—

MIW*45205B(MR)
6 April 1982
SUPERSEDIW
MIL-+45205A(MR)
28 October 1966

MILITARY SPECIFICATION

WELDING, GAS METAL-ARC AND GAS TUNGSTEN-ARC, ALUMINUM

ALLOYS , READILY (4ELDAELZFOftSTRUCTURES, EXCKIDING ARH3R

This specification is approved for use by Army Materials & Mechanics

Research Center, Department of the Army, and is available for use by
all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Sccoe. This specification covers the welding of aluminum alloys for
Structural applications other than armor by the gas metal-arc or gas
tungsten-arc welding process.

1.2 Classification. WeLding performed under this specification shall be

classified in accordawe with the nature of the service requirements of the
weldment as folkws:

Class A - Weldments wlmse faiiure could result in injury to personnel

OK in an assigned missiOn not ‘beingfuifiiieti(see 6.2j.
\
Class B - *ldments wmse failure would not result in injury to .
personnel or in unfulfill.kentof anassiqned mission
(see 6.2).

2. APPLICABLE DOCUrmTS

2.1 Government documents.

2.1.1 Specifications and standards. Unless otherwise specified (see 6.2),

the following specifications and standards of the issue listed in that issue
of the Department of Defense Index of Specifications and Standards (Dc015S)
specified in the solicitation, form a part of this specification to the extent
specified -rein.

7
&leneficialcomments (recommendations, additions, deletions) and any pertinent
data which may be of use in improving this document stwuld be addressed to:
irector, US Army Materials and Mechanics Research Center, AlTN: DlW04R-SSS,
tertown, MA 02172 by using the self-addressed Standardization Document
mprovement Proposal (DD Form 1426) appearimg at the end of this document or
letter. I

@4SC A3185{
MIi#+45205B

SPXIFICATIONS

~L

-R-566 - Rods, and E&?ctrodes; Welding, Aluminum and Aluminum

Alloys

IULITARY

Dd)-D-10130- Drawirqs Engineering and Associated Lists

MIL-E-16053 - EIKtrodes, Melding, Bare Aluminum ALLoys
.
STANDhRDa

FEDERAL

FED-STD- 100 “ Engineering Drawing Practices

FED. Test Metlmd STD. No. L5L - Metals: Test Methods

MIKTARY

MIL-BTD-22 - Welded Joint Designs

MIL-STD-453 - Inspection, Radiographic

(Copies of specifications aml standards required by manufacturers in

connection with specific acquisition functions should be obtained from the
contracting activity or as directed by the contracting officer.)

2.2 Other Publications. The followiq documents form a part of this ....,.-:
specification to the extent specified herein. Unless otkrwise indicated, the
issue in effect on date of invitation for bids or raquest for prcOo~al sha~l
apply.

AMERICAN @ELDING SOCIETY

ANSI/AWS A2.4 - Symbols for Weidi@ and Nondestrutiue Testing, including

Brazing
AN5X/A@S A3.O - Weldirv3Terms and Definitions

(Application for copies snould be addressed to American Welding Society,

2501 Northwest 7triStreet, Miami, Florida 33L25.)

(Technical society and technical associations specifications and standards

are generally avaiLable for reference from libraries. They are also dis-
tributed amo~ technical groups and using Federal agencies.)

2.3 Order of precedeme. In the event of a conflict between the text of

this ~ecification and the refere=es cited herein, the text of this specifi-
cation aha 11 take precerleme.

2
 MIL-+4S205B

3. REQUIREM%?TS

3.1 Materials.

3.1.1 Base materials. The base materials considered by this specification

shall be aluminum alloys which are weldable by the processes stipulated in 1.1.

3. L 2 Filler meta L Unless otherwise specified (see 6.2) , the ahminm

weldi~ rods shaLl conform to QQ-R-566; bare elwtrcxies shall conform to
MIL-E-16053. When the fil~er metal is not specified and a suitable type is
not available in the applicable specification, a commercial type sha L1 be
selected Whkh is capable of depositing a weld which will either meet or ex-
ceed the minimum mechanical requirements of the base material as specified on
the drawi~s, contract or order.

