MIL_STD_3040_Welding_Steel(TACOM)_29_June_2016_Superseding_Drawing_12479550.pdf

INCH-POUND

MIL-STD-3040

29 June 2016

SUPERSEDING

DRAWING 12479550

30 April 2003

DEPARTMENT OF DEFENSE

MANUFACTURING PROCESS STANDARD

ARC WELDING OF ARMOR GRADE STEEL

AMSC N/A AREA THJM

DISTRIBUTION STATEMENT C. Distribution authorized to U.S. Government agencies and their contractors; contains vulnerability information, 24 February 2016. Other requests shall be referred to U.S. Army Tank-Automotive Research, Development and Engineering Center, ATTN: RDTA-SIE-ES-SI MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or usarmy.detroit.rdecom.mbx.tardec standardization@mail.mil.

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mailto:usarmy.detroit.rdecom.mbx.tardec%20standardization@mail.mil 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. Comments, suggestions, or questions on this document should be addressed to U.S. Army Tank-Automotive Research, Development and Engineering Center, ATTN: RDTA-SIE-ES-SI MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or sent by email to usarmy.detroit.rdecom.mbx.tardec standardization@mail.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/.

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CONTENTS

PARAGRAPH Page

FOREWORD ..................................................................................................................... ii

1. SCOPE

1.1 Scope

1.2 Classification

1.2.1 Welding processes

1.2.2 Designation of welded connections

1.3 Application

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 Amplitude Rejection Level (ARL)

3.2 Contractor

3.3 Design engineer

3.4 Engineer

3.5 Entity

3.6 Fixture

3.7 Functional fixture

3.8 Manufacturer

3.9 Nominal thickness

3.10 Procuring engineering activity

3.11 Reference calibration standard

3.12 Repair

3.13 Rework

3.14 Root opening

3.15 Sheet steel

3.16 Standard welding terms and definitions

3.17 Welding symbols

4. GENERAL REQUIREMENTS

4.1 Safety precautions

4.2 Joint design

4.3 Restricted welding process

4.4 Equipment calibration

4.5 Welding fixtures

iv

4.6 Weld positions

4.6.1 Groove weld axis limits

4.6.2 Fillet weld axis limits

4.6.3 Welding positions

5. DETAILED REQUIREMENTS

5.1 Material

5.1.1 Base material

5.1.2 Backing material

5.1.3 Spacers material

5.1.4 Weld tab material

5.1.5 Shielding gases

5.1.6 Weld filler material

5.2 Personnel qualification

5.2.1 Weld personnel qualification

5.2.2 Weld inspector qualification

5.2.3 Mechanical testing personnel qualification

5.2.4 Non-Destructive Testing (NDT) personnel qualification

5.2.5 Personnel documentation

5.3 Weld procedure qualification

5.3.1 Prequalified welded joints

5.3.2 Preparation of weld procedures

5.3.3 Previous qualified welding procedures

5.3.4 Company name change

5.3.5 Revision

5.3.6 Class I

5.3.7 Class II and Class III

5.3.8 Documentation

5.4 Fabrication

5.4.1 Welding environment

5.4.2 Weld Procedure Specification (WPS)

5.4.3 Quality control

5.4.4 Position

5.4.5 Preheat, interpass & postweld heat treatment

5.4.6 Tack welding

5.4.7 Minimum fillet weld size

5.4.8 Intermittent fillet welds

5.4.9 Weld profiles

5.4.10 Arc strikes

5.4.11 Weld cleaning

5.5 Weld inspection

5.5.1 Hardness testing of welds

5.5.2 Visual inspection

5.5.3 Mechanical testing

5.5.4 Nondestructive Testing (NDT)

5.6 Repair and rework of welds

v

5.6.1 Limitations

5.6.2 Base material preparation

5.6.3 Rework procedures

5.6.4 Repair procedures

5.6.5 Weld metal removal

5.6.6 Crack repair or rework

6. NOTES

6.1 Intended use

6.2 Acquisitions requirements

6.3 Standard units of measure

6.4 Heat input

6.5 Subject term (key word) listing

APPENDIX A CLASS I WELD PROCEDURE QUALIFICATION

A.1 SCOPE

A.1.1 Scope A.1.2 Application

A.2 APPLICABLE DOCUMENTS

A.2.1 General A.2.2 Government documents A.2.2.1 Specifications, standards, and handbooks

A.3 PROCEDURE RECORDS

A.3.1 Procedure Qualification Records (PQRs) A.3.2 PQR base material A.3.2.1 Filler material A.3.2.2 Process qualification essential variables A.3.2.3 Non-destructive testing A.3.2.4 Mechanical testing A.3.3 Welding Procedure Specification (WPS)

A.4 TEST PLATE

A.4.1 Dimensions of test plate A.4.2 Different Thicknesses A.4.3 Different armor types A.4.4 Joint Type A.4.5 Preparation of the ballistic test plate A.4.6 Identification marking of test plates A.4.7 Marking of retest plates

A.5 BALLISTIC SHOCK TESTING

A.5.1 Ballistic shock test requirements A.5.2 Ballistic testing address vi

A.5.3 Visual examination of test plates A.5.4 Radiographic inspection of the test plate A.5.5 Test setup A.5.5.1 Temperature conditioning of test plate A.5.5.2 Test obliquity A.5.5.3 Proofing projectile A.5.6 Impact validity A.5.6.1 Valid impact A.5.6.2 No test

