ICS 25.166.

10

J 33

Record No.: 40018-2013

Power Industry Standard of the People's Republic of China

DL/T 754-2013
Replace DL/T 754-2001

Code of the Welding Technique for Bus

Issued on Mar. 7, 2013 Implemented on Aug. 1, 2013

Published by National Energy Administration
 DL/T 754-2013

Contents

Foreword............................................................................................................................................. 2

Introduction......................................................................................................................................... 3

1. Scope............................................................................................................................................... 4

2. Normative references...................................................................................................................... 4

3. General provisions.......................................................................................................................... 5

4. Materials and Machines.................................................................................................................. 5

5. Groove preparation..........................................................................................................................7

6. Welding............................................................................................................................................9

7. Quality inspection..........................................................................................................................11

8. Technical documents..................................................................................................................... 14

Appendix A (Normative Appendix) Busbar welding procedure test.............................................15

Appendix B (Normative Appendix) Rules for Busbar Welder Technical Examination................18

Appendix C (Informative Appendix) Relevant information and materials of commonly used

aluminum and copper........................................................................................................................20

Appendix D (Normative Appendix) Radiographic testing regulations for busbar welding joints23

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 DL/T 754-2013

Foreword

In addition to editorial modification, the main technical changes of this Code are as follows
compared with DL/T 754-2001:

— Expanded the scope of standard, and the name of the standard was changed as Code of the
Welding Technique for Bus;

— Stipulated the requirements for operation skill assessment of copper and aluminum busbar
welding welders;

— Supplemented the quality requirements for the copper and welding materials;

— Stipulated the selection principle of welding materials;

— Added the technical requirements for copper welding;

— Adjusted the contents of welding procedure tests, and attached as the normative Appendix
A;

— Increased the welded joint strength values of the heat-treated aluminum alloy from 60% to
75%;

— Adjusted the dimension and quantity sheet of welders' test specimen, and combined with
the new DL/T 679;

— Supplemented the provisions on the radiographic testing of copper busbar welding joint;

— Adjusted other parts of the original standard that don't adapt to the current technological
development.

This Code is proposed by China Electricity Council.

This Code is under centralized management by the Technical Committee on Welding of

Power Station of Standardization Administration in Electric Power Industry.

Organizations responsible for drafting this Code: China Electric Power Research Institute.

Organizations participated in drafting this Code: Beijing Power Equipment Group Co., Ltd.,
Csec Guohua (Beijing) Electric Power Research Institute Co., Ltd., Jiangsu Fangtian Power
Technology Co., Ltd., Zhejiang Thermal Power Construction Co., Ltd., Henan Electric Power Test
Research Institute.

Main drafters of this Code: Guo Jun, Liang Jun, Zhou Anben, Zhang Li, Qiao Yaxia, Ge
Zhaoxiang, Zhang Xuefeng, Li Xiqiang, Wu Yingli, Xu Jiangxiao.

This Code was first published in 2001, and this is the first revision.

The opinions and suggestions proposed during the implementation of this Code are to be
feedbacked to the Standardization Center of China Electricity Council at the following address:
No. 1 Ertiao Lane, Baiguang Road., Beijing 100761, China.

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 DL/T 754-2013

Introduction

In accordance with the requirements of the National Energy Administration for the Notice on
Issuing the First Batch of Energy Industry Standard Formulation (Revision) Plan in 2010 (GNKJ
(2010) No. 320), relevant unit organizations organized to revise the DL/T 754--2001 Code of the
Welding Technique for Aluminum Bus. Its format follows the provisions of GB/T 1.1-2009
Directives for Standardization - Part 1: Structure and Drafting of Standards.

During the revision process, this Code has absorbed the technological development
achievements of busbar welding in the power transformation field in recent years, and referred to
relevant international standards, national standards as well as relevant domestic industry standards
and regulations.

This Code is a relatively independent standard.

This Code can be used as the welding technical requirements recognized by owners,
supervisors, construction units and other interested parties involved in the power station and
power transmission and transformation field.

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 DL/T 754-2013

Code of the Welding Technique for Bus

1. Scope

This Code stipulates the technical requirements for the busbar welding work involved in
equipment manufacture, installation and maintenance of electric power industry.

This Code applies to the Tungsten Inert Gas Welding (TIG) and Metal-Inert Gas Welding
(MIG) of busbar made of pure aluminum and aluminum alloys and pure copper and copper alloys.

The welding of the aluminum alloy electric power fittings can be implemented with reference
to this Code.

2. Normative references

The following documents are essential for the application of this document. For any dated
reference documents, only the version with the required date applies to the Document. For undated
references, their latest versions (including all amendments) are applicable to this document.

GB/T 985.3 Aluminum and Aluminum Alloy Gas Welding Groove (GB/T 985.3-2008, ISO
9692-3:2000, MOD)

GB/T 3048.2 Test Methods for Electrical Properties of Electric Cables and Wires - Part 2:
Electrical Resistivity Test for Metallic Materials (GB/T 3048.2-2007, IEC 60468:1974, MOD)

GB/T 3048.4 Test Methods for Electrical Properties of Electric Cables and Wires - Part 4: DC
resistance test of conductors

GB/T 3190 Wrought Aluminum and Aluminum Alloys--Chemical Composition

GB/T 3323 Radiographic Examination of Fusion Welded Joints in Metallic Materials

GB/T 3880.1~GB/T 3880.3 General industrial aluminum and aluminum alloy plate and
stripes

