IMPELLED-ARC WELDING 18.1 Surface Preparation . 18.2 Flame Spraying . 18.3 Electric Arc Spraying 18.5 Post-Spray

23、Operations 18.4 Plasma Spraying . 18.5.1 Fusing . 18.5.2 Controlled Cooling . 18.5.3 Grinding 18.5.4 Machining 18.5.5 Sealing . 18.5.6 Diffusing 18.5.7 Burnishing and Polishing vi i . . . . - *. m- . C . . . . . . o . . . 4 . . . . . . . o . . . o . . Page 161 16 6 166 167 169 170 170 175 176 177 17

24、7 178 178 181 182 183 185 186 186 189 190 191 191 191 192 192 192 192 193 Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-Section _ MIL-HDBK-730 TH 9999970 OlllSOV O MIL-HDBK-730(MR) CONTENTS . continued Page 19. BRAZING 194 19.1 Fluxes and Atmosp

25、heres . 19-2 Brazing Techniques . 20. SOLDERING . 197 199 205 21 . UNDERWATER WELDING AND CUTTING 210 22.1 Weld Discontinuities 22.2 Causes and Cures of Major Weld Discontinuities . 22. 3 Significance of Weld Discontinuities 22.4 Weld Repair . 22.5 Fatigue and Fracture Control 210 213 220 221 222 22

26、.5.1 Quality Control Systems Loop (QCSL) . 222 224 25 . QUALIFICATION TESTING . 227 25.1 Proceduse Qualification . 25.2 Personnel Qualification . 227 228 26. NONDESTRUCTIVE EXAMINATION 234 26.1 Visual Examination . 26.2 Liquid-Penetrant Examination 26.3 Magnetic-Particle Examination . 26.4 Radiograp

27、hic Examination 26.5 Ultrasonic Examination . 26.6 Acoustic Emission Examination . 26.7 Eddy-Current Examination 234 234 236 237 239 241 241 27. HEALTH AND SAFETY . 27.1 Health . 242 242 27.1.1 Introduction - . 27.1.2 Elements of hazard 242 242 viii Provided by IHS Not for Resale No reproduction or

28、networking permitted without license from IHS -,-,-Section Page 27.1.2.1 Fumes. 242 27.1.2.2 Gases . . . . . . . . . . . . . . . . . . . . . e . 243 27.1.2.3 Radiation . . . . . . . . . . . . . . . . . . . . . 243 27.1.2.4 Noise. 243 27.1.2.5 Heat 243 27.2 Safety . . . . . . . , . . . . . . . . . .

29、. . . . . . . 249 27.2.1. Equipments for Materials Joining . . . . . . . . . . . 249 27.2.2. Goggles, Helmets-and Shields . . . . . . . . . . . . . 252 27.2.3. Ventilation. . . . .-. . . . . . . . . . . . . . . . 252 27.2.4. Fire Prevention. . . . . . . . . . . . . . . . . . 253 BIBLIOGRAPHY. . . .

30、. . . . . . . . . . . . . . . . . . . . . . . . 254 APPENDIX B - GOVERNMENT AND NONGOVERNMENT DOCUMENTS PERTAINING TO MATERIALS JOINING. rn . . 314 MIL-HDBK-730 TH m 7777970 0041705 2 m HIL-HDBK-730(MR) o CONTENTS - continued e ix Provided by IHS Not for Resale No reproduction or networking permitte

31、d without license from IHS -,-,-FIGURES No . Description Page 1 2 3 4 5 6 7 8 9 10 la, 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31. 32 33 34 35 36 34 38 3s 40 41 42 43 44 45 46 47 Heteropolar machine 6 Field system of a 4-pole de dynamo. 7 Sinueoidal waveform of ac . Electrode feed rate

32、 vs . weld current for E70T-1 10 Simplest transformer 11 Ideal transformer . 11 Straight and reverse polarities 14 Volt-ampere curves for dc transformer-rectifier and generator . 16 Weldpositions . 18 Short-circuiting metal transfer 19 Globular metal transfer 20 Spray tansfer mode . 20 Profile of we

33、ld penetration 22 Arc voltage vs . arc current using argon and helium shielding . . 23 Types of joints and welds . 31 Brazingjoints. . 32 Soldering joints . 33 Welding symbol . 34 Basic and supplementary weld symbols . 35 &23Positioners 36 Unitcells 37 Iron-Carbon eqEilibrium phase diagram . 40 Copp

34、er-Nickel equilibrium phase diagram 41 TTT diagram for carbon steel (O . 8gC) 43 CCT and TTT diagrams for eutectoid steel 44 Circuit diagram for SMAW 49 AW3 classification of mild steel covered electrode . 50 Magnetic force. field and current relationship . 54 Directions of arc blow at start and fin

