1、AMSC N/A AREA MFFP DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. METRIC MIL-STD-3049 5 September 2013 DEPARTMENT OF DEFENSE MANUFACTURING PROCESS STANDARD MATERIALS DEPOSITION, DDM: DIRECT DEPOSITION OF METAL FOR REMANUFACTURE, RESTORATION AND RECOATINGProvided by
2、 IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 ii FOREWORD 1. This standard is approved for use by all Departments and Agencies of the Department of Defense. 2. This standard defines the requirements for material selection, qualification, and insp
3、ection of components that will be repaired by Direct Deposition of Metal (DDM) of a metallic feedstock to a metallic substrate. This process is used for, but is not limited to, remanufacture of damaged and or worn parts, restoration of dimensionally discrepant parts, or part performance enhancement
4、with corrosion, wear and thermal protection. 3. Comments, suggestions, or questions on this document should be addressed to U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-EN/STND/TRANS MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or emailed to usar
5、my.detroit.rdecom.mbx.tardec-standardizationmail.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https:/assist.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license
6、from IHS-,-,-MIL-STD-3049 iii CONTENTS PARAGRAPH PAGE FOREWORD ii 1. SCOPE 1 1.1 Purpose 1 1.2 Process 1 1.3 Application 2 1.4 Limitations 2 2. APPLICABLE DOCUMENTS 3 2.1 General 3 2.2 Non-Government Documents 3 3. DEFINITIONS 5 4. GENERAL REQUIREMENTS 6 4.1 Part Eligibility 6 4.2 Feedstock 7 4.3 Ga
7、s 8 4.4 Fixturing 8 4.5 Deposition Process Control 8 4.6 Identification 9 5. DETAILED REQUIREMENTS 9 5.1 Procedure Qualification Record 9 5.2 Material Process Development 9 5.3 Part Repair Process Development 10 5.4 Part Repair Process Validation 11 5.5 Validation of PQR 13 6. NOTES 16 6.1 Intended
8、Use 16 6.2 Acquisition Requirements 16 6.3 Subject Term (key word) Listing 16Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 1 1. SCOPE 1.1 Purpose. This standard defines the requirements for material selection, qualification, and inspec
9、tion of components that will be repaired by Direct Deposition of Metal (DDM) of a metallic feedstock to a metallic substrate. This process is used for, but is not limited to, remanufacture of damaged and or worn parts, restoration of dimensionally discrepant parts, or part performance enhancement wi
10、th corrosion, wear and thermal protection. 1.2 Process. Direct Deposition of Metal is an additive manufacturing process, as defined in ASTM F2921, facilitating the building of surface layers to remanufacture or restore parts. In general, the process involves a preparatory effort to the substrate and
11、 fixture development, as required, to retain the work piece during the deposition process. Following Direct Deposition of Metal, the work piece undergoes post deposition processing such as grinding to meet dimensional requirements. Figure 1 below displays the DDM process. FIGURE 1. Direct Deposition
12、 of Metal Process. The process is conducted under an inert atmosphere or under vacuum. The surface of a substrate is prepared and then heated using a heat input such as laser or electron beam to form a melt pool. A feed material such as metal powder or filler wire is directed onto the substrate melt
13、 pool. The feedstock melts and upon cooling, solidifies unto the substrate to form a deposit as shown in Figure 2. The deposition thickness and width can vary and multiple layers can be applied to increase the deposition thickness. Fixture Development for Work piece, as required Substrate Surface Pr
14、eparation Direct Deposition of Metal Post Deposition Processing Processing of a three dimensional (3D) part model and machine path programming Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 2 FIGURE 2. Deposition on Substrate. 1.3 Appli
15、cation. This standard is to be used for the remanufacture, restoration or resurfacing of components by Direct Deposition of Metal. The Direct Deposition of Metal process is used to produce dense, pure, thick and well-bonded deposits of various metals and alloys, such as aluminum (Al), copper (Cu), n
16、ickel (Ni), titanium (Ti), as well as stainless steel, nickel-base alloys. Direct Deposition of Metal can be used to provide protective coatings and performance enhancing layers, such as corrosion, wear, thermal properties. 1.4 Limitations. This standard is not intended to be guidance for: a. Safety