GB/T 4842 Argon

GB/T 5231 Processing Copper and Copper Alloy Designations and Chemical Composition

GB/T 9460 Copper and Copper Welding Wire

GB/T 10858 Aluminum and Aluminum Alloy Welding Wires

CB/T 3692 Breakdown Test Methods for Fillet Welded Seams

DL/T 675 Qualification Exam Rules for NDT Personnel in Electric Power Industry

DL/T 679 Welder Technical Examination Procedures

DL/T 819 The Code of Welding Heat Treatment for Power Plant

DL/T 821 The Code of Radiographic Examination of Butt Welded Joints of Pressure Steels

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 DL/T 754-2013

Pipes and Tubes

JB/T 4730.5 Nondestructive Testing of Pressure Equipment - Part 5: Penetrant testing

SJ/T 10743 Inert Gas Shielded-arc Welding, Plasma Welding and Tungsten and Cerium
Electrodes for Cutting

3. General provisions

3.1 The welding procedure test shall be conducted before welding. In the event that there are
requirements for the busbar welding procedure qualification in of the busbar product standards,
the requirements shall be met. In the event that the busbar materials are supplied together with the
imported generator sets, its welding shall comply both with the specific provisions in contracts and
this Code.

3.2 If there are no requirements for the welding procedure test in the product standards, the
welding procedure test shall be carried out in accordance with the requirements of Appendix A.

3.3 The Welding Process (Operation) Instructions shall be compiled according to the welding
procedure test results and in combination with on-site construction conditions.

3.4 The busbar welders participate in assessment in accordance with the basic requirements of
DL/T 679 welder assessment and the provisions of Appendix B to this Code, and obtain the busbar
welder qualification certificate with corresponding conditions. Before the formal welding, the
simulation exercise corresponding to the actual situation should be carried out, and the busbar
welding can be carried out only after the appearance inspection meets the requirements.

3.5 The radiographic testing personnel shall obtain the qualification certificates in accordance with
the provisions of DL/T 675, and have been engaged in the corresponding level radiographic
testing.

3.6 The welding work shall comply with the national and industrial safety and environmental
protection regulations and other special regulations.

4. Materials and Machines

4.1 Base metal

4.1.1 The aluminum and copper materials shall comply with the provisions of design selection
standards, and be attached with the material quality certificates.

4.1.2 The purchased materials shall be checked randomly according to the batch number, and the
inspection results shall comply with the contract provisions or the corresponding provisions of
GB/T 3190, GB/T 3880.1 ～ GB/T 3880.3, GB/T 5231 and other standards. Imported materials
shall comply with the technical conditions stipulated in contracts. See Table C.1 ～ Table C.4 of
Appendix C for the designation, composition and mechanical properties of common aluminum
and copper.

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 DL/T 754-2013

4.2 Welding material

4.2.1 Welding materials shall be selected in accordance with the chemical composition,
mechanical properties and working conditions of the base metal and results of welding procedure
tests.

4.2.2 The quality of welding materials shall comply with the provisions of GB/T 9460, GB/T
10858 and relevant standards. See Table 1 for the model, chemical composition and scope of
application of common busbar wires.

Table 1 Model, Chemical Composition and Scope of Application of Common Busbar Wires
Welding Chemical Composition (Quality Fraction)
Melting
wire Category % Usage
point ℃
type Cu Sn Mg Mn Si Fe Al

Pure aluminum or
SAl1100 Aluminum - - - - ≤0.30 - 99.5 660
general aluminum alloy

Aluminum
Sal4043 - - ≤0.05 ≤0.05 4.5~6.0 ≤0.80 Allowance 580~610 General welding wire
and silicate

Aluminum, manganese
Aluminum and other aluminum
Sal3103 and - - - 1.0~1.6 ≤0.60 ≤0.70 Allowance 643~654 alloys with corrosion
manganese resistance and good
strength

Aluminum, magnesium
Aluminum and other aluminum
SAl5356 and - - 4.7~5.5 0.5~1.0 ≤0.25 ≤0.40 Allowance 638~660 alloys with corrosion
magnesium resistance and good
performance

Welded deoxidized
SCu1898 Pure copper ≥98.0 ≤1.0 - ≤0.50 0.1~0.4 ≤0.30 ≤0.01 - copper and electrolytic
copper

4.2.3 The selection of welding materials shall comply with the following provisions.

a) The chemical components of deposited metal shall be comparable to that of the base
metals;

b) The electrical resistivity shall not be lower than that of the base metals;

c) Good welding process performance;

d) The corrosion resistance shall not be lower than the corresponding requirements of the
base metals.

4.2.4 The oil stains, oxidation films and other impurities on the surface of welding materials shall
be removed before welding.

4.2.5 The purity of argon gas for welding shall not be lower than 99.99%, and shall comply with
the provisions of the GB/T 4842 standards.

4.2.6 The tungsten-cerium electrode for welding shall comply with the provisions of the SJ/T
10743 standards.

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 DL/T 754-2013

4.3 Welding machines

4.3.1 The welding equipment and instruments shall be inspected regularly, and the parts requiring
measurement and calibration shall be used within the validity period of calibration.

4.3.2 Before use, the instruments, equipment and instruments involved in welding shall be
confirmed to be suitable for the welding work.

4.3.3 For TIG welding aluminum busbar, it is recommended to use the AC square wave arc
welding power source. This arc welding power source shall have the function of non contact arc
starting.

4.3.4 The selected argon gas pressure reducing flowmeter shall be of accurate indicating, safe and
reliable and flexible adjustment.

