T9074-BC-GIB-010 Appendix C.pdf

T9074-BC-GIB-010/0200

NAVSEA Technical Publication

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

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

REVISION: ORIGINAL 11 DECEMBER 2002

BAR CODE

0910-LP-028-3740

APPENDIX C

55 Original

ELECTRODES, WELDING, MINERAL COVERED, IRON-POWDER,

LOW-HYDROGEN MEDIUM, HIGH TENSILE AND HIGHER-

STRENGTH LOW ALLOY STEELS

C.1. SCOPE

C.1.1 Scope This appendix covers iron-powder, low-hydrogen types of covered electrodes for the fabrication and repair welding of high tensile, and higher-strength low-alloy (HY/HSLA) steels for as-welded and stress-relieved applications. This appendix is based on AWS A5.5, although it contains numerous additional requirements. This appendix is a mandatory part of the specification.

C.1.2 Classification. Electrodes shall be of the types specified (see C.3.2), and shall be of the sizes and lengths specified in AWS A5.5 (see C.6.2).

C.2. APPLICABLE DOCUMENTS

This section is not applicable to this appendix.

C.3. REQUIREMENTS

C.3.1 General. Electrodes provided under this specification shall be in accordance with AWS A5.5 and as specified herein.

C.3.2 Chemical composition. Chemical composition of deposited weld metal shall be in accordance with table I and the approved formulation, which is bracketed by the maximum and minimum values in table I.

C.3.3 Mechanical properties of deposited weld metal. The mechanical properties of deposited weld metal shall be as specified in table II.

C.3.3.1 Stress relieved material. For qualification inspection and when specified for quality conformance inspection (see C.6.2), the MIL-10018-M1 and MIL-10718-M welded test assembly shall be stress relieved as follows: 1125 plus or minus 25F, held at this temperature for 1 hour minimum and furnace cooled at 200F per hour or slower to 500F.

C.3.4 Coverings of electrodes.

C.3.4.1 Composition. The chemical composition of the electrode covering, except as specified in C.3.4.2 and C.3.4.3, is optional with the manufacturer.

C.3.4.2 Total iron content. The total iron content of the covering, including any combined iron in addition to metallic iron powder, shall be not less than 15 percent.

C.3.4.3 Moisture content. The absorbed moisture of the covering shall be not greater than 0.10 weight percent when removed from the manufacturer's sealed container. After exposure to elevated temperature and humidity conditions as specified in AWS A5.5, the absorbed moisture of the covering shall be not greater than 0.20 weight percent. If the infrared detection method identified in AWS A4.4 is used for determining moisture content, the maximum absorbed moisture when removed from the manufacturer’s sealed container shall be 0.15 weight percent and after exposure to elevated temperature and humidity as specified in AWS A5.5, the maximum absorbed moisture shall be 0.2 weight percent.

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Table I. Chemical composition (wt. percent) of deposited weld metal. 1/

Element MIL-10018-M1 MIL-10718-M MIL-12018-M2 Carbon 0.06 0.07 0.07

Manganese 0.80 - 1.85 0.80 - 1.85 0.80 - 1.85 Silicon 0.65 0.60 0.65

Phosphorus 0.025 0.025 0.025 Sulfur 0.017 0.017 0.012

Chromium 0.40 4/ 0.40 4/ 0.65 Nickel 1.25 - 3.00 1.25 - 2.50 1.50 - 4.00

Molybdenum 0.50 0.25 - 0.50 0.90 Vanadium 0.05 0.05 0.05

Copper 2/ 2/, 3/ 2/, 3/ Boron --- 3/ 3/

1/ Single values are maximums.

2/ When specified (see C.6.2), use of the suffix RC with MIL-10018-M1, MIL-10718-M, or MIL-

12018-M2, for example MIL-10018-M1-RC, indicates that the maximum copper content of the deposited weld metal shall be 0.15 percent. The remaining basic compositional requirements remain unchanged for the specific type.

3/ Copper (except for suffix RC electrodes) shall be reported for information only. Boron shall be analyzed to the parts per million (ppm) level, reported for information and for use in calculating the carbon equivalent.

4/ When specified by the purchaser, a 0.20% maximum chromium content may be required for control of hexavalent chromium in fumes (see C.6.2)

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58 Original

C.3.4.4 Diffusible hydrogen. The diffusible hydrogen levels in milliliters per one hundred grams (mL/100 g) of deposited weld metal shall be not greater than the following values for welds deposited with electrodes removed from sealed manufacturer's containers:

(a) Electrodes 1/8 inch size and smaller, maximum average value of 3.2 mL/100 g and maximum single value of 4.0 mL/100g.

(b) Electrodes 5/32 inch size and larger, maximum average value of 3.5 mL/100 g and maximum single value of 4.3 mL/100 g.

A diffusible hydrogen control plan in accordance with 4.9 of Main Body is required.

C.3.4.5 Flaking and cracking of covering. The sum of the surface area of the core wire exposed by flaking and cracking of the covering shall not exceed that permitted for arc ends in accordance with AWS A5.5.

C.3.4.6 Slag characteristics. The slags deposited by the coverings shall be removable by hand tools (i.e., slag removal shall not require power tools, though power tools may be used) from the weld deposits. Slag characteristics shall be such that grinding during test plate preparation shall not be required for slag removal.

C.3.4.7 Dielectric strength. The coverings of electrodes at room temperature and in the dry condition, that is, as removed from freshly opened containers, shall have a dielectric strength that shall insulate against a difference potential of 110 volts (v), 60 hertz (Hz), alternating current (ac), unless otherwise specified by the purchaser (see C.6.2).

