MIL-STD-3040A.pdf

INCH-POUND

MIL-STD-3040A

24 March 2022

SUPERSEDING

MIL-STD-3040

29 June 2016

DEPARTMENT OF DEFENSE

MANUFACTURING PROCESS STANDARD

QUALIFICATION, FABRICATION, WELDING,

AND INSPECTION OF ARMOR AND NON-

ARMOR STEEL WELDMENTS

AMSC N/A AREA THJM

DISTRIBUTION STATEMENT A. Approved for public release. Distribution is unlimited.

Source: https://assist.dla.mil -- Downloaded: 2022-12-06T12:19Z Check the source to verify that this is the current version before use.

ii

FOREWORD

1. This standard is approved for use by all Departments and Agencies of the Department of Defense (DoD).

2. This standard does not specify armor capability in terms of protection. The user is responsible for defining the threat that the armor system must withstand.

3. This revision has resulted in many changes from the base document, but the most significant changes are:

a. Re-titling the document to clarify its use.

b. Addition of non-armor steels to the document.

c. Arranging the order of the document.

4. Comments, suggestions, or questions on this document should be addressed to U.S. Army Ground Vehicle Systems Center, ATTN: FCDD-GVS-SAT MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000, or emailed to usarmy.detroit.devcom-gvsc.mbx.standardization@army.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.

5. Questions or information with regards to this document related to ground vehicle systems should be addressed to usarmy.detroit.devom-gvsc.mbx.materials-joining@army.mil.

mailto:usarmy.detroit.devcom-gvsc.mbx.standardization@army.mil mailto:usarmy.detroit.devcom-gvsc.mbx.standardization@army.mil https://assist.dla.mil/ mailto:usarmy.detroit.devom-gvsc.mbx.materials-joining@army.mil iii

CONTENTS

PARAGRAPH PAGE

FOREWORD .................................................................................................................................. II

1. SCOPE

1.1 Scope

1.2 General ................................................................... Error! Bookmark not defined.

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

2.2.2 Other Government documents, drawings, and publications

2.3 Non-Government publications

2.4 Order of precedence

3. DEFINITIONS

3.1 Active flux

3.2 Amplitude Rejection Level (ARL)

3.3 Active supervision

3.4 Contractor

3.5 Deposition thickness

3.6 Design engineering activity

3.7 Digital radiography (DR)

3.8 Entity

3.9 Entity responsible representative

3.10 Essential variables

3.11 Field repair

3.12 Forced cooling

3.13 Inadvertent inspection

3.14 Manufacturer

3.15 Material Review Board (MRB)

3.16 Neutral flux

3.17 Nominal thickness

3.18 Procuring contracting officer (PCO)

3.19 Proofing Projectile Impact Testing (PPIT)

3.20 Reference standard

3.21 Repair

3.22 Steel

3.22.1 Armor grade steel

3.22.2 Non-armor grade steel

3.22.3 Sheet steel

3.23 Standard welding terms and definitions

3.24 Technical authority (TA)

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3.25 Weld repair procedure

3.26 Validation test plate

3.27 Welder qualification continuity record

3.28 Welding engineer

3.29 Welding equipment

3.30 Welding symbols

4. GENERAL REQUIREMENTS

4.1 Qualification requirements

4.1.1 Submission format

4.2 Qualification applicability

4.3 Responsibility

4.4 Previous qualification to MIL-STD-3040 revisions

4.4.1 Previous qualification to other standards

4.5 Safety precautions

4.6 Joint design

4.6.1 Weld joint classification requirements

4.6.2 Minimum fillet weld size

4.6.3 Intermittent fillet welds

4.7 Welding processes

4.7.1 Acceptable welding processes

4.7.2 Restricted welding processes

4.7.3 Additional welding processes

4.8 Weld positions

4.9 Quality control

4.9.1 Quality assurance system

4.9.2 Welding equipment calibration and verification

4.10 Welding prohibitions

4.11 Company name change

5. DETAILED REQUIREMENTS

5.1 Base material

5.1.1 Base material certification

5.1.2 Armor base material

5.1.3 Base material grouping

5.1.4 Backing material

5.1.5 Run off tab material

5.1.6 Material record retention

5.2 Welding materials

5.2.1 Identification

5.2.2 Filler materials

5.2.3 Shielding

5.3 Procedure Qualification Records (PQRs)

5.3.1 Requirements

v

5.3.2 PQR cross qualification

5.3.3 PQR revision

5.3.4 Supplemental PQRs

5.3.5 Previously qualified welding procedures

5.3.6 Bead width limitation for weaving

5.3.7 Base material repair qualification

5.3.8 PQR record retention

5.4 Essential variables

5.4.1 Essential variables

5.4.2 Base material essential variables

5.4.3 Filler material essential variables

5.4.4 Shielding

5.4.5 Joint design

5.4.6 Electrical parameters

5.4.7 General procedure parameters

5.5 Welding Procedure Specification (WPS)

5.5.1 Requirements

5.5.2 WPS essential variables

5.5.3 Minimum travel speed tables

5.5.4 WPS transfer requirements

5.5.5 Contracted sub-entity qualification

5.5.6 WPS revision

5.5.7 WPS record retention

5.6 Welder performance qualification

5.6.1 Requirements

5.6.2 Welder Qualification Records (WQR)

5.6.3 Welder and welding operator performance qualification

5.6.4 Welder and welding operator essential variables

5.6.5 Qualifying welder or welding operator through PQR

5.6.6 Previous welder or welding operator qualification

5.6.7 Transfer of qualification

5.6.8 Renewal of qualification

5.6.9 Maintenance of qualification

5.6.10 Retest requirements

5.7 Destructive testing of welds

5.7.1 Requirements

5.7.2 Tension/reduced-section tension testing

5.7.3 Bend testing

5.7.4 Macroetch testing

5.7.5 Hardness testing

5.7.6 Fillet weld break test

5.7.7 Proofing projectile impact testing

5.7.8 Charpy V Notch (CVN) testing

5.7.9 Destructive test failures

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5.7.10 Destructive testing record retention

