Raytheon

RAYTHEON COMPANY
LEXINGTON, MASSACHUSETTS

WS 33739A Page 0 of 18

NAVAL SEA SYSTEMS COMMAND DEPARTMENT OF THE NAVY PROCESS SPECIFICATION

FOR AEROSPACE FUSION WELDING

Prepared under Contract Number N00024-02-C-5100

WRITER DATE PROJECT APPROVAL DATE

K. COSTELLO
DESIGN APPROVAL

03-02-26
DATE

P. RYDER
CUSTOMER REP

03-02-26
DATE

P. SETMAER

03-02-26
RECORD OF REVISIONS

REV LTR/NO.

PAGE NUMBERS REVISED

AUTHORIZATION

DATE

EFFECTIVE DATE OR EQUIP SER NO.

ALL 0,8

ORIGINATED/RELEASED PER ED 6102536 See CN 240701

04-10-28

THIS SHEET FOR RAYTHEON COMPANY USE ONLY

Specification No. WS 33739A CAGE Code 53711 Page 1 of 18 NAVAL SEA SYSTEMS COMMAND DEPARTMENT OF THE NAVY PROCESS SPECIFICATION FOR AEROSPACE FUSION WELDING Contract Number N00024-02-C-5100

DISTRIBUTION STATEMENT D - DISTRIBUTION AUTHORIZED TO THE DOD AND U.S. DOD CONTRACTORS ONLY; CRITICAL TECHNOLOGY; 01 NOV 93. OTHER REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO DEPARTMENT OF THE NAVY, PROGRAM EXECUTIVE OFFICE FOR THEATER SURFACE COMBATANTS, PEO TSC 400G, 2531 JEFFERSON DAVIS HIGHWAY, ARLINGTON, VA 22242-5165. WARNING - THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC., 2751 ET SEQ) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED, TITLE 50, U.S.C., APP. 2401 ET.SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONS OF DOD DIRECTIVE 5230.25. DESTRUCTION NOTICE - DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT. DISCLOSURE STATEMENT - THIS INFORMATION IS FURNISHED UPON THE CONDITION THAT IT OR KNOWLEDGE OF ITS POSSESSION WILL NOT BE RELEASED TO ANOTHER NATION WITHOUT SPECIFIC AUTHORITY OF THE DEPARTMENT OF THE NAVY OF THE UNITED STATES; THAT IT WILL NOT BE USED FOR OTHER THAN MILITARY PURPOSES; THAT INDIVIDUAL OR CORPORATE RIGHTS ORIGINATING IN THE INFORMATION, WHETHER PATENTED OR NOT, WILL BE RESPECTED; THAT THE INFORMATION WILL BE PROVIDED THE SAME DEGREE OF SECURITY AFFORDED IT BY THE DEPARTMENT OF DEFENSE OF THE UNITED STATES.

Specification No. WS 33739A Page 2 of 18 1. SCOPE

1.1 This specification covers the requirements for fusion welding in conjunction with American Welding Society (AWS) D17.1. This specification replaces AMS-STD-2219, WS23719, MIS-47201, and G577917, and modifies AWS D1.1, D1.2, D1.6, and D9.1, but does not apply to ASME Boiler and Pressure Vessel codes. Unless otherwise specified herein the requirements of AWS D17.1 apply. 2. 2.1 APPLICABLE DOCUMENTS Government Documents The following documents of the issue in effect on the date of invitation for bids or requests for proposal, form a part of this specification to the extent specified herein. None 2.2 2.2.1 2.2.2 STANDARDS Military None Non-Government documents The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect at the present time shall apply. Aerospace Material Specification AMS-STD-1595 Qualification of Aircraft, Missile & Aerospace Fusion Welders

American National Standards Institute (ANSI)/American Welding Society (AWS) AWS D17.1:2001 Specification for fusion welding for Aerospace applications

(Copies of specifications, standards, drawings, and publications required by suppliers in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer/administrator.)

Specification No. WS 33739A Page 3 of 18 3. 3.1 3.2 REQUIREMENTS Any statement in AWS D17.1 that is not altered by this document shall apply. Order of precedence In the event of a conflict between specifications, the following list shall provide precedence: - Purchase Order/Contract requirements - Drawing requirements - This specification - Referenced specifications herein 3.3 3.3.1 Requirements for specific material types Structural steel welding requirements in accordance with AWS D1.1 When the Technical Data Package (TDP) imposes AWS D1.1, the modifications in Appendix 1 of this document shall apply. Structural aluminum welding requirements in accordance with AWS D1.2 When the TDP imposes AWS D1.2, the modifications in Appendix 2 of this document shall apply. Stainless Steel welding requirements in accordance with AWS D1.6 When the TDP imposes AWS D1.6, the modifications in Appendix 3 of this document shall apply. Sheet metal welding requirements in accordance with AWS D9.1 When the TDP imposes AWS D9.1, the modifications in Appendix 4 of this document shall apply. EQUIPMENT CATEGORIES New designs - All new designs where AWS D17.1 is imposed shall invoke the requirements of AWS D17.1 except as may be modified by the paragraphs herein, and as amended for specific material types. These new designs refer to all equipment types. Weld Classification Criteria - Weld classifications are selected based on the distinguishing characteristics of the weld design and the application. Mission criticality is the traditional characteristic that has been used in military specifications to determine joint classification. Other important characteristics should also be taken into account in determining weld classification.

