Attachment_0033_-TACOM_Ground_Combat_Vehicle_Welding_Code_-_S....pdf

19207-12479550 Revision A Page 1 of 165

Revisions

LTR Description Date (YY-MM-DD) Approved

--- Initial Release Direct ERR FOM U6466 01-12-07 T. A. Higgins

A Direct ERR FOM U8332 Incorporated ADCN 157519 03-04-30 T. A. Higgins

Acknowledgment Design Activity

U.S. Army Tank-Automotive and Armaments Command

Warren, Michigan 48397-6000

This code is based on commercial and military specifications; primarily ANSI/AWS B2.1, ANSI/AWS D1.1, MIL-STD 1941 and MIL-STD 1261.

This document was prepared by a team from United Defense, L.P., Ground Systems Division (UDLP) and the U.S. Army’s Tank-Automotive Armament Research, Development and Engineering Center (TARDEC).

Design Approval TARDEC/UDLP Weld Team

Ground Combat Vehicle Welding Code -

Steel Drawn Date Drawing Approval Size Cage Code

Richard J. Rush 01/12/06 Tom Altobelli A 19207 12479550

Downloaded from http://www.everyspec.com

19207-12479550 Revision A Page 2 of 165

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Preface

Introduction This document follows the AWS format, and is based on current practice in the manufacture of ground combat vehicles. The section that normally would be included to establish design standards has been eliminated from this code. This follows the practice within this industry of having design performed by structural design engineers using the latest in finite element analysis.

This code is divided into seven sections and five appendices.

Revisions This code and all revisions will be electronically maintained. Signed original copy of document located at AMSTA-TR-E/ART.

Recommendations for change must be submitted in writing to U.S. Army Tank-Automotive and Armament Research, Development and Engineering Center (TARDEC), Attention AMSTA-

TR-E/MEPS. Consensus of the standing Weld Team is required for revisions to this code.

Specification Cross Reference A table is included on page 4 to provide a cross-reference between this code and military standards and specifications (active and cancelled).

TARDEC/UDLP Weld Team

Charter Members x� Michael W. Davis – UDLP x� Steven W. Taylor – UDLP x� Richard J. Rush – UDLP x� David Berridge – UDLP x� Marvin Kohn - UDLP x� Terry A. Higgins – TARDEC x� Joe B. Regmont – TARDEC x� Lucien A. Vita – TACOM/ARDEC x� Claude Braafladt - UDLP

19207-12479550 Revision A Page 4 of 165

Table P.1 Cross Reference Table

Topic Applicable References

Stud Welding MIL-STD-1261, Classes 1, 2 and 3

Non Critical Welds AWS D1.1 Statically Loaded Welds

MIL-STD-1261, Class 1

MIL-STD-248

Critical Welds MIL-STD-1261, Class 2

AWS D1.1 Cyclically Loaded Welds

MIL-STD-1941, Attachments to Armor

MIL-STD-1185, Attachments to Armor

MIL-STD-1261, Class 3

MIL-STD-2219, classes A & B

MIL-STD-248

Ballistic Welds MIL-STD-1941

MIL-W-46086

MIL-STD-1185

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TABLE OF CONTENTS

Preface Introduction Revisions Specification Cross Reference TARDEC/UDLP Weld Team Charter Members 1 General Requirements

1.1 Scope

Appendices

1.1.1 Application

1.1.2 Limitations

1.2 Approval

1.3 Definitions

1.4 Welding Symbols

1.5 Equipment Calibration

1.6 Safety Precautions

1.7 Standard Units of Measurement

2 Design of Welded Connections

2.1 Intended Use

3 Prequalification of WPSs

3.1 Scope

3.2 Welding Processes

3.2.1 Prequalified Processes

3.2.2 Other Welding Processes

3.3 Base Metal/Filler Metal Combinations

3.4 Minimum Preheat and Interpass Temperature Requirements

3.4.1 Base Metal/Thickness Combination

3.4.2 Alternate SAW Preheat and Interpass Temperatures

3.4.2.1 Hardness Requirements

3.5 Limitation of WPS Variables

3.5.1 Combination of WPSs

3.6 General WPS Requirements

3.6.1 Vertical-Up Welding Requirements

3.6.2 Width/Depth Pass Limitation

3.7 Common Requirements of Partial and Complete Joint Penetration Groove and Fillet Welds

3.7.1 FCAW/GMAW in SMAW Joints

3.7.2 Corner Joint Preparation

3.7.3 Root Openings

3.7.4 Skewed T Joints

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3.8 Partial Joint Penetration Requirements

3.8.1 Definition

3.8.2 Details (Tubular)

3.9 Complete Joint Penetration Groove Weld Requirements

3.9.1 J- and U-Groove Preparation

3.9.2 Tubular Butt Joints

3.9.3 Tubular T-, Y-, and K-Connections

4 Qualification

4.0 Scope

4.1 General

4.1.1 Procedure Qualification Record (PQR)

4.1.1.1 Impact Test Requirements

4.1.2 Welding Procedure Specification (WPS)

4.1.3 Qualification of Welding Procedures

4.1.4 Qualification of Welders, Welding Operators, Tack Welders, and Robotic Applications

4.2 Common Requirements for WPS and Welding Personnel Performance Qualificatio

4.2.1 Qualification Responsibility

4.2.2 Qualification to Other Codes or Standards

4.2.3 Aging

4.2.4 Records

4.2.5 Positions of Welds

4.3 General

4.4 Qualification Thickness Limitations

4.5 Qualification Position Limitations

4.6 Methods of Testing and Acceptance Criteria

4.7 Special Test Weldment Acceptance Criteria

4.8 Groove Test Weldments and Acceptance Criteria

4.9 Fillet Test Weldments and Acceptance Criteria

4.10 Cladding Test Weldment and Acceptance Criteria

4.11 Hardfacing Test Weldment and Acceptance Criteria

4.12 Sheet Metal Weldments and Acceptance Criteria

4.13 Welding Procedure Specification Data

4.13.1 Joint Design

4.13.2 Base Metal

4.13.3 Filler Metal

4.13.4 Position

4.13.5 Preheat and Interpass

4.13.6 Heat Treatment

4.13.7 Shielding Gas

4.13.8 Electrical

4.13.9 Variables (see 4.14.9)

4.14 Procedure Qualification Variables

4.14.1 Joint Design

4.14.2 Base Metal

4.14.3 Filler Metals

4.14.4 Position

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4.14.5 Preheat and Interpass Temperature

