Académique Documents
Professionnel Documents
Culture Documents
Specification
CPW 23
Rvision : T
Revision:
Rvise le:
Revised: 2004-02-18
mise le :
Issued: 1958-05-12
Page: 1 de/of 22
o Aucun
None of the above
AVERTISSEMENT - Le prsent document appartient Pratt & Whitney Canada Cie. (P&WC). Il est dfendu de dtenir, d'utiliser, de reproduire ou de
divulguer quelque information y figurant, pour quelque motif que ce soit - y compris pour la conception, la production ou la rparation de pices -, ou
d'obtenir une homologation FAA ou autre, sans l'autorisation expresse et crite de P&WC. La rception ou l'entre en possession du prsent document
ne correspond nullement une autorisation, quelle que soit la source dudit document. La possession, l'usage, la reproduction ou la divulgation par
quiconque sans l'autorisation expresse de P&WC sont formellement interdits et pourraient entraner des poursuites en vertu du code criminel ou du code
civil.
WARNING - This document is the property of Pratt & Whitney Canada Corp. (P&WC). You may not possess, use, copy or disclose this document or any
information in it, for any purpose, including without limitation to design, manufacture, or repair parts, or obtain FAA or other government approval to do
so, without P&WCs express written permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission,
use, copying or disclosure by anyone without P&WCs express written permission is not authorized and may result in criminal or civil liability.
P&WC et le Fournisseur ont expressment exig que la prsente spcification ainsi que tout document indiqu en rfrence soient rdigs en langue
anglaise. Si une version franaise de la prsente spcification ou de tous documents connexes a t transmise au Fournisseur et quil y a conflit et/ou
discordance entre les versions franaise et anglaise, P&WC et le Fournisseur conviennent quun tel conflit et/ou quune telle discordance devront tre
rsolus en donnant priorit la version anglaise.
P&WC and the Supplier have expressly requested that this specification and any documents referenced hereto be written in the English language. In the
event that a French version of such specification or documents has been provided to the Supplier and there is a conflict and/or inconsistency between
the French and the English versions thereof, P&WC and the Supplier agree that such conflict or inconsistency shall be resolved by giving precedence to
the English version.
RESISTANCE WELDING
SPOT, STICH, SEAM AND
PROJECTION
1.
SCOPE
1.1
Purpose
This specification covers the engineering requirements and the visual acceptance standards
for resistance welds between parts, including parts with foil-backed porous sheet abradable
materials.
1.2
Description
Resistance welding is a group of welding processes that produces coalescence at the
overlapping surfaces of a joint by the heat obtained from resistance to the flow of electric
current through the workpieces from electrodes that serve to concentrate the welding current
and pressure at the weld area. Stitch (overlapping-spot) welding is considered separately from
seam welding; seam welding is considered to be welding using roller type electrodes.
2.
APPLICABLE DOCUMENTS
The following publications form a part of this specification to the extent specified herein; unless
otherwise specified the latest issue shall apply.
CPW 23
Revision: T
2.1
2.1.1
2.1.2
2.1.3
CPW Specifications
CPW 24
CPW 100
CPW 435
CPW 543
Section YC-3
AWS Publications
Available from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
AWS
Welding Handbook
ANSI/AWS A2.4
3.
DEFINITIONS
3.1
3.1.1
3.1.2
Coalescence (Coalescence)
The fusing together of the materials being welded to form one body.
3.1.3
3.1.4
Crack (Fissure)
A fracture type discontinuity characterized by a sharp tip and high ratio of length and depth to
opening displacement (width).
CPW 23
Revision: T
3.1.5
3.1.6
Discontinuity (Discontinuit)
An interruption of the typical structure of a weld, such as a lack of homogeneity in the
mechanical, metallurgical or physical characteristics of the material or weldment. A
discontinuity is not necessarily a defect.
3.1.7
3.1.8
3.1.9
3.1.10
3.1.11
3.1.12
Nugget (Noyau)
The cast weld metal zone joining the parts in spot, stitch, seam or projection welds.
3.1.13
3.1.14
3.1.15
3.1.16
3.1.17
CPW 23
Revision: T
3.1.18
3.1.19
3.1.20
3.1.21
MTE&Q
Materials Technology Engineering & Quality Group.