3.3.2 3.3.3 3.3.4 4. 4.1

4.1.1

4.1.1.1 Mission Criticality - Critical components are typically identified as Class A. Critical applications are where a failure of any portion would cause loss of system, loss of major component, loss of control, unintentional release of critical stores, or endanger personnel. Semi-critical applications are identified as Class B and non-critical components Class C. Semi-critical applications are where a failure would reduce overall efficiency of the system but loss of the system or endangering of personnel would not be experienced.

Specification No. WS 33739A Page 4 of 18 4.1.1.2 Stress Level - As stress levels increase and safety factors are reduced, the need for additional inspection increases. Welded joints with low safety factors should be classified as Class A, intermediate as Class B, and high safety factor joints should be classified as C. Specific cut-off points are program and design unique. It is recommended that each program establish these safety factor cutoff points to optimize the design. 4.1.1.3 Loading Environment - Components that will be subject to fatigue environments should be identified as Class A. Each program may establish its own definition of fatigue. A traditional approach is to consider any application where reversing loads exceed 25% of yield strength to be a potential fatigue application. 4.1.1.4 Ductility - Applications where the resulting weld or heat affected zone will have low ductility should be given higher classification. Low ductility exists when yield strength approaches ultimate strength. The risk of low ductility materials is that failures occur suddenly and without advance warning. Critical flaw sizes will be low and therefore warrant the more stringent acceptance criteria and inspections found in Classes A or B. 4.1.1.5 Heat Treat - Components selected for heat treat will often fit one of the previous categories. The decision to heat treat is deliberate due to low margin or high residual stress. The heat treat process represents risk of inducing or exacerbating flaws. Class A or B is recommended on heattreated welds. 4.1.2 Weld Classification Guidelines - The following are recommendations to aid in the selection of a suitable class for each weld.

4.1.2.1 Class A Welds - Class A welds are subject to the highest level of weld quality inspection and have the tightest acceptance criteria. Generally, Class A welds are those welds that have severe consequences if they fail and/or are subjected to high levels of stress. Welds in fatigue critical structures are generally Class A. Class A may also be selected for welds that require a high level of nondestructive inspection. Other considerations in specifying welds as Class A include heat treatment and the weldability of the base metals. If the welded assembly is to be heat treated to a high strength level (and/or low ductility levels) after welding, then it may be appropriate to classify the welds as Class A. Likewise, if the base alloy is difficult to weld (like a high carbon equivalent steel alloy or A201-T7 aluminum casting alloy) the weld should be considered for an A classification. 4.1.2.2 Class B Welds - Class B welds are subject to an intermediate level of weld quality inspection and acceptance criteria. Generally Class B welds are those welds that have consequences if they fail and/or are subjected to moderately high levels of stress. Welded fatigue critical structures are generally not Class B. Welds classified as B are sometimes heat treated for strength or stress relief. Base alloys that are subject to surface cracking during welding or heat treatment (such as alloy steel and some aluminum alloys) and are not classified as Class A are usually classified as Class B.