.3.1.3 Shielding qas. The shielding gas used shall be of uniform com-
position and quality. Impurities, particularly moisture as shown by dew point
determination, s~ll be within IMX imum guaranteed by the contractor. The
shieldi~ gas used shall be suitable for the welding of aluminum.

3.1.4 Joint design. Joint design shall be in accordance with MIL-STD-22.

3.2 PreProduction requirements.

3.2.1 Preparation of weLdin9 procedures and drawings. Unless otherwise

~cified (see 6.2) prior to the production fabrication of any wel.dment,the
contractor or manufacturer shall prepare in accordance with DoD-STD-LUO and
..:
A-k)
DoO-o-10uu an isometric, perspective, or Ott&r su&b. 0.6 ~,*
auAe ti:zk”;.~
.-
atructure showirq the location of each joint a!xlstall establish a recorded
I
joint welding procedure(s) to cover all welding (imluding a genera-loutline
for the repair of base metal and repair of we~ded joints) to be Performed
under this specification (see 6.2.2).

3.2.1.1 Submittal of procedures and drawinqs for certification. For class

A wehiments, the recordd joint welding procedure and drawincs shall be sub-
mitted In triplicate to the contracting officer wto wi11 forward two copies to
the procuring activity for certification. For Class B welfiments,the recorded
joint weiding procedure shall be retained by the contractor or mnutacturer
and made available to the Government upon request. Prior to repair of base
metal and repair of welded Joints for koth Class A and B weldrnents,the
recorded Joint weldinq procedure, drawinqs, and a general out Line for the
repair of base metal and repair of welded ]oints sm~l Ix?sutxnittedin
triplicate to the contracti~ officer who wi lL forward two copies to the
procuring activity for certification.

3.2.1.2 Factors. Factors to be included in the recorded joint welding pro-

cedure are listed in table I alo~ with the requirements for recertification.

3.2.1.3 Recertification of welding procedure. When changes are made in any

o!!the factors as indicated in table 1, the recorded joint we~dim Procedure
shall be revised, and, if class A, smll be resukinittedthrough the con-
tracting officer for review. Class B weldments need only be recertIKied when
the joint geometry is changed.
L.

3
MxL+-45205B

TASLE 1. Factors r~uired in t~ joint welding procedure and th changes

in the factors wherein the welding procedure must be rwertif ied.

Tfm Joint welding procedure

recorded
for weldments shall be re-
class A
Factors required certified wtmn:

1. Alloy of base material A charge in all~ outside the

aluminum producer’s declared chemical
range is made, unless a specific waiver
is granted by tfw contracting officer.

2. Thickness of t~ base material T* basis thickness plus tilerame is

changed.

3. ALLoY of filhr metal A change in the alloy of the filler

metal is made or when a change in brati
of tm same cqsition of filler metal
is nmie except when the new brand is
qualified under MIL-E-16053.

4. Filler metal sizes for The fiLler metal diameter is chnged.

all passes.

5. Position of welding Change in welding position.

6. Weldi@ process [see 1.1) There is a change frcm!or!?pr@2@sn or

and operation (mnualv semi- operation to anottir. .“,,
automatic and autoOatic)

7. Shiel.dirqgas ~sition A change is made in the composition of

the gas invoLting one or more oi the
folbwing:

(L) A clwmge from one inert-gas to

another.
(2) Nben using mixed inert-gas
shieldinq, a change in excess of
PLUS or minus 30 percent of the
minor qas constituent.
(3) @lhen acLive qases or other addi-
tives are combined with the
inert-gas.

8. ShieMirq gas flow A change of plus or minus 25 percent is

msde in the rate of gas f~ow for ●ach noz-
zle size shown in each welding procedure.

9. Joint design Ths originally established geometry or

basic dimensions plus tolera=es are
charqed.

4
 t41&+45205B

n TASLE I. Factors reauired in the noint welding Procedure and the charmes in
the factors wherein the weLdin9 procedure must bs recertified.
—. (cent’d)

The recorded joint weldiw procedure

for class A welcbnentsshall be re-
Factors rquired certified when:

10. Number and sequence of passes N~&r, squeme, or both are charqed.

L1. Mlding current ati arc- Outside the limits established In r-

voltage rarqe for all passes corded joint weiding Procedure.