A.6 TEST RESULTS

A.6.1 Evaluation of test A.6.2 Test decision A.6.3 Magnetic particle or dye penetrant test A.6.4 Photographic record A.6.5 Repair of test plate A.6.6 Rejection of ballistic test plate A.6.7 Retest

APPENDIX B REFERENCE MATERIALS

B.1 SCOPE

B.1.1 Scope B.1.2 Application

FIGURE Page

1. Groove weld axis limits

2. Fillet weld axis limits

3. Groove weld plate positions

4. Groove weld pipe positions

5. Fillet weld plate positions

6. Rotated fillet weld pipe positions

7. Fixed fillet weld pipe positions

8. Welder and welding operator qualification plate T less than 0.5 inches inclusive.

9. Welder and welding operator qualification plate T greater than 0.5 inches

10. Class II & III welder qualification groove plate

11. Class II & III welder qualification groove plate horizontal

12. Class II & III welding operator qualification groove plate

13. Class II - III welder and welding operator qualification plug

14. Class II & III welder qualification fillet weld

15. Class II & III PQR, welder, and welding operator qualification pipe or tube

16. Class II & III procedure plate test sample locations

17. Class II & III fillet weld procedure qualification

18. Class II & III fillet weld procedure macroetch view vii

19. Temperature measurement technique

20. Visual inspection access

21. Top view of sample locations for CVN testing

22. Front view for CVN sample locations for single and double V groove

23. CVN notch orientation

24. Fillet weld break test direction of force

25. Excavated weld metal A-1. Ballistic test plate (H plate) A-2. Type I-A, single V-grooved butt joint A-3. Type I-B, single V-grooved butt joint with backing material A-4. Type II, double V-grooved butt joint A-5. Examples of cracks in ballistic shock test plates B-1. Welder/welding operator qualification record (WQR) example B-2. Procedure qualification record (PQR) example B-3. Welding procedure specification (WPS) example

TABLE Page

I. Filler material selection II. Welder and welding operator qualification positions for plate III. Welder and welding operator qualification positions for pipe and tube IV. Welder and welding operator essential variables V. Welder and welding operator qualification criteria for Class II and III welds VI. Procedure qualification positions for plate VII. Procedure qualification positions for pipe and tube VIII. Procedure plate groove qualification criteria IX. Procedure plate fillet qualification criteria XI. Procedure essential variables XII. Groove weld tolerances XIII. Preheat and interpass temperatures XV. Liquid penetrant material classifications A-I. Test plate thickness A-II. Test plate joint type A-III. Type II, double V-grooved root opening A-IV. Ballistic shock test requirements

1. SCOPE

1.1 Scope. This standard provides requirements applicable to various arc welding processes for welding and repairing armor welds which are constructed from qualified armor grade steel (wrought and cast armor grade steel). This standard defines the requirements for armor grade steel weld fabrication, inspection, repair, and qualification of procedures and personnel.

1.2 Classification.

1.2.1 Welding processes. The welding processes are classified as follows:

a. Shielded Metal Arc Welding (SMAW)

b. Gas Metal Arc Welding (GMAW) to include pulsed transfer (GMAW-P), globular transfer (GMAW-G), short circuit transfer (GMAW-S), and spray transfer (GMAW-SP)

c. Submerged Arc Welding (SAW)

d. Gas Tungsten Arc Welding (GTAW)

e. Flux Core Arc Welding (FCAW)

f. Other fusion welding processes may be used with permission of the procuring engineering activity.

1.2.2 Designation of welded connections. Weld classes do not relate or correlate with material classes as defined in the applicable military specifications for armor grade steels. The loading of welded members should be classified as follows:

a. Class I welds. This class of weld is applicable to weld joints that are critical to the structural integrity of a system. A failure of any portion of this weld, when subjected to conditions defined by system/sub-system requirements, could result in a loss of system, loss of life, loss of major component, loss of control, unintentional release of critical stores, or a mission-critical failure. A failure of these welds would be considered catastrophic or critical for the severity in the risk assessment matrix in accordance with ATP 5-19.

b. Class II welds. A failure of any portion of this weld class, when subjected to conditions defined by system/sub-system requirements, could result in a reduction of overall efficiency of the system or could result in injury, or endangering of personnel. A failure of these welds would be considered moderate for the severity in the risk assessment matrix in accordance with ATP 5-19.

c. Class III welds. A failure of any portion of this weld class, when subjected to conditions defined by system/sub-system requirements, would not affect the efficiency of the system or endanger personnel. A failure of these welds would be considered negligible for the severity in the risk assessment matrix in accordance with ATP 5-19.

d. Welds without class designations. When weld class is not specified in the contract or drawing, Class I weld designation will apply.

1.3 Application. This standard covers welding armor grade steel to armor grade steel, and armor grade steel to non-armor grade steel of any tensile strength.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4 or 5 of this specification. This section does not include documents cited in other sections of this specification 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 specification, 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-46100 - Armor Plate, Steel, Wrought, High-Hardness 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-E-22200/10 - Electrodes, Welding, Mineral Covered, Iron- Powder, Low-Hydrogen Medium, High Tensile and Higher-Strength Low Alloy Steels

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-2035(SH) - Nondestructive Testing Acceptance Criteria

NOTE: Naval Sea Systems Command (NAVSEA) will be referred to as Army throughout the referenced MIL-STD.