4.3.5 The heat treatment instruments, equipment and instruments for welding shall comply with
relevant provisions of DL/T 819.

5. Groove preparation

5.1 General provisions

5.1.1 The position of the busbar welding joint shall comply with the following provisions.

a) The edge away from the support insulators and busbar splints shall not be less than
100mm;

b) The position of the butt welded seams on different plates of the same busbar shall be
staggered, with a distance not less than 50mm.

5.1.2 The busbar surface shall be clean and smooth, without cracks, wrinkles, inclusion,
deformation and distortion and internal damage.

5.1.3 No oxide film shall be existed on the contact surface butted to busbar, and the processing
shall be smooth.

5.1.4 The busbar welding can be carried out only after all sections are in place and adjusted and
the error value complies with the provisions.

5.2 Groove form and processing

5.2.1 The groove form and dimension of busbar welding shall comply with the GB/T 985.3 or
design drawings. See Table 2 for the basic form and dimension of common groove.

5.2.2 The machining or plasma arc cutting can be used for the groove processing. In case of
plasma arc cutting, the machine allowance of 1mm~2mm shall be reserved.

5.2.3 Base plates or washers at the root shall be placed for the single-side welding. It is
recommended to use the homogeneous materials for unremovable base plates or washers.

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 DL/T 754-2013

Table 2 Basic Form and Dimension of Groove

Weldment Dimension of joint structure

Joint Groove thickness Scope of

S/N Graph a b p
type type δ application
(°) mm mm
mm

0.5 ~
1 <5 - - Plates
2

Plates or pipe
2 5 ~ 12 35 ~ 40 2~3 1~2
fittings
Butt Joint
3 > 10 30 ~ 35 2~3 1.5 ~ 3 Plates

6~8 Plates or pipe

4 >5 25 ~ 30 1~2
5~6 fittings

5 3 ~ 12 - - - Plates

6 T Joint > 10 35 ~ 40 1~2 2~3 Plates

7 > 15 35 ~ 40 1~2 2~3 Plates

Overlap Plates or pipe

8 >5 Overlapping length L ≥2δ
joint fittings

5.3 Preweld cleaning

5.3.1 The oil stains, oxidation films and other impurities on the groove parts shall be removed
before welding.

5.3.2 The cleaning scope of the weldments shall include the groove surface and its adjacent base
metals. The cleaning scope of the adjacent base metals shall be 10mm~15mm.

5.3.3 The mechanical or chemical method can be used. The cleaning of various dirt shall meet the
following requirements.

a) Degreasing: Remove the oil stains from the surface with gasoline, acetone and other
organic solvent.

b) Remove oxidation film: The mechanical means can be used for cleaning, and it is
recommended to use wire brushes; the chemical method can also be used for cleaning, and the
specific steps are shown as below: Soak in 5%~10%NaOH water solution (about 70℃) for
30s~60s, rinse with clean water, then soak in 15%HNO3 water solution (normal temperature) for
2min, rinse with clean water, and carry out the drying treatment.

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 DL/T 754-2013

5.3.4 The weldments shall be welded immediately after cleaning.

6. Welding

6.1 Environmental requirements

6.1.1 The temperature of the welding site shall not be lower than 5℃. The lowest temperature can
be measured in the spacial scale of 1m radius centered on the welding site.

6.1.2 The welding site shall be equipped with windproof, moisture-proof, rain-proof and
snow-proof facilities.

6.2 Preheating temperature

6.2.1 When the TIG method is used to weld the weldments with the thickness of more than 15mm,
the weldment shall be preheated before the welding, and the preheating temperature is between
50℃-100℃.

6.2.2 If the TIG and MIG methods are used to weld the copper busbar, the preheating temperature
of the copper busbar is shown in Tables 3 and 4.

Table 3 TIG Welding Parameter of Copper Busbar

Diameter, mm Number of
Panel Welding Argon Preheating
Groove welding
thickness, Welding Tungsten current, flow, temperatur
Nozzle type layers
mm wire electrode A L/min e℃
(front/back)

0.8 ~ 1 2 2 8 ~ 10 80 ~ 90 5~6 I 1 -

1~3 2 3 8 ~ 10 150 ~ 200 6~8 I 1/1 or 1 -

3~5 3 3~4 10 ~12 200 ~ 240 8 ~ 10 V 1 ~ 2/1 200 ~ 350

5~7 4 4~5 12 ~ 14 260 ~ 300 10 ~ 14 V 2/1 350 ~ 450

7 ~ 10 5 6 14 ~ 16 300 ~ 350 14 ~ 18 X 2/1 ~ 2 450 ~ 550

Table 4 Recommended MIG Welding Parameter of Copper Busbar

Diameter, mm Number of
Panel Welding Argon Preheating
Groove welding
thickness, current, flow, temperature
Welding wire Nozzle type layers
mm A L/min ℃
(front/back)

3~5 1.2 14 220 ~ 270 16 I 1 -

5~7 1.6 14 250 ~ 290 16 V 1/1 or 1 -

7 ~ 10 1.6 16 280 ~ 300 18 V (1~2)/1 300 ~ 350

Multi
> 10 1.6 16 300 ~ 320 18 V 350 ~ 450
layer/1

6.3 Weldment assembly

6.3.1 The weldment of the positioning welding shall be determined in accordance with the

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 DL/T 754-2013

weldment specification and welded seam dimension.

6.3.2 The requirements for the welding materials, welding process, preheating temperature and
welder qualifications of the positioning welding shall be same as those required for formal
welding.

