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MIL-STD-3040A-002.pdf
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MIL-STD-3040A-002.pdf
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INCH-POUND
MIL-STD-3040A
24 March 2022
SUPERSEDING
MIL-STD-3040
29 June 2016
DEPARTMENT OF DEFENSE
MANUFACTURING PROCESS STANDARD
QUALIFICATION, FABRICATION, WELDING,
AND INSPECTION OF ARMOR AND NON-
ARMOR STEEL WELDMENTS
AMSC N/A AREA THJM
DISTRIBUTION STATEMENT A. Approved for public release. Distribution is unlimited.
Source: https://assist.dla.mil -- Downloaded: 2022-05-27T17:23Z
Check the source to verify that this is the current version before use.
MIL-STD-3040A
ii
FOREWORD
1. This standard is approved for use by all Departments and Agencies of the Department of
Defense (DoD).
2. This standard does not specify armor capability in terms of protection. The user is
responsible for defining the threat that the armor system must withstand.
3. This revision has resulted in many changes from the base document, but the most significant
changes are:
a. Re-titling the document to clarify its use.
b. Addition of non-armor steels to the document.
c. Arranging the order of the document.
4. Comments, suggestions, or questions on this document should be addressed to
U.S. Army Ground Vehicle Systems Center, ATTN: FCDD-GVS-SAT MS #268,
6501 E. 11 Mile Road, Warren, MI 48397-5000, or emailed to usarmy.detroit.devcom-
gvsc.mbx.standardization@army.mil. Since contact information can change, you may want to
verify the currency of this address information using the ASSIST Online database at
https://assist.dla.mil.
5. Questions or information with regards to this document related to ground vehicle systems
should be addressed to usarmy.detroit.devom-gvsc.mbx.materials-joining@army.mil.
Source: https://assist.dla.mil -- Downloaded: 2022-05-27T17:23Z
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MIL-STD-3040A
iii
CONTENTS
PARAGRAPH PAGE
FOREWORD .................................................................................................................................. II
1. SCOPE ............................................................................................................................... 1
1.1 Scope ....................................................................................................................... 1
1.2 General ................................................................... Error! Bookmark not defined.
2. APPLICABLE DOCUMENTS ......................................................................................... 1
2.1 General .................................................................................................................... 1
2.2 Government documents .......................................................................................... 1
2.2.1 Specifications, standards, and handbooks ............................................................... 1
2.2.2 Other Government documents, drawings, and publications ................................... 3
2.3 Non-Government publications ................................................................................ 4
2.4 Order of precedence ................................................................................................ 8
3. DEFINITIONS .................................................................................................................. 8
3.1 Active flux .............................................................................................................. 8
3.2 Amplitude Rejection Level (ARL) ......................................................................... 8
3.3 Active supervision .................................................................................................. 8
3.4 Contractor ............................................................................................................... 9
3.5 Deposition thickness ............................................................................................... 9
3.6 Design engineering activity .................................................................................... 9
3.7 Digital radiography (DR) ........................................................................................ 9
3.8 Entity ....................................................................................................................... 9
3.9 Entity responsible representative ............................................................................ 9
3.10 Essential variables ................................................................................................... 9
3.11 Field repair .............................................................................................................. 9
3.12 Forced cooling ........................................................................................................ 9
3.13 Inadvertent inspection ............................................................................................. 9
3.14 Manufacturer ........................................................................................................... 9
3.15 Material Review Board (MRB) ............................................................................ 10
3.16 Neutral flux ........................................................................................................... 10
3.17 Nominal thickness ................................................................................................. 10
3.18 Procuring contracting officer (PCO) ..................................................................... 10
3.19 Proofing Projectile Impact Testing (PPIT) ........................................................... 10
3.20 Reference standard ................................................................................................ 10
3.21 Repair .................................................................................................................... 10
3.22 Steel....................................................................................................................... 10
3.22.1 Armor grade steel .................................................................................................. 10
3.22.2 Non-armor grade steel........................................................................................... 11
3.22.3 Sheet steel ............................................................................................................. 11
3.23 Standard welding terms and definitions ................................................................ 11
3.24 Technical authority (TA) ...................................................................................... 11
Source: https://assist.dla.mil -- Downloaded: 2022-05-27T17:23Z
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MIL-STD-3040A
iv
PARAGRAPH PAGE
3.25 Weld repair procedure........................................................................................... 11
3.26 Validation test plate .............................................................................................. 11
3.27 Welder qualification continuity record ................................................................. 11
3.28 Welding engineer .................................................................................................. 11
3.29 Welding equipment ............................................................................................... 12
3.30 Welding symbols .................................................................................................. 12
4. GENERAL REQUIREMENTS ...................................................................................... 12
4.1 Qualification requirements.................................................................................... 12
4.1.1 Submission format ................................................................................................ 12
4.2 Qualification applicability .................................................................................... 13
4.3 Responsibility ....................................................................................................... 13
4.4 Previous qualification to MIL-STD-3040 revisions ............................................. 13
4.4.1 Previous qualification to other standards .............................................................. 13
4.5 Safety precautions ................................................................................................. 14
4.6 Joint design ........................................................................................................... 14
4.6.1 Weld joint classification requirements.................................................................. 14