(Copies of these documents are available from http://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 TECHNIQUES PUBLICATIONS

ATP 5-19 - Risk Management

(Copies of this document are available from http://armypubs.army.mil/doctrine/ATP_1.html.)

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 Y14.43 - Dimensioning and Tolerancing Principles for Gages and Fixtures

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

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

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

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

ASTM INTERNATIONAL

http://quicksearch.dla.mil/ http://armypubs.army.mil/doctrine/ATP_1.html http://www.asme.org/ https://www.asnt.org/

ASTM E8/E8M - Standard Test Methods for Tension Testing of Metallic Materials

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

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 E164 - Standard Practice for Contact Ultrasonic Testing of Weldments

ASTM E340 - Standard Test Method for Macroetching Metals and Alloys

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

ASTM E1032 - Standard Test Method for Radiographic Examination of Weldments

ASTM E1417/E1417M - Standard Practice for Liquid Penetrant Testing ASTM E1444/E1444M - Standard Practice for Magnetic Particle Testing ASTM E2699 - Standard Practice for Digital Imaging and

Communication in Nondestructive Evaluation (DICONDE) for Digital Radiographic (DR) Test Methods

(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/3.0 - Standard Welding Terms and Definitions (DoD adopted)

AWS A5.1/A5.1M - Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding

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

AWS A5.17/A5.17M - Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding

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

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

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

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AWS A5.36/A5.36M - Specification for Carbon and Low-Alloy Steel Flux Cored Electrodes for Flux Cored Arc Welding and Metal Cored Electrodes for Gas Metal Arc Welding

AWS QC1 - Standard for AWS Certified Welding Inspectors AWS Z49.1 - Safety in Welding Cutting, and Allied Processes

(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

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 Amplitude Rejection Level (ARL). The horizontal level on the instrument display 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.

3.2 Contractor. Also known as the prime contractor; the organization having a direct contract with the procuring activity. In this standard, the term contractor refers to the prime contractor.

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

3.3 Design engineer. The individual with overall design authority of vehicle, sub-assembly, or component. The design engineer is responsible for determining class of welds in accordance with 1.2.2 and ATP 5-19 with final weld classification approval from procuring engineering activity.

3.4 Engineer. A duly designated individual who acts for and on behalf of the Government, contractor or manufacturer on all matters within the scope of this standard.

3.5 Entity. A complete and separate company, manufacturer, organization or contractor.

3.6 Fixture. A system to secure parts in place during manufacturing.

3.7 Functional fixture. A fixture that uses gage elements and makes physical contact with datum features on the fabricated part.

3.8 Manufacturer. The organization actually performing the operations covered by this standard. The contractor may or may not be the manufacturer.

3.9 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.

3.10 Procuring engineering activity. The subject matter experts (SME) designated by the procuring activity. Obtaining permission from the procuring engineering activity will be done by contacting the contracting officer and directing the request through the SME.

3.11 Reference calibration standard. A sample of material acoustically similar to the material to be tested containing known reflectors with which the ultrasonic system is calibrated to establish acceptance/rejection levels.

3.12 Repair. Reprocessing of nonconforming material in accordance with approved written procedures and operations to reduce, but not completely eliminate, the nonconformance.

The purpose of repair is to bring nonconforming material into a usable condition. Repair is distinguished from rework in that the item after repair still does not completely conform to all of the applicable drawings, specifications or contract requirements.

3.13 Rework. Reprocessing of nonconforming material to make it conform completely to the drawings, specifications or contract requirements.

3.14 Root opening. Root openings listed in this document are also known as “design openings”, or the openings which would exist after completion of the weld if the root face had not been melted away. The dimensions in this standard for the root opening are used on drawings to give correct over-all dimensions for the structure. The “design opening” is not ordinarily the root opening which is actually visible before welding, as the opening should include an increase for the amount of contraction across the joint during welding. Therefore, the root opening equals the “design opening” plus the shrinkage allowance.

3.15 Sheet steel. Sheet steel is any steel plate with a thickness of 0.1875 inches (4.8

mm) or less.

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

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

AWS A2.4.

4. GENERAL REQUIREMENTS

4.1 Safety precautions. Safety precautions shall conform to the latest edition of

AWS Z49.1.

Note: This standard may involve hazardous materials, operations, and equipment. This standard does not address any of the safety problems associated with their use. It is the responsibility of the user to establish appropriate safety and health practices. The user should determine the applicability of any regulatory limitations prior to use.

4.2 Joint design. The weld joint design shall be the responsibility of the design engineer and shall be available for review by the procuring engineering activity if requested.

There are no prequalified joint types defined in this standard.

4.3 Restricted welding process. GMAW-short circuit (GMAW-S) and globular transfer

(GMAW-G), shall not be allowed for Class I welds unless the welding process passes a ballistic shock test in accordance with Appendix A.

4.4 Equipment calibration. The contractor shall develop and maintain an equipment calibration program for all welding equipment that has a factory calibrated certification.

4.5 Welding fixtures. Fabricated parts that require fixtures or frames, as determined by the design engineer, shall use fixtures or frames designed to minimize the distortion of the components being welded and to ensure that drawing tolerances are maintained. When the design engineer designates the use of a functional fixture, the fixture shall be designed in accordance with ASME Y14.43.