4.14.6 Post Weld Heat Treatment

1) Omission or inclusion of PWHT

4.14.7 Shielding Gas

4.14.8 Electrical Characteristics

4.15 General

4.16 Testing

4.16.4 Cladding

4.16.5 Hardfacing

4.17 Examination Procedures and Acceptance Criteria

4.17.1 Visual Examination

4.17.1.1 Test Weldments

4.17.2 Radiographic Examination

4.17.3 Bend Tests

4.17.4 Fillet-Weld Bend-Break Tests

4.17.5 Macro Examination

4.18 Performance Qualification Variables

4.18.1.1 Welders

4.18.1.2 Welding Operator

5 Fabrication

5.1 Scope

5.2 Base Metal

5.2.1 Specified Base Metal

5.2.2 Base Metal for Weld Tabs, Backing, and Spacers

5.2.2.1 Weld Tabs

5.2.2.2 Backing

5.2.2.3 Spacers

5.3 Welding Consumables and Electrode Requirements

5.3.1 General

5.3.1.1 Certification for Electrodes or Electrode-Flux Combinations

5.3.1.2 Suitability of Classification

5.3.1.3 Shielding Gas

5.3.1.4 Storage

5.3.1.5 Electrode Condition

5.3.2 SMAW Electrodes

5.3.2.1 SMAW Electrode Storage Conditions

5.3.2.2 Approved Atmospheric Time Periods

5.3.2.3 Rebaking Electrodes

5.3.2.4 Electrode Restrictions for ASTM A514 or A517 Steels

5.3.3 SAW Electrodes and Fluxes

5.3.3.1 Electrode-Flux Combination Requirements

5.3.3.2 Condition of Flux

5.3.3.3 Flux Reclamation

5.3.4 GMAW/FCAW Electrodes

5.3.4.1 Low-Alloy Electrodes for GMAW

5.3.4.2 Low-Alloy Electrodes for FCAW

5.3.5 GTAW

5.5.5.1 Tungsten Electrodes

5.3.5.2 Filler Metal

5.4 WPS Variables

5.5 Preheat and Interpass Temperatures

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5.6 Backing, Backing Gas, or Inserts

5.7 Backing

5.7.1 Fusion

5.7.2 Full Length Backing

5.7.3 Backing Thickness

5.8 Welding Environment

5.8.1 Maximum Wind Velocity

5.8.2 Minimum Ambient Temperature

5.9 Compliance with Design

5.10 Preparation of Base Metal

5.11 Tack Welds

5.11.1 General Requirements for Tack Welds

5.11.2 Incorporated Tack Welds

5.11.2.1 Additional Requirements for Tack Welds Incorporated in SAW Welds

5.11.2.2 Unincorporated Tack Welds

5.12 Control of Distortion and Shrinkage

5.12.1 Procedure and Sequence

5.12.2 Sequencing

5.12.3 Minimized Restraint

5.12.4 Temperature Limitations

5.13 Fillet Weld Assembly

5.14 Technique for Plug and Slot Welds

5.14.1 Plug Welds

5.14.1.1 Flat Position

5.14.1.2 Vertical Position

5.14.1.3 Overhead Position

5.14.2 Slot Welds

5.15 Rework/Repairs

5.15.2.1 Overlap or Excessive Convexity

5.15.2.2 Excessive Concavity of Weld or Crater, Under-size Welds, Undercutting

5.15.2.3 Excessive Weld Porosity or Incomplete Fusion

5.15.2.4 Cracks in Welds

5.16 Peening

5.16.1 Tools

5.17 Caulking

5.18 Arc Strikes

5.19 Weld Cleaning

5.19.1 In-Process Cleaning

5.19.2 Cleaning of Completed Welds

6 Inspection

6.1 General

6.1.3 Inspector Qualification

6.2 Inspection of Welding Procedure Specification and Equipment

6.3 Inspection of Welder, Welding Operator, and Tack Welder Qualifications

6.4 Inspection of Work and Records

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6.5 Obligations of the Contractor

6.6 Nondestructive Testing

6.6.1 Non-Critical Welds

6.6.2 Critical Welds

6.6.3 Ballistic Welds

6.6.4 Procedures

6.6.4.1 Radiographic Testing

6.6.4.2 Radiation Imaging Systems

6.6.4.3 Ultrasonic Testing

6.6.4.4 Magnetic-Particle Testing

6.6.4.5 Dye Penetrant Testing

6.6.5 Personnel Qualification

6.7 General

6.8 Extent of Testing

6.9 Radiographic Procedures

6.9.10 Quality of Radiographs

6.9.11 Density Limitations

6.10 Acceptability of Welds

6.11 Examination, Report, and Disposition of Radiographs

6.12 General

6.12.1 Visual

6.12.2 Liquid Penetrant and Magnetic-Particle

6.12.3. Radiographic

6.12.4 Ultrasonic

7 Stud Welding

7.1 Scope

7.2 Workmanship

7.2.1 Cleanliness

7.2.2 Coating Restrictions

7.2.3 Base-Metal Preparation

7.2.4 Moisture

7.2.5 Ferrule Condition

7.2.6 Arc Shield Removal

7.2.7 Acceptance Criteria

7.3 Technique

7.3.1 Automatic Machine Welding

7.3.2 GTAW, GMAW, SMAW Fillet Weld Option

7.3.2.1 Surfaces

7.3.2.2 Stud End

7.3.2.3 Stud Fit (Fillet Welds)

7.3.2.4 Fillet Weld Minimum Size

7.4 Stud Application Qualification Requirements

7.4.1 Responsibilities for Tests

7.4.2 Preparation of Specimens

7.4.2.1 Test Specimens

7.4.3 Number of Specimens

7.4.4 Test Required

7.4.5 Test Methods

7.4.5.1 Bend Test

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7.4.5.2 Torque Test

7.4.5.3 Tension Test

7.4.6 Qualification Test Data

7.5 Production Control

7.5.1 Pre-Production Testing

7.5.1.1 Start of Shift

7.5.1.2 Production Member Option

7.5.1.3 Flash Requirement

7.5.1.4 Bending/Torque Test

7.5.1.5 Event of Failure

7.5.2 Production Welding

7.5.3 Repair of Studs

7.5.4 Operator Qualification

7.5.5 Removal Area Repair

APPENDICES

Appendix A Code Approved Base Metals and Filler Metals Requiring Qualification per Section 4 Appendix B Welding of Armor Steel

B1 INTRODUCTION

B1.1 Application B1.2 Base Metal

B2 REFERENCED DOCUMENTS

B2.1 Issues of Documents B2.1.1 Military Documents B2.1.2 Other Publications B2.1.2.1 American Society for Testing And Materials (ASTM) B2.1.2.2 American Welding Society (AWS) B2.1.2.3 American National Standards Institute (ANSI)