3.1.22
SPDG
P&WC Special Process Development Group.
4.
SYMBOLS
The nugget size, spacing, extent and other fabrication information relating to welds will be
specified by standardized symbols placed on the drawing. These symbols are described in
ANSI/AWS A2.4 and in 4.1 and 4.2. Symbols may be supplemented by notes giving additional
information.
4.1
Stich Welding
The symbol for stitch welding will be the standard spot welding symbol with an S enclosed by
parentheses and placed to the right of the spot weld symbol above the reference line.
4.2
Nugget Size
Nugget size will always be enclosed in parentheses.
5.
TECHNICAL REQUIREMENTS
5.1
Weld Schedules
Weld schedules, necessary for the production of welds having nugget sizes no smaller than
those specified on drawings by corresponding welding symbols and supplementary notes,
shall be established by making and testing of not less than twenty five consecutive spot welds
or 12.5 inches (317 mm) of stitch or seam weld prior to welding parts. Weld schedules shall
include all details of the machine set-up and all welding parameters. Control test specimens
shall be cut from material of the same or equivalent specification numbers and the same
nominal thickness, and cleaned in the same manner as the parts represented and should,
when practicable, approximate the shape of a section of the part represented. Contacting
overlap in the control test specimens shall not be greater than the contacting overlap in the
part represented. Control shall be in accordance with MCL Manual Section YC-1.
CPW 23
Revision: T
5.1.1
Screen or Strainer
Control test specimens for schedules for screen or strainer elements shall be shear tested.
5.1.2
A and B Tests
Once established, weld schedules shall be verified by the fabrication and testing of specimens
similar to the control test specimens at the beginning and end of a production run, designated
A and B tests. When applicable, intermediate test specimens, designated as Ax, must be
submitted at intervals of every two hours. Non-operational breaks are not counted as interval
time. Deviation to this requirement can be dispositioned by SPDG or MTE&Q, without review
by Quality Review.
5.1.3
Machine Setting
The heat input (phase shift) setting shall not be changed by more than 10% and any other
machine setting shall not be changed by more than 5% of the value established for the
particular welding schedule. Should it become necessary to change the settings by more than
these values, a new weld schedule is required. Deviation to this requirement can be
dispositioned by SPDG or MTE&Q, without review by Quality Review.
No changes to machine settings are permitted after acceptance of an A test and before
submission of a B test.
5.1.4
Production Run
A production run is defined as the consecutive welding of a group of parts without interruption,
carried out under one weld schedule without a machine failure, a machine shutdown, set up,
or electrode change. Deviation to this requirement can be dispositioned by SPDG or MTE&Q,
without review by Quality Review.
5.1.5
Seam Welding
The motor speed control for seam welding is a reference setting only, and is determined
according to the number of spots per inch on the control test piece (5.4.2).
5.1.6
Stitch Welding
The A and B tests and the production run shall be carried out by the same operator. Deviation
to this requirement can be dispositioned by SPDG to MTE&Q, without review by Quality
Review.
Thickness combinations falling within the following limits shall not require separate weld
schedules provided the nugget size can be produced with a heat input (phase shift) setting
that lies within 10% of the value established by the original schedule, all other conditions
being the same:
a) Foil
The variation in thickness (with regard to the original schedule) of the outer sheet shall be
within .001 inch (0.03 mm) and the variation in the summed thickness of all sheets shall
be within .003 inch (0.08 mm).
b) Sheet (outer) up to .040 inch (1.02 mm) Inclusive
The variation in thickness of either outer sheet shall be within .004 inch (0.10 mm) and
the variation in the summed thickness of all sheets shall be within .006 inch (0.15 mm).
c) Sheet (outer) over .040 inch (1.02 mm)
CPW 23
Revision: T
For aluminum and magnesium alloys the variation in thickness of either outer sheet shall
be within 10%. For materials other than aluminum and magnesium, the thickness of
either outer sheet shall be within 20%. The variation in the summed thickness of all
sheets shall be within 10%.
