Specification Weld requirements for fillet joint by fusion welding process. - Weld requirements

Transcription

1 Class: Test Instruction and conditions of delivery Specification Weld requirements for fillet joint by fusion welding process Class No.:61 JED 879 Previous Edition Part name (for databases) - Weld requirements Scope Te specification refers to te requirements of fillet joint by fusion welding process (for examble fork and piston welding in actuator products) 2 General requirements Blowoles, lack of root penetration, lack of fusion, undercut and oter welding defects on te welded region will reduce te component s weld joint strengt. Terefore, in order to obtain sound welded joints wic are free from weld defects, te supplier and te WABCO Product Engineering Team sall effect an intensive intercange of know-ow at an early stage of development prior to making canges of welding power source, gas mixture or filler wire etc. 3 Assessment Te assessment of permissible welding defects as to be made wit or witout optical enlarging means suc as magnifying glasses, microscopes etc. Examination of a test specimen by te naked eye, or under low magnification (upto 10X) wit etcing using preferably 3% Nital. Te test specimen sall be prepared and etced in accordance wit EN 1321 on one side to clearly reveal te fusion line, te Heat Affected Zone (HAZ) and te buildup of te runs. Te macroscopic/ microscopic examination sall include unaffected parent metal. 4 Definitions and representation in drawings Fillet welding illustration a Troat tickness as specified in te drawing PM rod Toe Face PMrod Parent material pus rod PMfork Parent material - fork PMfork Root a Compiler Approved Product Group: 4961 Continuation page 2 to 7 V.P.Balaji JED.dot Template version 03 Hans Voß Doc. Code Language Rev en - -

2 JED-879 : Page 2 Drawing representation fillet weld symbol as per ISO a Weld arrow line indicates te weld location on arrow side 2 Represents all around weld 3 Specifies te troat tickness a 4 Welding symbol represents fillet weld 5 Concave welding sape Permissible weld defects Te limits for permissible weld defects on components are defined in te following defects catalogue. Weld defects Acceptance Criteria No cracks of any type 1. Crater crack - Crack in te crater at te end of a weld wic can be Longitudinal Traverse Radiating All type of cracks - Star cracks/crater cracks No cracks of any type 2. Toe crack Crack at te weld toe as depicted as A 3. Root crack Crack at te root of te weld as depicted as B 4. Heel crack Crack at te base metal starts from root as depicted as C

3 JED-879 : Page 3 t 5. Lack of side wall fusion - lack of union/joint between te weld metal and te parent material >= 1/10 t Maximum = 3/10 t in plate/fork side 6. Lack of root penetration - one or bot fusion faces of te root are not melted wen t < 3 mm < 0.05 t is allowed wen t > 3 mm I 7. Undercut - one or bot fusion faces of te root are not melted No surface porosity Internal porosity Single pore is allowed upto d 0.2 a 8. Porosity Pores caused by entrapped gas uniformly distributed porosity Maximum area of porosity is allowed upto 1% of te projected area

4 JED-879 : Page 4 a drawing specification Te troat tickness can be measured on wole lengt of seam except overlap area. a 10. Insufficient troat tickness - Actual troat tickness of te fillet weld is too small. = 0.2 mm a wen t < 3 mm = 0.5 mm a, but maximum 2 mm (wicever is lesser)wen t > 3 mm 11. Incorrect root gap - Excessive gap between te parts to be joined 12. Spatter - Globules of weld metal or filler metal expelled during welding and adering to te surface of parent material or solidified weld metal 13. Arc Strike - Local damage to te surface of te parent material adjacent to te weld, resulting from arcing or striking te arc outside te joint preparation 14. Slag - Aderent slag tat is not sufficiently removed from te surface of te weld 15. Burn troug - Collapse of te weld pool resulting in a ole in te weld 16. Incomplete welding Weld is intermittent or missing in all around weld 17. Poor restart - Local surface irregularity at a weld restart 18. Insufficient weld strengt Tensile strengt of te weld is lower tan te tensile strengt of parent material (lowest among two parent materials to be joined) Tis is applicable for all around weld Weld strengt parent material strengt (lowest among two parent materials) Weld strengt = Load Troat area Troat area = 2 π a (r + a / 2) Were a troat tickness r radius of te rod Few examples of actual weld defects are illustrated in annexure A

5 JED-879 : Page 5 6 Guarantee 6.1 General Te manufacturer is obliged to prove by regular random test tat te requirements are observed, and to keep te documents referring to tis inspection accessible to te customer. Te current supplies must correspond to te released sample, te requirements of te present specification, and to te drawings. 6.2 Initial sample On eac first delivery agreed amount of initial samples and te initial sample inspection report are to be submitted for dimensional inspection and material test. 6.3 Canges Te cange of te basic materials, substantial caracteristics of tem (raw materials) or of te manufacturing process - regardless of te kind of cange and its reason - is only permissible after previous release by te tecnical responsible departments. Te rules of WABCO cange management ave to be followed. 7. Document Versions Revision Date Canges Initial Version 8. Reference 7.1 ISO Welding and allied processes Classification of geometric imperfections in metallic materials Part 1: Fusion welding 7. 2 ISO Welding Fusion-welded joints in steel, nickel, titanium and teir alloys (beam welding excluded) Quality levels for imperfections 7.3 ISO Specification and qualification of welding procedures for metallic materials welding procedure test - Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys

6 JED-879 : Page 6 Annexure A Defects catalogue Examples Description Lack of root penetration not permitted Weld defect image Lack of fusion not permitted Porosity, lack of fusion and lack of root penetration not permitted

7 JED-879 : Page 7 Incomplete welding not permitted Undercut not permitted Size is more tan acceptance limit