Specification No. WS 33739A Page 5 of 18 4.1.2.3 Class C Welds - Class C welds are normally subject to the lowest level of inspection and acceptance criteria. Base metals and filler metals of Class C weldments are generally ductile in the welded condition and are generally easy to weld alloys. Class C welds are not generally heat treated after welding except for stress relief. Fatigue critical structures are never classified as Class C welds. The consequences of failure of an individual Class C weld should be low. 4.2 Existing Designs Existing designs where the technical data package (TDP) imposes AMS-STD-2219, WS23719, MIS-47201, G577917, or their predecessors shall be produced in accordance with sections 4, 5, and 6 of AWS D17.1 as modified herein. Section 8 shall not be used for non-flight hardware. ENGINEERING AUTHORITY Raytheon Engineering Authority - Raytheon Company shall maintain engineering authority, as defined in D17.1, in all instances. Raytheon Company will not relinquish this authority relative to the AWS welding specifications. Design Delegation When Raytheon subcontracts design, the design analysis and test documentation shall be submitted to Raytheon for review and approval prior to the beginning of any fabrication. This requirement does not release the subcontractor from responsibility for structural integrity of the design. PERFORMANCE AND PROCEDURE QUALIFICATION New Qualifications Welding performance and procedure qualification shall be in accordance with AWS D17.1, paragraph 4.4.3 unless otherwise stated on the engineering drawing. For class C welds, welding procedure specifications (WPS) and welding procedure qualification records (PQR) in accordance with AWS B2.1 are required. Alternatively, the manufacturer may use a Standard WPS as allowed by AWS B2.1 without performing a separate PQR provided the weld joints to be welded are within the scope of the Standard WPS. Existing Qualifications - Prior successful welding qualification to the performance and procedure requirements of AMS-STD-1595 as invoked by AMS-STD-2219, WS23719, MIS-47201, or G577917 shall constitute qualification to AWS D17.1. Other codes and/or specifications may be considered acceptable for qualification when approved by the engineering authority in writing. PROCESS CONTROL/PROCESS IMPROVEMENT Process control/Improvement Process control and improvement shall be in place for the welding and inspection processes used to manufacture product. Statistical Process Control (SPC) is the preferred method. In the event that process control and improvement tools are not utilized, the procuring activity shall be notified in writing and the product may be subjected to 100% customer reinspection.

5. 5.1

5.2

6. 6.1 6.1.1

6.2

7. 7.1

Specification No. WS 33739A Page 6 of 18 8. 8.1 FABRICATION AND REWORK Fabrication - Fabrication shall be in accordance with section 5 of AWS D17.1 except as amended herein. Weld classification shall be in accordance with callouts on the engineering drawings. In the event a classification is not called out, all welds shall be considered Class A welds. When MIS-47201 is invoked, welds not classified on the engineering drawings will be considered Class C welds. In-process corrections In-process corrections shall be documented. The maximum number of corrections by welding is limited to 2 attempts in the defect area. Grinding and dressing of a weld to remove surface discontinuities are not considered in-process corrections. Rework The number of rework attempts allowed for any given weld shall be as follows: Class B welds shall be limited to 2 rework attempts. Class A welds shall be limited to 1 rework attempt. Rework in excess of the limits stated shall be referred to the Material Review Board. Class C welds are not subject to rework limitation, but care must be exercised to ensure additional rework will not affect the integrity of the weld or the surrounding structure. INSPECTION Weld Inspection Visual weld inspections shall be conducted with the unaided eye. Once the initial assessment has been made with the unaided eye and a suspect area is identified, magnification may be used to determine acceptability. Magnification Initial use of magnification shall be with 5 diameters or 5x. Additional Magnification - When acceptability or rejectability can not be established with 5x magnification, up to 10 diameters or 10x magnification may be used to determine conformance to TDP requirements. Area Accessibility - For direct visual inspection, eye to workpiece distance shall not exceed 24 inches. Inaccessible Areas - When mirrors are used, the total distance of the eye to the mirror plus the distance of the mirror to the workpiece shall not exceed 24 inches. Additional Inspection Equipment - Where inspection distance exceeds 24 inches, the use of additional equipment shall be required. Obstructed Welds - Welds that will be covered or obstructed by subsequent operations shall be inspected prior to the subsequent operation.

8.2

8.3

9. 9.1

9.1.1 9.1.2

9.1.3 9.1.4 9.1.5 9.2

Specification No. WS 33739A Page 7 of 18 9.2.1 When to perform Visual Weld Inspections - Visual weld inspections shall be completed after all operations are performed on the weldment that may cause additional stress build-up in the part and may cause cracking. This includes all straightening operations. Visual Weld Inspector Qualification - In addition to the requirements specified in AWS D17.1 paragraph 6.1.2, any request for deviations from either AWS B5.2 (Specification for the Qualification of Welding Inspector Specialists and Welding Inspector Assistants) or QC1 (Standard for AWS Certification of Welding Inspectors) requirements shall require advance written approval from the Engineering Authority. Written Practice for certification of Visual Weld Inspectors - A written practice is required. The written practice shall specify the length of welding related experience (not to be less that 5 years) and the number of questions in a non-QC1 examination. There shall be at least 75 fundamental questions, 32 open book code questions and 32 practical questions. Time limits shall be specified for each section of the examination. The written practice shall specify that each section of the examination shall be graded separately. The minimum acceptable score for each section is 70% and that the arithmetic average of the 3 sections shall be at least 75%. Weld inspector requirements - The inspector shall be recertified at intervals not to exceed 4 years. The inspector shall also pass a vision test. Non-Destructive Equipment (NDE) and visual weld inspection personnel shall pass an annual eye examination. A technician trained in administering visual acuity examinations shall conduct the vision test. The standard of acceptance for the visual examination shall be, natural or corrected, near distance acuity such that the individual is capable of reading one of the following: Jaeger J1 at 12 inches, Jaeger J2 at 16 inches, or the Snellen English at 12 inches. Other equivalent vision tests may be substituted providing a licensed optometrist documents the equivalence. Far vision shall be 20/30 or better, natural or corrected in either eye. Where color contrast differentiation is required, for example inspection of titanium, the vision test must demonstrate inspection personnels capability of distinguishing and differentiating applicable colors or shades of interest. The color contrast differentiation test shall be conducted upon initial certification and not to exceed 3-year intervals thereafter.