6.3.3 The placement of positioning points shall be determined in accordance with the part shape,
weld length and the following requirements.

a) Plates: When the weld length is not more than 500mm, 2~3 points can be set; when the
weld length is greater than 500mm, one positioning point shall be set at each interval of 200mm.

b) Pipe fittings: When the diameter is less than 300mm, one positioning point shall be set at
each interval of 120°, but generally it is not less than 3 points; when the diameter is between
300mm~500mm, 3 ～ 5 points can be positioned; when the diameter is greater than 500mm, the
positioning welding shall be made once at each interval of 60°along the circumference.

6.3.4 It is recommended the weld length of the positioning welding between 20mm~30mm and the
special weldment up to 50mm.

6.3.5 If the weldment assembly needs the hammer shaping, it is recommended to use a mallet.

6.4 Welding procedure

6.4.1 Aluminum busbar welding

6.4.1.1 When the thickness of aluminum busbar exceeds 8mm, it is recommended to use the
multi-layer welding, and the welding parameters shall be determined according to the welding
procedure test.

6.4.1.2 The AC and non contact arc starting shall be used for TIG welding, and the welding
parameters are shown in Table 5.

6.4.1.3 The DC reverse polarity shall be used for MIG welding, and the welding parameters are
shown in Table 6.

6.4.2 Postwelding heat treatment

6.4.2.1 In case of strength requirements, the welded joints shall be processed with solid solution +
artificial aging.

Table 5 TIG Welding Parameter of Aluminum Busbar

Weldment Welding wire Tungsten Number of
Welding Argon flow, Nozzle
thickness, diameter, electrode welding
current, A L/min bore, mm
mm mm diameter, mm layers
5~6 4 4 180 ~ 240 10 ~ 20 10 ~ 12 1~2
7~8 4 4~5 240 ~ 280 10 ~ 20 12 ~ 14 2
9 ~ 12 5 5~6 280 ~ 340 10 ~ 20 14 ~ 16 2~3
12 ~ 20 6 6 340 ~ 380 10 ~ 20 16 ~ 18 3~4
6.4.2.2 For the welded joint with the designation 6063 aluminum, its solid solution treatment
process is shown as below. Keep the welded joint at the temperature of 500℃~520℃ for 1h, then

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 DL/T 754-2013

cool it with the normal temperature water, and carry out the artificial aging. The heat treatment
process parameters shall be verified in the process test.

Table 6 MIG Welding Parameter of Aluminum Busbar

Weldment Number of
Welding wire Welding Welding Wire feed Argon flow,
thickness, welding
diameter, mm current, A voltage, V rate, m/min L/min
mm layers

8 1.6 180 ~ 220 24 ~ 26 4.5 ~ 6.2 25 ~ 28 2

8 ~ 12 1.6 190 ~ 230 25 ~ 27 4.8 ~ 6.5 27 ~ 30 >2

12 ~ 20 1.6 200 ~ 240 25 ~ 27 5.0 ~ 6.5 27 ~ 30 >3

6.4.3 Copper busbar welding

6.4.3.1 When the thickness of copper busbar exceeds 7mm, it is recommended to use the
multi-layer welding, and the welding parameters shall be determined according to the welding
procedure test.

6.4.3.2 The DC straight polarity shall be used for TIG welding, and the welding parameters are
shown in Table 3.

6.4.3.3 The DC reverse polarity shall be used for MIG welding, and the welding parameters are
shown in Table 4.

6.4.4 Other requirements

6.4.4.1 The tubular busbar butt joint with the diameter greater than 300mm is recommended to use
the balanced welding.

6.4.4.2 The welding shall be carried out without the restricted conditions.

6.4.4.3 After passing the self-inspection, the welded joints shall be marked with the welder's steel
seal code or permanent mark near the welded seams according to the regulations.

6.4.5 Defects repair

6.4.5.1 If any defects are found upon inspection of welded joints, it shall identify the cause, work
out measure and repair them.

6.4.5.2 Defects shall be eliminated by mechanical means.

6.4.5.3 The weld repair process shall be conducted in accordance with the previous welding
process.

7. Quality inspection

7.1 The inspection and testing work of the welding quality shall carry out the three-level
inspection and acceptance system, and implement the method of combining self-inspection with
special inspection to do a good job in quality inspection and acceptance.

7.2 The inspection and testing work of the welding quality shall emphasize the supervision on the

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 DL/T 754-2013

whole welding process, carry out the inspection before, during and after welding, and strictly
follow the inspection items and procedures.

7.3 The inspection scope, items and quantity of welded joints shall be conducted in accordance
with the provisions of Table 7. The inspection proportion shall be calculated in accordance with
the weld length.

7.4 It is recommended to carry out the appearance inspection first and then other item inspection.

Table 7 Inspection Scope, Items and Proportion of Busbar Welding Joint

Inspection items and proportion, %

Appearance inspection Penetrant Radiographic

S/N Scope
Special testing for testing for Butt
Self-inspection
inspection overlap joint Joint

Conductor between generator

1 100 100 5 10
outlet and transformer

Conductor between major loop

2 100 50 5 10
and station transformator

AC and DC excitation
3 100 20 2 5
conductor

Conductor in transformer
4 100 20 2 5
substation

5 Other components 100 5 1 -

7.5 The shape and dimension of welded seams and the quantity of the weld surface shall comply
with the provisions of Table 8 and Table 9, respectively.