C.3.5 Electrode identification. The MIL grade shall be indicated on each electrode. When specified (see C.6.2), each electrode shall also be marked (in addition to the requirements of AWS A5.5) with the heat, lot, or other controlled marking code.

C.3.6 Visual/dimensional inspections. Sampling for visual and dimensional inspection shall be as specified in Main Body 4.4.3. Identification shall be in accordance with C.3.5. Electrode sizes, lengths and tolerances, electrode core wire and covering quality and concentricity, electrode grip end and arc end requirements shall be in accordance with AWS A 5.5.

C.4. VERIFICATION

C.4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. Qualification inspection (see 4.2)

b. Quality conformance inspection (see 4.3).

C.4.2 Qualification inspection. Electrodes selected for qualification shall be used for tests specified in table III. Type MIL-10018-M1 shall be tested in both the as-welded and stress-relieved conditions. Schedule A tests shall be conducted by the manufacturer, and upon successful completion of these tests, schedule B testing will be conducted at a Government test facility (see 6.3 of Main Body). The manufacturer or contractor will be responsible for funding schedule B testing unless other funding provisions are arranged with the Government or prime contractor.

C.4.2.1 Special instructions. When applying for test authorization, or after tests have been authorized and when samples are submitted, the manufacturer shall furnish the following information, as appropriate. (NOTE: This information, together with test results obtained with the

59 Original electrode sample, shall form a part of the qualification test; all information will be held in confidence by the Government.)

C.4.2.1.1 For covered electrode lots conforming to AWS A5.01 classification C4.

(a) The lengths of the electrodes and diameters of coating and core wire.

(b) Type under which approval is desired.

(c) Composition of core wire and covering(s) in terms of nominal percentages for each constituent. 1/

(d) Composition of the deposited weld metal.

(e) Recommended amperages for each weld test. 1/

(f) Brand name.

1/ Information shall be maintained at the manufacturer's plant for Government audit purposes;

need not be submitted.

C.4.2.1.2 For covered electrode lots conforming to AWS A5.01 classification C3, in addition to the information in C.4.2.1.1, the following shall be furnished for approval by the Government.

(a) Chemical composition control limits in core wire of each type electrode. 1/

(b) Method of determining core wire chemistry.

(c) Production line methods used to produce electrodes from chemically controlled core wire.

1/

(d) Procedure for control of moisture content between baking and packaging.

(e) Percent allowable variation from standard for each chemical element in the covering mixture of each type electrode. 1/

(f) Method of determining covering mixture chemistry.

(g) Production line methods used to produce electrodes from chemically controlled covering mixture. 1/

1/ Information shall be maintained at the manufacturer's plant for Government audit purposes;

need not be submitted.

C.4.2.1.3 Change Control Procedure. The manufacturer shall document the criteria and procedure for verifying the acceptability of any changes, which may be made in key processes after qualification of the product, that may affect the design or performance of the product. The change control procedure shall be maintained at the manufacturer's plant for Government audit purposes and need not be submitted. Any changes, which are determined necessary to a process that negatively affect the acceptable performance of the product shall be submitted to NAVSEA Materials Engineering Division for concurrence with the supporting data to show acceptability.

C.4.2.2 Qualification samples. Each manufacturer shall furnish sample packages and electrodes of the type to be qualified. Quantities shall be as requested by the qualifying activity or laboratory.

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Table III. Summary of tests required for qualification.

Schedule Test

A B Test Procedures Requirements

Chemical analysis X ---

AWS A5.5,

Main Body 4.8, and C.4.5 herein

Table I herein

Total iron in covering X --- C.4.6 herein C.3.4.2 herein Covering flaking and cracking X --- C.4.7 herein C.3.4.5 herein

Dielectric strength X --- C.4.8 herein C.3.4.7 herein Alloy identity X X AWS 5.01 Main Body 3.8

Covering moisture X X AWS A4.4 C.3.4.3 herein Diffusible hydrogen X X AWS A4.3 C.3.4.4 herein

Welded test assembly X X C.4.4 herein Figures 1 and 2 herein Nondestructive testing of

MIL-10718-M

X X Main Body 4.5 Main Body 3.7

Nondestructive testing of MIL- 10018-M1 and MIL-12018-M2 X X Main Body 4.5.1 and

C.4.9 herein Main Body 3.7.1

Visual and Dimensional Examination X X Main Body 4.4.3 C.3.6

Tension 1/ X X AWS B4.0 Table II herein Transverse side bend X X AWS B4.0 Table II herein Charpy V-notch 1/ 2/ X X AWS B4.0 Table II herein

Dynamic tear 2/ X X AWS B4.0 Table II herein Explosion test series 3/ --- X C.4.4.2 herein Table II herein

1/ Tests shall be conducted for the as-welded condition for all electrodes, and for the stress relieved condition for MIL-10018-M1 and MIL-10718-M electrodes.

2/ See figures 1 and 2 and their associated tables for requirements on Charpy V-notch and Dynamic tear testing. Tables IX, X, XI, XII and XIII specify when CVN or DT testing is required.

3/ When explosion testing is required, all sizes shall be qualification tested in accordance with MIL-STD-2149/NAVSEA Technical Publication T9074-BD-GIB-010/0300 for conformance.

However, when qualifying a smaller size electrode of a type previously qualified, if NAVSEA Materials Engineering Division determines the results of the mechanical property tests indicate that the weld metal properties are equivalent to the larger size electrode previously qualified, the explosion crack starter test shall be omitted.

C.4.3 Conformance inspection. Quality conformance inspection tests shall be performed in accordance with table IV. For each lot of material, sufficient samples shall be selected to perform the tests listed. Quality conformance tests shall be conducted by the manufacturer.

C.4.3.1 Lot.