B3 REQUIREMENTS

B3.1 Weldments B3.2 Armor B3.3 Preparation of Welding Procedures and Drawings B3.4 Welders or Welding Operator B3.4.1 Test Plate Requirements B3.4.2 Test Plate Acceptance B3.5 Ballistic Requirements B3.5.1 Heating of Weldments B3.5.2 Welding Attachments to Armor B3.6 Ballistic Test Plates B3.6.1 Submission B3.6.2 Macro Specimens B3.7 Ballistic Testing Requirements B3.7.1 Test Plates B3.7.2 Number of Test Plates B3.7.3 Fabrication of Test Plates B3.7.4 Ballistic Test Requirements B3.7.5 Ballistic Testing B3.7.6 Test Method B3.7.7 Evaluation of Test Results B3.7.8 Visual Examination of Test Plates B3.7.9 Radiographic Inspection of the Test Plate B3.7.10 Repair of Test Plate

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B3.7.11 Rejection of Ballistic Test Plate B3.7.12 Retests B3.8 Radiographic Procedure B3.8.1 Radiographic Drawings B3.8.2 First Production Weldment B3.9 Inspection of Production Weldments B3.9.1 Visual Inspection B3.9.2 Radiographic Inspection B3.9.3 Alternative Testing B3.9.4 Inspection of Weldments Subjected to Straightening B3.9.5 Marking of Repairs to Weldments B3.9.6 Quality Control Appendix C Forms Appendix D Illustrations — Stud Weld Positions, Weld Test Specimens and Test Fixtures D1 Standard Stud Test Weldment Positions D2 Guided Bend Specimens D2.1 Preparation of Groove weld Specimens D2.3 Subsize Transverse Face and Root Bends D2.4 Nonstandard Bend Specimens D3 Tension Specimens D4 Cladding and Hardfacing Specimens D5 Test Fixtures Appendix E Prequalified Joint Preparations and Joint Details

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LIST OF FIGURES

Figure 3.1 Weld Bead in which Depth and Width Exceed the Width of the Weld Face (see 3.6.2) Figure 4.1 — Positions of Groove Welds (see 4.2.5) Figure 4.2 — Positions of Fillet Welds (see 4.2.5) Figure 4.3 — Position of Test Plates for Groove Welds (see 4.2.5) Figure 4.4 — Position of Test Plates for Fillet Welds (see 4.2.5) Figure 4.5 — Position of Test Plate for Groove Welds (see 4.2.5) Figure 4.6 — Position for Test Pipes for Fillet Welds (see 4.2.5) Figure 4.7 — Tubular Butt Joint — Welder or WPS Qualification — without Backing (see Table 4.5) Figure 4.8 — Tubular Butt Joint — Welder or WPS Qualification — with Backing (see Table 4.5) Figure 4.9 — Location of Groove Weld Test Specimens — Pipe and Tube (see 4.8.1) Figure 4.10 — Location of Tension, Longitudinal Bend, and Toughness Specimens — Sheet and Plate

(see 4.8.1) Figure 4.11 — Location of Tension, Toughness, and Transverse Bend Specimens — Plate and Sheet (see

4.8.1) Figure 4.12 — Location of Fillet Weld Shear and Macroetch Test Specimens (see 4.9.4 and 4.9.6) Figure 4.13 — Fillet Weld Bend-Break and Macroetch Test Specimens (see 4.9.4 and 4.9.5) Figure 4.14 — Location of Cladding Test Specimens (see 4.10.1) Figure 4.15 — Location of Hardfacing Test Specimens (see 4.11.1) Figure 4.16 — Location of 1G, 2G, 5G, and 6G Bend Specimens —Pipe Groove Weldment (see 4.16.3) . 55 Figure 4.17 — Location of Bend Specimens — Combined Positions 2G and 5G (see 4.16.3) Figure 4.18 — Location of Transverse Bend Specimens — Plate Groove Weldment (see 4.16.3) Figure 4.19 — Location of Longitudinal Bend Specimens — Plate Groove Weldment (see 4.16.3) Figure 4.20 — Location of Fillet Test Specimens — Plate (see 4.16.3) Figure 4.21 — Location of Fillet Test Specimens — Alternate Weldment — Plate (see 4.16.3) Figure 4.22 — Location of Fillet Test Specimens — Pipe (see 4.16.3) Figure 4.23 — Location of Fillet Test Specimens — Alternate Weld — Pipe (see 4.16.3) Figure 4.24 — Location of Cladding Specimens — Plate (see 4.16.3) Figure 4.25 — Location of Test Specimen — Hardfacing Test Weldment — Plate (see 4.16.3) Figure 6.1 — Radiographic Identification and Penetrameter Locations on Approximately Equal Thickness

Joints (see 6.9.7) Figure 6.2 — Radiographic Identification and Locations on Transitions Joints (see 6.9.7) Figure 6.3 — Penetrameter Design (see 6.9.7) Figure 7.1 — Torque Testing Arrangement and Table of Testing Torques (see 7.4.5.2) Figure B3.1 — Specimen for Ballistic Armor Welder Qualification (see B3.4) Figure B3.2 — Ballistic Test Plate (see B3.6.2 and B3.7.1) Figure B3.3 — Examples of Weld Cracks That Can Occur From Projectile Impact, and Indication of

Measurement of Total Weld Crack for Acceptance Purposes (See B3.7.5 and Table B3.2) Figure B3.4 — Single Groove Welds (see B3.7.2) Figure B3.5 — Type 3 Ballistic Joint (see B3.7.2) Figure B3.6 — Type 4 Ballistic Joint (see B3.7.2) Figure B3.7 — Type 5 Ballistic Joint (see B3.7.2) Figure B3.8 — Type 6 Ballistic Joint (see B3.7.2) Figure B3.9 — Type 7 Ballistic Joint (see B3.7.2) Figure B3.10 — Type 10 Continuous Fillet Weld Ballistic Joint (see B3.7.2) Figure D1.1 — Welding Positions — Stud Welds (see D1.1) Figure D2.1 — Transverse Face and Root Bend Specimens (see D2.1) Figure D2.2 — Longitudinal Face and Root Bend Specimens (see D2.1) Figure D2.3 — Transverse Side Bend Specimens (see D2.1) Figure D3.1 — Reduced Section Tension Specimen — Rectangular (see D3) Figure D3.2 — Reduced Section Tension Specimen — Round (see D3) Figure D3.3 — Alternate Tension Specimen for Pipe 3 in. O.D. or Less (see D3) Figure D3.4 — Alternate Tension Specimen for Pipe 2 in. O.D. or Less (see D3) Figure D4.1 — Weld Cladding Side Bend Specimen (see D4) Figure D4.2 — Weld Cladding and Hardfacing Chemical Analysis Specimen (see D4)