12. Type of current, A.C. or D.C. A ctnnge in type of current, and in tfw
and polarity if D.C is used. case of D.C., the type polarity.

13. Method of joint edqe A change is made from mechanical to

preparation thermal, a combination of mec~nica~
and thermal to mechanical or thermal:
or vice versa.

14. Method of preparing root joint Method of preparation is thawed.

before welding second side.

15. Backing or spacer strip if Backing or spacer strip is added or

used. removed; or basic type of material of
:. -
back~~ or spacer strip is clmged.

16. Starting, preheat and inter- Ra~e is cha~ed.

psss temperature ranges.

17 ● Method of preweld and inter- Metlmd of cleaning is changed.

pass c leaniw

18. Postheatlnq Any change from the ~pro~~d ~at

treatment is made.

19. Type and diameter of Any cMnge in type and diameter OK

tungsten electrode tungsten e~ectrode.

L
MIL-W-45205B

3.2. L.4 Procedure fol repair welding.. The welding procedure for the repair
of welded joints (see 3.2. 1) shall i= Lude tk applicable factors listed under n
table I arrlin addition aha U im Lude the following:

(a)Method to be used in (chipping or other) for removi~ defects.

(b) of inspection used co insure removal of defects.
Met~d
(c) con~ur of cavitY Prior to welding, such as minimum rmt
dimensions and included angle.

3.2. 1.5 *rkmanlike specimens. When required (see 6.2) prior to the
production fabrication of any weLded Joints, the contractor she11 prepare
worluaanlikespecimens of all welded Joints representing tte acceptable weld
quality to be used in production. These specimens shell also represent the
minimum acceptable cleaning procedure. These specimens shall be prepared
usirq the welding procedures to be used in production and may be either an
actual part or sample Simulatirq all of the proposed weLds. Spcc imens
prepared to represent mukiple pass welds shall be made in such a manner as to
have at least two inches of each layer of weld metal exposed. Visual
examination for Class A worlunanl.ike specimens (see 4.2) shall be free of the
followirq defects:

a. Undercut
b. Overhp
c. Surface cavities
d. Surface cracks in weld metal, or in heat-affected
zone of base metal.
e. Lack of weld Penetration

Visual examination fOr Ciass B wo~k=hiike SpeCiirriis (See ~.~) Shdki !3Sf:ee
oi surface cracks in weld metal, or in mat-affected zone of base metal and
free from lack of weld penetration. Permissible undercut s~ LL not exceed 10
percent plate thickness, or l/16 inch, whichever is lesser. Overlap will be
permitted not to exceed 2T in any 6T length. Fine scattered (aver*e pore
diameter alua~ to or less than 0.030 inches) porosity exceedim 13 Poren in
any one square inch of weld face shall be rejected. Not more than tuo @res
nay exceed 0.030 inches in diameter; coarse scattered (average diameter
greater than O.030 inches) porosity exceeding 2 pores in any one square inch
of weld face s=ll be re]ected. No singLe pare may exceed 0.060 inches in
diameter, linear surface porosity in excess of O.500 inches or in excess of 25
percent of total length, whichever is Less, shall be reJected.

All workmanlike specimens shall be approved by the pr=urirq agency prior to

●~aging in production welding.
 ?41L+-45205B

3.2.1.6 c4ecMnicai test SPeCimens. ~~n specified (see 6.2) , the Con-
tractor stroll prepare a welded test specimen of the specified type for
=hanical testim (me 4.3) to determine t~ suitability of the joint w Ldim
procedure to be used in production.

3.2.2 Position drawitqs for radiwraphic inspection. @hen radiography is

SP=ified on the drawings, in the contract or order, a position drawing or
drawims she11 be prepared in @cordame with QoD-STD-100 and D@+- 1000 (see
6.2. 2) for each weldment bv the design menv emloYim SYfQ~lS in accorda~e
with AWS A2.4 and using welding terms ad def initions in accordance with AOE
A3.O. The position drawings shall contain the following information, as
applicable:

(a) Location of joints in we~dment

(b) Joint type (welding symbo1s may be used as shown in AwE, A2.4)
(c) Thickness of plate
(d) Location of films
(e) Position of films
(f) Direction of radiation
(g) Soundness standard for each joint
(h) Film type
(i) Kilovoltage
(j) Focal distance
(k) Penetrameter used

This information shelL be sutsnittedto the contracting officer for approval.