5.2
Procedure
5.2.1
Cleaning
Surfaces to be welded shall be cleaned free from objectionable protective coatings, dirt,
grease, oil and other foreign materials, and as free as practicable from oxides, except that a
film of light oil may be left on surfaces of parts made of carbon or low alloy steel. The final step
in removing oxides from aluminum and aluminum alloys should preferably consist of chemical
treatment as soon as practicable before assembling and welding. Wire brushes, if used for
cleaning corrosion resistant steels and corrosion and heat resistant alloys, shall have bristles
of austenitic corrosion resistant steel. No undesirable deposit or residue from cleaning
operations shall remain on surfaces to be welded.
Cleaning of titanium alloys shall be carried out in accordance with P&WC Specification
CPW 435.
5.2.2
Weld Type
The type of weld specified by the symbols shown on the drawing or any supplementary
document shall be made using the schedule established in 5.1. Where the drawing specifies
that an overlapping spot (stitch) weld is required, a seam weld may be substituted. The
inverse does not apply.
5.3
5.3.1
Nugget Size
5.3.1.1
Spot Welds
At the beginning of a production run, the effective nugget diameters of individual spot welds,
as measured at each interface in the joint, shall not be smaller than values specified on the
drawing. At the end of a production run, the nugget diameter of individual spot and projection
welds as measured at each interface joint shall not be less than that specified in Table 1 or
Table 1, or the values specified on the drawing, whichever is smaller (See Figure 8).
5.3.1.2
5.3.1.3
Projection Welds
At the beginning and at the end of a production run, the nugget size shall conform to the
drawing requirements.
CPW 23
Revision: T
5.3.2
Positioning
Welds shall be centred on the overlap (A) or shall be located as specified on the drawing
within .060 inch (1.52 mm), (see Figure 1). Edge distance (B) shall not be less than one-half
of the minimum overlap (A/2), or shall be specified on the drawing. Edge distance
requirements (B) are waived when finished parts are cut from rings which have been
previously welded all around.
Test pieces not welded in accordance with this requirement can be dispositioned by SPDG or
MTE&Q without review by Quality Review.
Distance B shall be measured from the center of the weld.The center of the weld shall be
considered to be in the center of the electrode indentation.
Figure 1: Spot, Stitch and Seam Welds
Spacing between individual spot welds in a row and between rows of spot welds shall be
within .060 inch (1.52 mm) of the spacing required by the drawing (See Figure 2). Test
pieces(B Test) not welded in accordance with this requirement can be dispositioned by SPDG
or MTE&Q without review by Quality Review.
CPW 23
Revision: T
Spacing between seam welds shall be within .060 inch (1.52 mm) of the spacing required by
the drawing, see Figure 3.
Test pieces not welded in accordance with this requirement can be dispositioned by SPDG or
MTE&Q without review by Quality Review.
5.4
Appendices (A, B, C, D)
Weld nugget and minimum overlap.
5.4.1
CPW 23
Revision: T
Figure 4: Overlap
5.4.2
5.4.3
Indentation
Unless otherwise specified on the drawing, the maximum indentation (T3 and T4) acceptable
on each of the outer surfaces of the joint shall be:
1. For Class A & B:
T3=10% of T1 or 0.005 (0.127 mm), whichever is greater
T4=10% of T2 or 0.005 (0.127 mm), whichever is greater (see Figure 5)
2. For Class C & D:
T3=15% of T1 or 0.005 (0.127 mm), whichever is greater
T4=15% of T2 or 0.005 (0.127 mm), whichever is greater (see Figure 5)
5.4.4
Penetration
Unless otherwise specified, the weld penetration for the A test, into each outer piece at the
centerline of the weld nugget shall not be less than 20% of the indented thickness (Ti) of the
thinner of the pieces being joined and not greater than 80% of the indented thickness of the
respective pieces (see Figure 6). For titanium and titanium alloys, penetration may be as high
CPW 23
Revision: T
10
as 90% of the indented thickness of the respective piece. For stitch and seam welds, the
above requirements shall be met at any point along the length of the weld.
For stich and seam welds which do not form a closed circuit, the above requirements shall be
met at any point along the length except for a distance equal to one-half the individual spot
diameter at the beginning and at the end of such welds. Evidence of fusion is required where
the penetration requirements are waived. For B tests for seam and stitch welds, penetration
shall not be less than 15% of the indented thickness of the thinner piece. Local lack of
penetration (5% to 15% between nuggets) and/or excessive penetration (over 80%) can be
dispositioned by SPDG or MTE&Q, without review by Quality Review. Excessive penetration
shall be FPI per CFPM-4 to CFPS E.5. Parts not acceptable to these FPI standards shall be
subject to Quality Review.