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Figure D5.1 — Guided Bend Fixture — Bottom Ejecting Type (see D5) Figure D5.2 — Guided Bend Fixture — Bottom Type (see D5) Figure D5.3 — Guided Bend Fixture — Wrap Around (see D5) Figure D5.4 — Stud Weld Test Fixture (see D5) Figure D5.5 — Stud Weld Torque Fixture (see D5) Figure D5.6 — Stud Weld Tension Test Fixture (see D5) Figure E.1 (Sheet 1) — Prequalified Partial Joint Preparation (PJP) Groove Welded Joint Details (see 3.8)

Top — Single square-groove weld, butt joint Bottom — Double square-groove weld, butt joint Figure E.1 (Sheet 2) — Prequalified Partial Joint Preparation (PJP) Groove Welded Joint Details (see 3.8)

Top — Single V-groove weld, butt or corner joint Bottom — Double V-groove weld, butt joint Figure E.1 (Sheet 3) — Prequalified Partial Joint Preparation (PJP) Groove Welded Joint Details (see 3.8)

Top — Single-bevel-groove weld, butt, or T-, or corner joint Bottom — Double bevel-groove weld, butt, or T-, or corner joint

Figure E.1 (Sheet 4) — Prequalified Partial Joint Preparation (PJP) Groove Welded Joint Details (see 3.8) Top — Single U-groove weld, butt or corner joint Bottom — Double U-groove weld, butt joint

Figure E.1 (Sheet 5) — Prequalified Partial Joint Preparation (PJP) Groove Welded Joint Details (see 3.8) Single U-groove weld, butt, or T-, or corner joint

Figure E.1 (Sheet 6) — Prequalified Partial Joint Preparation (PJP) Groove Welded Joint Details (see 3.8) Double J-groove weld, butt, or T-, or corner joint

Figure E.1 (Sheet 7) — Prequalified Partial Joint Preparation (PJP) Groove Welded Joint Details (see 3.8) Flare bevel groove weld, butt or T- or corner joint

Figure E.2 (Sheet 1) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Square-groove weld with backing, butt or corner joint Bottom — Square-groove weld without backing, butt joint

Figure E.2 (Sheet 2) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Square-groove weld, T- or corner joint Bottom — Single-V-groove weld, butt joint

Figure E.2 (Sheet 3) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Single V-groove weld, corner joint Bottom — Single-V-groove weld, butt joint

Figure E.2 (Sheet 4) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Single-V-groove weld, corner joint Bottom — Double-V-groove weld, butt joint

Figure E.2 (Sheet 5) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Double -V -groove weld, butt joint Bottom — Single-bevel-groove weld, butt joint

Figure E.2 (Sheet 6) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Single-bevel-groove weld, T- or corner joint Bottom — Single-bevel-groove weld, butt joint

Figure E.2 (Sheet 7) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Single-bevel-groove weld, T- or corner joint Bottom — Double-bevel-groove weld, butt, or T-, or corner joint

Figure E.2 (Sheet 8) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Double-bevel-groove weld, butt joint Bottom — Double-bevel-groove weld, T-, or corner joint

Figure E.2 (Sheet 9) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Single-U-groove weld, butt or corner joint Bottom — Double-U-groove weld, butt joint .. 162

Figure E.2 (Sheet 10) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Single-J-groove weld, butt joint Bottom — Single-J-groove weld, T- or corner joint

Figure E.2 (Sheet 11) — Prequalified Complete Joint Preparation (CJP) Groove Welded Joint Details (see 3.9) Top — Double-J-groove weld, butt joint Bottom — Double-J-groove weld, T- or corner joint

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LIST OF TABLES

Table P.1 Cross Reference Table Table 3.1 Table 3.2 Table 3.3 Prequalified WPS Requirements5 (See 3.6) Table 4.1 Test Methods for Procedure Qualification (see 4.6) Table 4.2 Thickness and Size Limitation for Fillet Welds for Procedure Qualification (see 4.4.1) Table 4.3 Thickness Limitations of Plate, Sheet Metal, and Pipe for Groove Welds for Procedure

Qualification (see 4.4.1) Table 4.4 Thickness Limitations for Cladding and Hardfacing for Procedure Qualification (see 4.4.1) Table 4.5 WPS Qualification — Production Welding Positions Qualified by Plate and Pipe Tests (see

4.5.1) Table 4.6 Table 3.1 and Appendix A Steels Qualified by PQR Steels (see 4.3.8) Table 4.7 Examination Requirements for Performance Qualification (see 4.15.8) Table 4.8 Electrode Classification Groups (see 4.16.1) Table 4.9 Allowable Base Metals for Performance Qualification (See 4.18.1.1) Table 4.10 Welder Qualification1 — Production Welding Positions Qualified by Plate and Tube Tests (see

4.16.2) Table 4.11 Pipe Diameter and Thickness Limitations for Performance Qualification on Groove Weld (see

4.18.1.1) Table 4.12 Plate Groove Weld Qualification Thickness Limitations for Performance Qualification (see

4.18.1.1) Table 4.13 Pipe Fillet Weld Qualification Limitations or Performance Qualification (see 4.18.1.1) Table 4.14 Sheet Metal Qualification Thickness Limitations for Performance Qualification (see 4.18.1.1).. 62 Table 5.1 Permissible Atmospheric Exposure of Low-Hydrogen Electrodes (see 5.3.2.2 and 5.3.2.3) Table 6.1 Visual Acceptance Criteria Matrix1,2,3 for all material thicknesses (see 6.6) Table 6.2 Penetrameter Requirements (see 6.9.1) Table B3.1 Thickness of Ballistic Test Plates (see B3.7.1) Table B3.2 Requirements for Ballistic Tests (see B3.7.6) Table B3.3 Severity Level Requirements for Full-Penetration Welds (see B3.7.9) Table B3.4 Ultrasonic Acceptance-Rejection Criteria (see B3.9.3)

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1 General Requirements

1.1 Scope

This code contains welding requirements applicable to welding ground combat vehicles, other alloy structures and components. It is to be used in conjunction with appropriate complementary codes or specifications for materials design and construction. It is not intended to supplant codes developed for use in specialized fabrication, such as the ASME Boiler and Pressure Vessel Code, aerospace codes, or military specifications; it is appropriate for use in fabrication of ballistic and non-ballistic primary structures, supporting structures and appurtenances.

When conformance to the code is stipulated in contract documents, all provisions of this code shall be complied with, except for those provisions that contract documents specifically exempt.

The following is a summary of the code sections and appendices:

1. General Requirements — This section contains basic information on the scope and limitations of the code.

2. Design of Welded Connections — This section has been omitted. Responsibility for this section resides with the design agency.

