THIS SPEC IS THE PROPERTY OF MITSUBISHI MOTORS CORPORATION. IT SHALL NOT BE > © EEE [CONFIDENTIAL] COPIED.USED,TRANSLATED OR TRANSFERRED IN WHOLE OR IN PART TO ANY THIRD PARTY 1/19 WITHOUT PRIOR WRITTEN PERMISSION OF MITSUBISHI MOTORS CORPORATION. SPEC. NO PROCESS SPECIFICATION ES-X75011 TITLE: ARC WELDING This specification is inactive. — Cannot be used for new drawing — This specification is replaced with ES-X58005. Contents 1. Scope 2. Application 2 3. Definition of welding term 2 4. Classification of weld quality 5. Competence verification of welders ~~ 6, Equipment and welding procedures 3 7. Weld quality 5 8. Test report 18 9, Designation in drawings 18 10, Supplier's responsibility 18 14. Others 18 7X] QI2019 [inactivation of spec 1 [aor.11, 13] H. Tomita \ [P2075 _ | Correction of errors: 59,1117 Way.17. 12] H. Tomita GJ2080 | Additon of wetd quay and revisigga@ontents | All pages [Sep.13,06] H. Tomita REVISION MOHTA = H.Tomita Y.FUKUHARA Jun28,74 ‘MITSUBISHI MOTORS CORPORATIONNO ES—x75011 29 1. Scope This specification covers fundamental requirements for the procedure of arc welding (hereinafter referred as welding) applicable to automotive parts for the quality of welding, and fabricators shall be drawn up the process standard in accordance with welding machines and belongs, when this specification applied. Remarks: The standards referred for this specification are shown in Attached Table 1 2. Application This specification is applicable to follow welding which applied to automotive steel parts assembling with carbon steel, high tensile strength steel, low alloy steel and stainless steel when specified with drawings or other specifications. (1) Shielded metal are welding (2) Gas shielded metal arc welding (a) CO, are welding (b) MAG welding (c) MIG welding (d) TIG welding (3) Gas welding (For repair welding) Revised parts with triangular symbol /q\ ofthis specification shall be applied to new parts released on and after Sep. 18, 2006. 3. Definition of Welding Term Carbon equivalent is calculated in terms of the following (from JIS G0203) 1 4 40 40 404 Cea, (%) = C +=Mn + Si +—Ni +—Cr+—Mo#—V 6 24 40 5 4 14 Others should conform to ISO 581, ISO 857-1 or JIS Z3001 4. Classification of Welding Quality Welding quality shall be classified into two classes of important and general portions, according to the required quality characteristics of the part. Requirements of each quality are different. In this specification, important portions mean the portion that indicated important quality characteristics (GB ). rl a MITSUBISHI MOTORS CORPORATIONNO ES—x75011 3g 5. Competence Verification of Welders (1) Welders shall pass competence verification tests carried by the Quality Control Department or by a department or organization authorized by the Production Department or shall pass substitutive competence verification tests. (2) Welders shall keep welding skill by periodic education of verification examination. 6. Equipments and Welding Procedures 6.1 General Requirements (1) All equipment and materials required for welding such as a welding machine, torch, ammeter, voltmeter, gas flowmeter, welding wire feed mechanism, metal drive mechanism for automatic welding equipment, the torch tip positioning mechanism, etc. shall be properly maintained or stored and always used in normal conditions. (2) Works for welding and jigs for fixing shalll be able to reliably earth. 6.2 Certification of a Welding Machine ‘welding machine and incidental equipment which have passed equipment certificated examination shall be used. 6.3 Establishment of Welding Conditions Welding conditions shall be established before welding parts and the weld quality shall conform to Par. 7. Established welding conditions shall be notified by keeping a note within easy sight of working personnel near a welding machine. The welding conditions shall be submitted, if it required by the quality control department. 