5.8 Nondestructive Testing (NDT) personnel qualification

5.8.1 Requirements

5.8.2 Visual inspector qualification

5.8.3 Other NDT methods

5.8.4 NDT re-examinations

5.8.5 Alternative NDT specifications and standards

5.8.6 Personnel qualification documentation

5.9 Nondestructive testing (NDT)

5.9.1 Nondestructive Testing (NDT) requirements

5.9.2 Nondestructive Testing (NDT) methods

5.9.3 Nondestructive testing record retention

5.10 Welding requirements

5.10.1 Welding environment

5.10.2 Welding Procedure Specification (WPS) accessibility

5.10.3 Position

5.10.4 Preheat and interpass temperatures

5.10.5 Post Weld Heat Treatment (PWHT)

5.10.6 Heat input calculations

5.10.7 Tack welding

5.10.8 Temporary welds for fabrication purposes

5.10.9 Weld profiles

5.10.10 Peening

5.10.11 Arc strikes

5.10.12 Weave and stringer passes

5.10.13 Backgouged roots

5.11 Workmanship requirements

5.11.1 Weld joint surface preparation

5.11.2 Weld cleaning

5.11.3 Welder and welding operator workmanship check

5.11.4 In-process hardness checks

5.11.5 Joint fit-up inspection

5.11.6 Distortion control

5.12 Repairs

5.12.1 Requirement

5.12.2 Repair procedures

5.12.3 Repair cycles

5.12.4 Mill defects

5.12.5 Repair of armor base material

5.12.6 Repairs of non-armor base material

5.12.7 Weld metal removal

5.12.8 Crack repair

5.12.9 Field repairs

5.12.10 Repair record retention

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6. NOTES

6.1 Intended use

6.2 Acquisitions requirements

6.3 Standard units of measure

6.4 Subject term (keyword) listing

6.5 Changes from previous issue

APPENDIX A: WELDING PROCEDURE QUALIFICATION OF CLASS I WELDS

A.1 SCOPE

A.1.1 Scope A.1.2 Application

A.2 APPLICABLE DOCUMENTS

A.2.1 General

A.3 REQUIRMENTS

A.3.1 Requirements

A.4 PROCEDURE RECORDS

A.4.1 Procedure Qualification Records (PQRs) A.4.1.1 Previous qualifications A.4.1.2 PQR base material A.4.1.3 Welding materials A.4.1.4 Process qualification essential variables A.4.1.5 Nondestructive Testing (NDT) A.4.1.6 Destructive testing A.4.2 Welding Procedure Specification (WPS)

A.5 TEST PLATE

A.5.1 Dimensions of test plate A.5.2 Plate flatness A.5.3 Test plate thickness A.5.3.1 Dissimilar thickness welds A.5.4 Test plate armor types A.5.5 Test plate joint type A.5.6 Preparation of test plate A.5.6.1 Preheat and interpass temperature A.5.6.2 Order of welding A.5.6.3 Backgouging of welds A.5.6.4 Tack welds A.5.7 Identification marking of test plates A.5.8 Marking of retest plates viii

A.6 PROOFING PROJECTILE IMPACT TESTING

A.6.1 Proofing Projectile Impact Testing (PPIT) requirements A.6.2 Proofing projectile impact testing address A.6.3 NDT examination of test plate A.6.3.1 Visual examination of test plates A.6.3.2 Volumetric NDT examination

A.7 TEST RESULTS

A.7.1 Evaluation of test A.7.2 Nondestructive testing after test A.7.3 PPIT Reports A.7.3.1 Photographic record A.7.4 Repair of test plate A.7.5 Rejection of test plate A.7.6 Retest

APPENDIX B: REFERENCE MATERIALS

B.1 SCOPE

B.1.1 Scope B.1.2 Application

TABLE PAGE

I. Base material groupings II. Welding specification and weld classification cross reference III. Weld classification decision matrix IV. Filler material groupings V. Essential variables VI. Procedure qualification testing requirements VII. Procedure qualification positions for plate VIII. Procedure qualification positions for pipe and tube IX. Procedure qualification test criteria for fillet welds X. Procedure qualification thickness limitations XI. Procedure cross qualification XII. Heat input guidance for 120ksi wires XIII. Preheat and interpass temperatures XIV. Minimum travel speed example (IPM) XV. Welder and welding operator qualification criteria XVI. Welder and welding operator qualification positions for plate XVII. Welder and welding operator qualification positions for pipe and tube XVIII. Welder and welding operator essential variables XIX. Welder and welding operator cross qualification categories XX. Visual testing acceptance criteria ix