C.4.3.1.1 MIL-10018-M1 and MIL-10718-M electrodes. For MIL-10018-M1 and MIL-10718-M electrodes, a lot shall be defined as a Class C3 lot as described in AWS A5.01.

61 Original

Table IV. Summary of tests required for quality conformance inspection. 1/ Test Test Procedures Requirements

Chemical analysis Main Body 4.8, AWS A5.5, and C.4.5 herein Table I herein

Alloy identity AWS A5.01 Main Body 3.8 Covering moisture AWS A4.4 C.3.4.3 herein Diffusible hydrogen AWS A4.3 C.3.4.4 herein

Welded test assembly C.4.4 herein Figures 1 and 2 herein Nondestructive testing of MIL-

10718-M Main Body 4.5 Main Body 3.7

Nondestructive testing of MIL- 10018-M1 and MIL-12018-M2 Main Body 4.5.1 and C.4.9 herein Main Body 3.7.1

Visual and Dimensional Examination Main Body 4.4.3 C.3.6

Tension AWS B4.0 Table II herein Charpy V-notch 2/ AWS B4.0 Table II herein Dynamic tear 2/ AWS B4.0 Table II herein

1/ For type MIL-10018-M1 and MIL-10718-M, stress relieved mechanical and impact properties shall be determined only when specified (see C.6.2).

2/ See figures 1 and 2 and their associated tables for the requirements on Charpy V-notch and Dynamic tear tests.

C.4.3.1.2 MIL-12018-M2 electrodes. For MIL-12018-M2 electrodes, a lot shall be defined as a Class C4 lot as described in AWS A5.01. Subject to Government approval, a lot may be defined as the amount produced in a continuous 8 hour period of a Class C3 lot as described in AWS A5.01. Under this definition, should any lot fail due to unacceptable toughness or yield strength, the lot definition shall revert back to Class C4 until five consecutive lots are successfully tested, and the Government approves the data.

When the modified 8 hour Class C3 lot definition is in use, and a series of 50 consecutive lots have been successfully tested, the lot definition may be changed to a Class C3 lot, subject to Government approval.

The failure of any lot due to unacceptable toughness or yield strength shall result in the lot definition reverting back to Class C4.

C.4.4 Weld metal test procedures.

C.4.4.1 Qualification and quality conformance samples.

C.4.4.1.1 MIL-10018-M1 electrode. The test assembly shall be welded, machined, and tested as specified in table V. Heat input requirements are as follows:

(a) As specified in Main Body 4.12 and Tables V, IX, and X.

(b) The operational heat input of at least 80% of all individual passes shall be within the specified heat input range. No pass shall have an operational heat input more than 5kJ/in outside the specified range.

(c) Average heat input shall fall within the heat input range specified.

62 Original

C.4.4.1.2 MIL-10718-M electrode. The test assembly shall be welded, machined, and tested as specified in table VI. Heat input requirements are as follows:

(a) As specified in Main Body 4.12 and tables VI, IX and XI.

(b) The operational heat input of at least 90% of all individual passes shall be within the specified heat input range.

(c) No pass shall have an operational heat input more than 5kJ/in outside the specified range.

(d) Average heat input shall fall within the heat input range specified.

C.4.4.1.3 MIL-12018-M2 electrode. The test assembly shall be welded, machined, and tested as specified in table VII. Heat input requirements are as specified in Main Body 4.12, C.4.4.1.1, and tables VII, XII and XIII.

C.4.4.2 Explosion crack starter tests.

C.4.4.2.1 Welding parameters. Fabrication of the explosion test assemblies and mechanical property prolongation assemblies shall be in accordance with table VIII.

C.4.4.2.2 Test requirements. Two crack starter tests shall be conducted in accordance with MIL-STD-2149/NAVSEA Technical Publication T9074-BD-GIB-010/0300. These tests shall be conducted at zero degrees Fahrenheit, unless otherwise specified by the NAVSEA Materials Engineering Division. The mechanical property prolongations shall be tested in accordance with MIL- STD-2149/NAVSEA Technical Publication T9074-BD-GIB-010/0300.

C.4.5 Chemical analysis. Welding of chemical analysis test pads for the electrodes in C.4.5.1 and C.4.5.2 shall be as specified in AWS A5.5. In event of variances with composition requirements or conflicting results by testing activities, analysis shall be verified by procedures specified in AWS A5.5.

C.4.5.1 Chemical analysis of MIL-10018-M1. For MIL-10018-M1 electrodes, if chemical analysis is not determined using chemical analysis test pads welded as specified in AWS A5.5, chemical analysis shall be determined from a milling sample taken from the centerline of the broken tensile specimens or drillings, or by optical emission spectroscopy on any sample that is taken and analyzed at the depth of the tensile specimen centerline.

C.4.5.2 Chemical analysis of MIL-10718-M and MIL-12018-M2. For each diameter of MIL-10718-M and MIL-12018-M2 electrodes, two chemistry pads per lot shall be prepared. One pad shall use electrode from the beginning of the lot and one pad shall use electrode from the end of the lot. Test results for both chemistry pads shall be reported, the values averaged, and the average shall be reported.

Averaged chemical analysis values from the chemistry pads shall meet the requirements for MIL-10718-M or MIL-12018-M2, as appropriate, specified in table I and shall determine acceptability of the lot.

In addition for each diameter of MIL-10718-M and MIL-12018-M2 electrode, electrodes from the beginning and end of each lot shall be used to prepare test welds (see figures 1 and 2 as appropriate). Electrodes from the beginning of the lot shall be used for the low cooling rate weld and electrodes from the end of the lot shall be used for the high cooling rate weld. The chemical analyses shall be performed on a milling sample taken from the centerline of the broken tensile specimen(s) or by optical emission spectroscopy on any weld metal sample that is taken and analyzed at the depth of the tensile specimen(s) centerline.

