1、MIL-W-46154(MR) 20 October 1970 . MILITARY SPECIFICATION WELDING, RESISTANCE, SPOT AND PROJECTION FOR FABRICATING ASSEMBLSES OF CARBON STEEL SHEETS 1. SCOPE 1.1 Typ e of welding. This specification covers the spot and projection resistance welding of carbon steel sheet fabricated assemblies in the c
2、arbon range of 0.40 to 0.60 percent (see 4.1 and 8.1). 1.2 Materials. The materials to be welded under this specification include, light steel sheets. . 2. APPLICABLE DOCUMENTS 2.1 The following documents of the issue in effect on date of invitation for bids or request for proposal, form a part of t
3、his specification to the extent specified herein. SPECIEICATIONS MILITARY MIL-1-45208 - Inspection Requirements, General Specification for STANDARDS MILITARY MIL-STD-20 - Welding Terms and Definitions (Copies of specifications, standards, and drawings required by contractors in connection with speci
4、fic procurement functions should be obtained from the procuring activity or as directed by the contracting officer.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-W-46254 TH 7777706 O250365 2 = MIL-W -46154 (MR) - 2.2 Other publications. The fo
5、llowing documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of invitation for bids or request for proposal shall apply. AMERICAN WELDING SOCIETY AWS A2.0-58 - Standard Welding Symbols Resistance Welding - Theory and Use
6、(Application for copies should be addressed to the American Welding Society, United Engineering Center, 345 East 47th Street, New York, New York.) RESISTANCE WELDER MANUFACTURERS ASSOCUTION Resistance Welding Manual (Application for copies should be addressed to the Resistance Welder Manufacturers A
7、ssociation, 1900 Arch Street, Philadelphia, Pa. 19103.) 3. PROCEDURE REQUIREMENTS 3.1 Recorded cleaning and welding procedures. Unless otherwise specified in the contract or order, the contractor, prior to production fabrication of any weldment shall establish or have the manufacturer establish and
8、record the cleaning, surface preparation, and welding procedures to cover all welding to be performed under this specification. This information shall be prepared in duplicate on an approved form (see appendix) utilizing symbols and terms in accordance with AWS A2.0-58, MIL-STD-20, or as specified o
9、n the drawing. The cover sheet shall be signed by the manufacturer and the contractor. corded cleaning and welding procedure shall be submitted to the procuring activity with the test records as specified in 6.4. factors listed in table I shall require revision of the recorded test procedure 3.2 Fac
10、tors. The factors to be included in the cleaning and welding proce- The re- Any changes in any of the dure shall be as shown in table I. . -. . e 2 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NIL-W-qbLSq TH = 9999906 O250366 3 MIL-W-46154(MR) Tab
11、le I - Factors in the recorded cleaninR and welding procedures and changes requiring quality control tests Factors to be included in Procedure changes requiring revised recorded welding procedure procedures and tests 1. Base metal composition 2. Thickness range of metal 3. Welding heat schedule 4. M
12、etal cleaning and surface pre- parat i on 5. Welding current range 6. Electrode force range When a change in composition outside the producers declared chemical range is made to either of the metals to be j oined. When the thickness range is changed. When-weld cycle range is changed. When method of
13、cleaning and preparation is changed. When current setting changes outside the declared range are made. When changes in electrode force out- side the declared range are made. 4. MAJImIAL REQUIREMENTS 4.1 Carbon content. The maximum carbon content of any material to be welded shall be in the range of
14、0.40 to 0.60 percent (see 8.4). 4.2 Surface preparation. The material surfaces shall be cleaned by a suitable method and shall be free from dirt, oil, and oxides in the weld area. The application of coatings or sealers, when required, shall be included as a part of the recorded welding procedure and
15、 shall not be considered foreign matter. 5. WELDING EQUIPMENT REQUIREMENTS 5.1 Welding machine. The welding machine shall consist of a suitable source of electrical energy, suitable electrodes, means of adequately cooling the electrodes, means of reliably controlling the magnitude of the current, th
16、e welding force, and the time of current flow to fulfill the requirements specified herein, and, when applicable, means of controlling the magnitude of current flow during tempering. so that no current flows until the static welding force is applied at the welding electrodes. The current shall be cu
17、t off before the force is removed. The force and current controls shall operate Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-I- T NIL-W-II TH 9999906 0250367 5 M MIL-W-46154(MR) . 5.2 Meld tm . The weld timer shall control the following timing fun