Table 8 Allowable Range of Shape and Dimension of Welded Seams

Unit: mm

Width of welded seam

Surplus height of Height difference of
(wider than groove Welding leg dimension
welded seam weld surface
Joint width)
type Other Other Broadenin Broadenin
Downwar Downwar Dimension
positio positio g on two g on each K K1
d welding d welding difference
n n sides side

Butt
2~4 2~4 ≤2 ≤2 2~4 1~2 - - -
Joint

Overla
- - ≤2 ≤2 - - δ+(1~3) δ ≤2
p joint

Note: δ is the material thickness. When the material thickness of both sides is different, δ refers to the thinner material
thickness.

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 DL/T 754-2013

Table 9 Allowable Range of Defects on Weld Surface

Name of defects Allowable range

Cracks, incomplete fusion, dense pores,

Not allowed
burn-through

Welded seam
Not allowed
One-side with a liner

Incomplete welded The depth shall be not greater than 5% of the weldment
Welded seam
welding seam thickness and not greater than 1mm, and the total length shall be
without a liner
not greater than 20% of the weld length.

Double-side welded seam Not allowed

The depth shall be not greater than 10% of the weldment

Undercut thickness and not greater than 1mm, and the length shall be not
greater than 20% of the weld length.

One-side welded seam without The root convex shall be not greater than 4mm, and the concave
a liner shall be not greater than 2mm.

One-side
welded seam The root convex shall be not greater than 3mm, and the concave
Root
with removable shall be not greater than 2mm.
convex and
liner
concave With a liner
One-side
welded seam No through-welding convex and concave are allowed on the
without back of the liner.
removable liner

7.6 The deformation and bending deviation of weldments shall be not greater than 0.2%, and the
staggered joint value (off-centering) shall be not greater than 0.5mm (≤ 0.15δ, but not greater than
3.0mm). See Figure 1.
Unit: mm

a) Schematic of Post-welding Deformation b) Schematic Diagram of Staggered Joint

Figure 1 Schematic Diagram of Post-welding Deformation and Staggered Joint

Measurement

7.7 The penetrant testing for overlap joints shall be carried out in accordance with the provisions
of JB/T 4730.5, and no cracks, incomplete fusion and dense pores will be qualified.

7.8 The radiographic testing for butt joints shall be carried out in accordance with the requirements
of Appendix D, and the results of Class II or above will be qualified.

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 DL/T 754-2013

7.9 In case that there are unqualified results of the radiographic testing, the testing for the welded
seams of the same batch produced by the welder shall be carried out by doubling the number of
unqualified welded seams. If there are still unqualified welded seams in the doubling testing, this
batch of welded seams shall be deemed unqualified.

7.10 The repaired welded joints shall be retested.

8. Technical documents

8.1 The technical documents of busbar welding shall include the following contents:

a) List of busbar welding engineering (welding quantity, penetrant testing quantity,

radiographic testing quantity, etc.);

b) Certificate of busbar materials;

c) Quality certificate of welding materials (wires);

d) Registration form of welder technical examination;

e) Inspection test reports and radiographic testing films, etc.;

f) System diagram of whole or partial busbar (marking the positions of welded joints,
penetrant testing and radiographic testing, etc.).

8.2 The records of relevant matters (such as design changes, repair records) in the busbar welding
process shall be organized into documents.

8.3 After the materials are collected and sorted out, the materials shall be handed over in
accordance with the contract provisions.

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 DL/T 754-2013

Appendix A
(Normative Appendix)

Busbar welding procedure test

A.1 The welding procedure test shall be organized by the Process (or Technology) Management
Department of enterprises, presided by the responsible person of welding technology, and
completed by experienced welders.

A.2 The welding procedure test can be carried out according to the material type and structural
form. The main contents of the welding procedure test are shown as below.

a) Selection of welding materials and matching with base metals;

b) Adjustment of welding parameters (welding current, welding voltage, welding speed,

argon flow, weld preheating, etc.).

A.3 The welding procedure test shall be conducted for butt welded seam and fillet welded seam
specimens (made T-joint) respectively, and the specimen specifications are shown in Figure A.1.
See Table A.1 for the specimen specifications. The fillet weld length l shall be not less than 1/2L.

Table A.1 Specifications of Welding Procedure Test Specimens

Dimension of test specimen, mm Number of
Welding Form of
test specimen,
Method welded seam δ L B B1
pcs

Butt welded
TIG, MIG 6≤δ≤10 ≥300 ≥240 - 1 for each type
seam

Fillet welded
TIG, MIG 6≤δ≤10 ≥300 ≥150 ≥40 1 for each type
seam

a) Plate specimens b) T-joint specimens

Figure A.1 Dimension and Specification of Specimens

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 DL/T 754-2013

A.4 The applicable thickness range of weldment of the welding procedure test specimen is 0.5~2.5
times of the specimen thickness (δ).

A.5 The welding procedure test specimens shall be cut by mechanical means or plasma cutting
method. The testing items and sampling methods of butt joints are shown in Figure A.2, the
processing specifications of specimens are shown in Figure A.3, and the processing size of
specimens are shown in Table A.2. The processing size and specific test method of the fillet
welded seam breakdown test specimen of T-joint shall be implemented in accordance with the
provisions of CB/T 3692.