3.2.3 Qualification of weiaer or weiainq operatof. -Lhe >iea--ba-m

- q“uaA&&&ul=
b*”,,&
the welder or welding @erator will not be r~uired by the Government con-
., .””
tractim agency. It is the responsibility of the contractor, however, to “ “
determine the extent of welder tra ininq needed to produce items in accordance
with the requirements of this specification.

3.3 Production requirements.

3.3.L Fabrication. Fabrication of al~ Weldments shall be in accordance

with the contractor’ s certif led recorded joint weldi~ procedure.

3.3.2 Soundness. Unless otherwise specified (see 6.2), soundness as

determined by radiographic or macroscopic inspection wi 11 not be required
(see 3.2.2 and 3.4).

3.4 -r kmanship. Tha appeara~e of weldments produced shall be equal to or

batter than that smwn by the appropriate workmanlike specimen (see 3.2.1.5).

7
MIL-~45205B

4. CUALITY ASWRAMZ PROVISIONS

4.1 Reeporisibilityfor inspection. Unless Otbruimg specif led in ttm. cOn-

tract OKdOK, the contractor is re~nsible for the performa~e of
OK purChase
al~ inspection requirements as specified krein. Except as ot h rwise
specified in the contract or purchase order, the contractor may use his own or
any other facilities 8uitabLe for the perf ormame of the inspection
requirements ~ecified herein, unless disapproved by the Government. TM
Go=rnment reserves the right to perform any of the inspections set forth in
the specification where such inspections are deemed n~essary to assure
swplies and services conform to prescribed requirements.

4.2 Visual examination. All class A weldments sha~l be visually examined

to determine Cmf31iarce with this specification. The number of Class B
weldments shall be visually examined for compliance with this specification at
the frequemy specified in the contract or order (see 6.2) . Undercut,
Over Lap, surface cavities, surface cracks in weld material, or in
*at-affected zone of base metal shall be cause of rejection of weldment (see
3.2.1.5).

?estinq and inspection. When radi~ raphic inspection and tests for
4.3
mechanical Properties are specified on the drawings, in the contract or order,
methods of inspection and test specimens sha 11 be in accordance with
MIL-5T&453 and Fed. Test Method Std. No. 151, as applicable, at the frequemy
specified in the contract or order (see 6.2) .

4.3.1 Testinq. Unless otherwise specified on the drawinqs, in the contract

or order, the ammmt and ‘type of testing other than tisual, shall be PSrformed
at the discretion of the contractor or manufacturer. , .:*

5. PACKAGIUG

5.1 Not applicable.

6. N~ES

Intended use. The intended purpose of this specification is to cover

6.1
genera~ weLdirq of aluminum alloys for structural uses other trmn armor.
ExampLe of weldment classification are as foLlows:

Class A Class B

A. Pressure and lQuid tight 1. Storage containers

containers 2. Heater duct work
2. Turret platform 3. Fenders
4. Heat defLectors

a
 MIL+-+452058

L
6.2 Orderim ciat a.

6.2.1 Procurement requirements. Purclwers should select tke preferred

options permitted herein and ircLude the following information in procurement
d~uments.

(a) Title, number ard date of this specification.

(b) Class of weldment rquired (see i.2).
(c) Filler metal requirements (see 3.1.2).
(d) Preparation of welding procedure, if not required (see 3*2.1)“
(e) If workmanlike sp=imens~ are r~uired (see 3D2”105)*
(f) Mechanical test specimens, wmn rquir~ (see 3c2”L06~ ●

(g) Soundness, if required (see 3.3.2).

(h) Visuai examination number of ClAss S weldments (see 4.2).
(i) E’r~uency of radiographic and mec.hanica~property tests (see 4.3).

6.2.2 Data requirements. When this specification is used in an ttWUi SitiOn

which i=orporates a DD Form 1423, Contract Data requirements List (CDRL) , the
data requirements identified below shall be developed as specified by an
approved Data Item De=ription (DD Form 1664) and delivered in accordance with
the approved CDRL i~orporated into the contract. @hen the provisions of DAR
7-104.9 (n) (2) are invoked and the DD Form 1423 is not used~ tm ‘ata
specified below shall be deLivered by the contractor in accordance with the
contract or purchase order requirements. De Liverable data rquired by this
specification is cited in the followinq Paragraphs:

- Paragraph No.
.