Figure 6: Penetration
5.4.4.1
5.4.4.2
5.4.5
5.4.5.1
Tack Welds
At least 50% of the tack weld indentations shall be contained within the final weld and the
protruding portion shall not exceed 50% of the indention width of the final weld width unless
otherwise specified on the drawing.
CPW 23
Revision: T
5.4.5.2
11
5.4.6
5.4.7
Sheet Separation
Sheet separation, measured at a distance from the center of the weld equal to three times the
radius of the fused size as specified on the drawing, shall not, unless otherwise specified,
exceed the following requirements:
1. 0.15 times the total thickness of the outer sheet and the one adjacent to it, or .006 inch
(0.15 mm), whichever is greater, or
2. .003 inch (0.08 mm) between foil and the sheet adjacent to it.
When the distance to the edge of the sheet is less than three times the radius as defined
above, the sheet separation may be measured at the edge of the sheet.
5.5
Discontinuities
5.5.1
Acceptance Criteria
Interconnected voids and radial cracks in the weld nugget are considered as one discontinuity.
For Class A and B welds, dimension A of the discontinuity shall not exceed 15% of the
length of the long axis of the weld nugget, and dimension B shall not exceed 15% of the length
of the short axis. For Class C and D welds, dimension A shall not exceed 25% of the long
axis and dimension B shall not exceed 25% of the short axis (see Figure 7).
Figure 7: Discontinuities
CPW 23
Revision: T
5.5.2
12
5.5.3
Long Axis
The long axis shall be taken between the extreme boundaries of the nugget as shown in
Figure 7, or the ends of the residual interfaces, see Figure 8, whichever is smaller.
5.5.4
5.5.5
Incipient melting
Incipient melting shall not be considered a cause for rejection provided that it does not extend
to within 10% of the actual thickness of the sheet measured from the outer surface. When
incipient melting extends within 10% of the actual thickness of the sheet, measured from the
outer surface, parts shall be FPI per CFPM-4 to CFPS E.5.
6.
REOPERATION
A maximum of one reoperation by the original process within the limits of 5.1.6, of 100% of the
weld length is permitted as a result of a B test reject, provided the test pieces used as A and B
tests for the reoperation are representative of the reoperated part. The resultant reoperated
weld shall meet the requirements of this specification and all applicable quality standards. A
minimum of 75% of the reoperation weld width shall be contained within the original weld as
indicated by the indentation caused by the electrodes or wheels on the outer surfaces.
CPW 23
Revision: T
6.1
13
6.1.1
Filler Material
Shall not be used for reoperation by fusion welding.
7.
7.1
7.2
Weld Surfaces
Weld surfaces shall be clean and free from surface burning, cracks, pits, inclusions, foreign
materials (except for copper tinting), corrosion, expulsion of metal, excessive indentation and
sharp corners or edges in weld indentation. Heat tinting is acceptable.
7.3
Tack-welds
Tack-welds shall comply with 5.4.5.
7.4
Ball Tack-welds
Ball tack-welds shall comply with 5.4.6.
7.5
Positioning
Positioning shall comply with 5.3.2.
7.6
7.7
8.
CONTROL
Control shall be in accordance with P&WC Specification CPW 100.
CPW 23
Revision: T
9.
14
SOURCE QUALIFICATION
Processing shall comply with the Qualified Source - Laboratory Control Requirements of
P&WC Specification CPW 100.
Resistance welding sources and machines shall be qualified to MCL Manual Section YC-1.
Fusion welding sources and machines shall be qualified to MCL Manual Section YC-3.
10.
IDENTIFICATION
Unless otherwise specified, each welded assembly shall have documentation which provides
traceability of each weld to the corresponding test specimen. Documentation shall be retained
by supplier for a period of not less than ten years.
11.
ACKNOWLEDGMENT
Supplier shall mention this specification number and its revision letter in all quotations and
when acknowledging purchase orders.
12.
