1、MIL-STD-1252 30 JUN 1975 _. MILITARY STANDARD INERTIA FRICTION WELDING PROCESS, PROCEDURE AND PgZFORMANCE QUALIFICATION ? 1 I f FSG-THJM Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1252 30 JUN 1975 DEPARTMENT OF DEFENSE WASHINGTON, D. C.
2、20301 Inertia Friction Welding Process for MIL-STD-l252(WC) 1. This Military Standard is approved for use by all Departments and Agencies of the Department of Defense. 2. Recommended corrections, additions or deletions should be addressed to the Commander, Rock Island Arsenal, ATTN: SARRI-LE-S, Rock
3、 Island, Illinois, 61201. ii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-L252 TH 77777LL 0066428 T M i i Paragraph 1. 2. 3. 4. 4.5 4.6 4.7 MIL-STD-1252 30 JUN 1975 CONTENTS SCOPE Applicable Documents Definitions General Requirements Desig
4、n Conslderations Classification Upset Pag? 1 1 4 4 6 9 12 4.8 Flash 33 5. Detail Requirements 15 5.1.3 Weld Quality 16 5.2 Welding Procedures 17 5.3 Operator Qualification 18 6. Intended Use 20 1 . Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-flIL
5、-STD-L252 TH 77979LL 0066423 L MIL-STD-1252 30 JUN 1975 1. SCOPE 9 This standard contains design requirements and design cons derations for the use of inertia friction welding, requirements for certification of welding equipment, qualifi- cation of welding procedures, and qualification of operators
6、us- ing these procedures and equipment. 1.2 Classification Type and Class. Type 1. Weldments which have high stresses imposed on them or have severe fatigue requirements. Class A. Designates a solid stock joint or a solid stock joint subject to heat treatment after welding. For such a weld joint, no
7、 unwelded area is permitted. An unwelded center area will be acceptable only if the unwelded-area is removed by a subsequent .fabrication process. Class B. Designates a tubular configuration joint where no unwelded area is permitted. Flash should be removed from Type I weldments. This type and its c
8、lasses will be assigned to weldments in which failure could result in injury to personnel. f. Type II. Weldments which have light to moderate service stresses imposed on them or have low fatigue requirements, Class A. Designates a solid stock joint where center de- fects are acceptable. The acceptab
9、ility of such defects shall be determined by the procuring activity, but in any case the un- welded area shall not represent more than 10% of the total weld cross sectional area, Class B. Designates a joint involving a tubular configur- ation or a joint involving solid state components with nonessen
10、- tial metal removed from the center. Flash removal is-not mandatory for Type II weldments. This type and classes will be assigned to weldments in which failure will not result in injury to personnel. 2. Applicable Documents. 2.1 Government Documents. The following documents of the issue in effect o
11、n date of invitation for bids or request for herein. I 4 proposal form a part of the standards to the extent specified 1 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1252 TH 77777LL 0066430 8 I I MIL-STD-1252. 30 JUN 1975 I FEDERAL STANDAR
12、D Fed. Test Method Std. No. 151-Metals; Test Methods. (Activities outside the Federal Government may obtain copies of Federal Specifications and Standards as outlined under General Information in the Index of Federal Specifications and Standards and at prices indicated in the Index. The In- dex, whi
13、ch includes cumulative monthly supplements as issued, is for sale on a subscription basis by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 .-) (Single copies of this specification and other product spec- ifications required by activities outside the Federal
14、 Govern- ment for bidding purposes are available without charge at the General Services Administration Regional Offices in Boston, New York, Washington, D.C., Atlanta, Chicago, Kansas City, MO, Fort Worth, Denver, San Francisco, Los Angeles and Seattle, WA.) (Federal Government Activities may obtain
15、 copies of Federal Spec- ifications and Standards and the Index of Federal Specifications:. and Standards from established distribution points in their Agencies . 1 MILITARY SPECIFICATIONS . I MIL-1-6866 - Inspection, Penetrant Method of. MIL-1-6868 - Inspection Process, Magnetic Particle. MIL-1-687
16、0 - Inspection Program Requirements, Nondestruc- MIL-W-80244 - Welding Machines, Friction; Conventional MIL-H-8950 - Inspection, Ultrasonic, Wrought Metal, Pro- tive Testing, For Aircraft and Missile Mat- erials and Parts. and Inertia Types. cess for. MILITARY STANDARDS. MIL-STD-418 - Mechanical Tes
17、ts for Welded Joints. MIL-STD-453 - Inspection, Radiographic . (Copies of specifications, standards, drawings and publications required by suppliers in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer. ) 2 Provide
