1、_. MIL-HDBK-507 _ - . _ 70 02bY360 482 _- -. NOTE; MIL-STD-336 has been redesignated as a handbook, and is to be used for guidance purposes only. This document is na langer to be cited as a requirement. For administrative expediency, the only physical change fiom MIT,-STD-336 is thia cover page. How
2、ever, this document is no longer to be cited as a requirement. If cited as a requirement, contractors may disregard the requirements ofthis document and interpret its contents only as guidance. MIL,-HDBK-507 27 February 1998 DEPARTMENT OF DEFENSE HANDBOOK WELDING, FLASH, STANDARD LOW CARBON STEEL AM
3、SC N/A AREATHJM DISTRTBLTION STATEMENTA. Approved for public release; distribution is unlimited. . Licensed by Information Handling ServicesMIL-HDBK-507 9999970 02b43bL 317 NIL-STD-336 DEPARTHENT OF DEFENSE Washington, Dc 20301 Welding, Flach, Standard Lou Carbon Steel 1. This HTlitary Scrndard is a
4、pproved for use by all Departmento and Agtnciee of the Department of Defense. 2. Beneficial comments (recommendations, sdditione, deletions) and any pertinent data which may be of use in improving this document thoold be addressed to: US Army Tank-Automotive Command, ATTN: AHSA-GDS, Warren, ML 48397
5、-5000, by using the self-addressed Standardization Document improvement Proposal D Form 1426) appearlng at the end OE this document or by letter. Licensed by Information Handling ServicesMIL-HDBK-507 D 9999970 0264362 255 MIL-STD-336 FOREWORD This document contains information on a welding process w
6、here fusion is achieved over the entire abutting surfaces o two plates, bars or tubes wfthout utilization of filler metal in one welding operatioh This fusion fs achieved by the heat generated by the resistance to the flow of electric current between the feying surfaces followed by the application o
7、f pressure when the requited heating is completed. ._. Licensed by Information Handling ServicesMIL-HDBK-507 9999970 0264363 191 Paragraph 1 . 1.1 2 . 2.1 2.1.1 2.2 2.3 3 . 3 . t 3.1. I 3.1.2 3.1.3 3.1.4 3.1-5 3.1.7 3.1.6 4 . 4.1 4.1.1 !. . ! . 3 4.1.3 4.1.4 4.1.5 4.1.6 4.2 4.2.1 4.3 5 . 5.1 5.1. 1
8、5.1. 1.1 5 .I. 1.2 5 . 1.1.3 5,i.!t 5.2 5.2.1 5.2.2 5.2.3 5.2.3. ! 3.2.3.2 MIL-STD-336 CONENTC SCOPE Scope . REFERENCED DOCUMENTS . Government documents Specification . Other publications Order of .recedence. DEFINITIONS Definitions . Faying surface Plash . Production run Upset distance Weld failure
9、. Flash welding . Upset. GENERAL REQUIREMENTS . Requirements Equipment . ny, leti3n . Electrodes Control of machine variables Welding schedules . Flash removal . Materiais . Cleaning Incpeccion requirements . DETAILED REQUIREHE.TS Joint preparation . Joint alignnient tolerances Sheet and tubular joi
10、nts Bars Angular misalijinment. . Limitation on tubiog. . Certification of welding schedulps Flash velding schcdules . Welding schedule content General. Existing scheduies or mndffication of existing schedu!ps . EstabLishing welding schedules 1 1 4 4 4 1 4 4 4 4 L, 5 5 6 6 6 6 6 6 E 6 b e 9 9 9 . .