3. Prequalification — This section contains the requirements for exempting a non-armor Welding Procedure Specification (WPS) from the qualification requirements of this code.

4. Qualification — This section contains the qualification requirements for non-armor WPSs and welding personnel (welders, welding operators and tack welders).

5. Fabrication — This section contains the requirements for the preparation, assembly and workmanship of welded steel structures.

6. Inspection — This section contains criteria for the qualifications and responsibilities of inspectors, acceptance criteria for production welds, and standard procedures for performing visual inspection and NDT (nondestructive testing)

7. Stud Welding — This section contains the requirement for the welding of studs.

Appendices Appendix A — Code-Approved Base Materials.

This appendix contains tables that cross-reference and group the base and filler material qualification requirements. Within the type/grade grouping, other materials not specifically listed, may also be used with this document with Engineering approval.

Appendix B — Welding of Armor Steel. This appendix contains the welding, testing, procedure qualification, and performance qualification requirements of armor steel.

Appendix C — Forms. This appendix contains applicable forms for procedure qualification, performance qualification, and armor welding data sheets.

Appendix D — Illustrations – Weld Positions, Test Specimens and Test Fixtures. This appendix contains illustrations displaying dimensional information related to test specimens and fixtures.

Appendix E — Prequalified Joint Details and Joint Preparations. This appendix contains the Prequalified WPS limitations.

1.1.1 Application

This code is intended to be used for the following:

x� materials listed in Appendix A or other materials approved by Engineering as referenced in 1.1 Appendix A.

x� steel materials qualified using procedures established in:

• ASME Boiler and Pressure Vessel Code

• AWS Codes

• API Standards

• Canadian Welding Bureau codes x� Note: All procedures qualified using the above listed standards and codes require UDLP review and approval.

x� welding of armor steel. Any special requirements specified in Appendix B, “Welding of Armor Steel” supersedes any conflicting requirements found elsewhere in this document.

1.1.2 Limitations

This code is not intended to be used for pressure vessels or pressure piping.

1.2 Approval

All reference to a need for approval by the procuring activity or customer shall mean approval by the

19207-12479550 Revision A Page 17 of 165

Government, or the duly designated person who acts for and on behalf of the Government in all matters within the scope of this code.

In addition, where contractor approvals shall be required, the term contractor shall refer to the prime contractor

1.3 Definitions

The welding terms used in this code shall be interpreted in accordance with the definitions given in the latest edition of ANSI/AWS A3.0, Standard Welding Terms and Definitions.

Modified PQR – A PQR that has been developed from existing procedures qualified in accordance with a military standard or specification and grandfathered into an AWS PQR format.

Modified WPS – A WPS that has been created from a modified PQR(s) developed from an existing workmanship sample in accordance with a military standard or specification.

Skewed T-Joint – T-joint with a dihedral angle equal to or greater than 60 degrees. All T-joints less than 60 degrees shall be considered to be groove welds.

1.4 Welding Symbols

Welding symbols shall be those shown in the latest edition of ANSI/AWS A2.4, Symbols for Welding, Brazing, and Nondestructive Examination. Special conditions shall be fully explained by added notes or details.

1.5 Equipment Calibration

The manufacturer is required to develop and maintain a welding equipment calibration program. This program shall consist of, as a minimum, an annual comparison check of the machine output with instrumentation calibrated using standards traceable to the National Institute of Standards and Technology (NIST). The standard may be a load bank, voltmeter/ammeter, clamp-on meter, etc.

Machine output for amperage and voltage must be within r 10% of full scale. Proper documentation and evidence of the implementation must be maintained and is subject to random audit. Location for calibration shall be as follows:

x� GMAW/SAW/FCAW – At wire feeder x� GTAW/SMAW – At power supply x� All other processes – As close as practical to the welding process

1.6 Safety Precautions

Safety precautions shall conform to the latest edition of ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society.

Note: This code may involve hazardous materials, operations, and equipment. The code does not purport to address all of the safety problems associated with its 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.

1.7 Standard Units of Measurement

Values in this code will normally be stated in U.S.

customary units.

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2 Design of Welded Connections

2.1 Intended Use

This document does not address the design of welded connections. The responsibility for the design and designation of weld criticality is a function of the appropriate design agency.

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3 Prequalification of WPSs

3.1 Scope

Prequalification of WPSs (Welding Procedure Specifications) shall be defined as exemption from the WPS qualification testing required in section 4.

All prequalified WPSs shall be documented using the form found in Appendix C or an alternate form provided the same variables are addressed. In order for a WPS to be prequalified, conformance with all of the applicable provisions of section 3 shall be required. WPSs that do not conform to the requirements of section 3 may be qualified by tests in conformance with section 4. The use of a prequalified joint shall not exempt the contractor from using sound engineering judgment in determining the suitability of application of these joints to a welded assembly or connection.

Welders, welding operators and tack welders that use prequalified WPSs shall be qualified in conformance with section 4, Part C or those codes/standards listed in 1.1.1.

3.2 Welding Processes

3.2.1 Prequalified Processes

Shielded metal arc welding (SMAW), submerged arc welding (SAW), gas metal arc welding (GMAW) (except GMAW-S, short circuiting transfer and GMAW-P, pulse mode), and flux cored arc welding (FCAW) WPSs which conform to all of the provisions of section 3 shall be deemed as prequalified and are therefore approved for use without performing WPS qualification tests for the process.

3.2.2 Other Welding Processes.

Other welding processes not covered by 3.2.1 may be used, provided the WPSs are qualified by applicable tests as prescribed in section 4. In conjunction with the tests, the WPSs and limitation of essential variables applicable to the specific welding process shall be established by the contractor developing the WPS. The range of essential variables shall be based on documented evidence of experience with the process but may not exceed the limits specified in section 4. Any change in essential variables outside the range so established shall require requalification.

3.3 Base Metal/Filler Metal

Combinations

Only base metals and filler metals listed in Table 3.1 and Appendix A Table M1 (Group 1,2,3) may be used in prequalified WPSs.

Reference engineering drawings to determine the filler metal strength requirements to match or undermatch base metal strength.

3.4 Minimum Preheat and Interpass

Temperature Requirements

The preheat and interpass temperature shall be sufficient to prevent cracking. Table 3.2 shall be used to determine the minimum preheat and interpass temperatures. For all materials not listed in Table 3.2, preheat and interpass temperatures shall be established on a PQR and documented on a WPS. Preheat and interpass temperature limitations for armor steels are indicated in Appendix B.

3.4.1 Base Metal/Thickness Combination

The minimum preheat or interpass temperature applied to a joint composed of base metals with different minimum preheats from Table 3.2 (based on category and thickness) shall be the highest of these temperatures.