17、 This standard does not purport to address all of the safety concerns associated with the Direct Deposition of Metal process. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to
18、use. Personnel involved with Direct Deposition of Metal machinery such as lasers or electron beam should always read, understand, and follow all of the safety guidelines provided by the machine tool manufacturer, as well as all other applicable pertinent safety standards. b. Machine and Equipment -
19、This standard does not cover specific machine and equipment requirements. Personnel involved with the use of Direct Deposition of Metal machinery are to follow equipment installation and system verification guidelines provided by the machine tool manufacturer. c. Manufacturing Components This standa
20、rd is intended for remanufacture, restoration or resurfacing processes only and does not cover the manufacture of net shape or components from seed. d. Non-metallic materials The standard is restricted to the primary use of various metallic feedstocks and metallic substrates. Heat Input Deposition F
21、eed Substrate Melt Pool Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 3 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this standard. This section does not include docu
22、ments cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of
23、this standard, whether or not they are listed. 2.2 Non-Government documents. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. GENERAL MOTORS CORPORATION (GM)
24、 GMW14872 - Cyclic Corrosion Laboratory Test (Copies of this document are available from General Motors North America, c/o Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112 or or as directed by the contracting officer.) AMERICAN SOCIETY FOR QUALITY (ASQ) ANSI/ASQ Z1.4 - Sampl
25、ing Procedures and Tables for Inspection by Attributes (Copies of this document are available from www.asq.org or American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203.) AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) ASME Y14.43 - Dimensioning and Tolerancing Principles for
26、 Gages and Fixtures (Copies of these documents are available online at http:/www.asme.org or from American Society of Mechanical Engineers, Orders/Inquiries, P.O. Box 2300, Fairfield, NJ 07007-2300.) ASTM INTERNATIONAL ASTM B557 / B557M - Standard Test Methods for Tension Testing Wrought and Cast Al
27、uminum- and Magnesium-Alloy Products Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 4 ASTM C633 - Standard Test Method for Adhesion or Cohesion Strength of Thermal Spray Coatings ASTM E8 / E8M - Standard Test Methods for Tension Testing
28、 of Metallic Materials ASTM E94 - Standard Guide for Radiographic Examination ASTM E606 / E606M - Standard Test Methods for Strain-Controlled Fatigue Testing ASTM F2921 - Standard Terminology for Additive ManufacturingCoordinate Systems and Test Methodologies ASTM G65 - Standard Test Method for Meas
29、uring Abrasion Using the Dry Sand/Rubber Wheel Apparatus ASTM D1002 - Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal) ASTM D2295 - Standard Test Method for Strength Properties of Adhesives in Shear by Tension
30、Loading at Elevated Temperatures (Metal-to-Metal) ASTM D3846 - Standard Test Method for In-Plane Shear Strength of Reinforced Plastics ASTM E1030 - Standard Test Method for Radiographic Examination of Metallic Castings ASTM E18 - Standard Test Methods for Rockwell Hardness of Metallic Materials ASTM
31、 E10 - Standard Test Method for Brinell Hardness of Metallic Materials ASTM E384 - Standard Test Method for Knoop and Vickers Hardness of Materials ASTM B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus (Copies of these documents are available from www.astm.org or ASTM International,
32、 P.O. Box C700, West Conshohocken, PA 19428-2959.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 5 AMERICAN WELDING SOCIETY (AWS) AWS A5.32 / A5.32M - Filler Metal Specification For Shielding Gases For Welding (Copies of these document
33、s are available from www.aws.org or American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.) SAE INTERNATIONAL SAE AMS 2680C - Aerospace Material Specification Electron Beam-Welding For Fatigue Critical Applications (Copies of these documents are available from www.sae.org or SAE Customer
34、Service, 400 Commonwealth Drive, Warrendale, PA 15096-0001.) 2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence unless otherwise noted. Nothing in this document, however, supersedes applica