11、iv . Licensed by Information Handling ServicesMIL-HDBK-507 D 9999970 02b43b4 O28 MIL-STD-3 36 CONTENTS . Continued . Paragraph 5.2.4 5.2.5 5.3 5 . 3.1 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.1.5 504.6 5.5 5.5.1 5.5.2 5.6 5.6.1 5e7 Production run Individual part cer.ification . Certification test specimens Typ
12、es of specimens Test procedures . Contractor inspection . Production control Sample testing Visual examination Destructive tensfle teSts . Tensile test., Test requiremenrs.D . Whole specimens . Machine malntenance . Rerests . Cerrificatfon of equipment . Strip teat coupons 6 . NOTESe. 6.1 Intended u
13、se.,*. 6.2 Proceetive stmoephets uelding . 6.3 Subject tem (key word) listing . FIGURES Figure 1 . Recommended end preparation for flash butt welding of tubing. flac sheet. and ba.6 Figure 2 . Record of welding schedule Page_ 9 9 9 9 10 10 10 io 10 10 10 IO 10 11 11 11 II 12 12 12 l? 7 8 V Licensed
14、by Information Handling ServicesMIL-HDBK-507 9979970 02b43b5 Tb4 MIL-STD-3 36 1, SCOPE 1.1 Scope. This standard covers procedures for the flash welding of standard low carbon steels with a carbon content not greater than 0.23. u I Licensed by Information Handling ServicesMIL-HDBK-507 W 9999970 02b43
15、bb 9TO MIL-CID-336 2. REFERENCED DOCWENT 2.1 Government document. 2.1.1 Specifications. Unless otherwise specified, the folloving specification of the issue listed in that issue of the Department of 9efense Index of Specifications and Standards DoDISS) specified in the solicitation forms a part of t
16、his standard to the extent specified herein. SPEC 1F ICATI ON MILITARY MIL-U-6873 - Welding; Flash, Carbon and Alloy Steel (Copies of specifications, standards, handbooks, drawings, publications, and other Government documents required by the contractors in connection with specific acquisition funct
17、ions should be obtained from the contracting activity or as directed by the contracting activity.) 2.2 Other publications. The following document (SI form a part of this standard to the extent specified herein. Unless otherwise specified, the issues of the documents which are Don adopted shall be th
18、ose listed in the issue of the DODLSS specified in the solicitation. Unless otherwise specified, the issues of documents not listed in the WDISC shall be the issue of the nongovernrnentai documents which is current on the date of the solicitation ASRI A370 - Mechanical Testing of Steel Products, AST
19、M Ea - Tension Testing of Metallic Materials. (Application for copies should be addressed to American Society for Testing an Materials, 1916 Race Street, Philadelphia, PA 19203.) AMERICAN UELDING SOCIETY hNSI/AWS A3. O - Standard Welding Terms and Definitions. (Applications for copies should be addr
20、essed to American gelding Society, Inc., 550 N.W. LeJeune Road, P.O. Box 351040, Niaai, Florida 33135.) (Nongovernment standards are generally available for reference from libraries. They are also distributed among nongovernment standards bodies and using Federal agencies. 2.3 Order of precedence. T
21、n the everit of a conflict becueen che rext OE this standard and the references cited herein, the text of th from joints in hollow shapes will not he required. 4.2 Materials. Standard low carbon steels of not greater than 0.23 carbor! content may be welded provided thnc all requirements of this stan
22、dard are met. 4 Licensed by Information Handling ServicesMIL-HDBK-SO7 = 9999970 O264369 bOT MIL-STD-336 4.2.1 Cleaning. The surfaces of the parrs contacting the electrodes, and the surfaces at the fusion zones, shall be clean end free from oxides, pains, grease, dirt or foreign matter which would in
23、terfere with the flow of current or fusion of the metal. preferred. to remove Imbedded sand particles prior to welding. Chemical cleaning or grit blasting are 4- Ssnd blasting may be employed provided the surfaces ate treated 4.3 Inspection requirements. Flash welded joints shall be sound and free f
24、rom injurious defects such as cracks, inclusions, die burns and porosity which afEccr the strength or serviceability OF the part. 5 Licensed by Information Handling ServicesMIL-HDBK-507 m 9999770 02b4370 321 MIL-STD-336 5. DETAILED REQUIREMENTS 5.1 - Joint preparation. Joints shall be designed and p
25、repared such that mating parts be aligned in a manner that the heat generated by the flow of current will be unifornily distributed over the section. joint preparation shall be deternined by the cantractor and shall becutne a part of the welding schedule. Recommended practices are shown in figure I.
