1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. JUNE 2009 Page 1 of 11 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER:
2、TMS-9511 TITLE: ARC WELDING - ALUMINUM CURRENT REV No.: 0906 DATE: June 2009 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. C-1 - August 2001 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous m
3、aterials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to use. Change Notice: Replac
4、ed “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; moved Section 1.1 Inspection to end of spec as Section 6.0; added CEMS B-50 requirement; added Welded Joints as Section 4.4; added sentence in Section 5.5; added Sections 7.0-10.0; editorial changes. Refer
5、ence: File 40-11 Keywords: Arc Welding, Aluminum 1.0 APPLICATION This specification covers the arc welding of structural members which are made from wrought or cast aluminum or aluminum alloy components. The aluminum alloy can be either a nonheat-treatable (e.g., 5052) or heat-treatable (e.g., 6061)
6、 grade. The specification covers two levels of quality: Class A Welded joints with specific engineering requirements for stress, function, or reliability. It shall be designated on the engineering drawing using a note or a suitable symbol. Class B Welded joints which have non-critical requirements f
7、or stress, function, or reliability. It shall apply to all welds not designated as Class A. 1.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 2.0 SCOPE This we
8、ld specification pertains to fillet welds in tee or lap joints, bevel or flare-vee groove welds, square groove welds, and plug or slot welds. The welds shall be made using a gas-metal arc process with a suitable shielding gas such as argon, helium or a mixture of the two gases (MIG: Gas Metal-Arc or
9、 TIG: Gas Tungsten-Arc). These processes are to be used interchangeably unless otherwise specified. The location of joints to be welded shall be designated on the engineering drawing using the appropriate welding symbols (per AWS A2.4) and notes to indicate size, type, length and location. 3.0 REFER
10、ENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo re
11、production or networking permitted without license from IHS-,-,-NUMBER: TMS-9511 TITLE: ARC WELDING - ALUMINUM REVISION: 0906 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume a
12、ll patent liability. 2009 by Navistar, Inc. JUNE 2009 Page 2 of 11 Quality System Standard ISO 9001 or TS-16949 AWS A5.10 NAVISTAR Manufacturing Standard MS-D-13 AWS A2.4 CFR Title 29, Part 1910 CEMS B-50 AWS D1.2 4.0 REQUIREMENTS 4.1 Filler Metal The filler metal shall be selected on the basis of t
13、he base metals being joined, and it shall be determined from AWS A5.10 unless otherwise specified on the engineering drawing (see Table 1 below). Table 1 - Guide to the Choice of Aluminum Filler Metal for General Purpose Welding 6005, 6009 5083 2014 6010,6061 5086 5005 2024 1100 Base metal 6063 5182
14、 5052 5050 3004 2036 3003 1100, 3003 A C A* A* A* B E 2014, 2024, B - - - - B 2036 3004 A* C* A* A* A* 5005, 5050 A* C* A* A* 5052 C* C* D* CODE 5083, 5086, C* C* A = ER 4043 5182 B = ER 4145 C = ER 5356 6005, 6009 D = ER 5654 6010, 6061 A E = ER 1100 6063 * ER 5183, ER 5356, ER 5554, ER 5556, and E
15、R 5654 may be used. In some cases they provide (1) improved color match after anodizing, (2) highest weld ductility, and (3) higher weld strength. * ER 5183, ER 5356, ER 5556 may be used. NOTES: 1. Recommendations in this table apply to gas shielded arc welding processes. For oxyfuel gas welding, on
16、ly ER 1100, ER 4043, and ER 4145 filler metals are ordinarily used. 2. Where no filler metal is listed, the base metal combination is not recommended for welding. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitt
17、ed without license from IHS-,-,-NUMBER: TMS-9511 TITLE: ARC WELDING - ALUMINUM REVISION: 0906 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Nav
18、istar, Inc. JUNE 2009 Page 3 of 11 4.2 Weld Length Weld length shall be shown on the engineering drawing. Welds shall be acceptable if they are short according to the following table: TABLE 2 WELD LENGTH TOLERANCE Specified Length Tolerance cm in mm in 15 and Under 6 and Under 6 1/4 Over 15 Thru 30.