3.4.2 Alternate SAW Preheat and Interpass

Temperatures

Preheat and interpass temperatures for parallel or multiple electrode SAW shall be selected in conformance with Table 3.2. For single-pass groove and fillet welds or combinations of base metals, preheat/interpass temperatures may be established which are sufficient to reduce the hardness in the heat-affected zones of the base metal to less than 215 Brinell hardness number for steel having a minimum specified tensile strength not exceeding 60,000 psi, and 265 Brinell hardness number for steel having a minimum specified tensile strength greater than 60 000, but not exceeding 70,000 psi.

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Table 3.1 Prequalified Base Metal-Filler Metal Combinations for Matching Strength (see 3.3)

G Steel Specification Requirements Filler Metal Requirements r o

Min.Yield Point/

Tensile

Min. Yield Point/

Tensile Strength u Strength Range Electrode Strength Range p Steel Specification1,2 ksi ksi Specification3,6 ksi ksi

ASTM A364 36 58-80

ASTM A53 Grade B 35 60 min ASTM A106 Grade B 35 60 min SMAW ASTM A131 Grades A, B, CS, D, DS, E

34 58-71 AWS A5.1 or A5.57

ASTM A139 Grade B 35 60 min E60XX 50 62 min ASTM A381 Grade Y35 35 60 min E70XX 60 72 min ASTM A500 Grade A 33 45 min E70XX-X 57 70 min Grade B 42 58 min ASTM A501 36 58 min SAW ASTM A516 Grade 55 30 55-75 AWS A5.17 or A5.237 Grade 60 32 60-80 F6XX-EXXX 48 60-80 ASTM A524 Grade I 35 60-85 F7XX-EXXX or 58 70-95 Grade II 30 55-80 F7XX-EXX-XX

I ASTM A529 42 60-85

ASTM A570 Grade 30 30 49 min GMAW Grade 33 33 52 min AWS A5.18 Grade 36 36 53 min ER70S-X 60 72 min Grade 40 40 55 min Grade 45 45 60 min Grade 50 50 65 min ASTM A573 Grade 65 35 65-77 FCAW Grade 58 32 58-71 AWS A5.20 ASTM A709 Grade 364 36 58-80 E6XT-X 50 62 min API 5L Grade B 35 60 E7XT-X 60 60 72 min Grade X42 42 60 (Except -2, -3, -10, -GS) ABS Grades A, B, D, CS, DS

58-71 AWS A5.297

Grade E5 58-71 E7XTX-XX 58 70-90 ASTM A131 Grades

AH32,

DH32, EH32

46 68-85 SMAW

Grades

AH36,

DH36, EH36

51 71-90 AWS A5.1 or A5.57

ASTM A441 40-50 60-70 E7015, E7016 60 72 min ASTM A516 Grade 65 35 65-85 E7018, E7028 Grade 70 38 70-90 E7015-X, E7016-X 57 70 min ASTM A537 Class 1 45-50 65-90 E7018-X

II ASTM A572 Grade 42 42 60 min ASTM A572 Grade 50 50 65 min ASTM A5885 (4 in. and under) 50 70 min SAW

ASTM A595 Grade A 55 65 min AWS A5.17 or A5.237 Grades B and C 60 70 min F7XX-EXXX or F7XX-

EXX-XX

58 70-95

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Table 3.1 (continued) Prequalified Base Metal-Filler Metal Combinations for Matching Strength (see 3.3)

G Steel Specification Requirements Filler Metal Requirements r o

Min.Yield Point/

Tensile

Min. Yield Point/

Tensile Strength u Strength Range Electrode Strength Range p Steel Specification1,2 ksi ksi Specification3,6 ksi ksi ASTM A6065 45-50 65 min

ASTM A607 Grade 45 45 60 min GMAW Grade 50 50 65 min AWS A5.18 Grade 55 55 70 min ER70S-X 60 72 min ASTM A618 Grades Ib. II, III

46-50 65 min

ASTM A633 Grade A 42 63-83 Grades C, D 50 70-90 FCAW (2-1/2 in. and under)

AWS A5.20

ASTM A709 Grade 50 50 65 min E7XT-X 60 72 min II Grade 50W 50 70 min (Except -2, -3, - 10, -

GS)

ASTM A710 Grade A, Class 2 > 2 in.

55 65 min AWS A5.297

ASTM A808 (2-1/2 in. and under)

42 60 min E7XTX-X 58 70-90

API 2H6 Grade 42 42 62-80 Grade 50 50 70 min API 5L Grade X52 52 66-72 ABS Grades AH32, DH32, EH32

45.5 71-90

Grades AH36, DH36, EH36

51 71-90

SMAW AWS A5.57

E8015-X, E8016-X 67 80 min E8018-X

SAW

ASTM A572 Grade 60 60 75 min AWS A5.237

III Grade 65 65 80 min F8XX-EXX-XX 68 80-100 ASTM A537 Class 25 46-60 80-100 GMAW ASTM A633 Grade E5 55-60 75-100 AWS A5.287 ASTM A710 Grade A, Class

2 d 2 in.

60-65 72 min ER80S-X 68 80 min

ASTM A710 Grade A, Class 3 > 2 in.

60-65 70 min FCAW AWS A5.297

E8XTX-X

68 80-100

Notes:

1. In joints involving base metals of different groups, either of the following filler metals may be used: (1) that which match the higher strength base metal, or

(2) that which matches the lower strength base metal and produces a low-hydrogen deposit. Preheating shall be in conformance with the requirements applicable to the higher strength group.

2. Match API standard 2B (fabricated tubes) according to steel used

3. When welds are to be stress-relieved, the deposited weld metal shall not exceed 0.05 percent vanadium.

4. Only low-hydrogen electrodes shall be used when welding A36 or A709 Grade 36 steel more than 1 in. thick

5. Special welding materials and WPS e.g., E80XX-X low-alloy electrodes) may be required to match the notch toughness of base metal (for applications involving impact loading or low temperature), or for atmospheric corrosion and weathering characteristics.

6. The designation of ER70S-1B has been reclassified as ER80S-D2 in A5.28-79. Prequalified WPSs prepared prior to 1981 and specifying AWS A5. 18, ER70S-1B, may now use AWS A5.28-79 ER80S-D2 when welding steels in Groups I and II.

7. Filler metals of alloy group B3, B3L, B4, B4L, B5, B5L, B6, B6L, B7, B7L, B8, B8L, or B9 in ANSI/AWS A5.5, A5.23, A5.28, or A5.29 are not prequalified for use in the as-welded condition

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Note: The Brinell hardness number shall be determined in conformance with ASTM E10. If another method of hardness is to be used, the equivalent hardness number shall be determined from ASTM E140, and testing shall be performed according to the applicable ASTM specification.