6.4 Procedures (1) Welded portions shall be clean by removing harmful impurities before welding. (2) In case carbon equivalent of base materials in over 0.43%, necessity of preheating and maximum hardness shall be discussed for each parts with the Production Engineering department, the Quality Control Department, and the affected Design Departments. The following shall be used as a guide for the preheating temperature (To). To (1C) = 1440Pc — 396 Here: Weld cracking sensitivity index (Pe) (%) Pom + H/60 + 1600, Where H is amount of diffusible hydrogen (mL/100gFe) and t is plate thickness (mm) Chemical composition on sensitivity of welding crack (Pom) (%) = C + Si/30 + Mn/20 + Cu/20 + Ni/60 + Cr/20 + Mo/15 + V/10 + 5B (3) Unless otherwise specified, ee specified in drawing shall be carried out after welding. MITSUBISHI MOTORS CORPORATIONNO ES—x75011 4g (4) If important parts of maximum hardness of weld over 35HRC (345HV) or general parts over 40HRC (392HV) shall be plated, be dipped in to an acid for descaling, or be coated with phosphate, etc., the parts shall perform elimination of hydrogen brittleness (baking) by specification ES-X70015. (6) After Welding, all slag of gas welding and shielded metal arc welding shall be removed. And then slag of gas shielded metal arc welding may not be removed. However, when a flux cored wire is used, slag shall be removed after welding (6) When shielded metal arc welding is interrupted and started again, slag at an interrupted portion shall be removed. (7) Spatters developed by welding shall be removed if they may affect appearance, machining and assembling etc. It is not necessary to remove slight spatters. And it shall be avoided to stack at high strength parts such as face hardening parts or springs, ete. (8) Welding beads shall not be removed with a file or grinder except for indication of drawings or requirement of assembly processes. 6.5 Welding Materials In principle the base materials shalll be removed hot rolled scale. ‘Welding rods or wires shall be free from harmful defects such as peeling of a covering materials, cracks, soil, changes in quality, moisture absorption, etc. and kept ina dry place. Welding rods or wires shall conform to the following standard. (1) Low Carbon Stee! For shield metal arc welding, welding rods used in low carbon steel welding shall pass ISO 2560 or JIS 23211. For CO, arc welding, MIG welding, and MAG welding, welding rods shall pass ISO 864 or JIS 23312 TIG welding wire shall pass ISO 636 or JIS 23316. (2) Medium Carbon Steel, High Carbon Steel, High Tensile Strength Steel, and Low Alloy Steel (a) When heat treatment after welding is specified in drawings Welding rods and wires shall be the equivalent base material or shall have characteristics to satisfy the requirements. (b) Unless heat treatment after welding is specified in drawings For shield metal arc welding, welding rods shall pass ISO 2560 or JIS Z3212 For CO; arc welding, MIG welding, and MAG welding, welding rods and wires shall pass ISO 864 or JIS 23312. TIG welding wire shall ae or JISZ3316. “ MITSUBISHI MOTORS CORPORATIONNO ES—x75011 5/19 (3) Stainless Stee! (a) Welding shall be shielded metal arc welding, TIG welding, or MIG welding. Z\,__ For MIG welding, Ar gas shall be used as inert gas. Several percent of O2 or CO, gas may be added to the inert gas to stabilize the arc or increase the depth of penetration, (b) Welding rods and wires used for welding similar stainless steels shall pass ISO 3581 or JIS 23221 for shielded metal arc welding and AWS A5.9, JIS Z3321 AWS 5.22, JIS 23323 for MIG welding and TIG welding Welding rods and wires used for welding various classes of stainless steels shall conform to Table 1, unless specified in drawings. (c) Welding rods and wires used for high Cr and Ni stainless steel shall be used for welding dissimilar stainless steels. Welding rods and wires specified in Par. 6.5 (1) or Par. 6.5 (3) (b) shall be used for welding stainless and low carbon steels. (d) The welding rods and wires used for welding of on-board exhaust system parts shall be as specified by ES-X25034 Table 1 Material of Matrix Welding Rod and Wire ‘sUS304 D308, D308L, D309, D310 Y308, Y308L, Y309, Y310 D316, D317 SUS316 Y316, Y317 SUS309 D309, D310 SUS310S Y309, Y310 D308, D309, D310, D410 Sus403 308, Y309, Y310, YF430 susaos 0308, 0309, D310, D410 Sus4t0 308, Y309, Y310, YF430 SUS410L SUS430 D308, D309, D310, D430 