SUBJECT TO TECHNOLOGY LEVEL “TL1Y” SECURITY AS DESCRIBED IN ENGINEERING STANDARD C1.9. DO NOT REPLICATE OR FORWARD THIS DOCUMENT UNTIL ENGINEERING STANDARD C1.9 HAS BEEN REVIEWED AND APPROVALS HAVE BEEN GRANTED.
THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.
DATE CHG NO NUMBER
AUDIT OF EXTERNAL WELD
05 APR 2010
14
MC1000-901
1.0 SCOPE
This audit has been designed to reflect the quality of welded asmblies with respect to external weld characteristics.
2.0 APPLICATION
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2.1 This practice ts quality levels for external weld characteristics and explains the procedure to be ud in auditing welds on finished asmblies or units.
2.2 The audit is to be conducted by qualified personnel who are not directly responsible for weld conformance of parts.
2.3 The audits are to be conducted on a monthly basis for parts produced within a plant or facility.
2.4 The audit parts will be randomly lected from parts that have been subjected to normal inspection methods. Random lection can be made by the traditional chip method, computer program, or any suitable method developed by the plant, as long as the lection is unbiad. (Every welded asmbly at a plant should have an equal chance of being lected for this audit.) A minimum number of millimeters (mm) are required for reporting the monthly plant conformance. The number of mm is determined by a plants’ electrode usage per year. Listed below is the method ud to determine the number of mm to audit:
Annual Electrode Usage
Minimum Weld
Audited/Month
单词记忆网Under 100,000 kg (220,000 lb.) 15,000 mm
100,000 – 225,000 kg (220,000 - 500,000 lb.) 40,000 mm 225,000 – 680,000 kg (500,000 - 1,500,000 lb.) 100,000 mm
680,000 kg (1,500,000 lb.) & Over 200,000 mm
Figure 1 - Audit Length
2.5 On parts chon for the audit, the lection of the weld or welds to be audited on that part number may be a random and unbiad sample or a complete piece part audit. The total length of weld audited each month should be taken from a reprentative mix of the products produced at the facility.
SUBJECT TO TECHNOLOGY LEVEL “TL1Y” SECURITY AS DESCRIBED IN ENGINEERING STANDARD C1.9. DO NOT REPLICATE OR FORWARD THIS DOCUMENT UNTIL ENGINEERING STANDARD C1.9 HAS BEEN REVIEWED AND APPROVALS HAVE BEEN GRANTED.
mardi grasTHE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.
DATE CHG NO NUMBER
AUDIT OF EXTERNAL WELD
05 APR 2010
14
MC1000-901
3.0 WELD CHARACTERISTICS
3.1 External weld characteristics are evaluated as follows:
Cracks
Porosity (Singular, Cluster, and Elongated) Inclusions Convexityborg
Concavity/Underfill Excess Penetration Lack of Penetration Fillet Weld Size Lack of Fusion Undercut Toe Radius Overlap
Poor Restarts/Tie-Ins
Non-Uniformity/Roughness
Cleaning, Grinding and Chipping
4.0 DEFECT DESCRIPTIONS
4.1 Cracks - Cracks in ba metal or weld metal are not permitted, with the exception of transver cracks on hard surfacing welds only.
4.2 Porosity - Clustered porosity is permitted with a maximum length of cluster in any weld equal to
3 mm. Maximum size of any single pore is 1 mm in diameter with no more than six (6) holes in any 300 mm of weld, or a maximum of one (1) pore in any 50 mm of weld in welds less than 300 mm in length. Elongated cavities can have a maximum height or width of 3mm and a maximum length of affected area equal to 10% of the weld length, not to exceed 25 mm in length.
4.3 Inclusions - Slag, Flux or Oxide Inclusions can have a maximum height or width of 1 mm and a maximum length in any weld equal to 10% of the weld length, not to exceed 25 mm. Puckering (Oxide Inclusion- Aluminum) and Metallic Inclusions are not permitted.
SUBJECT TO TECHNOLOGY LEVEL “TL1Y” SECURITY AS DESCRIBED IN ENGINEERING STANDARD C1.9. DO NOT REPLICATE OR FORWARD THIS DOCUMENT UNTIL ENGINEERING STANDARD C1.9 HAS BEEN REVIEWED AND APPROVALS HAVE BEEN GRANTED.
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THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.
DATE CHG NO NUMBER
AUDIT OF EXTERNAL WELD
05 APR 2010
14
MC1000-901
4.4 Groove Weld Convexity - It is intended that groove weld be flush or level. For audit purpos the following tolerances will be allowed:
Weld Face Width
Maximum Convexity 5 mm or Less 1.0 mm 5 mm < Width <10 mm 1.5 mm 10 mm =< Width =< 20 mm 2.0 mm 20 mm < Width < 30 mm
3.0 mm
30 mm and Over 4.0 mm
comexFigure 2 - Groove Weld Size
Figure 3 - Groove Weld Size
Note: Any groove weld outside the tolerance for convexity will be rated unsatisfactory for size.