35、ble laws and regulations unless a specific exemption has been obtained. 3. DEFINITIONS 3.1 Direct Deposition of Metal. Additive manufacturing process that builds layers of feedstock (e.g. powder or wire) metal onto a substrate. 3.2 Substrate. The material, work piece, part, component or substance on
36、 which metal is deposited by a feed. 3.3 Feed. A material delivery mechanism, that delivers material in the form of powder or wire to create the deposition. 3.4 Feedstock. The feedstock for the direct metal deposition process should be either metallic wire or powder. 3.4 Essential Variables. Those e
37、lements, either material or process, that are critical in establishing the deposition procedure. These elements and the values should be documented as part of the Part Qualification Record (PQR), e.g. power, scanning velocity, energy source diameter, feedstock feed rate. Changes in these elements, a
38、fter a part has been qualified, require a change in the written PQR and may require requalification, depending on the element being changed and the magnitude of the change. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 6 3.5 Control Pa
39、rameters. Those process elements that are important in the deposition procedure and generally remain constant or within a limited tolerance. These elements should be documented in the PQR and often include elements associated with specific equipment and feedstock being used for the deposition. 3.6 P
40、ass. A single traverse by the nozzle over the work piece. 3.7 Layer. Multiple passes over the work piece that result in complete coverage. 3.8 Major Parts (fixturing). Parts that have specific GD&T requirements on drawing (nominal and allowed tolerance). 3.9 Minor Parts (fixturing). Parts that do no
41、t have specific GD&T requirements on drawing. 3.10 Heat input on substrate. Measurement of the heat applied to the substrate (combination of power and scanning velocity) which is an example of an Essential Variable. 3.11 Procedure Qualification Record. The Procedure Qualification Record (PQR) is a r
42、ecord that contains all the essential variables and control parameters of the process that are used to remanufacturer, restore or resurface components. PQR also contains fixturing requirements and test records. 4. GENERAL REQUIREMENTS 4.1 Part Eligibility. The parts shall be identified as candidate
43、for Direct Deposition of Metal processing. Eligible candidates shall have no through-fractures and application of Direct Deposition of Metal requires approval by a design responsible engineer. Completely fractured parts are ineligible for remanufacturing, restoration or surface enhancement. 4.1.1 In
44、coming Inspection. Received part(s) shall be inspected to verify suitability, for repair, using NDT methods including, but not limited to the following: a. Visual (see 5.5.1.1) b. Magnetic Particle Inspection (see 5.5.1.4) c. Dye Penetrant (see 5.5.1.3) d. X-Ray (see 5.5.1.2) 4.1.2 Surface Preparati
45、on 4.1.2.1 Cleaning of Surfaces. All surfaces, to receive deposits shall be thoroughly cleaned to remove oil, grease, dirt, paint, oxidation and other foreign materials. Cleaning procedures shall not embrittle, pit, or damage surfaces to be coated. Specifically noted is a restriction of acidic chemi
46、cal cleaning, which shall not be used on hardened steel surfaces above Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3049 7 HRC 35 due to risk of hydrogen embrittlement. Cleaning shall take place no more than four hours prior to processing
47、using Direct Deposition of Metal. 4.1.2.2 Surface Modification. Existing surfaces can be modified by machining, grinding or other as appropriate process. All carburized, nitrated or otherwise surface modified substrates shall be removed prior to DDM. Hardened surfaces above HRC 35 of substrates may
48、require pre-annealing to soften material for improved Direct Deposition of Metal processing. 4.1.2.3 Abrasive Blast. To decrease the surface reflectance, the surfaces designated for Direct Deposition of Metal shall be abrasive blasted. Aluminum shall not be abrasive blasted due to entrapment of particles and potential porosity. 4.1.2.3.1 Blast Contamination. All blast media shall be free of contamination that will affect the substrate material, for example a blasting cabinet and media that had been used on ferrous substrates in the past, shall not be used to blast nonferrous substra