4.6 Weld positions. Weld positions flat (F), horizontal (H), vertical (V) and overhead (OH) shall be classified in accordance with the following.

4.6.1 Groove weld axis limits. The limits set forth in figure 1 shall be used to determine weld positions for groove welds. The positions for figure 1 shall be as follows: A is flat, B is horizontal, C is overhead, and both D and E are vertical.

FIGURE 1. Groove weld axis limits.

4.6.2 Fillet weld axis limits. The limits set forth in figure 2 shall be used to determine weld positions for fillet welds. The positions for figure 2 shall be as follows: A is flat, B is horizontal, C is overhead, and both D and E are vertical.

FIGURE 2. Fillet weld axis limits.

4.6.3 Welding positions. Welding positions shall be in accordance with figure 3 through figure 7. Pipe rotation along the axis shall only be allowed for 1G in figure 4, and all figures in figure 6. Welding position shall remain within the axis limits (see 4.6.1 and 4.6.2) during the duration of the welder, welding operator, or procedure qualification for the specified position (see 5.2.1 and 5.3).

FIGURE 3. Groove weld plate positions.

FIGURE 4. Groove weld pipe positions.

FIGURE 5. Fillet weld plate positions.

FIGURE 6. Rotated fillet weld pipe positions.

FIGURE 7. Fixed fillet weld pipe positions.

5. DETAILED REQUIREMENTS

5.1 Material.

5.1.1 Base material. All accepted armor grade steel shall be limited to materials qualified under the latest revisions of MIL-A-11356, MIL-DTL-12560, or MIL-DTL-46100.

Any other armor grade steel shall be approved by the procuring engineering activity prior to use.

Any material not qualified under MIL-A-11356, MIL-DTL-12560, or MIL-DTL-46100 that is approved by the procuring engineering activity to be used as armor shall be qualified as a Class I weld for the welder or welding operator (see 5.2.1) and for procedure qualification (see 5.3) The base material shall be as specified in the contract documents or the applicable drawing. Unless otherwise specified, armor grade steel shall be welded in the fully quenched and tempered condition in accordance with MIL-A-11356, MIL-DTL-12560, or MIL-DTL-46100. If a discontinuity is the result of poor mill process, repairs of the base material may be made in accordance with MIL-A-11356, MIL-DTL-12560, or MIL-DTL-46100.

5.1.1.1 Base material certification. The material certification from the steel manufacturer shall be verified by the contractor against the requirements of the applicable specification prior to its usage. All certification documentation for armor steel base material shall be kept by the contractor for the period of performance of the contract, at a minimum.

5.1.1.2 Non-armor grade steel. When a change of non-armor grade steel welded to armor grade steel (Class II and III only) occurs, separate process qualifications shall not be necessary if all other essential variables are met.

5.1.2 Backing material.

5.1.2.1 Permanent backing material. For permanent steel backing material for Class I, II, and III welds, the thickness of the backing material shall be equal to the thickness of the thinnest base material used up to 0.375 inches (9.5 mm). Permanent backing for Class I welds shall not be permitted, unless approved by the procuring engineering activity. If permanent backing material is allowed for Class I welds, the backing material shall be identical with the base material. If base materials are not identical in a Class I weld, then the backing material shall be identical to the lowest hardness range base material in accordance with material specifications. All certification documentation for Class I weld permanent backing material shall be kept by the contractor for the period of performance of the contract, at a minimum.

5.1.2.2 Removable backing material. Removable backing material of any suitable material shall be allowed for all classes of welds at the discretion of the design engineer. If using steel backing material, when both base materials are identical, the backing material shall be identical with the base material. If using steel backing material when base materials are not identical, the backing material shall be identical to the lowest tensile strength material.

5.1.3 Spacers material. Spacers shall be fabricated from material identical to the base material. If using steel spacers when base materials are not identical, the spacer material shall be identical to the lowest tensile strength material. If steel spacers are used for Class I welds, all certification documentation for armor steel spacer material shall be kept by the contractor for the period of performance of the contract, at a minimum.

5.1.4 Weld tab material. Weld tab material shall be steel material and removed at the completion of welding before NDT or visual inspection. Weld tabs shall be allowed for all classes of welds.

5.1.5 Shielding gases. All shielding gas or gas mixtures shall be in accordance with

AWS A5.32M/A5.32, and shall be certified by the gas manufacturer. All certification documentation shall be kept by the contractor for the period of performance of the contract, at a minimum. A gas or gas mixture used for shielding shall be of a welding grade and shall have a dew point in accordance with table 4 of AWS A5.32M/A5.32. When shielding gas mixers are required, calibrated mass flow meters shall be used for proportioning the percentages of gases to conform to the requirements of the weld procedure specification (WPS) (see 4.4). The procuring engineering activity may conduct reviews of the calibration and certification documentation to assess conformance to this standard.

5.1.6 Weld filler material. Only weld filler identified in the WPS shall be used during welding. Table I contains a list of recommended filler materials that may be used for the corresponding welding processes and base materials. The use of these recommended filler materials does not guarantee successful process qualification testing. All welding processes, regardless of filler material, shall be qualified in accordance with this document. Each filler material listed in table I has the military specification and equivalent AWS specification listed.