TABLE PAGE

XXI. NDT per weld classification A-I. H-test plate thickness and qualification range. 116

FIGURE PAGE

1. Overlap visual

2. Recommended engineering drawing weld note

3. Welding symbol classifications

4. Groove procedure qualification mechanical test plate

5. Fillet procedure qualification test plate

6. Class I welder and welding operator qualification plate thickness less than 0.5 inches inclusive

7. Class I welder and welding operator qualification plate thickness greater than 1.0 inches

8. Class II, III, and IV welder qualification groove plate

9. Class II, III, and IV welder qualification groove plate horizontal

10. Class II, III, and IV welding operator qualification groove plate

11. Class II, III, and IV welder and welding operator qualification plug weld assembly

12. Class II, III, and IV welder qualification fillet weld assembly

13. Class II, III, and IV PQR, welder, and welding operator qualification pipe or tube assembly

14. Excavated weld metal flow chart

15. Visual inspection

16. Temperature measurement technique

17. Hole repair

18. Excavated weld metal A-1. Proofing projectile impact testing test plate (H plate) A-2. Type I-A, single V-groove butt joint, without backing A-3. Type I-B, single V-groove butt joint with backing material A-4. Type II, double V-groove butt joint B-1. Procedure Qualification Record (PQR) example B-2. Welding Procedure Specification (WPS) example B-3. Welder/Welding Operator Qualification Record (WQR) example

1. SCOPE

1.1 Scope. This standard contains the minimum requirements for qualification of welding procedures, qualification of personnel, testing, fabrication, inspection, and repair of armor and non-armor steel weldments. This standard is intended to be used to facilitate the fabrications of new weldments, repair of existing weldments, and govern the requirements associated with any weldment made in accordance with this document. The qualification tests required by this document are devised to demonstrate the adequacy of the welding procedures and to demonstrate the ability of welders or welding operators to produce sound welds. This standard should not be applied in the cases of: structural tubular T-Y-K- connections; pressure vessels, or media moving or process piping under high or low pressure.

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 documents 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 this standard, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks 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.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-A-11356 - Armor, Steel, Cast, Homogeneous, Combat-Vehicle Type (1/4 to 8 Inches, Inclusive)

MIL-DTL-12560 - Armor Plate, Steel, Wrought, Homogeneous (For Use in Combat- Vehicles and For Ammunition Testing)

MIL-DTL-22200/1 - Electrodes, Welding, Mineral Covered, Iron-Powder, Low- Hydrogen Medium and High Tensile Steel, As-Welded or Stress-Relieved Weld Application

MIL-DTL-24403/1 - Electrodes - Welding, Flux Cored, Ordinary Strength and Low Alloy Steel

MIL-DTL-32332 - Armor Plate, Steel, Wrought, Ultra- High-Hardness

MIL-DTL-46100 - Armor Plate, Steel, Wrought, High- Hardness

MIL-DTL-46186 - Armor Plate, Steel, Wrought, Very High Hardness

MIL-E-19933 - Electrodes and Rods - Welding, Bare, Chromium and Chromium- Nickel Steels

MIL-E-21562 - Electrodes and Rods-Welding, Bare, Nickel Alloy

MIL-E-22200/2 - Electrode, Welding Covered (Austenitic Chromium-Nickel Steel)

MIL-E-22200/3 - Electrodes, Welding, Covered, Nickel Base Alloy, and Cobalt Base Alloy

MIL-E-22200/8 - Electrodes, Welding, Covered, Low - Hydrogen, and Iron - Powder Low - Hydrogen, Chromium - Molybdenum Alloy Steel and Corrosion Resisting Steel

MIL-E-23765/1 - Electrodes and Rods – Welding, Bare, Solid and Alloyed Cored, Ordinary Strength and Low Alloy Steel

MIL-E-23765/2 - Electrodes and Rods - Welding, Bare, Solid, or Alloy Cored; and Fluxes, Low Alloy Steel

MIL-E-23765/4 - Electrodes – Welding, Bare, Solid;

and Fluxes, Submerged Arc Welding, Carbon and Low Alloy Steels

MIL-E-24403/2 - Electrodes - Welding, Flux Cored, Low-Alloy Steel

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-22 - Welded Joint Design MIL-STD-1916 - DoD Preferred Methods for

Acceptance of Product MIL-STD-2035 - Nondestructive Testing Acceptance

Criteria

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-1222 - Guide to the General Style and Format of U.S. Army Work Package Technical Manuals

(Copies of these documents are available from https://quicksearch.dla.mil/.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications 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.

ARMY TECHNICAL MANUALS

TM 1-1500-335-23 - Technical Manual - Nondestructive Inspection Methods, Basic Theory

TM 1-1500-366-23 - Technical Manual – Nondestructive Inspection General Procedures and Process Controls

(Copies of these documents are available from https://armypubs.army.mil/.)

ARMY TEST AND EVALUATION COMMAND

TOP 2-2-711 - US Army and Evaluation Command Test Operations Procedure “Ballistic testing of armor weldments”

(Copies of this document are available from https://apps.dtic.mil.)

NAVY TECHNICAL PUBLICATIONS

NAVSEA S9074-AQ-GIB-010/248 - Requirements for Welding and Brazing Procedure and Performance Qualification

NAVSEA T9074-AS-GIB-010/271 - Requirements for Nondestructive Testing Methods

NAVSEA S9074-A1-GIB-010/1628 - Fillet weld and partial penetration groove tee weld size, strength and efficiency determination

NAVSEA T9074-BC-GIB-010/0200 - Filler Materials for Critical Applications Requirements for Flux Cored Welding Electrodes, Bare Welding Electrodes, and Fluxes, and Covered Welding Electrodes for Low-Alloy Steel Applications

(Copies of this document are available from https://www.navsup.navy.mil/public/navsup/nll/.)

https://quicksearch.dla.mil/ https://armypubs.army.mil/ https://apps.dtic.mil/ https://www.navsup.navy.mil/public/navsup/nll/

2.3 Non-Government publications. 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.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME BPVC Section IX - ASME Boiler and Pressure Vessel Code Section IX Welding, Brazing, and Fusing Qualifications

(Copies of these documents are available online at http://www.asme.org.)