Table A.2 Processing Size of Specimens

Type of test Name of test Dimension of test specimen, mm

specimen specimen Length B Breadth b1 Thickness S

Tensile test ≥200 20 6≤S≤10

Plates
DC resistance test 240 5 5

Unit: mm

1, 2 - Tensile test; 3, 4 - Resistance measurement

Figure A.2 Schematic Diagram of Testing Items and Sampling Methods of Butt Joints

Figure A.3 Working Diagram of Tensile Test Specimens of Butt Joints

A.6 The results of the welding procedure test shall be checked and judged. On the basis of uniform

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 DL/T 754-2013

shape of welded seams, smooth transition of joint edge and shape dimension meeting requirements,
the radiography, resistance measurement and tensile tests shall be carried out for the butt joint
specimens; and the welded seam section inspection shall be conducted for the fillet welded seam
specimens.

A.7 The overall conditions of the welded joints for the welding procedure test shall have no
obvious abnormalities and defects, and the shape dimension and surface of welded seams shall
comply with the provisions of Clause 7.5 of this Code.

A.8 The welded seam defects shall be checked at the breaking edge of T-joint, and the allowable
range shall comply with the provisions of Table A.3.

Table A.3 Allowable Range of Welded Seam Section Defects Based on the T-joint Breaking
Edge Check
Name of defects Allowable range

Crack, incomplete fusion, incomplete

Not allowed
welding

The maximum dimension in any direction shall be not greater than 1/3
Single pore and slag inclusion
thickness, but shall not exceed 8mm.

Dispersed defect area No more than 10% of the tested area

A.9 The radiographic testing and result evaluation of the welded joint specimens shall be carried
out in accordance with the requirements of Appendix D.

A.10 The DC resistance value of the welded joints shall be not greater than 1.05 times of that of
raw materials with the same specification and dimension, and the resistance and resistivity test
shall be carried out in accordance with the requirements of GB/T 3048.2 and GB/T 3048.4,
respectively.

A.11 The tensile strength of welded joints shall not be less than the lower limit of the standard
tensile strength of raw materials. In terms of aluminum alloy strengthened by heat treatment, the
tensile strength of its welded joints shall not be less than 75% of the lower limit of the standard
tensile strength of raw materials.

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 DL/T 754-2013

Appendix B
(Normative Appendix)

Rules for Busbar Welder Technical Examination

B.1 The organization and procedure of the busbar welder technical examination shall comply with
the provisions of DL/T 679.

B.2 If a welder has obtained the qualification for aluminum busbar welding, he/she also is
qualified for copper busbar welding.

B.3 The busbar welder technical examination shall be based on the various technological
parameters of the welding procedure test, and shall be organized and implemented in accordance
with the welding method and welding position. The assessment materials shall be randomly
selected from Tables C.1~C.3 of Appendix C.

B.4 Welders who participate in the busbar welding technical examination shall also obtain the
qualifications stipulated by DL/T 679 for Class III welders.

B.5 The assessment contents of welders' basic knowledge shall comply with the provisions of
DL/T 679.

B.6 The welder skill assessment shall comply with the following provisions:

a) The Tungsten Inert Gas Welding (TIG) and Semi-automatic Metal-Inert Gas Welding
(MIG) shall be assessed separately.

b) The welding position shall comply with the provisions of DL/T 679. The substitution
principle of welding position of plates shall comply with the provisions of DL/T 679.

c) If the fillet joint 2F, 3F and 4F assessments are qualified, the overlap joint assessment can
be exempted.

d) If the assessments of four positions of butt joints, namely flat, horizontal, vertical and
resupine (1G, 2G, 3G, 4G) are qualified, the pipe welding can also be engaged.

e) The specimens of a welder who has completed the process test specimen welding have
passed various tests, such welder shall be deemed as having pass the corresponding operation skill
assessment.

B.7 See Table B.1 for the dimension and quantity of test specimen used for assessment.

B.8 The preweld cleaning of specimens and welding wires for assessment shall comply with the
provisions of Chapter 5 of this Code.

B.9 The appearance inspection shall be conducted for all assessment specimens. The radiographic
testing shall be carried out for butt joints, and the penetrant testing shall be carried out for fillet
joints. The testing requirements shall comply with the Chapter 7 of this Code. Two pieces of

18
 DL/T 754-2013

specimens shall be cut from the butt joint for the tensile test.

Table B.1 Dimension and Quantity of Test Specimen

Number of test
Dimension of test specimen, mm
Type of test Joint Welding specimen, pcs

specimen Type Method Length Breadth Breadth Thickness Welding

Quantity
L B B1 δ position

Butt 1G, 2G, 1 for each

TIG/MIG ≥300 ≥240 - 10
Joint 3G, 4G type
Plates
Fillet 1 for each
TIG/MIG ≥300 ≥150 ≥50 10 2F, 3F, 4F
joint type

B.10 The tensile test of butt joints shall be sampled and tested in accordance with the provisions of
Appendix A.

B.11 The grade evaluation of welder technical examination and the issuance and revocation of the
qualification certificate shall comply with relevant provisions of DL/T 679.

B.12 In the event that qualified welders have not been engaged in corresponding welding work for
6 consecutive months, the original assessment unit shall organize the process skill assessment, and
no assessment records will be deemed as having interrupted the corresponding welding work.

B.13 The filling mode of a welder's certificate is welding method + designation of base metal +
welding position (such as TIG-1060-2G).

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 DL/T 754-2013

Appendix C
(Informative Appendix)

Relevant information and materials of commonly used aluminum and copper

The relevant information and materials of commonly used aluminum and copper are shown
in Tables C.1～C.4.