Each military filler classification has an AWS equivalent classification listed. For corresponding welding process see 1.2.1. Any filler material not listed in table I may be used if all process qualification criteria are met in accordance with this standard. When welding non-armor grade steel to armor grade steel, the filler material shall match or exceed the non-armor grade steel tensile strength. Any non-armor grade steel that is over 120 ksi tensile strength, and is not used as armor, shall be allowed to under match filler material.

TABLE I. Filler material selection.

Material specification Process Military electrode specification

AWS electrode specification equivalent

Military electrode classification

AWS electrode classification equivalent

MIL-DTL-12560

or

MIL-DTL-46100

SMAW MIL-E-22200/10C

MIL-E-22200/1

A5.1/A5.1M A5.5/A5.5M

MIL-7018-M

MIL-8018-C3

MIL-8018-C3SR

MIL-9018-M

MIL-10018-XX

MIL-11018-XX

MIL-12018-XX

E7018M E8018-C3 E9018M

E10018M E11018M E12018M E12018M1

SAW

MIL-E-23765/1

MIL-E-23765/2

MIL-E-23765/4*

A5.17/A5.17M A5.18/A5.18M A5.23/A5.23M A5.28/A5.28M

MIL-70S-X

MIL-100S-1

MIL-120S-1

ER70S-X

ER100S-1

ER120S-1

GMAW MIL-E-23765/1

MIL-E-23765/2

A5.18/A5.18M A5.28/A5.28M

MIL-70S-X

MIL-80S-3

MIL-100S-1

MIL-120S-1

ER70S-X

ER80S-D2

ER100S-1

ER120S-1

GTAW MIL-E-23765/1

MIL-E-23765/2

A5.18/A5.18M A5.28/A5.28M

MIL-70S-X

MIL-80S-3

MIL-100S-1

MIL-120S-1

ER70S-X

ER80S-D2

ER100S-1

ER120S-1

FCAW MIL-E-24403/2 A5.36/A5.36M

MIL-100TXX

MIL-101TXX

MIL-110TXX

MIL-120TX

MIL-121TX

E10XTX-X

E11XTX-X

E12XTX-X

MCAW N/A A5.36/A5.36M N/A

E70C-XXX

E80C-XXX

E90C-XXX

E100C-XXX

E110C-XXX

E120C-XXX

MIL-A-11356

SMAW MIL-E-22200/1 A5.5/A5.5M

MIL-10018-XX

MIL-11018-XX

MIL-12018-XX

E10018M E11018M E12018M E12018M1

SAW MIL-E-23765/2 A5.23/A5.23M

A5.28/A5.28M

MIL-100S-XX

MIL-120S-XX

ER100S-1

ER120S-1

GMAW MIL-E-23765/2 A5.28/A5.28M MIL-100S-1

MIL-120S-1

ER100S-1

ER120S-1

GTAW MIL-E-23765/2 A5.28/A5.28M MIL-100S-1

MIL-120S-1

ER100S-1

ER120S-1

FCAW MIL-E-24403/2 A5.36/A5.36M

MIL-100TXX

MIL-101TXX

MIL-110TXX

MIL-120TX

MIL-121TX

E10XTX-X

E11XTX-X

E12XTX-X

MCAW N/A A5.36/A5.36M N/A

E100C-XXX

E110C-XXX

E120C-XXX

NOTE: “*” are Flux for SAW

5.1.6.1 Filler material handling. Welding electrodes shall be handled carefully to prevent damage to their coatings, if coatings exist. Damaged containers shall have their contents examined for excessive moisture content, cracked coatings or other damage to the electrodes.

Filler spools or drums shall be examined for distorted spools, entwined winding on spooled wire, or surface contaminates. Filler material damaged to the extent that it does not meet specification requirements (see table I) shall not be used for production welding.

5.1.6.2 Filler material storage. Bare filler material, flux core wire, and neutral granular flux shall be stored in a dry area. Low hydrogen covered electrodes shall be stored in accordance with 5.1.6.2.1.

5.1.6.2.1 Covered electrodes. Any low hydrogen covered electrode not qualified in accordance with a military specification shall be stored in accordance with applicable industry standards or manufacturers’ suggested storage and environmental exposure recommendations.

Covered electrodes qualified in accordance with military specifications are MIL-7018-M, MIL- 8018-C3, MIL-8018-C3R, MIL-9018-M, MIL-10018-XX, MIL-11018-XX, MIL-12018-XX, or their AWS equivalents that includes the “M” designator as listed in table I. Covered electrodes which have been in physical contact with water shall not be used. Covered electrodes shall be used within 9 hours of removal from hermetically-sealed, manufacturer packaging or removal from a vented holding oven maintained at 225 to 300°F (107 - 149°C). Electrodes not used within 9 hours after issue or otherwise exposed to ambient conditions shall be held for at least 8 hours in a vented holding oven maintained at 225 to 300°F (107 - 149°C) prior to reissue.

Covered electrodes exposed to ambient conditions for longer than 9 hours may be baked to remove moisture content or disposed of. Only one baking of any covered electrode shall be permitted. Baking of covered electrodes shall be in accordance with the following conditions:

a. Electrodes shall be placed in the oven for baking before the temperature of the oven exceeds 300°F (149°C).

b. During baking, the temperature of the oven shall not be raised more than 300°F

(149°C) per hour when the oven temperature is 500°F (260°C) or above.

c. The total elapsed time at oven temperatures above 500°F (260°C) shall be kept to a minimum.

d. Covered electrodes shall be baked at a temperature of 800 ± 25°F (427 ± 14°C) for a total time of 30 minutes to 1 hour.

e. Electrodes shall be spread on suitable trays in the oven. Electrodes may also be placed into open aluminum cans and held in the vertical position. Trays or cans shall not be fabricated using any solder or joint filler which liquefies at less than 1000°F (538°C).

f. Automatically controlled, forced convection or circulation ovens which bake electrodes in accordance with the requirements of this paragraph shall be used.

g. Oven controls and recording instruments shall be checked at periodic intervals in accordance with an established calibration program.