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 - Qualification and Certification of Nondestructive Testing Personnel

ASNT SNT-TC-1A - Personnel Qualification and Certification in Nondestructive Testing

(Copies of this document are available online at https://www.asnt.org.)

ASTM INTERNATIONAL

ASTM E10 - Standard Test Method for Brinell Hardness of Metallic Materials.

ASTM E18 - Standard Test Methods for Rockwell Hardness of Metallic Materials

ASTM E23 - Standard Test Methods for Notched Bar Impact Testing of Metallic Materials

ASTM E92 - Standard Test Methods for Vickers Hardness of Metallic Materials

ASTM E94/E94M - Standard Guide for Radiographic Examination Using Industrial Radiographic Film

ASTM E140 - Standard Hardness Conversion Tables for Metals Relationship Among Brinell Hardness, Vickers Hardness, Rockwell Hardness, Superficial Hardness, Knoop Hardness, Scleroscope Hardness, and Leeb Hardness

ASTM E165/E165M - Standard Practice for Liquid Penetrant Testing for General Industry

Source: https://assist.dla.mil -- Downloaded: 2022-12-06T12:19Z Check the source to verify that this is the current version before use.

http://www.asme.org/ https://www.asnt.org/

ASTM E340 - Standard Practice for Macroetching Metals and Alloys

ASTM E566 - Standard Practice for Electromagnetic (Eddy Current/Magnetic Induction) Sorting of Ferrous Metals

ASTM E1032 - Standard Test Method for Radiographic Examination of Weldments Using Industrial X-Ray Film

ASTM E1254 - Standard Guide for Storage of Radiographs and Unexposed Industrial Radiographic Films

ASTM E1417/E1417M - Standard Practice for Liquid Penetrant Testing

ASTM E1441 - Standard Guide for Computed Tomography (CT)

ASTM E1444/E1444M - Standard Practice for Magnetic Particle Testing for Aerospace

ASTM E1570 - Standard Practice for Fan Beam Computed Tomographic (CT) Examination

ASTM E1742/E1742M - Standard Practice for Radiographic Examination

ASTM E2033 - Standard Practice for Radiographic Examination Using Computed Radiography (Photostimulable Luminescence Method)

ASTM E2445/E2445M - Standard Practice for Performance Evaluation and Long-Term Stability of Computed Radiography Systems

ASTM E2698 - Standard Practice for Radiographic Examination Using Digital Detector Arrays

ASTM E2699 - Standard Practice for Digital Imaging and Communication in Nondestructive Evaluation (DICONDE) for Digital Radiographic (DR) Test Methods

ASTM E2737 - Standard Practice for Digital Detector Array Performance Evaluation and Long-Term Stability

ASTM E3024/E3024M - Standard Practice for Magnetic Particle Testing for General Industry

ASTM E3052 - Standard Practice for Examination of Carbon Steel Welds Using Eddy Current Array

(Copies of these documents are available from www.astm.org.)

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 - Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS A3.0M/A3.0 - Standard Welding Terms and Definitions Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying

AWS A5.01M/A5.01 - Welding and Brazing Consumable – Procurement of Filler Metals and Fluxes

AWS A5.4/A5.4M - Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding

AWS A5.5/A5.5M - Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding

AWS A5.9/A5.9M - Welding Consumables-Wire Electrodes, Strip Electrodes, Wires, and Rods for Arc Welding of Stainless and Heat Resisting Steels- Classification

AWS A5.18/A5.18M - Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding

AWS A5.20/A5.20M - Specification for Carbon Steel Electrodes for Flux Cored Arc Welding

AWS A5.22/A5.22M - Specification for Stainless Steel Flux Cored and Metal Cored Welding Electrodes and Rods

AWS A5.23/A5.23M - Specification for Low-Alloy Steel Electrodes and Fluxes for Submerged Arc Welding

AWS A5.28/A5.28M - Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding

Source: https://assist.dla.mil -- Downloaded: 2022-12-06T12:19Z http://www.astm.org/

AWS A5.29/A5.29M - Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding

AWS A5.32M/A5.32 - Welding Consumables - Gases and Gas Mixtures for Fusion Welding and Allied Processes

AWS B2.1/B2.1M - Specification for Welding Procedure and Performance Qualification

AWS B4.0 - Standard Methods for Mechanical Testing of Welds

AWS B5.1 - Specification for the Qualification of Welding Inspectors

AWS B5.2 - Specification for the Training, Qualification, and Company Certification of Welding Inspector Specialists and Welding Inspector Assistants

AWS C1.1M/C1.1 - Recommended Practices for Resistance Welding

AWS C1.4M/C1.4 - Specification for Resistance Welding of Carbon and Low-Alloy Steels

AWS C5.4 - Recommended Practices for Stud Welding

AWS C6.1 - Recommended Practices for Friction Welding

AWS C6.2/C6.2M - Specification for Rotary Friction Welding of Metals

AWS D1.1/D1.1M - Structural Welding Code – Steel AWS D8.1M - Specification for Automotive Weld

Quality-Resistance Spot Welding of Steel

AWS D8.8M - Specification for Automotive Weld Quality-Arc Welding of Steel

AWS D14.3/D14.3M - Specification for Welding Earthmoving, Construction, Agricultural, and Ground-Based Material Handling Equipment.