Results of chemical analysis from the high and low cooling rate test welds (see Tables VI and VII) shall be averaged and used to determine the carbon equivalent for the lot (see Main Body 4.8.3). When specified (see C.6.2), MIL-10718-M and MIL-12018-M2 electrodes representing the highest and lowest carbon equivalent lots in the order shall be identified for receipt inspection by the user.

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P E

N D rig e

V I.

W el di ng p ar am et er s fo r M

IL

-1

-M w el d m et al te st s am pl e.

3/

, 6

9/

8-

M

B as e M st ee l i n ac co rd an ce w ith

M

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T ec hn ic al P ub lic at io n T9

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E le ct ro de s iz e (in ch es

7/

W el di ng p ro tic al u p tic al u p tic al u p di ng c ur re nt p lu s or m in us p er nt

(a ps

P la te th ic kn es s

3/

3/

3/

3/

3/

3/

C oo lin g h h h h h h t c on fig ur at io n

Fi gu gu re

Fi gu re

Fi gu re

Fi gu re

Fi gu re

Fi gu re

Fi gu re

Fi gu t i np ut

(k J/ in to to to to to to to to to to to to

P re he at a nd in te rp as s te m pe ra tu re (F

) 7 ni ng o f w el d be ad s sh al l n ot b e pe rm itt ed

U nl es s ot he rw is e sp ec ifi ed (s ee C

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W he n on ly C ha rp y V

-n ot ch te st s ar e to b e co nd uc te d, th e ba se p la te m at er ia l s ha ll be H

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T9

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0, b ut th e pl at e m at er ia l c an b as

-ro lle d co nd iti on w ith ou t b ei ng q ue nc he d an d te m pe re d, n or te st ed fo r m ec ha ni ca l p ro pe rti es

If it is n ec es sa ry to s pl ic e tw o pl at es to ge th fo rm th e ba se p la te s, th ey c an b e w el de d w ith fu ll pe ne tra tio n w el ds

M ai n

B od y 3.

fo r a dd iti on al w el di ng in fo rm at di ng c ur re nt s ha ll be d ire ct c ur re nt , e le ct ro de p os iti ve

(D C

E P d.

c.

re ve rs e po la rit y) di ng c ur re nt s ha ll be s el ec te d by th e m an uf ac tu re r c on si st en t w ith o th er s pe ci fie d pa ra m et sp lit

-w ea ve te ch ni qu e

(th e pr ac tic e of d ep os iti ng o nl y tw o w id e-w ea ve b ea ds p er la ye

r) sh al l b e lim ite d to th e fir st

/2 T of w el d jo in t t hi ck ne ss

E ac h w el d la ye r b ey on d th e fir st

/2

T of w el d jo in t t hi ck ne ss s ha ll co nt ai n th re e or m or e be ad s w hi ch a re d ep os ite d in s eq ue nc e ac ro ss th e w el d jo in n te st s ar e co nd uc te d us in g

M

IL

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/N A

V S

E A

T ec hn ic al P ub lic at io n T9

4-

B D

-G

IB

-0

/0 or

A S

TM

A st ee l ( se e C

.6 .2 th e m in im um p re he at a nd m ax im um in te rp as s te m pe ra tu re s fo r t he h ig h co ol in g ra te te st s ha ll be

F an d

F, re sp ec tiv

E le ct ro de s fro m th e be gi nn in g of th e lo t s ha ll be u se d fo r t he lo w c oo lin g ra te w el d an d el ec tro de s fro m th e en d of th e lo t s ha ll be u se d fo r t he h ig h co ol in g ra te w lte rn at e N

A V

S E

A M at er ia ls

E ng in ee r D iv is io n ap pr ov ed w el d pa ra m et er s m ay b e sp ec ifi ed b y th e pu rc ha se r ( se e C

.6 .2

4- B

C -G

IB

-0

/0

A P

P E

N D rig e

V

II.

W el di ng p ar am et er s fo r M

IL

-1

-M w el d m et al te st s am pl

, 3

8-

M

B as e m st ee l i n ac co rd an ce w ith

M

IL

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/N A

V S

E A

T ec hn ic al P ub lic at io n T9

4-

B D

-G

IB

-0

/0

E le ct ro de s iz e te st ed

(i nc s) di ng p ro tic al u p tic al u p or iz on ta l di ng c ur re nt p lu s or m in us p er nt

(a pe re s) la te th ic kn es s

(in ch es

3/

3/

3/

3/

C oo lin g h h h h t c on fig ur at io n

Fi gu t i np ut (k

J/ in

) 8 he at a nd in te rp as s te m pe ra tu re (F

) 8 to to to to to to to to ni ng o f w el d be ad s sh al l n ot b e pe rm itt ed n on ly C ha rp y V

-n ot ch te st s ar e to b e co nd uc te d, th e ba se p la te m at er ia l s ha ll be H

Y -1 s te el in a cc or da nc e w ith th e ch em ic al c om po si tio n re qu ire m en ts o f M

IL

-S -1

/N A

V S

E A

T ec hn ic al P ub lic at io n T9

4-

B D

-G

IB

-0

/0

0, b ut th e pl at e m at er ia l c an b e in th e as

-ro lle d co nd iti on w ith ou t be in g qu en ch ed a nd te m pe re d, o r t es te d fo r m ec ha ni ca l p ro pe rti es

If it is n ec es sa ry to s pl ic e tw o pl at es to ge th er to fo rm th e ba se p la te s, th ey s ha ll be w el de d w ith fu ll pe ne tra tio n w el ds

M ai n B od y

3.