3.4.2.1 Hardness Requirements

Hardness determination of the heat-affected zone will be made on the following:

x� Initial macroetch cross sections of a sample test specimen.

x� The surface of the member during the progress of the work. The surface shall be ground prior to hardness testing:

(a) The frequency of such heat-affected zone testing shall be at least one test area per weldment of the thicker metal involved in a joint of each 50 ft. of groove welds or pair of fillet welds.

(b) These hardness determinations may be discontinued after the procedure has been established to the satisfaction of the contractor.

3.5 Limitation of WPS Variables

All prequalified WPSs to be used shall be prepared by the manufacturer, fabricator, or contractor as written prequalified WPSs, and shall be available to those authorized to use or examine them. The written WPS may follow any convenient format (see Appendix C for examples). The welding parameters set forth in this subsection shall be specified on the written WPSs within the limitation of variables prescribed in 4.14 for each applicable process.

Changes beyond those specified on the written WPS considered essential variables, shall require a new or revised prequalified written WPS.

3.5.1 Combination of WPSs

A combination of qualified and prequalified WPSs may be used without qualification of the combination, provided the limitation of essential variables applicable to each WPS is observed.

3.6 General WPS Requirements

All the requirements of Table 3.3 shall be met for prequalified WPSs.

3.6.1 Vertical-Up Welding Requirements

The progression for all passes in vertical position welding shall be upward, except that undercut may be repaired vertically downwards when preheat is in accordance with Table 3.2, but not lower than 70°F.

However, when tubular products are welded, the progression of vertical welding may be upwards or downwards, but only in the direction(s) for which the welder is qualified.

3.6.2 Width/Depth Pass Limitation

Neither the depth nor the maximum width in the cross section of weld metal deposited in each weld pass shall exceed the width at the surface of the weld pass (see Figure 3.1).

3.7 Common Requirements of Partial

and Complete Joint Penetration Groove and Fillet Welds

3.7.1 FCAW/GMAW in SMAW Joints

Groove preparations detailed for prequalified SMAW joints may be used for prequalified GMAW or

FCAW.

3.7.2 Corner Joint Preparation

For corner joints, the outside groove preparation may be in either or both members, provided the basic groove configuration is not changed and adequate edge distance is maintained to support the welding operations without excessive melting.

3.7.3 Root Openings

Joint root openings without backing may vary as noted in Appendix E, however, for automatic or machine welding using FCAW, GMAW, and SAW processes, the maximum root opening variation (minimum to maximum opening as fit-up) may not exceed 1/4 in. Variations greater than 1/4 in. shall be locally corrected prior to automatic or machine welding.

3.7.4 Skewed T Joints

For skewed T joints, the dihedral angle must be 60° or greater. For joints with dihedral angles less than 60°, qualification is required per Section 4.

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Table 3.2 Prequalified Minimum Preheat and Interpass Temperature3 (See 3.4)

C at eg or y

Steel Specification Welding Process

Thickness of Thickest Part at Point of Welding, in

Minimum Preheat and

Interpass Temperature, °F ASTM A36 ASTM A516 1/8 to 3/4 incl. None1 ASTM A53 Grade B ASTM A524 Grades I & II ASTM A106 Grade B ASTM A529 Over 3/4 ASTM A131 Grades A, B, CS, D, DS, E

ASTM A570

ASTM A573

All grades Grade 65 thru 1-1/2 incl. 150

ASTM A139 Grade B ASTM A709 Grade 36 Over 1-1/2 thru

ASTM A381 Grade Y35 API 5L Grade B 2-1/2 incl. 225 ASTM A500 Grade A

Grade B

ABS

Grade X42 Grades A, B, D, CS, DS

A

ASTM A501 Grade E

Shielded metal arc welding with other than low-hydrogen electrodes

Over 2-1/2 300 ASTM A36 ASTM A570 All grades ASTM A53 Grade B ASTM A572 Grades 42, 50 ASTM A106 Grade B ASTM A573 Grade 65 ASTM A 131 Grades A, B, ASTM A588 CS, D, DS, E ASTM A595 Grades A, B, C 1/8 to 3/4 incl. None1

AH 32 & 36 ASTM A606

DH 32 & 36 ASTM A607 Grades 45, 50, EH 32 & 36 ASTM A618 Grades Ib, II,III ASTM A139 Grade B ASTM A633 Grades A, B

Grades C, D

Over 3/4

ASTM A381 Grade Y35 ASTM A709 Grades 36, 50, 50W thru 1-1/2 incl 50

ASTM A808

ASTM A441 API 5L Grade B ASTM A500 Grade A Grade X42 Grade B API Spec. 2H Grades 42, 50 Over 1-1/2 ASTM A501 ABS Grades AH 32

& 36 thru 2-1/2 incl. 150

ASTM A516 Grades 55 & 60 DH 32 & 36

65 & 70 EH 32 & 36

ASTM A524 Grades I & II ABS Grades A. B, D, ASTM A529 CS, DS Over 2-1/2 225

B

ASTM A537 Classes 1 & 2 Grade E

Shielded metal arc welding with low-hydrogen electrodes, submerged arc welding2, gas metal arc welding, flux cored arc welding

1/8 to 3/4 incl. 50

ASTM A572 Grades 60 & 65 Over 3/4 ASTM A633 Grade E thru 1-1/2 incl. 150 API 5L Grade X52

Over 1-1/2 thru 2-1/2 incl

C

Shielded metal arc welding with low-hydrogen electrodes, submerged arc welding2, gas metal arc welding, flux cored arc welding

Over 2-1/2 300

Notes:

I . When the base metal temperature is below 32°F, the base metal shall be preheated to at least 70°F and this minimum temperature maintained during welding.

2. For modification of preheat requirements for submerged arc welding with parallel or multiple electrodes, see 3.4.2.

3. See 5.8.2 and 5.5 for ambient and base-metal temperature requirements.

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Table 3.3 Prequalified WPS Requirements5 (See 3.6)

SAW3 Variable Position Weld Type SMAW Single Parallel Multiple

GMAW/

FCAW6

Fillet (Note 1) 5/16 in.

Groove (Note 1) 1/4 in Flat Root Pass 3/16 in.

1/4 in. 1/8 in.

Fillet 1/4 in. 1/4 in. Horizontal Groove 3/16 in. Requires WPS Qualification Test 1/8 in.

Vertical All 3/16 in. (Note 2) 3/32 in

Maximum Electrode Diameter

Overhead All 3/16 in. (Note 2)

5/64 in.