18、ctions: Single impulse Welding Squeeze time Weld time Hold time Multiple impulse Welding Squeeze time Heat time C o01 time Weld interval Pulse frequency Hold time 5.3 Welding current. Means for controlling the welding current between specified limits shall be provided. tapped transformers, phase shi
19、fting heat control circuits or both. This may be accomplished by use of 6. PREPRODUCTION REQUIREMENTS 6.1 Certification of welding equipment and recorded cleaninp and welding procedures. Prior to welding the first production assembly of each specific design, the contractor or the manufacturer, or bo
20、th, shall weld and test the welds in one assembly or simulated specimen under Government surveillance, The assembly or specimen shall be welded in accordance with the recorded procedure. This certification test shall be carried out on each welding machine that will be used for the production of weld
21、ments of each specific design. 6.1.1 Simulated specimens. When a simulated specimen is used, the material thickness, composition range, weld edge distance, spot spacing, and the general weld area contour and metal fit shall be the same as the production part. When the application of weld primer or s
22、ealer is required by the re- corded procedures for production assemblies, the simulated specimens shall have these materials applied before welding in the same manner as applied to production parts. When a substantial amount of magnetic material such as the assembly fixture, locators, etc., is inser
23、ted in the throat of the welding machine during the welding of a production part, this condition shall be closely duplicated for the simulated specimen. 6.2 Visual examination of welded assembly or simulated specimen, All welds shall be subject to visual examination to determine compliance with 7.3.
24、1. 6.3 Testing. The welded assembly or simulated specimen shall be subjected to the peel tests in accordance with 7.3.3. 6.4 Reporting of results. The manufacturer shall record the results of this certification and shall submit copies of the results together with the re- corded procedures through th
25、e contractor and contracting officer for review by the procuring activity. rrii 4 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-W-4614 TH W 7777906 0250368 7 W MIL -W -46 1 54 (MR) . 6.5 Rejection. Failure of the welded assembly or simulated sp
26、ecimens to meet the requirements for visual examination (see 7.3.1) or the peel test (see 7.3.3) shall result in the rejection of the recorded welding procedure. 7. PRODUCTION REQUIREMENTS 7.1 Qualitv control. The contractor shall establish or have the manu- facturer establish and use the systematic
27、 quality control procedure specified in MIL-1-45208. 7.1.1 Production checking. Periodically during a production run, a welded assembly or simulated specimen shall be tested as shown in section 6. frequency of testing shall be as specified in the contract or order. The 7.2 Procedure inspection. All
28、welding operations shall be subject to inspection for compliance with the certified welding procedures and quality control procedures of the contractor and manufacturer. and quality control procedures shall be approved by the purchaser. The certified welding 7.3 Weldment inspection. 7.3.1 Visual exa
29、mination. The outer surface of all welds shall be smooth and free of cracks, tip pickup, pits, metal expulsion, and other defects. 7.3.2 Tolerances. Tolerances on spot weld spacing and edge distance shall be as specified in-the contract or order or on the drawing. 7.3.3 Peel tests. Welded assemblies
30、 or- simulated specimens shall be tested by the peel tests in accordance with the provisions for such testing established in the quality control procedures. 7.3.3.1 Test procedure for spot welds. The weldment or simulated specimen shall be separated by driving a chisel between the welded components
31、in an unwelded area or by peeling one sheet back against the weld until failure occurs around the periphery of the weld or until the part fails. Failure of the base metal outside the weld area shall be considered evidence that the welds are satisfactory. The minimum button diameter, as measured in t
32、wo perpendicular directions at the faying surface shall conform to table II. 5 z . Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-W-qbLSq TH 9799706 0250369 9 W MIL-W -46154 (MR) Table II - Peel test requirements Thickness of thinner part- i/ Mi
33、nimum button diameter- 11 Inches Inches o. O10 o. 10 .o20 .13 .O31 .16 .O40 .19 ,050 .22 .O62 .25 .O78 .29 .O94 .31 .lo9 .32 ,125 .33 dor intermediate thicknesses , direct interpolation may be used. 7.3.3.2 Test procedure for projection welds. The weldment or simulated specimen shall be separated by