AWS D14.8M - Standard Methods for the Avoidance of Cold Cracks

AWS D17.1/D17.1M - Specification for Fusion Welding for Aerospace Applications

AWS D17.2/D17.2M - Specification for Resistance Welding for Aerospace Applications

AWS QC1 - Standard for AWS Certified Welding Inspectors

AWS RWM - Resistance Welding Manual

AWS WHB-1.0 - Welding and Cutting Science and Technology VOLUME 1

(Copies of these documents are available from www.aws.org.)

CANADIAN STANDARDS ASSOCIATION

CSA W178.2 - Certification of Welding Inspectors

(Copies of this document are available online at http://www.csa.ca.)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO/IEC 17025 - General Requirements for the Competence of Testing and Calibration Laboratories

(Copies of this document are available online at www.iso.org.)

NATIONAL AEROSPACE STANDARD

AIA/NAS NAS410 - NAS Certification & Qualification of Nondestructive Test Personnel

(Copies of this document are available online at www.aia-aerospace.org.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. DEFINITIONS

3.1 Active flux. An active flux is defined as being one that readily oxidizes the alloying elements, or adds significant alloy content to the weld.

3.2 Amplitude Rejection Level (ARL). The horizontal level on the instrument display, such as in ultrasonic inspection, which is established as either a percentage of full-scale height or as a decibel (dB) level based on the peak amplitude of the signal received from the applicable reflective surface in the calibration standard.

3.3 Active supervision. Direct on-site readily available supervision supplied by the certified visual inspector (CVI) (see 5.8.2.1) in the form of necessary instructions to ensure the authorized visual inspectors (AVI) (see 5.8.2.2) can execute specific inspections (see AWS

QC1).

http://www.aws.org/ http://www.csa.ca/ http://www.iso.org/ http://www.aia-aerospace.org/

3.4 Contractor. The organization having a direct contract with the United States Government. In this standard, the term contractor refers to the prime contractor.

3.5 Deposition thickness. The depth of weld metal deposited in a weld joint for each process, transfer mode, or filler material classification used. This term is associated with single and multipass welds, complete and partial penetration joints, and multi-process welds.

Commonly referred to as t.

3.6 Design engineering activity. The authorized personnel with overall design authority of the system, sub-system, or component.

3.7 Digital radiography (DR). All radiography methods whereby images are in a digital format.

3.8 Entity. All sites of an organization under the same quality assurance management plan and using the same quality manual, performing work to which this document is applicable.

3.9 Entity responsible representative. Any representative of an entity that is specifically authorized to approve equipment, material, or procedures within the scope of this document.

3.10 Essential variables. Essential variables are those elements, either material or process, that are important in establishing a welding procedure. These variables are defined as part of a welding procedure. Changes in these variables, after a procedure has been qualified, require a change in the written procedure and may require requalification, depending on the element being changed and the magnitude of the change based on the requirements of this document.

3.11 Field repair. Reprocessing of nonconforming material in accordance with approved written repair procedures and operations to address the nonconformity in theater. The purpose of a field repair is to restore partial functionality to an item being repaired on an as-needed basis.

Field repairs are distinguished from other repairs, in that the item, after repair, is temporarily excused from completely conforming to all of the applicable drawings, specifications or contract requirements. The system will be brought back into full conformity once the repaired item reaches a facility that is capable of performing a complete repair. This type of repair is not to be used in manufacturing of new vehicles or repairs at a facility capable of performing a complete repair.

3.12 Forced cooling. The cooling of welds using any other method greater than 5 mph air movement at ambient air temperature.

3.13 Inadvertent inspection. Unplanned or unintentional observed indications or defects discovered during nondestructive testing (NDT) processing of nearby areas.

3.14 Manufacturer. The entity performing the operations covered by this standard. The contractor may or may not be the manufacturer. The manufacturer may also be known as the sub-contractor or sub-contracting entity.

3.15 Material Review Board (MRB). A board consisting of contractor and government personnel necessary to review, evaluate, and determine or recommend disposition of nonconforming material referred to it.

3.16 Neutral flux. A neutral flux is defined as being one that does not readily oxidize the alloying elements or add significant alloy content to the weld.

3.17 Nominal thickness. The thickness that is specified on the plans or drawings without application of any allowed tolerance. The abbreviation for nominal thickness is T.

3.18 Procuring contracting officer (PCO). The individual authorized on behalf of the government, and who is responsible for overall procurement under the contract.

3.19 Proofing Projectile Impact Testing (PPIT). This test was previously referred to as the Ballistic Shock Test (BST). This is a high velocity impact test performed with a blunt nose proofing projectile to evaluate the performance of the weld under this type of impact. This test is performed in accordance with TOP 2-2-711, Ballistic testing of armor weldments. This test is not correlated to system level performance specifications or other system requirements.

3.20 Reference standard. A material or object for which all relevant chemical and physical characteristics are known and measurable, used as a comparison for, or standardization of, equipment or instruments used for nondestructive testing.

3.21 Repair. Reprocessing of defective welds, discontinuities, adjacent welding regions, base material, and improperly located components or weldment features; as to subsequently bring into conformance with this document, drawings, specifications, and contract requirements.

3.22 Steel. For the purposes of this document, steel covers all base materials incorporated under this standard, including armor grade steel (see 3.22.1) and non-armor grade steels (see 3.22.2).

3.22.1 Armor grade steel. Any steel that is manufactured and qualified to a military specification for armor grade steel, such as MIL-DTL-12560, MIL-DTL-46100, MIL-DTL- 32332 and MIL-A-11356, or approved by the procuring contract officer for use as armor.

Cast homogeneous armor. Armor grade steel qualified under MIL-A-11356.

Referred to as cast armor.

High hardness armor. Armor grade steel qualified under MIL-DTL-46100.