18、d by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-. MIL-STD-3252 TH 7777733 0066433 T MIL-STD-1252 30 JUN 1975 2.2 Other publications. The following documents form a part of this specification to the extent specified herein. Un- less otherwise indicated, the
19、issue in effect on date of invi- tation for bids or request for proposal shall apply. American Welding Society (AWS) Standard. AWS A2.0 r Welding Symbols AWS A2.2 - Nondestructive Testing Symbols AWS 4.0 - Standard Methods for Mechanical Testing Of Welds AWS B1.l - Welding Inspection- (Application f
20、or copies should be addressed to the American Weld- ing Society, 2501 N.W. 7th Street, Miami, PD 33125). American Society for Nondestructive Testing. SNT-TC-IA - Nondestructive Testing Handbook, Volume I and 11. (Application for copies should be addressed to the American Soc- iety for Nondestructive
21、 Testing Inc. 914 Chicago Ave. Evanston, Ill. 60202). American Society for Testing and Materials (ASTM) Publication. ASTM A370 - Mechanical Testing of Steel Products. ASTM E3 - Preparation of Metallographic Specimen$. ASTM E10 - Test for Brinell Hardness of Metallic Materials. ASTM E92 - Test for Vi
22、ckers Hardness of Metallic Materials. ASTM E94 - Recommended Practice for Radiographic Testing. ASTM E99 - Reference Radiographs for Steel Welds. ASTM El09 - Dry Powder Magnetic Particle Inspection. ASTM E112 - Estimating the Average Grain Size of Metals. ASTM El25 - Reference Photographs for Magnet
23、ic Particle Indications on Ferrous Castings. ASTM 138 - Wet Magnetic Particle Inspection. ASTM E164 - Ultrasonic Contact Inspection of Weldments. ASTM E165 - Liquid Penetrant Inspection. ASTM E309 - Recommended Practice f.or Eddy Current Testing of Steel Tubular Products with Magnetic Satur- ation.
24、(Application for copies should .be addressed to the American So- ciety for Testing and Materials, 1916 Race Street, Philadelphia, Pa . 19103. ) (Technical society and technical association specifications and . standards are generally available for reference from libraries. They are also distributed
25、among technical groups and using Fed- eral agencies. ) 3 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-L252 TH 77777LL 00bb1132 L = MIL-STD-1252 30 JUN 1975 3. Definitions. 3.1 Center Defect. This is a centrally located, unbond- ed section
26、of the faying surfaces. The lack of bonding may be caused by too low rotational velocity, too low.energy, exces- sive thrust load, joint configuration, faying surface condition or slippage in chuck or fixture, 3.1.1 Flash, Flash or weld flash is the material extrud- ed from the wmnterface due to the
27、 forging action of the applied thrust load. Flash will be obtained on both the 0.D and 1.D of tubular parts in equal amounts during the welding process. between the welded and unwelded components. Upset results from the displacement of the material at the weld interface and is dependent on weld ener
28、gy, rotation velocity and thrust load. 3.1.2 Weld upset or upset.loss is the difference in length 3.1.3 Inertial Mass and Weld Energy. a, Inertial Mass: MI = WK2 where W is weight in pounds of the flywheel assembly and K is the radius of gyration ln feet, Units: lb - ft2 Units: ft = lb 3.1.4 Paying
29、Surface. That surface of a member which Is in contact oranother member to which it is to be joined. 3.1.5 Joint Efficiency. The ratio of the strength, of a joint to the strength of the base metal (expressed in percent. 1 3.1.6 Thrust Force. The force exerted at the faying sur- face to produce fricti
30、on and upset. 4. General Requirement 4.1 Inertia Friction Welding. Two metallic parts to be joined are securely chucked, one in a tailstock fixture and the other ln the rotating spindle. The spindle rotation is brought to a predetermined R.P.M to produce the desired surface velocity and to generate
31、the proper level of kinetic energy in the rotat- ing Inertial mass (spindle mass). The flywheel may or may not 4 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-I MIL-STD-1252 30 JUN 1975 i be attached, depending on the kinetic energy requirements of
32、 specific applications. At the desired RPM the spindle drive is disengaged allowing only the kinetic energy to drive the spindle. When the drive has disen aged, the controlled hy- draulic ram pressure (thrust force 7 forces the parts together at the faying surfaces. The hydraulic ram may be mounted
33、either at the headstock or tailstock depending- on the design of the machine. Friction between the two surfaces converts the kinetic energy to heat which combines with the thrust force to create a forging action and welds the two parts together thereby stopping the spindle. 4.2 Materials. Material t
