1、 MIL-DTL- 45210B(MR)29 March 1999SUPERSEDINGMIL-W- 45210A(MR)15 January 1965DETAIL SPECIFICATIONWELDING, RESISTANCE, SPOT: WELDABLE ALUMINUM ALLOYSThis Specification is approved for use by all Departments and Agencies of theDepartment of Defense.1. SCOPE1.1 Scope . This specification covers resistan
2、ce spot welding procedures forweldable aluminum alloys.1.2 Materials . The materials to be welded under this specification includesheet, bar, and shapes of non heat-treatable alloys and the 60XX series of heat-treatable alloys.2. APPLICABLE DOCUMENTS2.1 General . The documents listed in this section
3、 are specified in sections 3and 4 of this specification. This section does not include documents in othersections of this specification or recommended for additional information or asexamples. While every effort has been made to ensure the completeness of thislist, document users are cautioned that
4、they must meet all specifiedrequirements cited in sections 3 and 4 of this specification, whether or notthey are listed.2.2 Non-Government Publications . The following documents form a part of thisspecification to the extent specified herein. Unless otherwise specified, theissues of the documents wh
5、ich are DoD adopted are those listed in the issue ofthe DoDISS cited in the solicitation. Unless otherwise specified, the issues ofdocuments not listed in the DoDISS are the issues of the documents cited in thesolicitation (see 6.2).AMERICAN WELDING SOCIETY (AWS)AWS- 4 Metals and Their Weldablity We
6、lding Handbook, Volume 4(Copies should be obtained from the American Welding Society, 550 NW LeJeuneRoad, Miami, FL 33126.)2.3 Order of precedence . In the event of a conflict between the text of thisdocument and the references cited herein, the text of this document takesprecedence. Nothing in this
7、 document, however, supersedes applicable laws andregulations unless a specific exemption has been obtained.AMSC N/A AREA THJMBeneficial comments (recommendations, additions, deletions) and anypertinent data which may be of use in improving this document should beaddressed to: Director, US Army Rese
8、arch Laboratory, Weapons and MaterialsResearch Directorate, ATTN : AMSRL-WM-M, Aberdeen Proving Ground, MD 21005-5069 by using the Standardization Document Improvement Proposal (DD Form1426) appearing at the end of this document or by letter.INCH-POUNDProvided by IHSNot for ResaleNo reproduction or
9、networking permitted without license from IHS-,-,-MIL-DTL- 45210B(MR)3. REQUIREMENTS3.1 First article . When specified in the contract or purchase order (see 6.2)and before production has commenced, samples of the specified item shall be madeavailable to the contracting officer or his authorized rep
10、resentative forapproval in accordance with 4.2 - 4.5. The approval of the first articlesamples authorizes the commencement of production but does not relieve thesupplier of responsibility for compliance with all applicable provisions of thisspecification. The first article samples and test forgings
11、shall bemanufactured by the process proposed for use on production.3.2 Recorded welding procedures . Unless otherwise specified in the contractor order, the contractor, prior to production fabrication of any weldment, shallestablish or have the manufacturer establish and record the cleaning and weld
12、ingprocedures to cover all welding to be performed under this specification. Achange in any of the factors listed in table I shall require revision of therecorded test procedures.3.3 Welding factors . The factors to be included in the welding procedureshall be as shown in table I.3.4 Surface prepara
13、tion . The material surfaces shall be cleaned by a suitablemethod to remove dirt, oils, and deleterious oxides in the weld area. Allrequired coatings or sealants shall be included as a part of the recordedwelding procedure and shall not be considered foreign matter.3.5 Welding equipment requirements
14、 .3.5.1 Welding machine . The welding machine shall consist of a suitable sourceof electrical energy, suitable electrodes, means of adequately cooling theelectrodes, and a means of reliably controlling and indicating the magnitude ofthe current, the welding force, and the time of current flow to ful
15、fill therequirements specified herein. The force and current controls shall operate sothat there is an absence of current flow (i.e. zero current) prior to applyingthe welding force at the electrodes. Also, the current shall be cut off beforethe force is removed.2Provided by IHSNot for ResaleNo repr
16、oduction or networking permitted without license from IHS-,-,-MIL-DTL- 45210B(MR)TABLE I. Factors in the recorded welding procedure and changes requiringquality control test ._Factors to be included Procedural changes requiringin recorded welding revised procedures and testprocedure_ _1. Metal alloy
17、 composition When a change in alloy or alloycomposition outside the aluminumproducers declared chemical range is made to either of the metals that areto be joined.2. Thickness range of metal When the thickness range is changed.3. Weld time range When weld cycle range is changed.4. Metal cleaning Whe
18、n method of cleaning is changed fromthe recorded methods in the weldingprocedure.5. Welding Current When current setting changes outside thedeclared range are made.6. Type of current When a change in type or polarity ismade.7. Electrode force range When changes outside the declared rangeare made._3.