5.1.6.2.1.1 Storage in holding ovens. Electrodes which have been baked shall be transferred to holding ovens without being allowed to cool below 150°F (66°C). Transfer shall be accomplished with the electrodes protected from inclement weather. Electrodes shall be stored in vented holding ovens after manufacturer containers have been opened. Holding oven temperature shall be 225 to 300°F (107 - 149°C).

5.1.6.2.1.2 Rebaking. Electrodes shall not be baked by the receiving activity more than once unless each electrode brand is initially tested after a maximum proposed number of baking cycles and shown to meet electrode specification requirements for moisture, usability, all-weld metal tensile mechanical properties and chemistry. Recertification of each electrode brand shall be performed annually.

5.1.6.2.2 Submerged-arc granular flux.

5.1.6.2.2.1 Preparation for use. Prior to the start of any welding operation, granular flux shall be heated to 500°F (260°C) minimum for one hour. Flux shall be heated in clean, uncoated metal containers.

5.1.6.2.2.2 Reuse. Unfused granular flux may be reused subject to the following conditions:

a. Flux shall be collected from clean, dry work pieces.

b. Reclaimed flux shall be reheated at 500°F (260°C) minimum for one hour.

5.1.6.3 Welding filler material identification. Electrodes, flux-cored electrodes, welding wire and flux shall be identified by type up to the point of usage.

5.1.6.3.1 Covered electrodes. Each covered electrode shall have distinguishable color code, type designation or classification number marking. If markings are destroyed by baking or other means, electrodes shall not be used until identification is restored.

5.1.6.3.2 Bare electrodes. Each spool or coil of bare electrodes shall carry an identifying label. Each piece of bare filler metal shall have distinguishable color code, type designation or classification number marking.

5.1.6.3.3 Granular flux. Each container of granular flux shall be labeled as to type.

5.2 Personnel qualification.

5.2.1 Weld personnel qualification. Before assigning any welder or welding operator, the contractor shall possess valid certification that their personnel have passed qualification tests in accordance with 5.2.1.4.

5.2.1.1 Welder Qualification Records (WQR). The contractor shall document the results of the welder or welding operator qualification test in a WQR for every welder or welding operator. The procuring engineering activity may conduct reviews of the WQRs to assess conformance to this standard. The WQRs shall be retained for the period of performance of the contract, at a minimum. A WQR example is shown in figure B-1. The WQR shall include, at a minimum:

a. Contractor/manufacturer.

b. Welder or welding operator identification

c. Date of test.

d. Information contained in table IV.

e. Results of qualification test.

f. Certifying signature with job title.

5.2.1.2 Previous welder or welding operator qualification. Previous qualification tests by welders or welding operators that are properly documented are acceptable with the approval of the procuring engineering activity.

5.2.1.3 Expiration of qualification period. The welder or welding operator shall requalify in accordance with 5.2.1.4 for the following reasons:

a. Has not welded in the qualified process for a period exceeding six months.

b. As requested by contractor or procuring engineering activity due to a specific reason to question the abilities of the welder or welding operator.

5.2.1.4 Welder and welding operator performance qualification. A qualified WPS (see 5.3.7.2) shall be used for each welder or welding operator qualification plate. Qualifying as a welder shall not qualify the individual as a welding operator or vice versa. A welder’s performance qualification is measured in their ability to create a test plate which meets the acceptance criteria of this standard. A welding operator’s performance qualification is measured in their ability to successfully operate the welding equipment and produce a test plate which meets the acceptance criteria of this standard.

5.2.1.4.1 Welder and welding operator qualification base material. Test material shall be in accordance with the qualified WPS (see 5.3.7.2) for the welder or welding operator test coupon.

5.2.1.4.2 Welder and welding operator qualification positions. Each welder and welding operator shall be qualified in the position or positions (see 4.6) which shall be welded in accordance with the applicable WPS (see 5.3.7.2). Welder and welding operators who qualify in one or more positions shall be considered qualified in other positions in accordance with table II and table III. Welding 3G, 5G, 6G, 3F, and 5F in the down direction shall not be authorized unless welding sheet steel. For plug welding, the welder or welding operator is only qualified in the position the test coupon is welded in.

TABLE II. Welder and welding operator qualification positions for plate.

Qualification testing per class Allowable qualified positions Groove Fillet

Weld class type Position qualified on Plate Pipe/tube Plate and pipe/tube

Plate groove (see figure 3)

1G F F F 2G F,H F,H F,H 3G1 F, V1 F, V1 F, H,V1

4G F, OH F, OH F, OH

3G1 & 4G F, V1, OH F, V1, OH All 2G, 3G up, & 4G All All All

Plate fillet (see figure 5)

1F F 2F F, H 3F1 F, H, V1

4F F, H, OH

3F1 & 4F All NOTE 1: Vertical down shall only be allowed when welding sheet steel.