34、o be welded shall be in accord- ance with the material and heat treatment requirements specified on the applicable drawing(s). The materials specified shall meet the requirements of the latest issue of the material specifica- tions and standards in effect on the date of invitation for bids. 4.2.1 Fe
35、rrous, nonferrous and dissimilar metals may be welded by inertia welding. For information purposes table I is a partial list of motals and metal combinations which may be welded . TABLE I METALS JOINED BY ImTIA WELDING (PARTIAL LIST) SIMILAR METALS Carbon Steels Aluminum Alloys Cobalt Alloys Sintere
36、d Steels Copper Titanium Stainless Steels Brasses, Bronzes* Zincalloy Tool Steels Molybdenum Inconel Alloy Steels Waspalloy Nickel Alloys *except bearing types DISSIMILAR METALS High-speed steel to various Colbalt - base alloys to steel steels- 347 stainless to 17-4 PH Sintered steels to wrought ste
37、els Copper to 1100 or 6061 aluminum 316 stainless steel to in- Copper to medium - carbon steel cone1 Stainless steel to medium and low - carbon steels Aluminum bronze to medium carbon 1100 or 6061 aluminum to medium - carbon steel Nickel .- base alloys to steel 5 -. Copper to various brasses steel P
38、rovided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1252 TH 7779713 00681134 5 -II MIL-STD-1252 30 JUN 1975 4.2.2 The following are not recommended for inertia welding : a. Tin and leaded bronze bearing materials. c. Metals subject to “hot shortne
39、ss“. d. Carburized surfaces. . b. Steels containing over 15% lead, sulfur or sele- n ium . 4.2.3 Cast iron cannot be inertia welded. 4.3 Heat Treatment. Post-weld heat treatment of the weld zone may be needed to develop the required joint efficiency specified . is examinea metallographihally the hea
40、t affected zone (HAZ) shall be uniform across the smallest part joined. The HA2 shall be I free of discontinuities such as cracks, inclusions, porosity or brittle phases. Acceptance standards of the base metal spec- ifications shall be used to determine the acceptability of weld defects resulting fr
41、om inclusions and stringers in the base“ metal. There shall be indications of plastic flow of material at and adjacent to the faying surfaces. 4.4 Metallographic. When a section through the weld zone 4.5 Design considerations. 4.5.1 In inertia friction welding, one part is held stationary and the se
42、cond part is rotated. Designs which are readily adaptable to “Chucking“ are advantageous as tool- ing requirements are simplified. 4.5.2 Ideally the contact area should be circular, how- ever some deviation can be accommodated. Hexagonal and octa- gonal shapes can be welded, but radial orientation o
43、f corners may be impractical. Prior development of necessary tooling shall be considered before final design for other than round joints, or components which must have a controlled rotation relationship. The rotating members should be symmetrical to the center axis of the joint interface. It is poss
44、ible to rotate nonsym- metrical components by counterbalancing the chucking mechanism. But such designs should be finalized only after an economic evaluation. 4.5.3 As a general rule, the minimum cross-sectional area of the part and the surface area chucked should each be equal to the faying surface
45、 area. This is recommended to provide ad- equate gripping surface to avoid slippage, and to resist the Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-L252 TH m 77777LL 00661135 7 MIL-STD-1252 30 JUN 1975 torque developed during welding witho
46、ut deforming the part, In any circumstance, the material strength to cross section relationship must be such as will withstand a torque equiv- alent to a shearing stress of 12,000 - 15,000 PS1 at the weld interface. 4.5.4 Fr3ction weld joints are basically “butt“ joints, The five most basic variatio
47、ns are illustrated in Figure I. FIGURE I FIVE BASIC TYPES OF WELD JOINTS r“l TYPE 1 SOLID ROUND TO MATCHED SOLID ROUND TYPE 2 SOLID ROUND TO LARGER FLAT AREA TYPE 3 TUBULAR TO MATCHED TUBULAR COMPONENT “ 1 TYPE 4 TUBULAR TO LARGER FLAT ARM TYPE 5 TUBULAR COMPONENT TO SOLID ROUND COMPONENT 4.5.5 Angl
48、e joints are usually designed with faces 30“ to 45“ from the center line, although angles as low as 8“ have been made. For the more easily forged materials, the greater angles are preferred to prevent pushing the one part through the hole. Figure II illustrates two types of welding angular joints. 7
49、 i- Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-FIGURE II ANGULAR WELD JOINTS I TYPE 1 PLATE - BAR TYPE 2 TUBE - TUBE 4.5.6 If design strength requirements are such that the entire joint cross section need not be welded, consider removal of nonessent,ial metal from the center. See Figure III for illustration of the princi
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