AEROSPACE WELDING

1 PURPOSE & APPLICATION
1.1 This procedure defines the process for performing Aerospace
Welding.
1.2 This procedure applies to all employees involved in Aerospace
Welding.
1.3 This procedure meets at a minimum AWS D17:2001 Specification
for Fusion Welding for Aerospace Structures.

2 RESPONSIBILITIES
2.1

The Quality Director
2.1.1 Oversees personnel certification and audits the process.
2.2 The Production Manager
2.2.1 Coordinates employee training and certification.
2.3 The Welder
2.3.1 Completes the certification process in the time frame
established by the Production Manager.
2.3.2 Keeps the work area clean and free from objects that are
detrimental to the process.

3 PROCEDURE
3.1

Weld Classifications
3.1.1 Classifications will be Class A, Class B, or Class C.
3.1.2 Classifications refer to the level of inspection required and to
the acceptance criteria in MQ-04-42-02-00.
3.2 Welding Consumables
3.2.1 Consumables used in welding (bare welding wire and welding
rods, electrodes, inserts and fluxes) will be identified with at least the
material, specification procured, and size.
3.2.2 If the identification marking is destroyed or missing, the
consumable will be disposed in accordance with Nonconforming
Material Control MQ-05-05-00-00.
3.2.3 When required traceability of the consumables must be
maintained throughout the welding process.
3.2.4 Welding filler materials shall be stored in a clean and dry
environment, such that each material are segregated by size and
material to prevent contamination of materials.

Aerospace Welding
MQ-04-42-00-00 rev 01

3.2.5 Heating may be employed as necessary to prevent moisture
accumulation.
3.2.6 Low Hydrogen SMAW and FCAW electrodes will be handled
and stored in accordance with the manufacturer’s recommendations.
3.2.7 Fluxes shall be labeled and segregated by type and /or by
their particular application.
3.2.8 Fluxes will be stored in sealed containers to prevent moisture
pickup.
3.3 Welding Gases
3.3.1 The shielding gases shall be procured to the following
requirements unless otherwise required by the customer.
Gas Requirements
Gas

Specification

Argon
Helium
Oxygen
Nitrogen
Hydrogen
Acetylene
Carbon Dioxide

MIL-A-18455
BB-H-1168
B-O-925, Type I or II
A-A-59503, Type I or II, Class I, Grade B
BB-H-886, Type I or II
BB-A-106, Grade B
BB-C-101, Grade B

3.3.2

Alternate
Specification
CGA G-11.1
CGA G-9.1
CGA G-4.3
CGA G-10.1
CGA G-5.3
CGA G-1.1
CGA G-6.2

Recommended Shielding Gases

Recommended Shielding Gases for Welding
Gas
Material
Ar He Ar-He Ar-O(1) Ar-H N CO2
Aluminum
X
X
X
Cobalt
X
X
X
X
Copper
X
X
X
Magnesium
X
X
X
Nickel
X
X
X
(3)
CRES(2)
X
X
X
X
(4)
Plain Carbon Steel X
X
X
X
Low Alloy Steel
X
X
X
X

|1|
Expires 1 day after printing

Ar-CO2

(4)
(4)