Commonly referred to as high hard or HHA.

Rolled homogeneous armor. Armor grade steel qualified under

MIL-DTL-12560. Commonly referred to as RHA.

Ultra-high-hardness armor. Armor grade steel qualified under MIL-DTL-32332.

Commonly referred to as ultra-hard or UHA.

Very high hardness armor. Armor grade steel qualified under MIL-DTL-46186.

Commonly referred to as very hard or VHA.

3.22.2 Non-armor grade steel. Steel not manufactured and qualified to a specification for armor grade steel (see 3.23.1), covered by a base material group number per table I of this document, NAVSEA S9074-AQ-GIB-010/248, or the Welding Procedures Qualified by Employer section of AWS B2.1/B2.1M and Annex C, or the Ferrous and Nonferrous P-Numbers Grouping of Base Metals Table of ASME BPVC Section IX.

High strength steel. For the purposes of this document, high strength steel is defined as any S-3, S-4, S-5 or S-11 steel with a yield strength greater than 90ksi (620MPa). This includes some grades of high strength low alloy (HSLA) steels, high yield strength (HY) steels, as well as many quenched and tempered steels.

3.22.3 Sheet steel. Sheet steel is any steel article with a thickness of 0.1875 inches (4.8

mm) or less.

3.23 Standard welding terms and definitions. All standard welding terms and definitions are located in the latest edition of AWS A3.0M/A3.0.

3.24 Technical authority (TA). Entity responsible to establish, approve, and assess conformance to technical, safety, and certification requirements and policy for both products and processes within this document. The term TA term can refer to the overall TA for a program or the TA for a specific engineering or technical discipline or design consideration. For example, the government welding engineer is the TA for welding procedure qualification review and the design engineer is the TA for joint design classification.

3.25 Weld repair procedure. A unique document that works in conjunction with a qualified welding procedure specification (WPS) to provide a detailed plan for each area that requires repair.

3.26 Validation test plate. A test plate weldment which is nearly identical to the original

Procedure Qualification Record (PQR) test plate, used to confirm procedure parameters and robustness of a process and practices, to authorize the transfer of a Class I WPS.

3.27 Welder qualification continuity record. A document or database that contains the record of the welder or welding operators training and usage of welding processes and procedures they are qualified to perform. The record is to show continuity of usage of the qualified process for each welder or welding operator and notes the date the process has to be used before expiration of qualification.

3.28 Welding engineer. The Government or entity’s engineer assuming technical authority for welding engineering responsibilities, including but not limited to, weld design, quality, procedure and personnel qualification and development. For full descriptions of responsibilities, see AWS D1.1/D1.1M, and for qualifications and experience see AWS D14.3/D14.3M.

3.29 Welding equipment. All non-consumable equipment used for, or in support of, welding, and that provides instantaneous information to the user about the welding process.

Information can be in the form of data output such as the amperage reading on the welding machine, or temperature measuring devices or gauge readings such as flow meters for shielding gases.

3.30 Welding symbols. Welding symbols are to be those shown in the latest edition of

AWS A2.4.

4. GENERAL REQUIREMENTS

4.1 Qualification requirements. All entities shall qualify procedures and personnel in accordance with this standard and submit applicable documents (see 5.3, 5.5, 5.6, and 5.8) to the procuring contract officer or technical authority upon request, prior to welding any production weldments (see 6.2). This document shall serve as the fabrication or construction document, when a fabrication or construction document is referenced in any other document, unless otherwise required by the procuring contract officer.

4.1.1 Submission format. Procedure Qualification Records (PQRs), Welding Procedure

Specifications (WPSs), and Welder Qualification Records (WQRs) shall be in an organized and efficient packet. Guidance and overview in the form of a supplementary table of contents, outlines, tables, charts, or matrices are encouraged. The quantity of each document type should be identified in the submission along with number of pages. Illegible or blurry submissions are unacceptable and shall be re-produced if clarity cannot be met.

PQR submission format. Each PQR shall be uniquely identified with a traceable identifier and submitted to the procuring contract officer or technical authority with all applicable supporting documentation upon request. Supporting documentation for PQRs includes but is not limited to; nondestructive and destructive test data and results, material certifications, lot conformance testing results, shielding certifications, shot records, and any modification of the PQR (see 5.3, 5.4, 5.7 and 5.9). PQR and supporting documentation shall be put into a packet and delivered for all applicable requests.

WPS submission format. WPSs shall be uniquely identified with a traceable identifier and submitted to the procuring contract officer or technical authority with all applicable supporting documentation upon request. Supporting documentation for WPSs includes but is not limited to supporting PQRs, shot records, and testing data/results (see 5.4, 5.5, 5.7, and 5.9). Each WPS and supporting documentation shall be put into a packet and delivered for all applicable requests.

WQR submission format. Each WQR shall be uniquely identified with a traceable identifier and submitted to the procuring contract officer or technical authority with all applicable supporting documentation upon request. Supporting documentation for WQRs includes but is not limited to nondestructive testing results, WPS used for WQR Test, and destructive testing results (see 5.6, 5.7, and 5.9). WQR and supporting documentation shall be put into a packet and delivered for all applicable requests.

4.2 Qualification applicability. Qualifications performed and approved in accordance with this document are intended to be based on material type and weld classification, and are applicable to any weldment that aligns with the scope of the qualification.

4.3 Responsibility. When this document is specified by the contract or drawing, each entity qualifying procedures under the requirements of this document shall prepare written welding procedures and perform the required tests to qualify these procedures. Prior to any fabrication, the entity shall produce all procedure qualification records, welding procedure specifications, and welder qualification records for all welds in accordance with this document and shall be delivered to the procuring contract officer upon request. Examples of a blank PQR and WPS are located in FIGURE B-1 and FIGURE B-2 respectively.