4.6.2 Minimum fillet weld size ...................................................................................... 16
4.6.3 Intermittent fillet welds ......................................................................................... 16
4.7 Welding processes ................................................................................................ 16
4.7.1 Acceptable welding processes .............................................................................. 16
4.7.2 Restricted welding processes ................................................................................ 17
4.7.3 Additional welding processes ............................................................................... 17
4.8 Weld positions ...................................................................................................... 17
4.9 Quality control ...................................................................................................... 17
4.9.1 Quality assurance system ...................................................................................... 18
4.9.2 Welding equipment calibration and verification................................................... 18
4.10 Welding prohibitions ............................................................................................ 18
4.11 Company name change ......................................................................................... 18
5. DETAILED REQUIREMENTS ..................................................................................... 18
5.1 Base material. ........................................................................................................ 18
5.1.1 Base material certification .................................................................................... 19
5.1.2 Armor base material .............................................................................................. 19
5.1.3 Base material grouping ......................................................................................... 19
5.1.4 Backing material ................................................................................................... 19
5.1.5 Run off tab material .............................................................................................. 20
5.1.6 Material record retention....................................................................................... 20
5.2 Welding materials ................................................................................................. 20
5.2.1 Identification ......................................................................................................... 20
5.2.2 Filler materials ...................................................................................................... 20
5.2.3 Shielding ............................................................................................................... 23
5.3 Procedure Qualification Records (PQRs) ............................................................. 24
5.3.1 Requirements ........................................................................................................ 24
Source: https://assist.dla.mil -- Downloaded: 2022-05-27T17:23Z
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MIL-STD-3040A
v
PARAGRAPH PAGE
5.3.2 PQR cross qualification ........................................................................................ 27
5.3.3 PQR revision ......................................................................................................... 28
5.3.4 Supplemental PQRs .............................................................................................. 28
5.3.5 Previously qualified welding procedures .............................................................. 28
5.3.6 Bead width limitation for weaving ....................................................................... 28
5.3.7 Base material repair qualification ......................................................................... 28
5.3.8 PQR record retention ............................................................................................ 29
5.4 Essential variables ................................................................................................. 29
5.4.1 Essential variables ................................................................................................. 29
5.4.2 Base material essential variables .......................................................................... 29
5.4.3 Filler material essential variables.......................................................................... 30
5.4.4 Shielding ............................................................................................................... 31
5.4.5 Joint design ........................................................................................................... 31
5.4.6 Electrical parameters ............................................................................................. 33
5.4.7 General procedure parameters .............................................................................. 34
5.5 Welding Procedure Specification (WPS).............................................................. 35
5.5.1 Requirements ........................................................................................................ 36
5.5.2 WPS essential variables ........................................................................................ 36
5.5.3 Minimum travel speed tables ................................................................................ 36
5.5.4 WPS transfer requirements ................................................................................... 36
5.5.5 Contracted sub-entity qualification ....................................................................... 37
5.5.6 WPS revision ........................................................................................................ 38
5.5.7 WPS record retention ............................................................................................ 38
5.6 Welder performance qualification ........................................................................ 38
5.6.1 Requirements ........................................................................................................ 38
5.6.2 Welder Qualification Records (WQR).................................................................. 38
5.6.3 Welder and welding operator performance qualification ..................................... 38
5.6.4 Welder and welding operator essential variables.................................................. 40
5.6.5 Qualifying welder or welding operator through PQR........................................... 41
5.6.6 Previous welder or welding operator qualification ............................................... 41
5.6.7 Transfer of qualification ....................................................................................... 41
5.6.8 Renewal of qualification ....................................................................................... 41
5.6.9 Maintenance of qualification ................................................................................ 41
5.6.10 Retest requirements ............................................................................................... 42
5.7 Destructive testing of welds .................................................................................. 42
5.7.1 Requirements ........................................................................................................ 42
5.7.2 Tension/reduced-section tension testing ............................................................... 42
5.7.3 Bend testing .......................................................................................................... 42
5.7.4 Macroetch testing .................................................................................................. 43
5.7.5 Hardness testing .................................................................................................... 43
5.7.6 Fillet weld break test ............................................................................................. 44
5.7.7 Proofing projectile impact testing ......................................................................... 44
5.7.8 Charpy V Notch (CVN) testing ............................................................................ 44
5.7.9 Destructive test failures......................................................................................... 45
Source: https://assist.dla.mil -- Downloaded: 2022-05-27T17:23Z
Check the source to verify that this is the current version before use.
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