Date Printed
Oct 25, 2010

3. 3. 3.12. 3.8 Filler material for tack welds shall be the same as that used for subsequent welding unless otherwise specified on the engineering drawing. welding torches. once used.14.6.5.4.4. If contamination is suspected. The shielding method and the shielding gas shall be included in the Production router. will be permanently marked a minimum of ½” all the way around the bottom of the handle in the following colors for each material. 3. as needed.13.14 Welding 3.3 Previously cleaned surfaces shall be protected from contamination.1 The welding arc shall not be struck on any portion of the base metal away from the surfaces to be joined.5 Preweld cleaning and other preparation 3. 3.5. Alkaline cleaning.12 Filler materials used shall be the ones specified on the Engineering drawing and listed on the Production router.2 In process correction |2| Expires 1 day after printing Date Printed Oct 25.2. 3. 3.4 Welding Equipment 3.5.4.9 Weld start and run-off tabs. abrasive blasting. 3. or machining) shall be used before welding.4 Only austenitic stainless steel wire brushes may be used on all other materials. When indication of an arc strike or an arc burn is present in an area other than the deposited weld metal. regulators.6 and 3.2 The requirements of section 3. 3.25% nominal C 3. 3. 3. scale.6. Wire brush marking colors Material Aluminum and its Alloys Cobalt and its Alloys Copper and its Alloys Magnesium and its Alloys Nickel and its Alloys CRES Alloys(1) Carbon and low Alloy Steels Titanium and its Alloys Color Green Orange Blue Purple Yellow Red Black White Note: (1) CRES = Corrosion resisting steel 3.7 should be considered during tack welding operations.8. or other contaminants. They shall be welded with the same filler materials as specified on the Engineering drawing.1 All surfaces to be welded and surfaces that may affect quality of the resulting weld (ex.3 Austenitic stainless steel wire brushes or carbon steel wire brushes may be used on carbon or low alloy steels. 3. 3. Welding filler materials and fixtures) shall be free from slag. when used.Titanium X X 3. They do not require calibration.1 Interpass cleaning of titanium or titanium alloy parts shall only be performed following a visual inspection and acceptance of the surface discoloration requirements of AWS D17 Section 6. grease.7 Preheating and Interpass temperature shall be established for materials susceptible to cracking during or after welding and be included in the Production router. 3. filler material feeders.2 Gas flow meters and pressure gages are for reference only.4. scraping. etc) shall be capable of producing welds that meet the acceptance criteria of MQ-04-42-02-00. 3.4. shall be composed of the same alloy as the joint members. the weldment shall be rejected as required in AWS D17 Section 6.6 X Note: (1) 8% Oxygen Maximum (2) CRES=Corrosion resisting steel (3) Allowed for backing only (4) Only recommended on plain carbons steels or low alloy steels with a max . surface oxides. 3.5.14.2 Chemical methods (ex.3 Flange joint fit-up shall be in accordance with the Engineering drawing.11 Tungsten electrodes. Wire brushing. 3. when required shall be in accordance with AWS A5. dirt.6. or etching) or Mechanical methods (ex. protective finishes.5. the surface shall be cleaned again per Paragraph 3. such as titanium) shall be protected from oxidation during welding. solvent wipe.1 The edge of each joint member shall be prepared as specified on the Engineering drawing.10 The weld and the heat-affected zones (incl deposited weld metal behind the weld pool in reactive materials. 3. Aerospace Welding MQ-04-42-00-00 rev 01 Preweld joint preparation and fit-up 3. 3.5 All wire brushes.1 Tack welds shall be consumed during subsequent welding unless removed in other processing. oils. 2010 .13 Interpass cleaning shall be performed in accordance with paragraph 3.8.2 The gap between joint members being welded and between backing strips (when used) and joint members being welded shall be in accordance with the Engineering drawing.1 Equipment (welding machines.

Aerospace Welding MQ-04-42-00-00 rev 01 4 REVISION HISTORY – Authored by Travis Mcilnay.14. The weld toe area shall comply with the requirements of MQ-04-42-02-00. slag.5.15.) 3.2.2. scale.1 When specified on the Engineering drawing.14.1 Added reference to Inspection Instruction MQ-04-42-02-00.2 When necessary to aid in the interpretation of nondestructive inspection indications.3. 4. When fit or function of the final assembly dictate material removal.3 The correction shall occur before any heat treating operations. 3. Remaining reinforcement must be visually evident above the surface plane of the adjacent joint member and extend throughout the weld bead width.1 Any correction made by the welder before submitting the weld for acceptance inspection is and in-process correction. The weld toe area shall comply with the requirements of MQ-04-4202-00. Removal of such material shall not reduce the weld bead size or base metal thickness below the Engineering drawing requirements.4 Before initiating an in-process correction the surfaces to be welded shall be cleaned in accordance with paragraph 3. When the in-process correction requires more than one attempt at the same flaw location the Production router must me changed to accommodate and document this correction.14.14.2. 3. 3. 3. approved 9 December 2006. 2010 .3 Weld reinforcement removal shall be accomplished using methods that do not reduce the thickness of the base metal and may only be removed for one or more of the following reasons. Approvals Document Custodian 9 Dec 2006 Date Quality Director 9 Dec 2006 Date President or Vice President 9-Dec 2006 Date |3| Expires 1 day after printing Date Printed Oct 25. 3.1 Postweld cleaning of welded titanium parts shall only be performed after completion of a visual inspection and acceptance of the surface discoloration in accordance with MQ-04-42-02-00.14.2.3.2. Authored by Travis Mcilnay. 3. or other foreign material.2 The correction shall not change the metallurgical or physical condition of the base metal.14. 3. 3. 3. (Note: for the purpose of this requirement a thermal stress relief operation is not considered to be a heat treat operation.15 The completed weldment shall be free of spatter.3. approved 4 December 2006. Remaining reinforcement must be visually evident above the surface plane of the adjacent joint member and extend throughout the weld bead width.14. flux.14.5 One in-process correction attempt is allowed in each individual flaw location.16 Welder certification will be in accordance with MQ-04-42-01-00.