3.2.1 Drawinqs, EWineeri@ and . DI-E-7031.

Associated Lists

3.2.1 Qualification Data. UDI-R-23384

blelding Procedure

(Copies of data item descriptions required by the contractors in connection

with SPecif ic functions stmuld be obtained from the ~uirinq
muisition
activi~y or as directed by the contracting officer).

6.3 Difference between contractor and manufacturer. The term “contractor”

as used in this specification is defined as tbheorganization hatiw a direct
contract with the Government agency. The term “manufacturer” is fiei ined a~
the organization actually performing the operations covered by this
specification. The contractor may or may not be the manufacturer: heme, when
“contractor or manufacturer” is used, it designates them as seParate parties
or as one and the same when ‘or lmth” is used.

Custodian: Preparing activity:

Army - W? Army - W

Review activities:
Army - AR, AT Project No. THJM-A012

User activities:
Army -ME, AL

(WP #OOOU/~0909A FOR AMMRC USE ONLY)

-
 I

7 INSTRUCTIONS: Ina eootiouias tomskeourstsdadbtiondocuments

effoti bener,
th.DoD prddes this
formforwe in
submitting comrtwnts sod sw@JtioM foP im~vements. ~ ueers Of sdim ~ documents m Imitd to provide
SUggdiOK?& W form MSY k d- fOhd sb~ tbe b bdksti, tsped d- tbe loose edge (~ ~~ ~~~) , and
msiled.
Inblock 5, be w specific ss poemible Aout particular problem areu such u wording which required iat&pretetiin, wu
too rigid, rwtricthe, loose, smbiguow or wss iocompstible, and gin propoesd wording cbsnga wbkh would sliewis~ the
problems. Enterinblock 6 anY remsrks not relsted to ● specific psmgmph t.~ block7 isfib!OUt,an
oftbedocumea
●cknowledgement will be mskd to you within 30 dsys to let you know tbst your commenti were received snd sre being
amsidered.

NOTE: l’hia form msy not be used to request copies of documenti, nor to request wahers, deviatioM, or clarification of
apecificstion rwquirementa on currentcoatmcts. Comumnb submitkdon thie or imply ●uthotbtion
formdo ootcoastituse
to waive sny portion of the referenced
document(s) or tosmendcon~ requkwments.

(Fold akwu thu Ii?w)

11111 ?io ●OS7AGk

NECESSARY
IF MAILEO
IN THE
UNIT?EO STATIES

r 1
OFFICtAL BuSINES
●ENALTY FoR ●nlv ATE USE S300
BUSINESS REPLY MAIL
FIRST CLASS PERMIT NO 120S2 WASHINGTON D C
,
POHAGE WILL BE PAID 8YTHE DEPARTMENT OF THE ARMY

Director
Army Materials & Mechar.icsResearch Ctr
Attn: AMXMR-QS
Watertown, tiassachusetts 02172
 STANDARDIZATION DOCUMENT IMPROVEMENT PROPOSAL
{See[nwucrioru- Reverse Side)
I. 00 CUMEN7 NUMBC n 2. OOCIJMSNT TITLE n
,
la MAMI OF SUOMl~lNG ORGANIZATION ]4. TYPE OF ORGANIZATION (M+ o#M) .
VENDOR

n ~ER
h AD DHESS (Stmct. CftY. Stab, ZIP C-) I

c1 MANuFACTURER

DTHE R (sPd/Y ):
Cl—
I
L PROOLEM AREAS
a P.fagr* Numbu atd Wording:

b Ruomrtuntmd Wo.ding.

c. R.UOn/R@tiOn.1~ for Ueomm8ndmion:

..
4
●

:. A-ME OF SUBMITTER (L-(, Fw, (, MI) - optt~n~ b. WORK TELEPHONE NUMBER (Jnckir Arm
1- ~odc J - CYotiond

MAILING AOORESS (Strwf, City. Stem, ZIP Cods) - Ootionbl & OATE OF SUBMISSION IYYMMDDI