fo r a dd iti on al w el di ng in fo rm at di ng c ur re nt s ha ll be d ire ct c ur re nt

, e le ct ro de p os iti ve (D

C E

P d.

c.

re ve rs e po la rit y) r 3 /3

2-a nd

/1 6-in ch e le ct ro de s, a h ea t i np ut ra ng e sh al l b e sp ec ifi ed b y th e pu rc ha si ng a ct iv ity

(w ith th e ag re em en t o f t he m an uf ac tu re r) to re fle ct m in im um a nd m ax im um c oo lin g ra te th e pu rc ha si ng a ct iv ity w ill us e

(s ee

C .6

.2

H ea t i np ut ra ng es fo r 1

/8

- a nd

/3 2-in ch e le ct ro de s sh al l b as sp ec ifi ed u nl es s ot he rw is e sp ec ifi ed b y th e pu rc ha si ng a ct iv ity

(w ith th e ag re em en t o f t he m an uf ac tu re r) to re fle ct th e m in im um a nd m ax im um c oo lin g ra te th e pu rc ha si ng a ct iv ity w ill us e (s ee C

.6 .2 r t he se te st p la te s, re su lts fr om e ac h si de s ha ll be re po rte d se pa ra te ly

, w ith s id e de pi ct in g re su lts fr om th e fir st s id e w el de d.

F ai lu re o f e ith er s id e sh al l c on st itu te fa ilu re o f t he e nt ire te st a ss em di re ct io n of w el di ng s ha ll be th e sa m e fo r a ll be ad s in a w el dm en t.

T he s pl it-w ea ve te ch ni qu e sh al l b e lim ite d to th e fir st

/2 T of w el d jo in t th ic kn es s.

E ac h w el d la ye r b ey on d th e fir st

/2

T of w el d jo in t t hi ck ne ss s ha ll co nt ai n th re e or m or e be ad s, w hi ch a re d ep os ite d in s eq ue nc e ac ro ss th e w el d jo in di ng p ar am et er s sh al l b e se le ct ed b y th e m an uf ac tu re r c on si st en t w ith th e sp ec ifi ed h ea t i np ut

(s ee n ot e 5, a bo ve le ct ro de s fro m th e be gi nn in g of th e lo t s ha ll be u se d fo r t he lo w c oo lin g ra te w el d an d el ec tro de s fro m th e en d of th e lo t s ha ll be u se d fo r t he h ig h co ol in g ra te w

4- B

C -G

IB

-0

/0

A P

P E

N D rig e

V

III

E xp lo si on te st s am pl e w el di ng p ar am et er s.

5/ , 6

-1

-M

M

IL

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-M

-1

-M

B as e m

Y

-8 in a cc or da nc e

-S -1

/N A

V S ni ca l P ub lic at io n T9

4-

B D

-G

IB

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H Y

-1 in a cc or da nc e

-S -1

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V S ni ca l P ub lic at io n T9

4-

B D

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IB

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H Y

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V S ni ca l P ub lic at io n T9

4-

B D

-G

IB

-0

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W el di ng p ol ar ity

D st a ss em bl y re qu ire m en ts

M

IL

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TD

-2

9/ N

A V

S E

A T ec hn ic al

P ub lic at io n

T9

4- B

D -G

IB

-0

/0

E le ct ro de s iz a sm le r 3/ rg le r 3/ le r 3/ di ng p os tic al u p tic al u p tic al u p he at a nd in te rp as s te m pe ra tu re s

+2 5F

/-0 F

H ea t i np ut ni ng o f w el d be ad s sh al l n ot b e pe rm itt ed jo in t s ur fa ce s sh al l n ot b e cl ad o r b ut te di ng a m pe ra ge s ha ll be in a cc or da nc e w ith th e m an uf ac tu re r's re co m m en da tio ns a nd th e ac tu al v al ue s us ed s ha ll be re co rd ed re po rte he at in pu t s ha ll be to kJ

/in fo r t he

/8

- o r 5

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/3 in ch s iz e el ec tro de s

(s ee n ot e an d

M ai n B od y

4.

M ai n

B od y 3.

fo r a dd iti on al w el di ng re qu ire m en ts xp lo si on te st in g sh al l b e co nd uc te d on

/8 o r 5 /3

2-in ch e le ct ro de s iz es

E xp lo si on te st in g of o th er e le ct ro de s iz es (f ro m th e sa m e m an uf ac tu re r) ar e no t r eq ui re d pr ov id ed th e sa m e ba si c fo rm ul at io n an d de si gn a s us ed in th e qu al ifi ed e le ct ro de s iz e

(1 /8

- o r

5/

-in ch

) i s us ed in th e ot he r s iz es o f e le ct ro de

, m od ifi ed a s re qu ire d fo r t he d iff er en ce s in c or e si ze , c oa tin g th ic kn es s an d po si tio n re qu ire m en ts o f t he se d iff er en t s iz e el ec tro de

67 Original

C.4.6 Total iron in covering. The total iron content of the covering shall be determined by wet chemical or spectrographic methods. In the case of dispute, the referee method shall be ASTM E 316.

C.4.7 Flaking and cracking of covering. Six electrodes shall be tested for flaking and cracking tendency in accordance with C.4.7.1 and C.4.7.2. Welding current shall be as specified in table V, VI and VII as appropriate. The welding shall consist of depositing a weld bead on a plate surface.

C.4.7.1 Flaking and cracking during welding. Three electrodes shall be tested. The electrode shall be consumed to a stub not exceeding 2 inches in length. If flaking or cracking is observed during welding, the welding shall be stopped immediately and the arc end of the electrode examined for conformance to the requirements of C.3.4.5. If no flaking or cracking is observed during welding, the 2-inch stub length of electrode, which is normally discarded, shall not be examined.