Table C.1 Designation, Chemical Composition, Supply Status and Mechanical Properties
of Commonly Used Aluminum
Chemical Composition (Quality Fraction)
Mechanical property
%
State Wall Percentage
Tensile
Designation of thickness, elongation
strength
Si Fe Cu Mn Mg Al supply mm after
Rm
fracture A
MPa
%

6.5~12.5 ≥70 ≥15

H112
1060 12.5~25 ≥60 ≥20
0.25 0.35 0.05 0.03 0.03 99.60
(L2) O All ≤118 ≥20

H112 dimensions ≤118 ≥20.0

H112 4.5~10.0 ≥110 ≥16

3A21
0.6 0.7 0.20 1.0~1.6 0.05 Allowance O All ≤137 -
(LF21)
H112 dimensions ≤167 -

H112 4.5~12.5 ≥175 ≥7

5A02 Or
0.40 0.40 0.10 2.0~2.8 Allowance O All ≤226 -
(LF2) Cr0.15~0.40
H112 dimensions ≤226 -

H112 4.5~10.0 ≥275 ≥16

5A05
0.50 0.50 0.10 0.30~0.6 4.8~5.5 Allowance O All ≥216 ≥15
(LF5)
H112 dimensions ≥255 ≥15.0

0.5~5.0 ≥20

O 5.0~12.5 ≤130 ≥15

6063 0.2~0.6 0.35 0.10 0.10 0.45~0.9 Allowance 12.5~20.0 -

0.5~5.0 240 ≥8
T6
5.0~10.0 230 ≥8

Note 1: H112 - Products based on hot processing and forming There are specified requirements for the mechanical property of products in
this state.

Note 2: O - The processed products with the minimum strength after full annealing

Note 3: T6 - Solid solution treatment, artificial aging.

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 DL/T 754-2013

Table C.2 Designation and Main Chemical Compositions of Commonly Used Red Copper
Main Chemical Composition
Total
Group Designation Code (Quality Fraction) %
impurities %
Cu+Ag P

1# copper T1 ≥99.95 - ≤0.05

Pure copper 2# copper T2 ≥99.90 - ≤0.1

3# copper T3 ≥99.70 - ≤0.3

1# deoxidized
TP1 ≥99.90 0.004 ~ 0.012 ≤0.1
Phosphorized copper
copper 2# deoxidized
TP2 ≥99.90 0.015 ~ 0.040 ≤0.15
copper

Table C.3 Designation and Main Chemical Compositions of Commonly Used Brass
Main Chemical Composition (Quality Fraction) % Total
Group Designation Code
Cu Fe Sn Mn Al Zn impurities %

Common 68 brass H68 67.0~70.0 0.1 - - - Allowance ≤0.3

brass 62 brass H62 60.5~63.5 0.15 - - - Allowance ≤0.5

59-1-1 iron HFe

Iron brass 57.0~60.0 0.6~1.2 0.3~0.7 0.5~0.8 0.1~0.5 Allowance ≤0.3
brass 59-1-1

Table C.4 Machining State and Mechanical Properties of Commonly Used Copper

21
 DL/T 754-2013

Tensile Percentage elongation

Alloy Type of Manufacturing method and
strength, after fracture %
designation materials material status
MPa A10 A5

1# copper (T1) Cold-rolled Soft 196 30 -

2# copper (T2) Plate Cold-rolled Hard 294 3

3# copper (T3) Hot rolling 196 30 -

1# deoxidized Soft 206 35 42

copper (TP1) Drawing Semi-hard 235 ~ 343 - -
Pipes
2# deoxidized Hard 294 - -
copper (TP2) Extruding - 186 35 -

Soft 294 40 -

68 brass (H68) Cold-rolled Semi-hard 343 25 -

Hard 392 15 -

Plate Soft 294 40 -

Cold-rolled Semi-hard 343 20 -

62 brass (H62)
Hard 412 10 -

Hot rolling 294 30 -

Soft 294 38 43
68 brass (H68) Drawing
Semi-hard 343 30 34

Soft 294 30 43
Drawing
62 brass (H62) Pipes Semi-hard 333 30 34

Extruding 294 33 43

Iron brass
Extruding 431 28 31
(HFe59-1-1)

22
 DL/T 754-2013

Appendix D
(Normative Appendix)

Radiographic testing regulations for busbar welding joints

D.1 Test range

This Regulation applies to the radiographic testing and quality grade assessment of busbar
welding joints of aluminum busbar (including pure aluminum, aluminum magnesium alloy,
aluminum manganese alloy) with thickness not greater than 40mm and the copper and copper
alloy with thickness between 2mm~40mm.

The radiographic testing shall also comply with the requirements of this Regulation, in
addition to the relevant provisions of DL/T 821.

D.2 Image Quality Indicator and Depthometer

D.2.1 The scope of applicable workpiece materials of image quality indicator and depthometer
with different materials shall comply with the provisions of Table D.1.

Table D.1 The Scope of Applicable Workpiece Materials of Image Quality Indicator and
Depthometer with Different Materials
Material
Al Cu
Project

Materials of image quality indicator and

Industrial pure aluminum 3# pure copper
depthometer

Scope of applicable workpiece material Aluminum, aluminum alloy Copper, copper alloy

D.2.2 The linear image quality indicator shall be used. When the image quality indicator is placed
next to the radiation source, the selection of image quality indicator shall be conducted in
accordance with the provisions of Table D.2. If the image quality indicator is next to the film, the
image quality indicator shall increase one grade accordingly.