19、5.2 Weld timer . The weld timer for single impulse welding shall be used tocontrol the following timing functions: squeeze time, weld time, and hold time.3.6 Shear load . For information (design) purposes, typical minimum ultimateshear load per spot weld shall be as shown in table II.TABLE II. Typic
20、al minimum ultimate shear loadper spot weld Typical minimum ultimateThickness (inch) shear load (pound-force) per spotthinner part * weld (for design purposes)0.10 500.020 1350.032 2350.040 3100.050 4300.063 6100.080 855 0.090 10000.100 11700.112 13400.125 1625* For intermediate thickness, direct in
21、terpolation may be used.3Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL- 45210B(MR)4. VERIFICATION4.1 Certification of welding equipment and recorded welding procedures . Priorto welding the first production assembly of each specific design,
22、 the contractoror the manufacturer, or both shall weld and test the welds in one assembly orspecimen under Government surveillance. The assembly or specimen shall bewelded in accordance with the recorded welding procedure. This certificationtest shall be carried out on each welding machine that will
23、 be used for theproduction of weldments for each specific design.4.1.1 Certification testing . The specific welding unit used must demonstratethat it has the electrical and mechanical capacity for producing the weldmentthat is being tested. Any new design and/or material used in a part must betested
24、 to ensure that the welding unit demonstrates an acceptable electrical andmechanical capacity for producing the new weldment. These tests shall becarried out on all welding machines used for production of weldments on each newdesign/material.4.2 Welding specimens . When a specimen is used, the mater
25、ial thickness,composition range, weld edge distance, spot spacing, and the general weld areacontour and metal fit shall be the same as the production part. When theapplication of weld primer or sealer is required by the recorded weldingprocedure for production assemblies, the specimens shall have th
26、ese materialsapplied before welding in the same manner as applied to the production parts.When a substantial amount of magnetic material such as the assembly fixtures,locators, etc., are inserted in the throat of the welding machine during thewelding of a production part, this condition shall be clo
27、sely duplicated for thespecimen.4.3 Visual examination of welded assembly or specimen . All welds shall besubject to visual examination. The outer surface of all welds shall be smoothand free of cracks, tip pickup, pits, metal expulsion, and other defects whichindicate that the welds were made with
28、contaminated electrodes, or withimproperly prepared surfaces.4.4 Tolerances . Tolerances on spot weld spacing and edge distance shall be inaccordance with applicable drawings.4.5 Peel testing . The welded assembly or specimen shall be subjected to thepeel test. The peel test shall be conducted by se
29、parating the welded componentsby driving a chisel between them in an unwelded area or by peeling one sheetback against the weld until failure occurs around the periphery of the weld oruntil the part fails. Failure of the base metal outside the weld area shall beconsidered evidence that the welds are
30、 satisfactory. The minimum average buttondiameter as measured in two perpendicular directions at the faying surface shallconform to table III.4Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL- 45210B(MR)TABLE III. Button diameter requirements
31、.Thickness of Minimum bottomthinner part, inch* diameter, inch*0 .010 0.080.020 0.110.032 0.14 0.040 0.160.050 0.180.063 0.200.080 0.230.090 0.240.100 0.260.112 0.270.125 0.28 _* For intermediate thickness, direct interpolation may be used. 4.6 Reporting of results . The manufacturer shall record th
32、e results of thiscertification and shall submit copies of the results together with the recordedwelding procedure through the contractor and contracting officer for review bythe procuring activity.4.7 Rejection . Failure of the welded assembly or specimens to meet therequirements for visual examinat
33、ion (see 4.3) or the peel test (see 4.5) shallresult in the rejection of the recorded welding procedure.4.8 Quality control . The contractor shall establish or have the manufacturerestablish and use a systematic quality control procedure.4.9 Sampling . Periodically during a production run, a welded
34、assembly orspecimen shall be tested as outlined in paragraphs 4.3, 4.4, and 4.5. Thefrequency of this testing shall be specified by the contracting officer afterreviewing the production rates and types of assemblies. The contractor or themanufacturer, or both, shall keep a record of these tests indi
35、cating date, time,machine identification, machine settings, and results. 4.10 Rejected Welds . If unsatisfactory welds are found during a productionquality control inspection, the production run shall be stopped and necessarycorrections made to the equipment or welding procedure. After correction, a
36、weldment or comparable specimen shall be welded and shall conform to theinspection requirements in 4.3, 4.4, and 4.5 before resuming production. Theseries of weldments in the period subsequent to the last acceptance qualitycontrol inspection shall be rejected or may be rewelded in accordance with 4.