C.4.7.2 Flaking and cracking during restart. Three electrodes shall be tested. The covering shall be grooved to the core wire completely around the electrode at the midpoint of the length.

The groove shall be prepared by grinding with the edge of a grindstone (intersection of the flat side of the grindstone with its periphery). The core wire shall be uncovered at the root of the groove to form a land 1/16 inch minimum in width measured along the length of the electrode. The core wire shall not be undercut. The electrode shall be consumed to the root of the groove in the covering, at which time welding shall be stopped without fusing the coating beyond the groove. The half-length electrode shall be removed immediately from the electrode holder and placed on a flat steel plate to cool until it can be held comfortably in the bare hand. After cooling, the electrode shall be inserted in the electrode holder and welding resumed. After the restart, the half-length electrode shall be consumed for 1 inch of its length.

Welding shall then be stopped, and the arc end of the electrode examined for conformance to the requirements of C.3.4.5.

C.4.8 Dielectric strength. Dielectric strength of coverings shall be determined by the method shown on figure 4. Methods other than the one shown in figure 4, yielding the required results, may be used as alternates if such methods are acceptable to NAVSEA Materials Engineering Division.

C.4.9 Nondestructive testing. Radiographic inspection is not required for MIL-12018-M2 weldments made at high cooling rates.

C.5. PACKAGING

C.5.1 Packaging. See note on special packaging in Main Body 5.1. For standard acquisition, packaging shall be in hermetically sealed containers as specified in AWS A5.5.

C.6. NOTES

C.6.1 Intended use. This specification is intended to cover several arc-welding electrodes of various alloys and strength levels that deposit weld metal that meets the mechanical property requirements given herein. These electrodes have an extremely low covering moisture content and should reduce the likelihood of underbead cracking in welding of such high yield strength steels as HY-80 and HY-100 of MIL-S-16216/NAVSEA Technical Publication T9074-BD-GIB-010/0300, HY-130 of MIL-S- 24371/NAVSEA Technical Publication T9074-BD-GIB-010/0300, and HSLA-80 and HSLA-100 of MIL-S- 24645/NAVSEA Technical Publication T9074-BD-GIB-010/0300.

C.6.1.1 MIL-10018-M1. This type is intended for general use in the welding of HY-80 and HSLA-80 steels for as-welded applications and stress-relieved. This electrode is intended for use with dc, electrode positive (DCEP) (dc, reverse polarity) electrical characteristics only.

68 Original

C.6.1.2 MIL-10718-M. This type is intended to cover low-alloy electrodes for welding joints in HSLA-80, HY-80, HSLA-100 and HY-100 steels where approved; and other applications where improved toughness and usability are required. This electrode is intended for use with dc, electrode positive (DCEP) (dc, reverse polarity) electrical characteristics only.

C.6.1.3 MIL-12018-M2. This type is intended for general use in the welding of HY-100 and HSLA-100 steel for as-welded applications. This electrode is intended for use with dc, electrode positive (DCEP) (dc, reverse polarity) electrical characteristics only.

C.6.1.4 MIL-10018-M1, MIL-10718-M, and MIL-12018-M2 types with suffix RC.

Restricted copper electrodes will be used when specified (see C.6.2 and Table I). These types are intended to cover electrodes for welding pressure and strength welds that will be subject to irradiation.

C.6.2 Acquisition requirements. Acquisition documents must specify the following:

(a) Title, number and date of this appendix.

(b) Type, size, and length required (see C.1.2).

(c) If stress relief of welded test assembly for MIL-10018-M1 or MIL-10718-M is required for quality conformance inspection (see C.3.3.1 and footnote 1/ to table IV).

(d) Whether the copper content is restricted as designated by the suffix RC to the appropriate type (see footnote 2/ to table I).

(e) Whether a maximum chromium content of 0.20% is required to control hexavalent chromium in welding fumes (see footnote 4/ of table I)

(f) Whether higher maximum yield strength is allowed for type MIL-12018-M2 (see footnote 3/ to table II).

(g) Whether electrodes shall have a dielectric strength other than a dielectric strength able to insulate against 110 volts, 60-Hertz alternating current (see C.3.4.7).

(h) Whether heat, lot, or other marking codes are required for individual electrodes (see C.3.5).

(i) Whether the highest and lowest carbon equivalent electrodes shall be identified (see C.4.5.2 and Main Body 4.8.3).

(j) What preheat and interpass temperature, and what heat inputs are required for MIL-10018-M1

(see footnote 6/ to table V)

(k) Whether a second test weldment is required using ASTM A710 or MIL-S-24645/NAVSEA

Technical Publication T9074-BD-GIB-010/0300 grade HSLA-80 steel base plate material (see footnote 8/ to table V and footnote 7/ to table VI).

(l) When an alternate base material is to be used with MIL-10718-M (see footnote 2/ to table VI).

(m) When alternate NAVSEA Materials Engineer Division approved weld parameters are to be used with MIL-10718-M (see footnote 9/ to table VI).

(n) The heat input range of MIL-12018-M2 electrodes (see footnote 5/ to table VII).

C.6.3 Subject term (key word) listing.

Core wire Shielded metal arc welding Welding electrode Chemical composition Mechanical properties Non-destructive testing Diffusible hydrogen Dielectric Strength

69 Original

Figure 1. Single-V style weld joint configuration. 1/

NOTES:

1/ See tables IX, X, XI, and XII.

