1、 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 1 of
2、 6 INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-9505 TITLE: Axle Housing Weld Specification REVISION: B-1 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: August 2001 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED
3、 FOR CURRENT REVISION This specification may involve hazardous materials, 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 applic
4、ability of regulatory limits prior to use. Change Notice: Reformatted and Editorial Changes Reference: File 14-5 Keywords: Axle Housing Welds 1.0 APPLICATION This specification covers the welding of truck axle housings made from plain carbon steel. Steels to be welded shall be killed and shall have
5、the following composition limits: Carbon - 0.40% max, Phosphorus - 0.04% max, and Sulfur - 0.05% max. This welding specification provides a commercial quality weld for truck applications subject to low-to-moderate stress in service. The specification covers a single quality level, which determines t
6、he frequency of inspection. 2.0 SCOPE This weld specification covers requirements for size, quality, etc., of fillet welds, flash-butt welds, and groove welds used in assembling axle housings. 2.1 The location or joints to be welded shall be designated on the engineering drawing using the appropriat
7、e symbols and notes to indicate type, size, length and location as required. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Stan
8、dard QS-9000 (ISO 9001) MILStd 105 INTERNATIONAL IQR Quality Standard AWS A2.0 INTERNATIONAL Manufacturing Standard D-13 CFR Title 29, Part 1910 AWS A3.0 3.1 Definitions The welding terms used in this specification shall be interpreted in accordance with the definitions given in AWS Definitions - We
9、lding and Cutting AWS A3.0. Welding symbols shall be those used in AWS Standard Welding Symbols AWS A2.0. Special conditions shall be fully explained by added notes or details on the engineering drawing. NUMBER: TMS-9505 TITLE: Axle Housing Weld Specification REVISION: B-1 This document is restricte
10、d and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 2 of 6 TABLE 1 INSPECTION FREQU
11、ENCY Based On Mil-Std 105 A.Q.L. 1% Lot or Batch Size* 91-150 Inspection Level II Normal Inspection* Sample Size 12 Accept-Reject 0-1 Tightened Inspection Sample Size 20 Accept-Reject 0-1 Reduced Inspection Sample Size 8 Accept-Reject 0-1 * Inspection procedures for other lot sizes shall be determin
12、ed from the applicable A.Q.L. in Mil-Std 105. * The following process shall be used to switch from one type of inspection to another: Normal to Tightened Two of five consecutive lots rejected. Tightened to Normal Five consecutive lots accepted. Normal to Reduced Preceding ten lots accepted. Reduced
13、to Normal Rejection of a lot. Production becomes irregular or delayed. Deviations from the as-specified inspection or quality control procedures can be made with the written consent of International after reviewing the detailed procedure. 4.0 REQUIREMENTS 4.1 Weld Length - Fillet Welds Weld length s
14、hall be shown on the engineering drawing. Weld length tolerances are shown in Table 2. NUMBER: TMS-9505 TITLE: Axle Housing Weld Specification REVISION: B-1 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corpor
15、ate Technical Standards. Suppliers are required to assume all patent liability. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 3 of 6 TABLE 2 WELD LENGTH TOLERANCE Specified Length Tolerance cm in cm in 5 and Under 2 and Under 0.3 1/8 Over 5 Thru 15 Over 2 Thru 6 0.6 1/4 Ove
16、r 15 Thru 31 Over 6 Thru 12 1.3 1/2 Over 31 Thru 61 Over 12 Thru 24 3.8 1 1/2 Over 61 Over 24 6.4 2 1/2 4.2 The effective weld length shall not include skips, voids, off-location welds, or any other discontinuities defined in the QUALITY section of this specification. 4.3 Weld Location 4.3.1 Fillet
17、and Groove Welds Weld shall be designated on the Engineering drawing by a welding symbol and shall be located laterally in the joint. When a specified starting or terminal location is shown, the start or end point of the weld shall be within the following tolerance: TABLE 3 WELD LOCATION TOLERANCE S
18、pecified Length Tolerance cm in cm in 5 and Under 2 and Under 0.3 1/8 Over 5 Thru 15 Over 2 Thru 6 0.6 1/4 Over 15 Over 6 1.3 1/2 4.3.1.1 All welds shall be centered laterally in the joint in a manner to insure fusion between the parts being joined. Portions of the weld which are undersize, or do no
19、t meet the minimum requirements for quality (undercut, porosity, craters) shall be considered as skips and are not considered in the weld length. 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 and included in the
20、 specified length. The hooked portion shall meet minimum undercut requirement and be free from voids, pinholes and craters, as defined in Quality. Required “No Weld“ areas shall be shown on the Engineering drawing using a specific note or dimension defining the location of the joint where no welding