TABLE III. Welder and welding operator qualification positions for pipe and tube.

Qualification testing per class Allowable qualified positions

Groove Fillet

Weld type Position qualified on Plate Pipe/tube Plate and pipe/tube

Pipe/box tube groove (see figure 4)

1G Rotated F F F 2G F,H F,H F,H 5G1 F, V1, OH F, V1, OH All

(2G+5G1) All All All 6G1 All All All

Pipe/box tube fillet (see figure 6 & figure 7)

1F Rotated F 2F F, H

2F Rotated F, H

4F F, H, OH

5F1 All

NOTE 1: Vertical down shall only be allowed when welding sheet steel.

5.2.1.4.3 Welder and welding operator essential variables. Each welder or welding operator qualification shall include the information from table IV for each qualification required.

The applicable information from table IV shall be included in the WQR.

TABLE IV. Welder and welding operator essential variables.

Essential variable Requalification of personnel is required when this change occurs

Personnel

Welders Welding operators

Welding process (see 1.2.1)

Change to an unqualified process X X

Position Change to an unqualified position X X

Base material thickness

Change to an unqualified thickness X X

Backing material If backing material is removed X X

Number of electrodes When going from single electrode to multiple, but not from multiple to single

X

Automatic to machine

Change from automatic to machine welding or vice versa X

Arc voltage control A deletion of automatic arc voltage control (GTAW only) X

Joint tracking software

A deletion of automatic joint tracking X

5.2.1.4.4 Class I fillet and groove welds. For Class I qualification for fillet or groove welds, the welder or welding operator shall fabricate a test plate in accordance with figure 8 or figure 9. Figure 8 (a single bevel groove) shall be qualified for thicknesses 0.5 inches (13 mm) or less. Figure 9 (a double bevel groove) shall be qualified for thicknesses greater than 0.5 inches (13 mm). When qualified in accordance with figure 9 the welder or welding operator shall be considered qualified for figure 8 and figure 9. Removable backing material shall be permitted. The entire weld of the test plate shall be nondestructively tested via UT (see 5.5.4.5.4) or RT (see 5.5.4.5.1). Welders and welding operators qualified in accordance figure 8 or figure 9 shall also be qualified for Class II & III welds in accordance with table V. Welders and welding operators shall qualify for the required positions in accordance with table II or table III. Figure 8 and figure 9 shall be complete joint penetration (CJP) welds.

FIGURE 8. Welder and welding operator qualification plate T less than 0.5 inches inclusive.

FIGURE 9. Welder and welding operator qualification plate T greater than 0.5 inches.

5.2.1.4.5 Class II & III welds. For Class II and III welds, the welder and welding operator shall qualify in accordance with table V. Unless specified in table V or figure 10 through figure 14, welders and welding operators shall fabricate test plates in the position required for qualification. Welder or welding operator test plates shall pass RT (see 5.5.4.5.1) or UT (see 5.5.4.5.4) of the test area of the welds. Backing material shall be removed before NDT.

TABLE V. Welder and welding operator qualification criteria for Class II and III welds.

Type of test weld T of test plate in (mm)

Mechanical tests (see 5.5.3)

Alternate qualification 3

Qualifies welder for T inclusive in (mm)

Min Max Welder groove weld

(figure 10 or figure 11) for plate1

0.375 (10) None Figure 8 or figure 9 0.125 (3) 0.5 (25)

T > 0.5 (13) None Figure 9 0.125 (3) Unlimited Welding operator groove weld (figure 12) for plate1 1 (25) None Figure 9 0.125 (3) Unlimited

Plug (figure 13) 0.375 (10) or greater 1 macroetch Figure 9 0.125 (3) Unlimited

Fillet (figure 14) 0.5 (13) fillet break test and 2 macroetch Figure 9 0.125 (3) Unlimited

Pipe or tube (figure 15) Any 4 macroetch No alternate 0.125 (3) Unlimited

Notes:

1. Qualification with groove welding shall qualify welder for fillet welding

2. Alternate qualification shall be in accordance with listed figures and 5.2.1.4.4.

FIGURE 10. Class II & III welder qualification groove plate.

FIGURE 11. Class II & III welder qualification groove plate horizontal.

FIGURE 12. Class II & III welding operator qualification groove plate.

Note:

1. 2 in (51 mm) minimum for welder; 3 in (76 mm) minimum for welding operator.

2. 3 in (76 mm) minimum for welder; 5 in (127 mm) minimum for welding operator.

FIGURE 13. Class II - III welder and welding operator qualification plug.

FIGURE 14. Class II & III welder qualification fillet weld.

FIGURE 15. Class II & III PQR, welder, and welding operator qualification pipe or tube.

5.2.2 Weld inspector qualification. Qualified inspectors shall be used for the verification of weld quality. All qualified weld inspectors shall pass an eye exam every three years at a minimum. The eye exam shall be administered by a qualified, licensed medical professional. The qualified inspector shall have 20/20 vision at a distance of 12 to 14 inches with or without corrective lenses. All weld inspectors shall be qualified in accordance with at least one of the following:

a. Current certification in accordance with the AWS QC1 for Certified Welding Inspector (CWI) or Senior Certified Welding Inspector (SCWI).

b. Current certified welding inspectors qualified by the Canadian Welding Bureau

(CWB) to Level II or the Level III requirements of CSA W178.2.

c. An individual who, by experience, and/or education in metals, fabrication, and testing is competent to perform visual inspection.