70 Original

Table IX. Welded test assembly stress relieved applications. 6/

10018-M1 and MIL-10718-M Type

Stress relieved Purpose Qualification Quality conformance Stress relief (See note 1/) (See note 1/) Welding parameters (See note 2/) (See note 2/) Joint configuration 3/ Figure 1 Figure 1 Width (W) (inches) 15 minimum 15 minimum Length (L) (inches) 5/ 24 minimum 24 minimum Root opening (R) (inches) 7/ 1/4 minimum 1/4 minimum Root face (F) (inches) 0 to 1/32 0 to 1/32 Included angle ( ) (degrees) 45 45

Backing strip dimensions (B) (thickness x width) (inches) 8/ 1/2 x 1-1/2 1/2 x 1-1/2

Test specimens (number/type) 4/ From each weld:

2 Tension 2 Bend

10 Charpy

From each weld:

2 Tension 10 Charpy

1/ Prior to machining specimens or removing backing strip, weldments shall be stress relieved in accordance with C.3.3.1.

2/ Welding parameters shall be in accordance with table V and table VI, as appropriate.

3/ Plate thickness (T) shall be in accordance with table V and table VI, as appropriate.

4/ Tensile specimens shall be all weld metal (longitudinal axis of the specimen shall be parallel to the welding direction) and shall be centered at 3/8 inch below the surface in the weld metal. CVN specimens shall have the notch perpendicular to the welded assembly top surface, shall be centered in the weld metal and the top surface of each specimen shall be 1/16 inch below the top surface of the welded test assembly. No specimens shall be removed from within 3/4-inch of the ends of the welded test assembly. See figure 3 for more specimen location information.

5/ For retests, when tensile and impact properties do not both need to be retested, the length of the plate shall not be less than 18 inches.

6/ See Main Body 3.15 for additional welding requirements.

7/ Root opening shall be 1/2" plus or minus 1/16" for MIL-10718-M 8/ Backing strip shall be 1/4" x 1-1/2" for the MIL-10718-M low cooling rate weld

71 Original

Table X. Welded test assembly MIL-10018-M1 as-welded. 6/

Type 10018-M1 Purpose Qualification Quality conformance Stress relief (See note 1/.) (See note 1/.)

Welding parameters (See note 2/.) (See note 2/.)

Joint configuration 3/ Figure 1 Figure 1 Width (W) (inches) 15 minimum 15 minimum Length (L) (inches) 5/ 30 minimum 24 minimum Root opening (R) (inches) 1/4 minimum 1/4 minimum Root face (F) (inches) 0 to 1/32 0 to 1/32 Included angle ( ) degrees 45 minimum 45 minimum Backing strip dimensions (B) (thickness x width) (inches) 1/2 x 1-1/2 1/2 x 1-1/2

Test specimens (number/type) 4/

From each weld:

2 Tension

2 Bend 10 Charpy

AND 4 DT

From each weld:

2 Tension 10 Charpy

OR 4 DT

1/ Welded test assemblies shall not be stress relieved. Heat soaking for hydrogen removal is prohibited.

2/ Welding parameters shall be in accordance with table V.

3/ Plate thickness (T) shall be in accordance with Table V.

4/ Tensile specimens shall be all weld metal (longitudinal axis of the specimen shall be parallel to the welding direction) and shall be centered at 3/8 inch below the surface in the weld metal. CVN specimens shall have the notch perpendicular to the welded assembly top surface, shall be centered in the weld metal and the top surface of each specimen shall be 1/16 inch below the top surface of the welded test assembly. The 5/8 inch DT specimens shall have the notch perpendicular to the welded assembly top surface and the top surface of each specimen shall be 1/16 inch below the top surface of the welded test assembly. No specimens shall be removed from within 3/4-inch of the ends of the welded test assembly. See figure 3 for more specimen location information.

5/ For retests, when tensile and impact properties do not both need to be retested, the length of the plate may be decreased below the minimum length, but shall not be less than 18 inches.

6/ See Main Body 3.15 for additional welding requirements.

72 Original

Table XI. Welded test assembly MIL-10718-M high & low cooling rate. 3/

Type 10718-M Purpose Qualification Quality conformance Stress relief 1/ 1/ Welding parameters 2/ 2/ Joint configuration 4/ Figure 1 Figure 1 Width (W) (inches) 15 minimum 15 minimum Length (L) (inches) 30 minimum 24 minimum Root opening (R) (inches) 1/2 plus or minus 1/16 1/2 plus or minus 1/16 Root face (F) (inches) 0 to 1/32 0 to 1/32 Included angle ( ) degrees 45 45 Backing strip dimensions (B) (thickness x width) (inches)

1/2 x 1-1/2 high cooling rate and 1/4 x 1-1/2 for low cooling rate

1/2 x 1-1/2 high cooling rate and 1/4 x 1-1/2 for low cooling rate Test specimens (number/type) 5/ From each weld:

2 Tension 2 Bend

10 Charpy AND 4 DT

From each weld:

2 Tension

10 Charpy OR 4 DT

1/ Welded test assemblies shall not be stress relieved. Heat soaking for hydrogen removal is prohibited.

2/ Welding parameters shall be in accordance with table VI.

3/ See Main Body 3.15 for additional welding requirements.

4/ Plate thickness (T) shall be in accordance with Table VI.

5/ Tensile specimens shall be all weld metal (longitudinal axis of the specimen shall be parallel to the welding direction) and shall be centered at 3/8 inch below the surface in the weld metal. CVN specimens shall have the notch perpendicular to the welded assembly top surface, shall be centered in the weld metal and the top surface of each specimen shall be 1/16 inch below the top surface of the welded test assembly. The 5/8 inch DT specimens shall have the notch perpendicular to the welded assembly top surface and the top surface of each specimen shall be 1/16 inch below the top surface of the welded test assembly. No specimens shall be removed from within 3/4-inch of the ends of the welded test assembly. See figure 3 for more specimen location information.