21、 is permitted. 4.3.2 Flash Butt Welds Shall have a maximum mismatch equal to 25% of the section thicknesses being welded, unless otherwise specified. 4.4 Weld Size The minimum weld leg size on each leg of the fillet welds shall be equal to the specified size, plus the amount of the gap. NUMBER: TMS-
22、9505 TITLE: Axle Housing Weld Specification REVISION: B-1 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. Ge32001 by Internat
23、ional Truck and Engine Corporation. AUGUST 2001 Page 4 of 6 4.5 Throat Thickness The minimum throat thickness of fillet welds shall be equal to 60% of the shortest weld leg size. Maximum throat thickness shall be limited to 100% of the longest leg size. 4.6 Fusion Weld deposits shall be metallurgica
24、lly bonded for the entire length of the weld leg. 5.0 Quality Unless otherwise specified, the following characteristics shall be permitted. No more than one of these characteristics shall be permitted in the weld if any other characteristic is at the maximum limit. The stress concentration effect of
25、 these characteristics should be considered in design calculations, and if objectionable, Applied Mechanics Group (AMG) or Materials Laboratory personnel should be consulted. 5.1 Undercut Shall be classified into four levels of acceptability as follows: Class A Shall not exceed 0.4 mm (.015 in) Clas
26、s B Shall not exceed 0.8 mm (.030 in) Class C Shall not exceed 1.1 mm (.045 in) Class D Shall not exceed 1.5 mm (.060 in) 5.2 Craters Unfilled craters are not considered part of the effective weld length, and are therefore limited by the weld length tolerance for discontinuities. They can be properl
27、y filled and counted in the weld length. 5.3 Cracks and Burn-Through Cracks in the weld and holes burned through the base stock shall not be permitted. 5.4 Visible Porosity 5.4.1 Frequency No more than four (4) significant pores shall be permitted in any 25 mm (1 in) of weld length with the average
28、limited to one (1) per 25 mm (1 in) of weld length. 5.4.2 Severity The maximum diameter of the pores shall be 1.6 mm (1/16 in) and shall be spaced at least 1.6 mm (1/16 in) apart. Pores shall be larger than 0.4 mm (1/64 in) in diameter to be considered significant. Porosity shall not be permitted in
29、 any weld specified as oil tight. 5.5 Inclusions Non-metallic inclusions shall be considered and judged as a discontinuity. 5.6 Flash-butt weld joints shall contain no voids, cracks, inclusions, or cast metal. NUMBER: TMS-9505 TITLE: Axle Housing Weld Specification REVISION: B-1 This document is res
30、tricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 5 of 6 6.0 SOURCE APPROVA
31、L AND QUALITY CONTROL 6.1 Supplier Requirements Suppliers must conform to the requirements of the International IQR Quality Standard which includes conformance to the QS-9000 (ISO 9001) Quality System Standard. A mutually acceptable Quality Control Plan as described therein is required for source ap
32、proval to the requirements of this specification. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted with
33、out approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering at TDTC and Purchasing and Supplier Development of the proposed change(s). Test data indicating conform
34、ance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tes
35、ts on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the plant metallurgist and/or the quality control manager of the using Intern
36、ational plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing and identification shall be in accordance with Manufacturing Std. D-13. NUMBER: TMS-9505 TITLE: Axle Housing Weld Specification REVISION: B-1 This document i
37、s restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 6 of 6 8.0 DESIGNATI
38、ON ON DRAWINGS Welding per TMS-9505 The above notation shall appear on the drawing, either in the tail of the weld symbol (if only one weld involved) or as a separate note. The following examples indicate the manner in which certain welds could be specified. 1. Fillet Weld: 2. Flash Butt Weld: 3. Ed
39、ge weld Symbol: A.0 GENERAL INFORMATION The weld process established by the supplier shall be selected which provides optimum quality and economical deposition. After the welding process has been established, the supplier shall inspect the first production prototypes and make periodic visual inspect
40、ions at the specified intervals for the various characteristics covered by this specification. Periodic destructive tests shall be used as required to supplement the visual inspection. The supplier shall have the responsibility to notify the purchaser in writing advising the exact nature of a modification in the processing methods and materials for which he is approved. Special Instructions, Etc, In TailUndercut Limit Class B Oil TightWeld Length Leg SizeNo Filler Required