NOTE: A qualified welding inspector is not qualified to perform Nondestructive Testing (NDT) unless the requirements of 5.2.4 are met.

5.2.3 Mechanical testing personnel qualification. Contractors that complete mechanical testing internally shall develop a training plan for mechanical testing personnel. The training plan shall be made available to the procuring engineering activity if requested. Contractors that sub-contract mechanical testing shall use ISO/IEC 17025 certified test facilities.

5.2.4 Non-Destructive Testing (NDT) personnel qualification. Individuals performing any method of NDT shall meet the qualification requirements for the applicable NDT level of certification in accordance with ASNT CP-189 or NAS410. The required NDT level shall be determined by the contractor’s NDT written instruction (see 5.5.4.1). Alternately, any certification through ASNT Central Certification Program (ACCP) shall be recognized as certified at the NDT level of examination.

5.2.4.1 NDT reexaminations. If there is reason to believe that an individual is unable to competently perform at the NDT level that the individual is certified, the Government shall request an operational or written examination be administered in accordance with ASNT CP-189 or NAS410. If an individual transfers from one entity to another, NDT reexamination shall be required in accordance with the new entities NDT written instruction for personnel qualification.

All personnel certified through ACCP shall be exempt from reexamination when transferring entities.

5.2.4.2 Other NDT methods. For NDT methods not covered by ASNT CP-189 or

NAS410, personnel shall qualify to comparable levels of competency by the administration of examinations for the particular method involved. A certified NDT Level III shall be responsible for the validity of the examinations.

5.2.4.3 Alternative NDT specifications and standards. If an alternative inspection program which meets all the requirements of this document is to be used, the alternative program shall be submitted to the procuring engineering activity for approval prior to being used.

5.2.5 Personnel documentation. The procuring engineering activity may conduct reviews of the personnel documentation to assess conformance to this standard. All personnel documentation shall be maintained for the period of performance of the contract, at a minimum.

5.3 Weld procedure qualification. Any welder or welding operator that qualifies a procedure shall be qualified as a welder or welding operator in accordance with 5.2.1.

5.3.1 Prequalified welded joints. The use of prequalified welded joint details shall not be permitted.

5.3.2 Preparation of weld procedures. Prior to the fabrication of any welds, the contractor shall create procedure qualification records (PQRs) and weld procedure specifications (WPSs) for all welds in accordance with 5.3.7.1 and 5.3.7.2 and make them available to the procuring engineering activity. PQRs and WPSs shall be signed by the contractor’s engineer or the engineer’s duly designated representative. PQRs and WPSs shall be retained for the period of performance of the contract, at a minimum. Examples of a blank PQR and WPS are located in figure B-2 and figure B-3 respectively.

5.3.3 Previous qualified welding procedures. In order to use a previously qualified welding procedure, a contractor shall submit a written request to the procuring engineering activity for approval to use the welding procedures prior to fabrication.

5.3.4 Company name change. Properly documented WPSs and PQRs qualified under the provisions of this standard by a company that later has a name change due to voluntary action or consolidation with a parent company may utilize the new name on its WPS documents while maintaining the supporting PQR qualification records with the old company name.

5.3.5 Revision. Any changes made to a PQR and WPS shall be identified, authorized and dated on the PQR and WPS by the contractor. The contractor shall notify the procuring engineering activity that a change was made. The revised PQR and WPS shall be made available to the procuring engineering activity upon request.

5.3.6 Class I. All Class I welds shall be qualified in accordance with Appendix A.

5.3.7 Class II and Class III.

5.3.7.1 Procedure Qualification Records (PQRs). Prior to any production, a welding

PQR shall be prepared. The PQR shall be submitted to the procuring engineering activity. All visual (see 5.5.2), mechanical (see 5.5.3), and NDT (see 5.5.4) results shall be documented within PQRs.

5.3.7.1.1 Multipass welds. Any weld that requires multiple passes of different process parameters shall have all parameters for that weld on a single PQR.

5.3.7.1.2 Groove welds for plate PQR. A PQR shall be prepared for each groove weld for plate in accordance with table VI, table VIII, table XI, and 5.1.6. All test plates for groove welds shall pass RT (see 5.5.4.5.1) or UT (see 5.5.4.5.4) before conducting mechanical testing.

5.3.7.1.3 Fillet welds for plate PQR. A PQR shall be prepared for each fillet weld for plate in accordance with table VI, table IX, table XI, and 5.1.6.

5.3.7.1.4 Fillet or groove welds for pipe or tube PQR. A PQR shall be prepared for each fillet or groove weld for pipe or tube in accordance with table VII, table XI, and 5.1.6. A test sample shall be fabricated and tested in accordance with figure 15.

TABLE VI. Procedure qualification positions for plate.

Allowable WPS qualified positions Groove Fillet

Weld class type Position qualified on PQR

Plate Pipe/tube Plate and pipe/tube

Plate groove (see figure 3)

Class I

1G F F F 2G F, H F, H F, H

3G up V up V up V up

4G OH OH OH

Class

II &

III

1G F F F 2G F,H F,H F,H

3G up F, V up F, V up F, H, V up

4G OH OH OH

Plate fillet (see figure 5)

Class I

1F F 2F…