REJECTION
Parts not welded in accordance with this specification or with authorized modifications will be
subject to rejection.
13.
NOTES
The (|) symbol is used to indicate technical and major editorial changes from the previous
issue of this specification.
Dimensions and properties in inch/pound units are primary; dimensions and properties in SI
units are shown as the approximate equivalents of the primary units and are presented only for
information.
CPW 23
Revision: T
15
APPENDIX A:
MATERIALS OTHER THAN ALUMINIUM,
MINIMUM DIAMETER OR WIDTH OF WELD (INCHES)
CPW 23
Revision: T
16
Minimum Contacting
Overlap(1)(2)(4)
Minimum Diameter or
Width(1) of Weld
Thickness Ratio
Thickness Ratio
1:1 to 1.5:1
Over 1.5:1
to 2.5:1
1:1 to 1.5:1
Over 1.5:1 to
2.5:1
.013 - .018
.240
.290
.100
.280
.330
.019 - .025
.280
.026 - .031
.310
.340
.120
.360
.430
.380
.140
.420
.510
.032 - .037
.340
.410
.160
.490
.590
.038 - .043
.360
.450
.170
.550
.660
.044 - .050
.390
.480
.190
.610
.740
.051 - .062
.440
.540
.210
.740
.890
.063 - .078
.490
.600
.230
.900
1.090
.079 - .093
.530
.660
.250
1.040
1.260
.094 - .125
.620
.760
.290
1.340
1.630
NOTES:
Dimensions are in inches.
1. Where pieces are not of equal thickness, values shall be based on thickness of the
thinner piece, except where the weld involves three or more thicknesses in which case
see Note 4.
2. Values include allowance for weld location tolerances. Dimensions on details and
weldments shall be such that, under adverse tolerances, values for minimum contacting
overlap are maintained.
3. Values are absolute minimum after applying the minus tolerance.
4. Three Thickness Joints: The above data in the table is for two-thickness joints. The
same data is used for welds involving three or more thicknesses provided:
a) Thickness ratio shall be the ratio between the thickness of the thinner section and
the total thickness of all remaining sections.
b) The minimum contacting overlap shall be based on the thickness of the thinner
flanking section.
c) The minimum weld size shall be that for the thinnest piece of the pile-up.
d) The minimum spacing of the welds shall be increased by 30%.
CPW 23
Revision: T
17
APPENDIX B:
MATERIALS OTHER THAN ALUMINIUM,
MINIMUM DIAMETER OR WIDTH OF WELD (METRIC)
CPW 23
Revision: T
18
Minimum Contacting
Overlap(1)(2)(4)
Minimum Diameter or
width(1) of weld
Thickness Ratio
Thickness Ratio
1:1 to
1.5:1
Over 1.5:1
to 2.5:1
1:1 to 1.5:1
Over 1.5:1 to
2.5:1
0.330 - 0.457
6.096
7.366
2.540
7.112
8.382
0.483 - 0.635
7.112
8.636
3.048
9.144
10.922
0.660 - 0.787
7.874
9.652
3.556
10.668
12.954
0.813 - 0.940
8.636
10.414
4.064
12.446
14.986
0.965 - 1.092
9.144
11.430
4.318
13.970
16.764
1.118 - 1.270
9.906
12.192
4.826
15.494
18.796
1.295 - 1.575
11.176
13.716
5.334
18.796
22.606
1.600 - 1.981
12.446
15.240
5.842
22.860
27.686
2.007 - 2.362
13.462
16.764
6.350
26.416
32.004
2.388 - 3.175
15.748
19.304
7.366
34.036
41.402
NOTES:
Dimensions are in millimeters.
1. Where pieces are not of equal thickness, values shall be based on thickness of the
thinner piece, except where the weld involves three or more thicknesses in which case
see Note 4.
2. Values include allowance for weld location tolerances. Dimensions on details and
weldments shall be such that, under adverse tolerances, values for minimum contacting
overlap are maintained.
3. Values are absolute minimum after applying the minus tolerance.
4. Three Thickness Joints: The above data in the table is for two-thickness joints. The same
data is used for welds involving three or more thicknesses provided:
a) Thickness ratio shall be the ratio between the thickness of the thinner section and the
total thickness of all remaining sections.
b) The minimum contacting overlap shall be based on the thickness of the thinner
flanking section.
c) The minimum weld size shall be that for the thinnest piece of the pile-up.
d) The minimum spacing of the welds shall be increased by 30%.