All Fillet 1000 A 1200 A

Groove weld root pass with opening

700 A

Groove weld root pass without opening

900 A

Groove weld fill passes

600 A

1200 A

Unlimited Maximum Current All

Groove weld cap pass

Within the range of recommended operation by the filler metal manufacturer

Unlimited

Within the range of recommended operation by the filler metal manufacturer

Flat 3/8 in. 3/8 in.

Horizontal 5/16 in. Unlimited 5/16 in.

Vertical 1/2 in. 1/2 in.

Maximum Root Pass Thickness (Note 3) Overhead

All

5/16 in.

Maximum Fill Pass Thickness

All All 3/16 in. 1/4 in. Unlimited 1/4 in.

Flat 3/8 in. Unlimited 1/2 in.

Horizontal 5/16 in. 5/16 in. 5/16 in. 1/2 in. 3/8 in.

Vertical 1/2 in. 1/2 in.

Maximum Single Pass Fillet Weld Size

Overhead

Fillet

Maximum Single Pass Layer Width

All (for

GMAW/

FCAW/

SMAW)

F & H (for SAW)

All Note 4 Split layers if w>5/8 in.

Split layers with tandem electrodes if w > 5/8 in.

If w >1in., split layers

Note 4

Notes:

(1) Except root passes

(2) 5/32 in. for EXX14 and low-hydrogen electrodes.

(3) See 3.6.2 for width-to-depth limitations.

(4) In the F, H, or OH positions for nontubulars, split layers when the layer width w > 5/8 in. In the vertical position for nontubulars or the 5G or 6G for tubulars, split layers when the width w > 1 in.

(5) Shaded areas indicate nonapplicability.

(6) GMAW-S in not prequalified

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Figure 3.1 Weld Bead in which Depth and Width Exceed the Width of the Weld

Face (see 3.6.2)

3.8 Partial Joint Penetration

Requirements

Partial joint penetration groove welds which may be used without performing the WPS qualification tests prescribed in section 4 are subject to all joint detail limitations specified in Appendix E (Figure E.1, Sheets 1-7).

3.8.1 Definition.

Except as provided in 3.9.2 and Appendix E (Figure E.2, Sheet 1, B-L1-S), groove welds without backing, welded from one side or groove welds welded from both sides, but without backgouging, are considered partial joint penetration groove welds.

3.8.2 Details (Tubular)

Details for partial joint penetration tubular groove welds that are accorded prequalified status shall conform to the following provisions:

x� (1) PJP tubular groove welds, other than T-, Y-, and K-connections, may be used without performing the WPS qualification tests, when these can be applied and meet all of the joint dimension limitations as specified in Appendix E (Figure E.1, Sheets 1-7).

x� (2) PJP T-, Y-, and K-tubular connections, welded by any process must be qualified in accordance with section 4.

3.9 Complete Joint Penetration Groove

Weld Requirements

Complete joint penetration groove welds which may be used without performing the WPS qualification test prescribed in section 4 are subject to all joint detail limitations specified in Appendix E (Figure E.2, Sheets 1-11).

3.9.1 J- and U-Groove Preparation

J- and U-grooves and the other side of partially welded double-V and double-bevel grooves may be prepared before or after assembly. After backgouging, the other side of partially welded double-V or double-bevel joints should resemble a prequalified U- or J-joint configuration at the joint root.

3.9.2 Tubular Butt Joints

For tubular groove welds to be given prequalified status, the following conditions shall apply:

x� Prequalified WPSs. Where welding from both sides or welding from one side with backing is possible, any WPS and groove detail that is appropriately prequalified in conformance with section 3 may be used, except that SAW is only prequalified for diameters greater than or equal to 24 in. Welded joint details shall be in conformance with section 3.

x� Nonprequalified Joint Detail. There are no prequalified joint details for complete joint penetration groove welds in butt joints made from one side without backing. See 4.12.2.

3.9.3 Tubular T-, Y-, and K-Connections

CJP T-, Y-, and K-tubular connections, welded by any process must be qualified in accordance with section 4.

WIDTH OF FACE

WIDTH OF FACE

DEPTH

DEPTH

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4 Qualification

4.0 Scope

The requirements for qualification testing of welding procedure specifications (WPSs) and welding personnel are described as follows:

Part A — General Requirements. This part covers both welding procedure and performance general requirements.

Part B — Procedure Qualification. This part covers the specific requirements for qualification of non-armor Welding Procedure Specifications (WPSs) through the development of Procedure Qualification Records (PQR). The requirements for qualification of armor WPSs are specified in Appendix B.

Part C — Performance Qualification. This part covers the specific testing requirements for non-armor performance qualification required by the code to determine a welder's, welding operator's or tack welder's ability to produce sound welds.

Armor performance qualification requirements are specified in Appendix B.

Part A General Requirements

4.1 General

The qualification requirements of this code are to assure that the procedures used in production meet a recognized standard. To accomplish this objective, each contractor or manufacturer shall do the following:

(1) Prepare a written preliminary WPS in accordance with Part B.

(2) Qualify the welding parameters described by the preliminary WPS in accordance with Part B of this section using materials, equipment, cleaning and preparation methods, welding conditions, etc.

that are developed. The actual test parameters used must be documented in the PQR.

(3) Qualify the welders, welding operators, and tack welders in accordance with Part C of this section prior to performing any production work.

(4) Maintain records of each of the above items on forms such as or similar to those shown in Appendix C.

(5) Impart knowledge of the procedures to be used to the welders, welding operators, and tack welders

4.1.1 Procedure Qualification Record (PQR)

Except for prequalified and ballistic WPSs, all procedures shall be qualified through a documented PQR in accordance with Part B. All ballistic procedures must be qualified per Appendix B shall be submitted for approval by the procuring activity.

4.1.1.1 Impact Test Requirements

When required by contract drawings or specifications, impact tests shall be included in the PQR. The impact tests, requirements, and procedures shall be in conformance with the provisions of this code, or as specified in the contract documents.

4.1.2 Welding Procedure Specification (WPS)

All WPSs qualified under the provisions of this section shall be documented using the form found in Appendix C or alternate form based on the codes/standards referenced in 1.1.1 provided the same variables are addressed.

4.1.3 Qualification of Welding Procedures

4.1.3.1 Only procedures qualified in

accordance with Part B of this section shall be recognized as approved procedures.

4.1.3.2 Procedures qualified to specifications

other than this code shall be documented by sufficient test data to satisfy the requirements of Part B of this section. These procedures must be reviewed and approved by the contractor.

4.1.3.3 The procuring activity should accept

properly documented evidence of previous qualification of the joint welding procedures to be employed, unless a new procedure…