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. 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 Argon Helium Oxygen Nitrogen Hydrogen Acetylene Carbon Dioxide 3.3.2 Specification 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 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

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.

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

Ar-CO2

(4) (4)

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

|1| Expires 1 day after printing

Date Printed
Dec 9, 2006

The shielding method and the shielding gas shall be included in the Production router. 3. when used. or machining) shall be used before welding.1 Tack welds shall be consumed during subsequent welding unless removed in other processing. scale.2 Chemical methods (ex. 3. once used.5.3 Austenitic stainless steel wire brushes or carbon steel wire brushes may be used on carbon or low alloy steels. 3.4. dirt.4. will be permanently marked a minimum of ½” all the way around the bottom of the handle in the following colors for each material. 3.9 Weld start and run-off tabs. oils. when required shall be in accordance with AWS A5. They do not require calibration. abrasive blasting. such as titanium) shall be protected from oxidation during welding. etc) shall be capable of producing welds that meet the acceptance criteria of MQ-04-42-02-00. They shall be welded with the same filler materials as specified on the Engineering drawing.7 should be considered during tack welding operations. 2006 3.4. 3.1 Equipment (welding machines. or etching) or Mechanical methods (ex.14.12 Filler materials used shall be the ones specified on the Engineering drawing and listed on the Production router. 3.5 All wire brushes. solvent wipe.4 Only austenitic stainless steel wire brushes may be used on all other materials.2 The requirements of section 3. the weldment shall be rejected as required in AWS D17 Section 6.1 All surfaces to be welded and surfaces that may affect quality of the resulting weld (ex.4 X X 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 . 3. When indication of an arc strike or an arc burn is present in an area other than the deposited weld metal. 3.2 Gas flow meters and pressure gages are for reference only.5.5. 3. 3.8.2.2 In process correction Date Printed Dec 9.4. 3.14.5. Preweld joint preparation and fit-up 3. 3. the surface shall be cleaned again per Paragraph 3.6 and 3. 3. Wire brushing.6. 3.6. Alkaline cleaning.8 Filler material for tack welds shall be the same as that used for subsequent welding unless otherwise specified on the engineering drawing.6 Aerospace Welding MQ-04-42-00-00 rev 01 |2| Expires 1 day after printing .14 Welding 3. 3. scraping. welding torches.5 Preweld cleaning and other preparation 3. surface oxides. or other contaminants. as needed. 3. 3. Welding filler materials and fixtures) shall be free from slag.4.8.Titanium 3.1 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. 3. filler material feeders.6. shall be composed of the same alloy as the joint members.1 The welding arc shall not be struck on any portion of the base metal away from the surfaces to be joined.3 Flange joint fit-up shall be in accordance with the Engineering drawing. 3.12. regulators. If contamination is suspected. grease.13 Interpass cleaning shall be performed in accordance with paragraph 3.3 Previously cleaned surfaces shall be protected from contamination.13.5.10 The weld and the heat-affected zones (incl deposited weld metal behind the weld pool in reactive materials.25% nominal C Welding Equipment 3. protective finishes.11 Tungsten electrodes.7 Preheating and Interpass temperature shall be established for materials susceptible to cracking during or after welding and be included in the Production router. 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 Note: (1) CRES = Corrosion resisting steel Color Green Orange Blue Purple Yellow Red Black White 3. 3.2 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 The edge of each joint member shall be prepared as specified on the Engineering drawing.

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. 3. The weld toe area shall comply with the requirements of MQ-04-42-02-00. Remaining reinforcement must be visually evident above the surface plane of the adjacent joint member and extend throughout the weld bead width.5.2.2.14. 3.1 Added reference to Inspection Instruction MQ-04-42-02-00. 3. approved 4 December 2006. flux.2 When necessary to aid in the interpretation of nondestructive inspection indications. 4.2. slag.3.) 3.14. Removal of such material shall not reduce the weld bead size or base metal thickness below the Engineering drawing requirements.3.1 Any correction made by the welder before submitting the weld for acceptance inspection is and in-process correction. Remaining reinforcement must be visually evident above the surface plane of the adjacent joint member and extend throughout the weld bead width.5 One in-process correction attempt is allowed in each individual flaw location. Authored by Travis Mcilnay.2 The correction shall not change the metallurgical or physical condition of the base metal. When fit or function of the final assembly dictate material removal. or other foreign material. scale. 3.14. Approvals 9 Dec 2006 Date Document Custodian Quality Director 9 Dec 2006 Date President or Vice President 9-Dec 2006 Date Aerospace Welding MQ-04-42-00-00 rev 01 |3| Expires 1 day after printing Date Printed Dec 9.2.3.14.1 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. 2006 .14. 4 REVISION HISTORY – Authored by Travis Mcilnay.4 Before initiating an in-process correction the surfaces to be welded shall be cleaned in accordance with paragraph 3.1 When specified on the Engineering drawing.15 The completed weldment shall be free of spatter. (Note: for the purpose of this requirement a thermal stress relief operation is not considered to be a heat treat operation.15.14.16 Welder certification will be in accordance with MQ-04-42-01-00.3 The correction shall occur before any heat treating operations.14. 3. approved 9 December 2006. 3.2. 3. 3. 3. The weld toe area shall comply with the requirements of MQ-04-4202-00. 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.

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