Master Guided Bend Testing - Easy Stepwise Instructions

Guided Bend Testing: AWS D1.2 for Al Structural Welds

Procedure:

1. Identify Filler Alloy - If using 4043 (F23), regardless of the base alloy welded, machine the specimen to 1/8" thickness and bend over a 2-1/16" diameter mandrel, as shown for 6XXX series (M23) base alloys in Figure 2.

2. Identify Base Alloy - If welded with any filler except F23, test as specified for the base alloy.

3. Relate Base Alloy to AWS M- Number and Bend Diameter

     Base Alloys                         M-No.                 Bend Dia. (in.)

   1060,1100,3003,
      AlcIad® 3003                       M21              4t(1-1/2" for 3/8" spec.)
                                                                                      (Fig.1)
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  3004, AlcIad® 3004,
    5052, 5154, 5254,
      5454, 5652                           M22           4t(1-1/2" for 3/8" spec.)
                                                                                      (Fig. 1)
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  6061, AlcIad® 6061,
   6063 & F23 Welds                  M23               2-1/16" for 1/8" spec.
                                                                                      (Fig. 2)
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   5083, 5086, 5456 & 
      Annealed M23                      M25        6-2/3t(2-1/2" for 3/8" spec.)
                                                                                      (Fig. 3)
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         7005 &                               M27
     Annealed 2219                      M24                8t(3" for 3/8" spec.)

4. Prepare Proper Specimen Thickness - All welds in 6061 & 6063 (M23) base alloys and all welds made with 4043 (regardless of base alloy) are machined to 1/8" thickness before bending & bent over a 2-1/16" dia. mandrel (Fig. 2)

5. Determine Base Alloy Temper - AlcoTec recommends the use of a “wrap-around” bend test rather than a plunger-type for uniform bending with all work-hardened or heat treated tempers and all dissimilar alloy combinations. (Fig. 4)

6. Machine or Sand Specimen in Longitudinal Direction (Transverse to Weld) - Avoid any scratches or machining grooves parallel to the weld. (Fig. 5)

7. Radius Specimen Corners - Apply generous radii to the longitudinal corners of the bend specimen to avoid corner tears. Use the max. radii permitted. (Fig. 6)

Note: The testing requirements on this sheet are also representative of those required by the ASME Section IX, with the differences of “M” numbers being “P” numbers and the omission of the annealed materials.