4.5 Underfill and Concavity - Incompletely filled groove welds are not permitted. Careful consideration needs to be given when plate mismatch is apparent. The weld depth must be maintained as a minimum. Root concavity on open root groove welds shall have a maximum depth of 0.5 mm for any length of weld, measured from the plate or tube root surface.
Figure 4 - Underfill and Concavity
4.6 Excess Penetration - Excess penetration may be visible in the ca of an open root weld that has some form of inspection access to the root. The maximum allowable weld metal protrusion beyond the back plate surface is 2 mm for any length of weld, in welds without drawing limitations. The maximum allowable weld metal protrusion beyond the back plate surface is 1 mm for any length of weld, in welds with “melt-thru” and “flush” weld symbols. No excess penetration is allowed in welds with “melt-thru” and “grind flush” weld symbols. If the penetration is not accessible to the auditor, this characteristic will not be considered.
SUBJECT TO TECHNOLOGY LEVEL “TL1Y” SECURITY AS DESCRIBED IN ENGINEERING STANDARD C1.9. DO NOT REPLICATE OR FORWARD THIS DOCUMENT UNTIL ENGINEERING STANDARD C1.9 HAS BEEN REVIEWED AND APPROVALS HAVE BEEN GRANTED.
THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.
DATE CHG NO NUMBER
AUDIT OF EXTERNAL WELD
05 APR 2010
14
MC1000-901
4.7 Lack of Penetration - The maximum reduced penetration is equal to 10% of nominal penetration, not to exceed 1 mm. The maximum allowed total length of reduced penetration is equal to 10% of the weld length. If the penetration is not accessible to the auditor, this characteristic will not be considered.
4.8 Fillet Weld Size - A weld will be classified as undersize on either leg or the throat. Both legs of fillet welds are to meet the minimum blueprint size. Maximum undersize allowed on
either leg is 1 mm, with a maximum length of undersized leg equal to 10% the total length of any weld if at least 10% of the total length is at least 1 mm over nominal size, otherwi, no undersize length is permitted.
4.8.1 The minimum throat size is to be 0.7 times the specified leg length, not including any penetration beyond the weld root. The weld throat may be reduced at the weld crater only. The maximum allowed undersize is 2 mm, and not to exceed 20% of the specified throat, not including any penetration beyond the weld root.
Figure 5 - Fillet Weld Size
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4.9 Lack of Fusion - Visual Lack of Fusion (breaking the surface) is not permitted. The high speed welding process can leave a thin non-uniform feather-edge of weld metal at the toe of the weld that is not fud to the ba metal. This defect is not always easy to e in the as-welded condition, but becomes plainly visible after painting, when capillary action draws the paint under the thin edge and leaves a crack-like line on the painted surface. This lack of fusion or failure to wet the ba metal is unacceptable.
weed4.10 Omitted Welds - Although omitted welds are not addresd specifically in 1E0099 as being a type of defect, omitted welds will affect the structural integrity of the weldment. Omitted welds shall be recorded as “Lack of Fusion” for the entire length of omission.
SUBJECT TO TECHNOLOGY LEVEL “TL1Y” SECURITY AS DESCRIBED IN ENGINEERING STANDARD C1.9. DO NOT REPLICATE OR FORWARD THIS DOCUMENT UNTIL ENGINEERING STANDARD C1.9 HAS BEEN REVIEWED AND APPROVALS HAVE BEEN GRANTED.
THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.
DATE CHG NO
香港大学世界排名NUMBER
AUDIT OF EXTERNAL WELD
05 APR 2010
14
MC1000-901
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4.11 Undercut - It is intended that the toe of the weld blend smoothly and gradually into the ba metal. When the undercut is more than 0.5 mm deep, measured from the plate surface, the weld shall be considered defective.
Figure 6 - Undercut
4.12 Toe Radius - When 1E2995 Applies, the interction at the toe is expresd as a toe radius rather than a toe angle. The minimum toe radius is 3 mm.
4.13 Overlap - Overlap is a profile defect in which there is a protrusion of weld material beyond the toe of the weld (e Figure 1 5). Overlap can occur at the toe of a fillet or groove weld. A weld will be judged to have excessive overlap when the angle at the toe of the weld between the weld metal and the plate is less than 90°. Weld toe angles below 90° will reduce fatigue life. A weld toe angle of 135° or more is desired.
Figure 7 - Overlap