19、5 Over 6 Thru 12 13 1/2 Over 30.5 Thru 61.0 Over 12 Thru 24 38 1 1/2 Over 61.0 Thru 122 Over 24 Thru 48 64 2 1/2 Over 122 Thru 244 Over 48 Thru 96 114 4 1/2 Over 244 Thru 488 Over 96 Thru 192 216 8 1/2 4.2.1 The effective weld length shall not include skips, voids, undersize welds, off-location weld
20、s, or any other discontinuities defined under Quality. 4.3 Weld Location The lateral location of the weld in the joint shall be shown by the proper weld symbol. Where desired, this may be supplemented by cross hatching on the Engineering drawing or by a note in the tail of the weld symbol. Where a s
21、pecified location is shown on the drawing, the starting point of a continuous weld shall be within the tolerance included in Table 3: TABLE 3 WELD LOCATION TOLERANCE Specified Length Tolerance cm in mm in 15 and Under 6 and Under 6 1/4 Over 15 Over 6 13 1/2 Intermittent 13 1/2 4.3.1 No welds shall b
22、e closer than 3 mm (1/8 in) from the edge or end of a joint. When it is required that a weld be hooked or boxed around a corner or end of a joint, it shall be indicated on the engineering drawing as a continuous weld and included in the specified length. Hooked welds shall be a portion of a continuo
23、us weld or an individual portion of the weld and shall be free from pinholes, voids, and craters. “No Weld“ areas shall be specified on the engineering drawing using a specific note or dimension to define the minimum length of the area where no welding is permitted (or the maximum dimension where we
24、lding is excluded from a specified reference point). All welds shall be centered in the joint to ensure fusion between the two members being joined. Portions of the weld off-joint shall be considered as skips or voids. 4.4 Welded Joints Weld joints in 6xxx series alloys shall be beveled or spaced to
25、 permit excess filler alloy dilution. Groove welded joints shall conform to AWS D1.2 recommended joint patterns. The joint patterns can be modified upon prior written approval from Materials Engineering, TDTC. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot
26、for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-9511 TITLE: ARC WELDING - ALUMINUM REVISION: 0906 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are requi
27、red to assume all patent liability. 2009 by Navistar, Inc. JUNE 2009 Page 4 of 11 4.5 Weld Size 4.5.1 Fillet Weld Size Weld leg length shall be shown on the engineering drawing, and it shall be the minimum length permitted. For Class A welds, leg length shall be equal to the thickness of the thinnes
28、t stock being welded or 3 mm (0.12 in), whichever is greater, unless otherwise indicated on the engineering drawing. Class B welds shall have a minimum leg length which is 60% of the thinnest stock being welded. When a gap is present for either class of weld, the leg length on the gap side shall be
29、increased by the amount of the gap. See Figure 1. 4.5.2 Fillet Weld Throat Depth Unless otherwise specified, a minimum throat depth shall be maintained throughout the length of the weld. The minimum throat depth shall be (1) no gap: 60% of the specified leg length or (2) gap: 60% of the total of the
30、 limit for convexity shall not be required, but all other requirements shall be met. Part configuration shall remain functional, and no overlap shall be permitted. See Figure 2. 4.5.3 Groove Welds Minimum effective weld size shall be shown on the engineering drawing and shall be determined as shown
31、in Figure 3. Note: It is necessary to deviate from the AWS definition to adequately define the size of flare-groove welds. 4.5.3.1 Class A Welds Effective weld size shall be 3 mm (1/8 in) minimum or 100% of the thinnest stock being welded, whichever is greater. 4.5.3.2 Class B Welds Effective weld s
32、ize shall be 60% of the thickness of the thinnest material being welded. When a gap is present, the effective weld size of the groove weld shall be increased by the amount of the gap. 4.5.4 Plug or Slot Weld A weld made through a hole in one member of a tee or lap joint joining that member to the ot
