tive region. Te shape and size of the intentional defect (Fig. 1) is similar to a surface defect specified by the AMS 2694A Weld Qualification Test Speci- men standard. Te gage section loca- tion of the two types of specimens (full weld and partial weld) with respect to the location of the weld repair is shown in Figure 2. To assure proper location of the
artificial defects and identifica- tion of each test sample, the three metalcasting facilities followed a
Table 1. Consensus Welding Parameters Used to Fabricate Weld Repair Specimens
Welding Process Weld Current Weld Polarity
Weld Amperage Weld Voltage Shielding Gas
Shielding Gas Flow Rate, cfh
Tungsten Electrode Diam., in.
Filler Metal Alloy
Filler Metal Diameter, in. Preheat Temperature, °F Interpass Temperature, °F
GTAW AC EN (a)
15 – 30 Argon 20 – 30
1/16 – 1/8 AMS 4246 1/16 – 1/8 200 – 600 150
(a) 100 amps per 0.10-inch of material thickness
step-by-step procedure for machin- ing defects into the half-weld plates (Figure 3) and full-weld plates (Figure 4). Te process parameters used for
accomplishing the weld repairs were a consensus of the parameters cur- rently used by the foundry participants of the AFS-AMC program to make repair welds on E357-T6 sand castings (Table 1). All 30 sample plates were heat treated to a T6 condition using the same process parameters the cast- ings used to determine the A and B design allowables. Tese were:
Solution Heat Treatment
• Solution temperature: 1,010F (543.3C)
• Time at temperature: 12 hours
Quench
• Maximum quench delay: 15 seconds
• Quench media: Water • Quench media temperature: 90F ±10 (32.2C ±5.6)
• Maximum quench media tem- perature rise: 25F (13.9C)
Aging
• Room temperature aging time: 12-24 hours
•
Aging temperature: 325F (162.8C)
• Time at aging temperature: 12 hours.
Fig. 2. The relative gage section location of test specimens with respect to location of weld repair is illustrated.
Figs. 3-4. The half-weld (left) and full-weld (right) test plates ready for welding are pictured. December 2013 MODERN CASTING | 43
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