34、 driving a chisel between the welded components in an unwelded area or peeling one sheet back against the weld until failure occurs. Failure at or outside the periphery of the weld area shall be con- sidered evidence that the welds are satisfactory. Lack of fusion under the projection shall be cause
35、 for rejection of the sample. It is not necessary to puilbuttons in this test, provided that at least 314 of the area of each individual projection weld shows positive fusion. 7.3.4 Reected welds. If unsatisfactory welds are found during a produc- After correction, tion quality control inspection, t
36、he production run shall be stopped and necessary corrections made to the equipment or procedure. a weldment or simulated specimen shall be welded and shall conform to the inspection requirements in 7.3.1 and 7.3.3 before resuming production. The series of weldments in the period subsequent to the la
37、st acceptable quality control inspection shall be rejected or may be rewelded in accordance with 7.3.5. 7.3.5 Rewelding of rejected weldments. A weldment from each rejected series may be rewelded in accordance with the new procedure. The repaired weldment shall meet the inspection requirements of th
38、is specification. If the weldment passes the inspections, the rejected weldments may be rewelded using the new procedure. A simulated specimen shall not be used for deter- mining weld quality of repair welding. permitted. Rewelding of projection welds is not 8. NOTES 6 Provided by IHSNot for ResaleN
39、o reproduction or networking permitted without license from IHS-,-,-MIL-W-YbL54 TH M 7777906 O250370 5 9 8.1 Intended use. Resistance welding under this specification covers only spot and projection welds. . 8.2 Certification testing The certification test is intended to as- certain that the specifi
40、c welding unit being used has the electrical and mechanical capacity to satisfactorily produce a particular weldment. 8.3 Definitions. 8.3.1 Contractor. As used in this specification, the term “contractor“ is defined as the organization having a direct contract with the Government activity. 8.3.2 Ma
41、nufacturer. The term “manufacturer“ is defined as the organiza- tion actually performing the operations covered by this specification. 8.4 percent. It is recommended that the maximum manganese content not exceed 0.90 .i Custodian: Army -M Review activities: Army - ME, MI, MU, WC 7 Preparing activity
42、: Army - MR Project No. THJM-AO29 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-W-46 154 (MR ) 10. SCOPE APPENDIX . 10.1 recorded joint welding procedures and the instructions for completing the f oms. This append-x contains a suggesteL form fo
43、r the sL“mitta1 of the 20 INSTRUCTIONS 20.1 The recorded procedure consists of four.sheets of an approved form. In completing the information required for a weldment, it may be necessary to use two or more pages of any one or all of the last three sheets of the illustrated form. 5 are of the same fo
44、rm but represent different weldments . This use is shown in the illustration, where sheets 4 and 20.1.1 Sheet one (a) Record number. Number selected by the contractor or manufac- turer to designate a particular procedure. (b) Part name, drawing number and revision date. Mame and number appearing on
45、the print for the weldment. (c) Manufactured by. Name of the company actually performing the welding. (a) Location. Full address of the manufacturer. (e) Approved by the manufacturm. Signature of responsible employee of company performing the welding. (f ) Approved by the contractor. Signature of re
46、sponsible employe of the company holding the Government contract. 20.1.2 Sheet two.- This sheet should contain an isometric or perspective Dimensions drawing or sketch showing all the resistance welded parts of thc weldment. Additional sheets may be used if additional views are required. are not req
47、uired, but the drawing or sketch should indicate the relationship of parts and weld locations. letter. Ail weld joints or parts should bear a reference 20.1.3 Sheet three (a) Joint reference. Theletter identifying the joint on sheet 2. (b) Welding procedure record number. Reference number from sheet
48、 1 and carried on each additional sheet for identification. 8 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-W-9bL54 TH E 7979906 0250372 7 W c (c) Material reference. Designation number for the grade of steel. The number will generally be an AI
49、S1 or SAE designation number. (d) Machine make, type and size. Data on the welding machine available from the name plate. on the machine. 20.1.4 Sheets four and five. One sheet should be prepared for each weld joint in the weldment or each joint requiring a different weld schedule or use of electrodes. (a) Joint reference. Identification letter assigned to the joint on sheet 2. (b) Processed condition of materia