33、her. Walls of the hole may or may not be parallel. The hole shall be completely filled with weld metal. A fillet welded hole or a spot weld shall not be construed as meeting this specification. See Figure 4. 4.6 Penetration 4.6.1 Fillet Welds and Square Groove Welds All welds shall penetrate to a de
34、pth which is 100% of the root of the weld minimum. See Figure 5. Burn through on opposite side shall be no greater than 50% of the thickness of stock being welded. 4.6.2 Groove Welds The root of the weld deposit in a groove weld shall penetrate below a line drawn between the outer bend radii (45 to
35、horizontal) in a flare-vee weld; outer bend radius (45 to horizontal) normal to straight member in a flare-bevel weld. See Figure 6. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-
36、,-NUMBER: TMS-9511 TITLE: ARC WELDING - ALUMINUM REVISION: 0906 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. JUNE 2009 Page 5 o
37、f 11 4.7 Fusion Fusion is the joining of two metals where coalescence or metallurgical bonding of one material to the other takes place. 4.7.1 Fillet Welds All welds shall have 100% minimum fusion for the total specified leg length of the weld. 4.7.2 Groove Welds All welds shall have 100% minimum fu
38、sion of the groove face for the specified weld size. See Figure 7. 4.7.3 Plug or Slot Welds Welds shall have 100% minimum fusion of side walls and entire bottom surface of hole. 5.0 QUALITY Unless otherwise specified, the following defects shall be permitted in welds. No more than one of these defec
39、ts shall be permitted if any other defect is at the maximum permissible limit. No other defects shall be permitted. If the stress raising effect of any permissible defect is objectionable in a particular design or application, Applied Mechanics Group (AMG) or Materials Engineering personnel should b
40、e consulted. 5.1 Undercut Unless closer limits are specified on the engineering drawing, undercutting at the terminal ends of the welds for a distance of 13 mm (0.50 in) shall not exceed 10% of the thickness of the member being undercut. In the balance of the weld length undercutting at any point sh
41、all not exceed a depth of 30% of the thickness of the undercut material. An average of all undercutting in the full length of the weld shall not exceed 20% of the thickness of the undercut material. External Porosity Class A Class B Frequency (Density) 1/2.5 cm average 1/1.3 cm average (1/in average
42、) (2/in average) Severity (Pore Size) (1) (2) 1.6 mm maximum 1.6 mm maximum (1/16 in maximum) (1/16 in maximum) (1)Pores smaller than 0.4 mm (1/64 in) diameter shall not be considered significant and are not included in the count. (2) Pores larger than 1.6 mm (1/16 in) diameter shall be considered d
43、iscontinuities or skips and included in the weld length tolerance. NOTE: Pores shall be separated by a distance equal to the pore diameter; otherwise, they shall be considered as skips. 5.2 Craters Unfilled craters in welds shall not be considered part of the effective weld length and shall be limit
44、ed by the weld length tolerance for discontinuities. Craters shall be properly filled and counted in the weld length. Craters shall be properly filled at the weld extremities. 5.3 Inclusions Foreign non-metallic inclusions shall be considered and judged as a discontinuity. Copyright Navistar Interna
45、tional Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-9511 TITLE: ARC WELDING - ALUMINUM REVISION: 0906 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without pe
46、rmission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. JUNE 2009 Page 6 of 11 5.4 Cracks, Burn-Through, Notches Cracks in the weld, unfilled holes in the welded members, and notches (See Figure 8) at the ends or edge of a weld joint
47、 shall not be permitted. 5.5 General Suppliers, including NAVISTAR plants, shall have the responsibility to notify the Product Quality Manager at the using plant in advance and in writing of any permanent change in the welding process such as rods, fixtures and processes. The changes shall be approved in writing by NAVISTAR before the change enters production. The weld quality of all parts ma