35、ish of a seam weld 55 Effect of ground current on arc deflection . 55 Effect of superimposed magnetic field on arc blow 56 Effect of twin arcs on reactions of magnetic field forces 57 Schematic presentation of GMAW . 59 Details of arc area in GHAW. 60 Oscillogram of pulsed-spray GMAW 61 Narrow gap w

36、elding . 63 Wire feed techniques in NGW . 64 Backing techniques in NGW. . 65 Gas-shielded flux-cored arc welding . 67 Self-shielded FCAW . 68 Nomle used in gas-ahielded FCAW 69 Nozzle used in self-shielded FCAW 69 Gun used in self-shielded FCAW . 70 EayoutforFCAW . 71 Volt-ampere curves . 3 Shieldin

37、g of the molten weld pool in SMAW . 26 X Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-1 MIL-HDBK-730 TH 7797770 OOLI3707 6.- FIGURES . continued 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

38、82 83 84 85 86 87 88 89 Description Page Fabrication of flux-cored electrodes 72 Work angle for fillet and groove welds . 75 Travel angles for groove and fillet welds 76 Deposition rate vs . welding current. electrode size and weld position . 77 Submerged-arc welding 78 WeldregionofSAW . 78 Twin-arc

39、 SAW 82 Stripwelding 83 Joints with steel or copper backup bars . 84 Joint preparations: expensive and inexpensive 85 Undercut in fillet welds . 85 Sequence of weld deposits in multi-pass fillet welds . 86 Effect of electrode position on weld profile in girth welds . 86 Flux support in girth welding

40、 by SAW . 87 Plot of welding current vs . work diameter 88 Submerged-arc plug welding 89 Effect of weld shape on tendency for weld cracking 90 Gas tungsten-arc welding . 91 Effects of dc polarities . 91a GTA spot welding 93 Hot wire addition to GTAW 93 Shapes of tungsten electrode tips 94 Torch and

41、filler metal positions in manual GTAW . 97 Effect of arc constricting on temperature and voltage 99 Modes of arc transfer in plasma-arc welding . 100 Schematic representation of GTAW and PAW . 101 Components of PAW 101 Keyholewelding . 102 PAW with high-frequency pilot arc initiation . 103 V-groove

42、joint for PAW and GTAW i 105 Backing bar for keyhole welding . 106 Electrogas welding using solid wire electrode 107 Electrogas welding using flux-cored wire electrode 108 Electroslag welding of consumable guide version . 111 Non-consumable guide version of ESW . 112 ESW speeds as a function of plat

43、e thickness . 113 Visible changes in the flame resulting from adjustments . 119 Oxyfuel gas welding . 120 Structure of oxyacetylene flame . 122 Gas welding techniques: forehand and backhand 123 Stud arc welding . 125 Operational sequence in stud arc welding . 126 . h xi Provided by IHS Not for Resal

44、e No reproduction or networking permitted without license from IHS -,-,-MILiHDBK-73 TH 7777770 004i-908 B MIL-HDBK-730(MR) FIGURES . continued Description No W 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 1W 1Q9 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 12

45、8 129 130 131 132 Operational sequences in capacitor-discharge stud welding Weld current vs . weld time for capacitor-discharge SW . . Satisfactory and some unsatisfactory SW results . Comparison of two basic SW methods Highlights of resistance spot welding Rocker-arm spot welding machine . gtandard

46、ized electrode shapes Points of resistance and heat generations Destructive test methods Overlapping spot and roll spot welding . Resistance butt-seam welding of tubing . Cross-section of foil butt-seam weld . High frequency resistance butt welding of tubing . Projection welding Flashwelding Accepta

47、ble and unacceptable flash welds . Hardness traverse across flash-welded joints in steels . . Upset welding Steps in making a thermit weld Details of crucible and mold . Permanent mold for repetitive thermit welding High-voltage triode electron-beam welder . Effect of vacuum pressure on weld penetra

48、tion and profile NonvacuumEBW Effect of changing work distance on weld profile . Influence of welding speed on weld penetration Types of EBW joints . Diagram of slow-flow C02 laser Schematics of FAF C02 laser system ?TF C02 laser system . Details of FAF C02 laser system . Perspective diagram of keyh

49、ole butt welding by LBW Plot of weld penetration vs. power density Double-acting die used in cold welding Cold-pressure butt welding Die action in cold butt welding . Use of mandrel in cold butt welding tube . Photomicrograph of explosion welded interface between etainless and carbon steels Explosion welding: angled interfa