37、11.4.11 Rewelding of rejected weldments . A weldment from each rejected series maybe rewelded in accordance with the corrected procedure. The repaired weldmentshall be tested for compliance with 4.3, 4.4, and 4.5. If the weldment passesthe inspection requirements, the remainder of the rejected serie
38、s of weldmentsmay be rewelded in accordance with the corrected procedure. A sample shall notbe used for determining weld quality of repair welding.5Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL- 45210B(MR)5.0 PACKAGING5.1 Packaging . For ac
39、quisition purposes, the packaging requirements shall beas specified in the contract or order (see 6.2). When actual packaging ofmateriel is to be performed by DoD personnel, these personnel need to contactthe responsible packaging activity to ascertain requisite packagingrequirements. Packaging requ
40、irements are maintained by the Inventory ControlPoints packaging activity within the Military Department or Defense Agencywithin the Military Departments System Command. Packaging data retrieval isavailable from the managing Military Departments or Defense Agencys automatedpackaging files, CD-ROM pr
41、oducts, or by contacting the responsible packagingactivity.6. NOTES(This section contains information of a general or explanatory nature that maybe helpful, but is not mandatory.)6.1 Intended use . Resistance welding under this specification is militaryunique. It is used in spot welding of weldable
42、aluminum alloys used for stowageboxes, vehicle fenders, air ducts, van skins, etc.6.2 Ordering Data . Purchasers should exercise any desired options offeredherein and acquisition documents should specify the following:(a) Title, number, and date of this specification.(b) Type of material (see 1.2).(
43、c) Issue of DoDISS to be cited in the solicitation, and if required, thespecific issue of individual documents referenced (see 2.2).(d) When first article is required (see 3.1).(e) Mechanical properties, if different from table II (see 3.6)(f) Destination of test samples (see 4.5).(g) Packaging requ
44、irements (see 5.1).6.3 Definitions .6.3.1 Contractor . The term “contractor” is defined as the organization havinga direct contract with the procuring activity.6.3.2 Contracting officer . The term “contracting officer” means the personexecuting a contract on behalf of the Government and any other of
45、ficer.6.3.3 Manufacturer . The term “manufacturer” is defined as the organizationactually performing the operations covered by this specification.6.3.4 Procuring activity . The term “procuring activity” refers to the activityof the Government which actually initiates the request for procurement andm
46、aintains the records of the procurement.6.4 Reference information . The Welding Handbook Volume 4, Metals and TheirWeldability contains information pertaining to minimum spot weld spacing.6Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL- 4521
47、0B(MR)6.5 Subject term (key word) listing .certificationnon heat-treatable alloyspeel test60XX heat-treatable alloysshear loadwelding machineweldmentsweld timerCONCLUDING MATERIALCustodian: Preparing activity:Army MR Army MRProject No. THJM-A4057Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL- 45210B(MR)STANDARDIZATION DOCUMENT IMPROVEMENT PROPOSALINSTRUCTIONS1. The preparing activit