Susés2 308, Y309, Y310, YF430 SUS436 7. Weld Quality Welded parts shall satisfy the followingyveld quality. For thin sheet or plate (the thickness less than 1.4 mm), if the requereytlens Par. 7.2, 7.3, 7.6, 7.8, 7.9, 7.10 of 7.11 cannot be satisfied, then discyggl@hs shall be held with the Quality Control Department and the affected Design Depagglfint. Unless the drawing specify, the macroscopic test shall be conducted on the cut surfaces at both ends of the effective weld length. MITSUBISHI MOTORS CORPORATIONNO ES—x75011 sig Test methods shall conform to followings. ISO 4969 (Steel - Macroscopic examination by etching with strong mineral acids) ISO 3452 (Non-destructive testing - Penetrant inspection — General principles) ISO 1106/1, /2, /3 (Recommended practice for radiographic examination of fusion welded joints - Part 1, Part 2, Part 3) ISO 5579 (Non-destructive testing - Radiographic examination of metallic materials by X- and gamma rays - Basic rules) ISO 2400 (Welds in steel - Reference block for the calibration of equipment for ultrasonic examination) JIS GOSS3 (Macrostructure detecting method for steel) JIS GO56S (Method for magnetic particle testing of ferromagnetic materials and classification of magnetic particle indication) JIS 22343 (Non-destructive testing - Penetrant testing — Part 1) JIS 23104 (Methods of radiographic examination for welded joints in steel) JIS 23106 (Methods of radiographic examination for welded joints in stainless steel) JIS Z 3060 (Method for ultrasonic examination for welds of ferritic steel) 7.1 Tolerance of Effective Weld Length The effective weld length of continuous welding shall be within 0 through +20% of a value specified in drawings. The effective weld length of intermittent welding shall be within 0 through +20% of a value specified in drawings and the pitch (the length between the center of an intermittent welding bead and the center of a next bead) shall be within 0 through +20% of a value specified in drawings. However, if the effective weld length is 50 mm or shorter, the effective weld length shall be within 0 through +10mm of a value specified in drawings. Remark : Effective weld length means the length of the portion where a part of the metal material has been joined by welding, and which satisfies the requirements in Table 3 and Table 4 Effective weld length Table 2_ Example of Dimensional Tolerance Drawing instruction _| Tolerance 50 mm or less Oto +10 mm a 100 mm Oto +20mm Arc start Are end 150 mm 0 to +30 mm 200 mm Oto +40 mm MITSUBISHI MOTORS CORPORATIONNO ES—x75011 719 7.2 Undercuts The depth of an undercut shall not exceed 20% of the thickness of a thinner sheet or plate and 1.0mm when the thinner sheet or plate is Smm thick or over. The total length of an undercut shall not exceed 20% of the total weld length. The depth of an undercut in important portions shall not exceed 10% of the thickness of a thinner sheet or plate and its total length shall not exceed 10% of the total weld length. 7.3 Overlaps An overlap shall not exceed 10% of the bead width and its total length shall not exceed A\, 20% of the total weld length. An overlap in important portions shall not exceed 5% of the bead width and its total length shall not exceed 10% of the total weld length 7.4 Blowholes The blowhole ratio, calculated by steps (1) to (3) below, shall be 35% or less. However, in the case of zinc galvanized steel sheets or plates and similar materials, if the required value can not be satisfied, discussions shall be held with the Material Engineering Department and the affected Design Departments. The blowhole ratio is measured by the procedure shown below, (1) Determine a measurement line which spans the 25 mm of a weld bead where there are the largest number of blowholes, and which intersects the most blowholes within this section. (2) Find the total length of all blowholes intersected by this line. (3) Calculate the blowhole ratio. Blowhole ratio = Blowhole length (mm) / Length where the most blowholes are located (25mm) x 100 25mm | __________| MITSUBISHI MOTORS CORPORATIONNO ES—x75011 sig 7.5 Inclusions Each size of inclusions shall not exceed 20% of the thickness of a thinner sheet or plate and 1.0mm maximum. Their number shall not exceed 4 in a bead length of 25mm. 7.6 Craters A crater (a recess developed at a weld end) shall not exceed 20% of the thickness of ZA\ athinner sheet or plate. A crater in important portions shall not exceed 10% of the thickness of a thinner sheet or plate. 