4.4 Previous qualification to MIL-STD-3040 revisions. Procedures and personnel previously qualified to earlier revisions of this document, for which records are available and qualifications have been maintained (see 5.3.8, 5.5.7, and 5.6.9), are acceptable for use to this document. Table II shall be used as a reference to determine the new weld classification (see 4.6.1) from the earlier revision of this document. All previously approved welding procedures and personnel qualifications, and their supporting documentation shall be submitted to the procuring contract officer and the technical authority for approval for each scope of work upon request (see 6.2). The technical authority may require requalification to this document on a case-by-case basis where any of the following apply:

a. There are specific concerns about the adequacy or accuracy of the welding procedures, the ability of the personnel to produce acceptable works, or which do not meet the requirements of the applicable fabrication document.

b. The existing qualification does not meet the requirements of the earlier revision of this document originally qualified to.

c. Any exceptions made to a previous procedure that does not meet the requirements of the earlier revision of this document originally qualified to.

4.4.1 Previous qualification to other standards. Procedures and personnel (5.6.6) previously qualified to other standards or documents, for which records are available and qualifications have been maintained (see 5.3.8, 5.5.7, and 5.6.9), are acceptable for use to this document. TABLE II shall be used as a reference to determine the new weld classification (see 4.6.1) from the earlier revision of this document. Previously approved welding procedures with incomplete records may submit a supplemental PQR (see 5.3.4) to re-attain qualification in accordance with the requirements of this document. All previously approved welding procedures and personnel qualifications, and their supporting documentation shall be submitted to the procuring contract officer and the technical authority for approval for each scope of work upon request (see 6.2). The technical authority may require requalification to this document on a case-by-case basis where any of the following apply:

a. There are specific concerns about the adequacy or accuracy of the welding procedures, the ability of the personnel to produce acceptable works, or works that are not able to meet the requirements of the applicable fabrication document.

b. The existing qualification does not meet the requirements of its original qualification document.

c. Any exceptions made to a previous procedure that does not meet the requirements of the original qualification document.

4.5 Safety precautions. This standard may involve hazardous materials, operations, and equipment. This standard does not address any of the safety issues associated with their use. It is the responsibility of the user to establish appropriate health and safety practices.

4.6 Joint design. The weld joint design shall be in accordance with engineering best practices and shall be the responsibility of the entity’s design engineering activity with the approval of the procuring contract officer for Class I and II welds upon request. For specific joint design recommendations and calculations, see the latest version of MIL-STD-22 and NAVSEA S9074-A1-GIB-010/1628, as applicable. All joint designs and joint design calculations, including finite element analysis (FEA) results, shall be delivered to the PCO for review upon request. Square groove, plug, or slot welds shall not be used for Class I and Class II joint designs without adequate supporting data, including a test plan for demonstrating weld soundness, which shall be submitted to the PCO for approval prior to use.

4.6.1 Weld joint classification requirements. Each weld made using this standard shall be classified based on the service conditions. The classification governs the extent to which quality assurance provisions are applied to the weld joint. The design engineering activity shall determine the classification of welds in accordance with this document and table III, with final weld classification approval by the procuring contract officer. Factors to consider when classifying welds include: high-strain-rate events, static loading vs. dynamic loading, cyclic loading, corrosion, temperature, material characteristics, probability of failure, consequences of failure.

Where a weld can be assigned to more than one class, the more stringent class shall be selected.

Where welds intersect or overlap another weld of a higher classification, the intersection point and 2 inches in all directions from the intersection point shall meet the quality assurance requirements of the higher classification (see FIGURE 1). Note that weld joint classification is not related to base material classes for armor grade steels, system level performance specification requirements or NDT acceptance criteria. Weld classes shall be chosen on the basis of the following definitions:

a. Class I welds. Welds constructed of armor grade steels welded to armor grade steels in critical load bearing elements in the primary loading path. Class I welds are typically used in primary load bearing connections and survivability. Square groove, plug, or slot welds shall not be used for Class I joint designs without adequate supporting data, including a test plan for demonstrating high strain rate soundness, which shall be submitted to the procuring contract officer and technical authority for approval prior to use. Failure of a Class I weld in service would be catastrophic and would result in the loss of life, system(s), control, major components, unintentional release of critical stores, or a mission-critical failure. A Class I Weld shall be categorized as “High” on the weld classification decision matrix. Possible examples of Class I welds include but are not limited to: turret structure, armor solution, monocoque armored hull, and exterior components and assemblies.

b. Class II welds. Welds constructed of nonarmor grade steels, in load bearing elements that are either in the primary or secondary loading path. Class II welds are typically used in primary load bearing connections. Square groove, plug, or slot welds shall not be used for Class II joint designs without adequate supporting data, including a test plan for demonstrating weld soundness, which shall be submitted to the procuring contract officer and technical authority for approval prior to use. Failure of a Class II weld in service would be catastrophic and would result in the loss of life, system(s), control, major components, unintentional release of critical stores, or a mission-critical failure. A Class II weld shall be categorized as “High” on the weld classification decision matrix. Possible examples of Class II weld include but are not limited to:

structural welds, drivetrain components, suspension components, steering components, highly stressed carriage components, ammunition boxes, lifting lugs, and critical components.