CPW 23
Revision: T
19
APPENDIX C:
ALUMINIUM,
MINIMUM DIAMETER OR WIDTH OF WELD (INCHES)
CPW 23
Revision: T
20
Minimum Contacting
Overlap(2)(3)(5)
Minimum Diameter or
Weld Width(2)
Minimum Weld
Spacing(2)(4)(5)
(Centerline to Centerline)
Thickness Ratio
1:1 to 2:1
.018 - .020
.375
.110
.375
.0225 - .0275
.400
.130
.400
.0295 - .0345
.500
.140
.440
.037 - .043
.560
.160
.480
.046 - .054
.620
.180
.500
.059 - .067
.700
.200
.560
.067 - .075
.750
.220
.630
.076 - .084
.800
.230
.750
.086 - .094
.850
.240
.850
.095 - .105
.900
.260
.950
.120 - .130
1.000
.280
1.200
.152 - .168
1.250
.320
1.300
.181 - .199
1.400
.350
1.400
Notes:
Dimensions are in inches.
1. For intermediate thicknesses not given, use the nearest smaller thickness.
2. Where pieces are not of equal thickness, values shall be based on thickness of the
thinner piece, except where the weld involves three or more thicknesses, in which case
see Note 5.
3. Values include allowance for weld location tolerances. Dimensions on details and
weldments shall be such that, under adverse tolerances, values for minimum contacting
overlap are maintained.
4. Values are absolute minimum - after applying minus tolerance.
5. Three Thickness Joints: The above data in the table is for two-thickness joints. The same
data is used for welds involving three or more thicknesses provided:
a) Thickness ratio shall be the ratio between the thickness of the thinner section and the
total thickness of all remaining sections.
b) The minimum contacting overlap shall be based on thickness of the thinner flanking
section.
c) The minimum weld size shall be those for the thinnest piece of the pile-up.
d) The minimum spacing of the welds shall be increased by 30%.
CPW 23
Revision: T
21
APPENDIX D:
ALUMINIUM,
MINIMUM DIAMETER OR WIDTH OF WELD (METRIC)
CPW 23
Revision: T
22
Minimum Contacting
Overlap(2)(3)(5)
Minimum Diameter or
Weld Width(2)
Minimum Weld
Spacing(2)(4)(5)
(Centerline to
Centerline)
Thickness Ratio
1:1 to 2:1
0.457 - 0.508
9.525
2.794
9.525
0.572 - 0.699
10.160
3.302
10.160
0.749 - 0.876
12.700
3.556
11.176
0.940 - 1.092
14.224
4.064
12.192
1.168 - 1.372
15.748
4.572
12.700
1.499 - 1.702
17.780
5.080
14.224
1.702 - 1.905
19.050
5.588
16.002
1.930 - 2.134
20.320
5.842
19.050
2.184 - 2.388
21.590
6.096
21.590
2.413 - 2.667
22.860
6.604
24.130
3.048 - 3.302
25.400
7.112
30.480
3.861 - 4.267
31.750
8.128
33.020
4.597 - 5.055
35.560
8.890
35.560
Notes:
Dimensions are in millimeters.
1. For intermediate thicknesses not given, use the nearest smaller thickness.
2. Where pieces are not of equal thickness, values shall be based on thickness of the
thinner piece, except where the weld involves three or more thicknesses, in which case
see Note 5.
3. Values include allowance for weld location tolerances. Dimensions on details and
weldments shall be such that, under adverse tolerances, values for minimum contacting
overlap are maintained.
4. Values are absolute minimum - after applying minus tolerance.
5. Three Thickness Joints: The above data in the table is for two-thickness joints. The same
data is used for welds involving three or more thicknesses provided:
a) Thickness ratio shall be the ratio between the thickness of the thinner section and
the total thickness of all remaining sections.
b) The minimum contacting overlap shall be based on thickness of the thinner flanking
section.
c) The minimum weld size shall be those for the thinnest piece of the pile-up.
d) The minimum spacing of the welds shall be increased by 30%.