26、 The details of 5.1. i Joint alignment tolerances. 5.1.1.1 Sheet and tubular joints. Far sheet thickness or wall thickness of tubing 0.080 inch and less, the misalignment of thickness shall not exceed 0.00e inch. For sheet or wall thickness greater than 0.080 inch, the misaiignment of thickness shal
27、l not exceed 10% of the nominal seccion thickness up to a maximum of 0.030 inch, except for the following two higher ratios where a smaller misalignment is required. O. D. Wail Ratio Misalignment Tolerance (maximum) Percent Maximum 35: 1 b 40: I 4 Misalignment shall be measured at, or near, the plan
28、e of the veld before the flash is removed. 5.1.1.2 CI Bars. The misalignment of the surfaces in joints between bars and rode shall noi, - ri -I 5.1.1.3 Angular misalignment. The angular misalignment of the welded joints shall not exceed 0.005 inch per inch of length. 5.1.1.4 Linftation on tubing. Tu
29、bing possessing a ratio of outside diameter ro wall thickness of greater than 30:l shall not be flash-uelded unless the equipment is c8pable of meettng the more rigid alignment tolerances or 35:l and 40:1 ratios specified in S.1.l.i. 5.2 Certification of welding schedules. 5.2.1 Flash welding schedu
30、les. Welding schedules shall be established by the contractor for each joint differing in material, area or contour from joints previously welded in accordance with approved schedules, or for each welding machine over an appropriate range of cross-sectional area, or wall thickness or both. h License
31、d by Information Handling ServicesL MIL-HDBK-CU7 9999770 0261i373 268 M IL - STD- 3 36 .O31 FLAT .O65 PLAIE - 7 +.O62 FLAT NOTE: a. THE ENDS OF PARTS TO BE UELDEO SHALL BE CUT SQUARE MITHIN PLUS OR MINUS 1/2 A DEGREE. b. UHEN THE NWINAl STOCK THICKNESS EXCEEDS THE VALUES GiVEN in THIS FIGURE, CHAMFE
32、R ONE OF THE PARTS AS SHOMN. IN THE EVEN7 IDENTICAL PARTS ARE TO BE YELDED TO EACH OTHER RESULTlNG IN EACH BEING CHAHFERED, CHANGE THE ANGLE TO 10. UNLESS OTHERWISE SPECiFIED. DIMENSIOf(5 ARE IN INCHES. FIGURE 1. Recamended end preparation for flash butt welding of tubing, flat sheets, and bar. CI 7
33、 Licensed by Information Handling ServicesMIL-HDBK-507 = 9999970 0264372 LT4 -. I I l tl IL-STD-3 36 5.2.2 Weld schedule content, A complete uelding schedule shall include the preparation of the pacts to be uelded, choice of electrodes and fittings, and appropriate machine conrrol devices and Settin
34、gs to provide the proper sequence of events. A typical Elesh welding schedule is shown in figure 2. .- - - . . - . . - - _. - - . - - - - i I Manufacturer of machine Type and serial number Capacity of machine - Transformer tap setting Transformer turna ratio Secondary voltage ( Approx) Flashing time
35、 (seconds) Beginning of upset to current cutoff - Burnaf f (inches) Upset travel (inchem) Platen travel control cam (when used) Area of electrode contact areas Work locatets employed Htsrizl id sutf;e candf:?cn Details of joint prcparacion: (Show sketch and dimensions.) * Signature (Welding Engr) *
36、Signature Covt inspector) *Note: The supervisory welding engineer or suthorized alternates and the authorized Government Inspector shall sign schedule form. FIGURE 2. Typical welding scheduie. 8 i l i l i i I i i I i I i I i i I ! i I I I I i i I i i i i i i i i I I I I I -1 I I I i 1 i I i i I I i
37、i ! i l I I i i l i i i i i i 1 I I I i i I .- i i i i I i Licensed by Information Handling Services- 9979970 02b4373 030 MIL-HDBK-SO? _. _-_. . 5.2.3 Establishing welding schedules. 5.2.3.1 General. The three initial welding schedules established by the u contractor for a given machine shall repres