c. Class III welds. Welds constructed of any combination of steels in load bearing elements. Class III welds are typically used in secondary load bearing or shared load connections. Failure of a Class III weld in service would reduce the overall efficiency of the system, and may result in the loss of life, system(s), control, major components, or a mission-critical failure. A Class III Weld shall be categorized as “Medium” on the weld classification decision matrix. Possible examples of Class III welds include but are not limited to: interior components and attachments, door or hatch components, leak-proof containers, ammunition racks, and moderately critical components.

d. Class IV welds. Welds constructed of any combination of steels in minor load bearing and noncritical elements. Failure of Class IV welds would have minor to no effect on the efficiency of a system and endangerment to personnel. Class IV welds are typically used in connections where any expected load transfer at the weld would be secondary or tertiary load bearing, shared load connections or negligible. Class IV welds shall be categorized as “Low” on the weld classification decision matrix. In any case, Class IV shall not be specified for welds used for making connections onto critical or primary load path elements, such as lift points, or elements directly related to personnel supporting activities, regardless of the loading condition or direction. Possible examples of Class IV welds include but are not limited to: ladders, handrails, stowage boxes, exterior attachments, brackets, fenders, heaters, air ducts, boiler casings, air vents, and most types of sheet metal assemblies, and non-critical components.

Armor welds without class designations. When a weldment is constructed of an armor grade steel welded to an armor grade steel, or to a steel approved for use as an armor solution, and does not have a weld classification, the technical authority shall assign the weld classification. The procuring contract office shall, in its best effort, contact the original design activity to define the susceptibility and severity of weld failure for this particular weldment. If the original design activity is unavailable, the technical authority shall work with the design engineering activity to define weld classification for this particular weldment. When a weldment consists of armor grade steel welded to non-armor grade steel, or non-armor grade steels welded together, that does not have a weld classification, the design engineering activity shall determine the classification of welds in accordance with this document.

Welding symbol requirements for classification. To minimize fabrication costs by avoiding over-inspection and unnecessary repair, all welds on a drawing shall be classified individually. This can be accomplished by including a note on the engineering drawing with the general format shown in figure 2 which specifies only the DoD nomenclature. The weld class shall then be indicated by one the following:

a. Detailing the specific weld class within the tail of welding symbol for each individual weld joint or,

b. By using specific flag notes with the welding symbol for the individual weld joints

(see figure 3) or,

c. By using detailed drawing notes, provided that all of the welds on each detail drawing are the same weld class.

4.6.2 Minimum fillet weld size. Unless specified in drawings or contract requirements, all fillet welds shall conform to the requirements listed in NAVSEA S9074-A1-GIB-010/1628.

4.6.3 Intermittent fillet welds. Intermittent fillet welds shall be allowed for Class III and

IV welds only. Length and pitch specified shall be a result of design calculations. The minimum fillet weld length shall be no less than 2 inches (50.8 mm).

4.7 Welding processes.

4.7.1 Acceptable welding processes. The following welding processes are acceptable for use in accordance with this document without restriction.

a. Shielded Metal Arc Welding (SMAW)

b. Gas Metal Arc Welding (GMAW) spray transfer mode (GMAW-Spray), and pulsed spray transfer mode (GMAW-P) only.

c. Gas Tungsten Arc Welding (GTAW)

d. Flux Cored Arc Welding (FCAW) (see 5.2.3.1.1)

4.7.2 Restricted welding processes. The following welding processes shall only be used within the limitations described herein. Any use outside of the limitations listed below shall require approval from the technical authority with supporting data.

a. GMAW utilizing a globular transfer mode (GMAW-G) shall be restricted to Class III and IV welds in the flat or horizontal position only.

b. GMAW utilizing a short circuit transfer mode (GMAW-S) shall be restricted to Class

IV welds only, and with both material thicknesses being of 3/16” (4.8 mm) and less.

c. Submerged Arc Welding (SAW) shall be restricted to the flux-electrode classifications in combinations as qualified. SAW shall require approval from technical authority prior to use for Class I and Class II joints.

d. Metal Cored Arc Welding (MCAW) shall require approval from the technical authority prior to use for Class I and Class II joints. No prior approval is required for Class III or IV joints.

4.7.3 Additional welding processes. Additional welding processes not covered by this document shall require qualification in accordance with the document listed within this section for each process below. Each welding process shall be identified on the engineering drawing.

a. Stud Welding (SW) – AWS B2.1, AWS C5.4, or AWS D1.1.

b. Resistance Welding (RW) – AWS C1.1M/C1.1, AWS C1.4M/C1.4, AWS D17.2/17.2M, or AWS RWM.

c. Resistance Spot Welding (RSW) – AWS D8.1M.

d. Friction Welding (FW) – AWS C6.1 or AWS C6.2/C6.2M.

e. Other Welding Processes – Unlisted welding processes shall qualify via applicable industry standards. Other welding processes may be used with approval of the procuring contract officer and the technical authority (see 6.2). Additional welding and workmanship requirements may be required, depending on the process to be approved.

4.8 Weld positions. For descriptions of all welding positions and position limitations, see the most recent version of AWS A3.0M/A3.0.

4.9 Quality control. It shall be the full responsibility of the entity to institute and maintain a quality program and the inspection standards necessary to ensure that the part, assembly, sub-assembly, and end product is produced and meets the requirements of the contract, drawings, applicable regulations, system relevant technical manuals and bulletins, and this document. The quality program shall also ensure that measuring, test and manufacturing equipment are properly maintained, and that appropriate actions are taken for nonconforming materials.

4.9.1 Quality assurance system. Each entity shall maintain a quality assurance system that is adequate to assure the procuring contract officer that all of the requirements of this document have been and are continuously being met.