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 DL/T 754-2013

Table D.2 Picklist of Image Quality Indicators

Unit: mm

Image quality index achieved Wire diameter Suitable penetrated thickness TA

16 0.100 -

15 0.125 ≤6

14 0.160 6~8

13 0.200 8 ~ 12

12 0.250 12 ~ 16

11 0.320 16 ~ 20

10 0.400 20 ~ 25

9 0.500 25 ~ 23

8 0.630 32 ~ 40

D.2.3 The grooved contrast blocks shall be used for depthometer. The structure and specification
of the grooved contrast blocks shall comply with the provisions of DL/T 821.

D.3 Penetrated thickness

The penetrated thickness TA shall be determined according to the measured value of the
penetration conditions. If it is difficult in measurement, it can be determined based on Table D.3.

Table D.3 Penetrated Thickness of Butt Joint

Unit: mm

Penetrated mode Thickness of base metal Groove type Penetrated thickness TA

V δ+2
Single-layer penetration δ
X δ+4

V 2δ+2
Double-layer penetration δ
X 2δ+4

D.4 Film quality

D.4.1 The image quality index of film shall meet the requirements of Table D.2, and the density D
range of film shall be 1.5~4.0.

D.4.2 The image position of the image quality indicator on the film shall be correct, and the
positioning marks and identification marks shall be completed and shall not cover the image of the
tested welded seams.

D.4.3 No pseudo defects, including scratches, fingerprints, dirt, stains and static traces, are
allowed on the film, which will hinder the film evaluation.

D.5 Quality Grade Assessment of Radiographic Testing

D.5.1 The quality of welded joints can be divided into Class I, II, III and IV according to the
nature and quantity of defects.

D.5.1.1 No cracks, incomplete fusion, incomplete welding and strip defects are allowed in Class I

24
 DL/T 754-2013

welded joints.

D.5.1.2 No cracks and incomplete fusion defects are allowed in Class II and III welded joints; the
length of incomplete welding shall not be greater than 10% of total length of welded seams, the
length of continuously incomplete welding in 500mm length shall not be greater than 50mm, and
the incomplete welding depth shall not be greater than 5% of the thickness of base metals. The
evaluation of strip defects is same as the incomplete welding defects.

D.5.1.3 In case that the defect dimension exceeds the Class III, the welded seam will be evaluated
as Class IV.

D.5.2 The quality grading of circular defects is shown as below:

D.5.2.1 The defects with the length-width ratio not greater than 3 are defined as circular defects,
which may be pores or slag inclusions with round, oval, conical and other irregular shapes.

D.5.2.2 The evaluation area of circular defects is a rectangle paralleled with welded seams, and its
dimension is shown in Table D.4. The evaluation area shall be positioned with the most serious
defects on the film.

D.5.2.3 Evaluation of single circular defect:

Level I: The defect dimension shall not be greater than 1/5 weldment thickness and not
greater than 4mm, with the defect quantity of no more than 1 in an area of 1000mm2;

Level II: The defect dimension shall not be greater than 1/4 weldment thickness and not
greater than 6mm, with the defect quantity of no more than 1 in an area of 1000mm2;

Level III: The defect dimension shall not be greater than 1/3 weldment thickness and not
greater than 8mm, with the defect quantity of no more than 1 in an area of 1000mm2;

D.5.2.4 When evaluating, the circular defects shall be converted into points according to Table D.5,
and accumulatively calculated in the evaluation area.

Table D.4 Evaluation Area of Circular Defects

Nominal thickness of base metal, δ
≤20 > 20
mm

Dimension of evaluation area,

10 × 10 10 × 20
mm × mm

Table D.5 Conversion Method of Circular Defect Points

Long diameter of defect ρ,
≤1 1<ρ≤2 2<ρ≤3 3<ρ≤4 4<ρ≤5 5<ρ≤6 6<ρ≤8 8<ρ≤10
mm

Number of defect points 1 2 3 6 8 10 15 25

D.5.2.5 See Table D.6 for the number of allowable defect points in welded joints at all levels.

25
 DL/T 754-2013

Table D.6 Number of Allowable Defect Points in Welded Joints at All Levels
Evaluation area,
10 × 10 10 × 20
mm × mm

Nominal thickness of
base metal δ, ≤5 5< δ≤10 10< δ≤20 20<δ≤40
mm

Class I 4 6 8 10

Class II 8 12 16 20

Class III 16 24 32 40

Class IV The number of defect points greater than Class III or defects

Note: When the nominal thickness of base metals is different, the thinner thickness shall prevail.

D.5.2.6 When the defect dimension is less than the value stipulated in Table D.7, the grading
evaluation doesn't count the number of such defect. For Class I welded joints and Class II welded
joints with the nominal thickness of base metal δ≤5mm, the number of defect points not counted
in the circular defect evaluation area shall not be more than 10. If more than 10, the quality of the
welded joints shall be degraded one level.

Table D.7 Defect Dimension Excluding Points

Unit: mm

Nominal thickness of base metal δ Long diameter of defect

≤10 ≤0.3

10<δ≤20 ≤0.4

20<δ≤40 ≤0.7

____________________________

26
 Power Industry Standard of the People's Republic of China

Code of the Welding Technique for Bus

DL/T 754-2013

Replace DL/T 754-2001

Published and issued by China Electric Power Press

(No. 19, West Street of Beijing Station, Dongcheng District,

Beijing, 100005 http://www.cepp.sgcc.com.cn)

Printed by Beijing Botu Color Printing Co., Ltd.

First edited and printed in August 2013 in Beijing

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