73 Original

Table XII. Welded test assembly MIL-12018-M2 low cooling rate. 6/

Type 12018-M2

Purpose Qualification Quality conformance

Stress relief 1/ 1/

Welding parameters 2/ 2/

Joint configuration 3/ Figure 1 Figure 1

Width (W) (inches) 15 minimum 15 minimum

Length (L) (inches) 30 minimum 5/ 24 minimum

Root opening (R) (inches) 1/2 minimum 1/2 minimum

Root face (F) (inches) 0 to 1/32 0 to 1/32

Included angle ( ) degrees 45 45

Backing strip dimensions (B) (thickness x width) (inches) 1/2 x 1-1/2 1/2 x 1-1/2

Test specimens (number/type) 4/

From each weld:

2 Tension

2 Bend 10 Charpy

AND 4 DT

From each weld:

2 Tension 10 Charpy

OR 4 DT

1/ Welded test assemblies shall not be stress relieved. Heat soaking for hydrogen removal is prohibited.

2/ Welding parameters shall be in accordance with table VII.

3/ Plate thickness (T) shall be in accordance with Table VII.

4/ Tensile specimens shall be all weld metal (longitudinal axis of the specimen shall be parallel to the welding direction) and shall be centered at 3/8 inch below the surface of the weld metal. CVN specimens shall have the notch perpendicular to the welded assembly top surface, shall be centered in the weld metal and the top surface of each specimen shall be 1/16 inch below the top surface of the welded test assembly. The 5/8 inch DT specimens shall have the notch perpendicular to the welded assembly top surface and the top surface of each specimen shall be 1/16 inch below the top surface of the welded test assembly. No specimens shall be removed from within 3/4 inch of the ends of the welded test assembly.

See figure 3 for more specimen location information.

5/ For retests, when tensile and impact properties do not both need to be retested, the length of the plate may be decreased below the minimum length, but shall not be less than 24 inches.

6/ See Main Body 3.15 for additional welding requirements.

74 Original

Figure 2 Double-V style weld joint configuration. 1/

1/ See table XIII.

75 Original

Table XIII. Welded test assembly MIL-12018-M2 high cooling rate. 7/ Type 12018-M2

Purpose Qualification Quality conformance Stress relief 1/ 1/ Welding parameters 2/ 2/ Joint configuration 4/ Figure 2 Figure 2 3/ Width (W) (inches) 15 minimum 15 minimum Length (L) (inches) 30 minimum 6/ 24 minimum Root opening (R) (inches) 0 to 3/16 0 to 3/16 Root face (F) (inches) 0 to 1/16 0 to 1/16 Included angle ( ) degrees 45 45

Test specimens (number/type) 5/

From EACH side:

2 Tension

2 Bend 10 Charpy

AND 4 DT

From EACH side:

2 Tension 10 Charpy

OR 4 DT

1/ Welded test assemblies shall not be stress relieved. Heat soaking for hydrogen removal is prohibited.

2/ Welding parameters shall be in accordance with table VII.

3/ Alternatively, high cooling rate quality conformance testing may be performed in accordance with figure

1 when approved by the Government provided:

(a) Test data from both figure 1 and figure 2 test plates demonstrate comparability with respect to cooling rate and performance.

(b) Written quality conformance test procedures submitted for approval establish welding parameter controls and comparative differences in acceptance criteria for figure 1 test plates.

(c) When both test plates are tested, results from the figure 2 test plate shall be the authoritative test.

4/ Plate thickness (T) shall be in accordance with Table VII.

5/ Tensile specimens from each side shall be all weld metal (longitudinal axis of the specimen shall be parallel to the welding direction) and shall be centered at 3/8 inch below the surface of the side represented by the specimen. CVN specimens from each side shall have the notch perpendicular to the welded assembly top surface, shall be centered in the weld metal and the top surface of each specimen shall be 1/16 inch below the surface of the side of the welded test assembly represented by the specimen. The 5/8 inch DT specimens shall have the notch perpendicular to the welded assembly top surface and the top surface of each specimen shall be 1/16 inch below the surface of the side of the welded test assembly represented by the specimen. No specimens shall be removed from within 3/4 inch of the ends of the welded test assembly. Specimen location from each side shall be as illustrated in Figure 3 (A).

6/ For retests, when tensile and impact properties do not both need to be retested, the length of the plate may be decreased below the minimum length, but shall not be less than 24 inches.

7/ See Main Body 3.15 for additional welding requirements.

76 Original

(A) PLAN VIEW OF TEST SPECIMEN LAYOUT FOR SINGLE-V AND EACH SIDE OF DOUBLE-V TEST

PLATES

(B) GROOVE PREPARATION OF SINGLE-V TEST PLATE

SHOWING ORIENTATION OF CHARPY V-NOTCH AND DYNAMIC TEAR TEST SPECIMENS

Figure 3. Welded joint test specimen layout

1/ See tables IX, X, XI, XII and XIII as appropriate. Note that no specimens shall be removed from within 3/4-inch of the ends of the welded test assembly.

L 1/

TENSILE SPECIMEN

BEND, CHARPY V-NOTCH

AND/OR DT SPECIMENS 1/

W 1/

1/

45 min.

1/

T

1/16"

77 Original

Figure 4. Circuit for dielectric strength determination.

1/ Wrap conducting aluminum foil around 6-inch length of electrode.

2/ Place electrode with grip-end on one lug and foil covered section on other.

3/ Close circuit breaker; press safety button and slowly rotate variac control.

4/ Record maximum voltage before breakdown.

5/ Dielectric strength is recorded voltage, multiplied by 10 (transformer ratio).

6/ When dielectric strength is below 300V, connect appropriate voltmeter across electrode terminals.