7.7 Cracks ‘Aweld shall be free from cracks that can be observed visually, by magnetic particle ZA. inspection, by color checking, ete 7.8 Gap of the Base Metal A gap of the base metal (C in Table 3 and Table 4), determined from the thickness of a thinner sheet or plate, shall be as described below. (1)t<2mm: Max. 0.5 mm (2)2mm (3)t2 3 mm: Max. 1.5mm t<3 mm: Max. 1.0 mm. If the required value is not satisfied by the dimensional tolerance of the base metal, discussions shall be held with the Quality Control Department and the affected Design Department 7.9 Burn Through (1) h shall be 0.5 mm or less. (2) Lis determined as follows, L is the total length for all portions, (1]t> 1mm (a) Welding of a pipe circumference: L shall be less than 40% of the circumference. (b) Straight bead welding: L shall be less than 25% of the total bead length. (2]t" 1mm L shall be less than 80% of the bead length for all beads. “~~ burn through MITSUBISHI MOTORS CORPORATIONNO ES—x75011 ote 7.10 Bead (Convex) Shape The flank angles shall be 100Yor more. Use a line 0.2 mm from the surface of the base metal, running parallel to it, and calculate the angles from the tangent lines at the points where this parallel line contacts the bead surface. LX toe of welding toe of welding toe of welding 7.11 Macroscopic Shape of the Cross Section of the Weld Portion The macroscopic shape of the cross section of the welding shall conform to Table 3 and Table 4, unless specified in drawings. Excess weld metal shalll not be cut off. 7.12 Strength of Weld joints Ifthe strength of a weld joint is specified in the drawing, the strength shall satisfy this requirement, 7.13 Repair Welding To determine whether or not repair welding is permitted, discussions shall be held in advance with the Quality Control Department and the affected Design Department. MITSUBISHI MOTORS CORPORATIONNOLLVYOd4OO SHOLIN IHSISNSLIN, Table 3 Welding penetration of plate remarks (1) Root of but weld or fillet weld shall be penetrated. (2) In the case of the plate thickness under 1.4mm, if the required value cannot be satisfied, discussion shall be held with the Quality Control Department and the affected Design Department. (3) Test method shall be cut the bead at right angle and see after etching @ penetration : P @ actual leg length : t ® reinforcement : r @ actual throat : d, d’ ® thickness : ty, ® butt length : t’ gap:¢ Actual throat thickness is to minimum value of d or shape of weld thickness macroscopic shape shape penetration reinforcement (reference . () hi fe fe r Unless the drawing specity, penetration rate shall be 70% or 4 ‘square groove 2.3mm or t over. Pp Beyond base metal less penetration rate (%)=—x 100 Full penetration t te" single V groove 2 and 2.3-8.0mm t single U groove But weld v partical penetration Unless the drawing specify, penetration rate shall be 100% or over ) Beyond base metal @ Under 2t or under 10mm Pp penetration rate (%)=—x 100 50~90" double V groove 3 and double U groove 6.0mm or t over Unless the drawing specify, penetration rate shall be 100% or over @ Beyond base metal @ r,f2 shall be under 2t. penetratigatfate (%) +P | Loszx-sa 6L/OLTable 3 (From previous page) NOLLWYOdYOO SHOLIN IHSIENS.LIN, shape of weld thickness macroscopic shape (t) shape penetration reinforcement (reference) AN both side welding of T joint 12mm or less | Pe d' Phe concave filet weld < De convex fillet weld ag q t 7 @Leg length shall be over drawing and within 150% of it. @uniess the drawing specify, +d ord’ shall be not less than 50% of the thickness of a thinner sheet or plate. +0 shall be not less than 70% of the thickness of a thinner sheet or plate -P, shall be 0.3mm or over. r shall not exceed 50% of f. one side welding of Tjoint 12mm or less @Leg length shall be over drawing and within 150% of it @unless the drawing specify, +d ord’ shall be not less than the thickness of a thinner sheet or plate. -0 shall be not less than 140% of the thickness of a thinner sheet or plate. -P,, shall be 0.3mm or over. r shall not exceed 50% of f. lap fillet weld 12mm or less @Leg length shall be over drawing and within {som ge @unless the drawing specify, “0 saga os than the thickness of a thier sheet or plate. -P shall be 0.3mm or over. r shall not exceed 50% of £. LLOSZX-Sa 6L/LLAX Table 3 (From previous page) NOILWYOdYOO SHOLIN IHSIENS.LIN shape of weld thickness (t) macroscopic shape ‘shape penetration reinforcement (reference) LN 'n" overlaid fillets Convex fillet weld Parallel type 42mm or less @Leg length shall be over drawing and within 150% of it @unless the drawing specify, -d ord’ shall be not less than 0.7 X (tyttyt+ tty). +0 shall be not less than AB. Here, AB 2 tyttst---+h, -P shall be 0.3mm or over. r shall not exceed 50% of f. overlaid fillets Convex fillet weld Angled type 42mm or less @Leg length shall be over drawing and within 150% of it @unless the drawing specify, +d ord’ shall be not less than 07% (totty “0 shall be “P ll be 0.3mm or over. r shall not exceed 50% of f. LLOSZX-Sa 6LiztAX Table 3 (From previous page) shape of weld thickness macroscopic shape NOLLYYOd4O9 SHOLIN IHSIENSLIN. shape penetration reinforcement (reference) A g @Leg length shall be over drawing nf] ¢ and within 150% of i lia : @Unless the drawing specity, on" : 5 eet , ty aid “| j +d ord’ shall be not less than oncave fillet wel - - P we Parallel type | cole OT x (lattsts He) 7 +0 shall be not less than AB. +} Here, AB 2 trttst +t, +P shall be 0.3mm or over. AN n 2 bP @Leg length shall be over drawing x f A d and within 150% of it g lala q @Unless the drawing specify, = on" ‘ 1 overiaid Mets 4 : -d ord! shall be not less than 10 | Concave fillet weld of , U ox (utt - a f | atte Angled ty : ngled type sl) ¢ P| -0 shallbe pte a AB. 4 B Here, tyttytee ett, bd -P gl be 0.3mm or over . g e= 3g € 5 @ z = 5 3 2 @ Q 8 2 a 3 2 a 3 z Table 3 (From previous page) thickness (ty shape of weld macroscopic shape shape penetration reinforcement (reference) 10mm or " edge joint less Unless the drawing specify, +d shall be not less than the thickness of a sheet or plate -P shall be not less than 50% of the thickness of a sheet or plate. Beyond base metal 20mm or 12 plug weld less Unless the drawing specify, When t<3mm Dz6mm , 30° <6 S60" When t=3 to 12mm D22t @When t> 12mm, 2att12 @P shape not less than 20% of thggiltkness of a sheet or plate. HdWever, D shall be over Do. Beyond base metal Center may become dented a few. shall be careful to penetrate root, LLOSZX-S3 6LibLAd Table 3 From previous page) NOILYYOdOO SHOLIN IHSIENSLIN shape of weld thickness ® macroscopic shape shape penetration reinforcement (reference) flare joint 43 | arc and line 42mm or less When tth + P; shall be not less than 20% of the thickness of a sheet or plate. P, shall be 0.3mm or over. QWhen t;>t, + actual leg length h, &>te + P; shall be not less than 20% of the thickness of a sheet or plate. P2 shall be 0.3mm or over. r shall not exceed 50% of f. 44 | arc and arc 410mm or less ye 7 Unless the drawing specify, -d shall be not less than the thickness of a sgpet or plate. *P shall be gress than 20% of the tigupfiess of a sheet or plate Beyond base metal LLOSZx-Sa 6L/SLNOLLVYOdYOO SHOLIN IHSIANSLIN Table 4 Welding penetration of bar and pipe remarks (1) (2) > itis same as Table 3. (3) D:: diameter of bar. shape of weld shape macroscopic shape penetration remarks Py @Leg length shall be drawing Dé » 2] te from -30% to +30% rt @Unless drawing specify, YW WAS “When 1.4t S 0.30, ag | Med or barand : «ee r shall not exceed 50% of t. plate | J 4 a2 tt. Te When 0.30 < 1.4t, ' D 7 @>03D -P shall be 0.3mm or over. 16 | Weld of bar and plate with pit Itis same as above. A: Same as above, B 0. shall bggnot less than 118 gehicinss ofa vr or plate. Itis same as above. LLOSZX-Sa 6L/9LNOILYYOdOD SHOLIN IHSIENSLIN Table 4 (from previous page) shape of weld shape macroscopic shape penetration remarks aN weld of pipe and v plate ‘De lt Leg length shall be over drawing and within 150% of it. @Unless the drawing specity, +2 