38、ent joints of che greatest and least cross-sectional areas to be welded in production plus one joint of fntermediate area. consistency of the resulting relds, 15 or more specimens shall be welded at each of the 3 points, the welds tested to destruction in tension or bending, and the test data submit
39、ted to the authorized inspector with a request for approval of the welding schedules represented. AcsernbIiec welded with the respective machine shall not be acceptable as item furnished on a Government contract untii approval of the welding .schedules has been obtained. schedules shall not be chang
40、ed during a production run, except as provided in 5.2.3.2. To deteraine the acceptability of the settings and the Weld 5.2.3.2 Additional schedules or modiffc?.tion of existing schedules. To weld parts with cross-ecctional areas oLher than those specff ically checked above, or to accomplish mfnor nb
41、dification of existing schedules as may be necessary, the contractor shall demonstrate that the settings for these secondary paints are acceptable on five sample parts or control speclmens. If unsatisfactory results are obtained for a secondary point, 2 sample of 15 shall be run to check the point,
42、after suitable adjustments in settings haw been made. required, but complete records shall be made readily available to opersting personnel and authorized inspection personnel or reference at any time. Specific approval of each additional schedule will not be 5.2.4 Production run. Unless otherwise s
43、pecified, one setting of the machine shall aatinfwtnrily ueld*thP maXimi.im aqd mini.rniirn cross-sertinna1 areas scheduled during a production run. during a run without the approval of the authorized inspector- u Ho change in setting shall be made 5.2.5 Indfcidual part certification. Uhen one, or a
44、 limited number of joint types are to be welded in production end complete qualification of the machine is not constdercd necessary or desirable, the contractor may establish individual schedules on the basic of 15 test specimens, subject to approval by the authorized inspector. 5.3 Certification te
45、st specimens. Either production parts or simuleted parcs may be used In welding certiffcation test specimens* be prepared under productfon conditonc. The mating surfaces to be joined and the electrode contact areas shall be indentical with the production part in cross-sectional area, contour, and fi
46、nish. The joints shall be welded in accordance uf th Che proposed welding procedure and with the requi rments speciied herein. The parts shall 5,3,1 ppri of spcirnens. Spceimrinci shall be tested in full SeCtiOn vhenever practicable. fill1 section, tensile coupons conforming to an appropriate type,
47、as defined under ASRI E8 may be Cikt from locations, such that the weld zone is included in the test section. The aggregate ueld area of the coupons shall be approrimately 50X of the area of the weld joint represented. Where test specimens are too large to be tested In 9 Licensed by Information Hand
48、ling ServicesMIL-HDBK-507 = 9997970 0264374 Ti7 E MIL-STD-336 5.4 Test procedures. 5.4.1 Contractor inspection. Unless otherwise specified, the contractor is responsible or the performance of all inspection requirements as specified herein. any of the inspections set forth in this standard. The Gove
49、rnment reserves the right to perform DK witness 5.4.2 Production control. All specimens required herein for checking production flash welding shall be welded in accordance with the established schedule. 5.4.3 Sample testing. Llnless otherwise specified on the drawing, in the contract, or order, the amount and type of testing other than visual, shall be performed at the discretion of the Government inspector. 5.4.4 Visual examination. Each flach-welded joint shall be examined for cracks, die burns, telescoping, and other indfcations of unsound ueId!