shall be not less than 140% of the thickness of a pipe(t,). +d and d’ shall be not less than the thickness of a pipe(t). -P, shall be 0.3mm or over. r shall not exceed 20% of f. 1g | Weld of pipe and plate with pit @Leg length shall be over drawing and within 150% of it. Unless the drawing specify, -whent S 0.30, oz when 0.30 0.3D «when 0,7t 30, dd’ 2 03D -P shall be 0.3mm or over, shall not exceed 20% of f. LLOSZX-SA BULLNO ES—xX75011 18/9 8. Test Report Supplier shall submit a specification confirmation test report which proves that the part satisfies all the items required in this specification to the Quality Control Department, and affected Designing Department prior to the start of mass production delivery. In addition to the above, the supplier shall also submit to the affected Design Department its own test report of the specification (test results, not nominal values), the processing conditions, the material designation, and trial production parts or materials for MMC. evaluation. 9. Designation in Drawings This specification shall be designated in drawings as follows: MATERIAL ARC WELDING ES-X75011 10. Supplier's Responsibility Prior to making any change in the welding machine, material or processing originally approved under this specification, whether or not such changes affect the ability to meet the specification requirements, the supplier shall notify the affected Designing Department of the proposed changes through the Quality Control and the Purchasing Department and obtain written approval 41, Others ‘Supplier shall contact the Material Engineering Department, Development Engineering Office, if any question arises. MITSUBISHI MOTORS CORPORATIONNO ES—xX75011 1919 Attached Table 1 + ISO 581 (Weldability - Definition) = ISO 857-1 (Welding and allied process - Vocabulary - Part 1) + ISO 2560 (Welding consumables — Covered electrodes for manual metal arc welding of non-alloy and fine-grain steels - Classification) + ISO 636 (Welding consumables — Rods and deposits for tungsten inert gas welding of non-alloy and fine-grain steels — Classification) + ISO 864 (Arc welding - Solid and tubular cored wires which deposit carbon and carbon manganese steel - Dimensions of wires, spools, rims and coils) + ISO 3581 (Welding consumables - Covered electrodes for manual arc welding of stainless and heat-resisting steels — Classification) + ISO 4969 (Steel - Macroscopic examination by etching with strong mineral acids) + ISO 3452 (Non-destructive testing - Penetrant inspection — General principles) + ISO 1106/1,/2,/3 (Recommended practice for radiographic examination of fusion welded joints - Part 1, Part 2, Part 3) + ISO 5579 (Non-destructive testing - Radiographic examination of metallic materials by X- and gamma rays - Basic rules) + ISO 2400 (Welds in steel - Reference block for the calibration of equipment for ultrasonic examination) + AWS A5.9 (Bare stainless steel welding electrodes & rods specification) + AWS A5.22 (Specification for bare stainless steel welding electrodes and rod) + JIS Z 0203 (Glossary of terms used in iron and steel (Products and quality) + JIS Z 3001 (Welding terms) + JIS Z 3211 (Covered electrodes for mild steel) + JIS Z 3316 (TIG welding rods and wires for mild steel and low alloy steel) + JIS Z 3212 (Covered electrodes for high tensile strength steel) ( Q ( + JIS Z 3312 (MAG welding solid wires for mild stee! and high strength steel) ¢ ( ( + JIS Z 3221 (Stainless steel covered electrodes) + JIS Z 3321 (Stainless steel, welding rods and solid wires) + JIS G 0553 (Macrostructure detecting method for steel) + JIS GO565 (Method for magnetic particle testing of ferromagnetic materials and classification of magnetic particle indication) + JIS Z 2343 (Non-destructive testing ~ Penetrant testing ~ Part 1)) = JIS Z 3104 (Methods of Radiographic examination for welded joints in steel) ( tl + JIS Z 3106 (Methods of Baclarapiggpfrinaton for welded joints in stainless steel) = JIS Z 3060 (Method for ultrasonig. amination for welds of ferritic steel) + ES-X70015 {Elimination of hypifgen brittleness (Baking) ~ Stee! parts} + ES-X25034 {FUSION-WEEDED EXHAUST SYSTEM PARTS) MITSUBISHI MOTORS CORPORATION