9.3

9.3.1

9.3.2

Specification No. WS 33739A Page 8 of 18 9.4 INSPECTION REQUIREMENTS: Inspection requirements shall be in accordance with section 6 of AWS D17.1 as amended below. NOTE: Figure 6.1 of AWS D17.1 (Acceptable and Unacceptable Weld Profiles) shall be disregarded. Weld size, weld overlap, weld fusion, throat size and reinforcements are addressed herein. Amendments to Table 6.1 of AWS D17.1
Acceptance Criteria (in.)
Fillet Weld Size Maximum fillet weld size Fillet Weld Size (X) Fillet less than 0.063 in. Class A 3X Class B 3X Class C 3X

greater than 0.063 to 0.157 in.

2-1/2 X

2-1/2 X

2-1/2 X

greater than 0.157 to 0.250 in.

2X

2X

2X

Fillet greater than 0.250 in.

1-1/2 X

1-1/2 X

1-1/2 X

Weld Reinforcement Machine welds (Excludes fillet welds) Discontinuity Material to 0.375 in. Class A 1/3 T or 0.030 in., whichever is greater 0.125 in. maximum Class B No stated requirement Class C No stated requirement

Material greater than 0.375 in.

No stated requirement

No stated requirement

Weld Reinforcement Manual welds (Excludes fillet welds) Discontinuity Material to 0.125 in. Class A 1 T maximum Class B No stated requirement Class C No stated requirement

Material 0.126 to 0.510 in.

1/3 T or 0.100 in., whichever is greater

No stated requirement

No stated requirement

Material greater than 0.510

0.170 in. maximum

No stated requirement

No stated requirement

Specification No. WS 33739A Page 9 of 18 Amendments to Table 6.1 of AWS D17.1 (Continued)
Weld Reinforcement Manual welds (Excludes fillet welds) Cont. Discontinuity Class A Class B Undercut Discontinuity For the full length of weld Maximum depth Class A 0.002 in. Class B 0.015 T or 0.002 in., whichever is greater Class C 0.10 T or 0.070 in., whichever is greater Class C

Individual defect Maximum depth

0.07 T or 0.030 in., whichever is less

0.10 T or 0.050 in., whichever is less

0.20 T or 0.070 in., whichever is less

Accumulated length in any 3 in. of weld maximum

0.20 in.

0.60 in.

1.00 in.

9.4.1

Underfill as pertains to groove welds and concavity as pertains to fillet weld requirements The underfill and concavity requirements as shown in table 6.1 of AWS D17.1 are not applicable. Underfill in a groove weld is equivalent to an undersized weld and undersized welds are not permitted. Fillet weld concavity is permissible to the extent that weld size requirements are satisfied. This amendment applies to all equipment types and categories. Groove weld acceptance criteria - Groove welds that are not filled flush with the adjacent parent material shall be rejected. This amendment applies to all equipment types and categories. NOTES Weld sizes specified are minimum values. Intermittent welding must be present within the zones specified. Extra welding is acceptable.

9.4.2 10. 10.1 10.2

Specification No. WS 33739A Page 10 of 18 APPENDIX 1 (The following appendix provides tailoring and modifications to AWS D1.1 and shall apply where D1.1 is a TDP requirement) 1.1 Visual Weld Inspector Responsibility The visual weld inspector responsibility is limited to post-weld inspection. Other pre-weld and process weld inspections are the responsibility of the fabricator or contractor. Visual Weld Inspectors - In addition to the requirements specified in AWS D17.1 paragraph 6.1.2 any request for deviations from AWS B5.2 requirements shall require approval from the Engineering Authority. Written Practice for certification of Visual Weld Inspectors - A written practice is required. The written practice shall specify the length of welding related experience (not to be less that 5 years) and the number of questions in a non-QC1 examination. There shall be at least 75 fundamental questions, 32 open book code questions and 32 practical questions. Time limits shall be specified for each section of the examination. The written practice shall specify that each section of the examination shall be graded separately. The minimum acceptable score for each section is 70% and that the arithmetic average of the 3 sections shall be at least 75%. Weld inspector requirements - The inspector shall be recertified at intervals not to exceed 4 years. The inspector shall also pass a vision test. Non-Destructive Equipment (NDE) and visual weld inspection personnel shall pass an annual eye examination. A technician trained in administering visual acuity examinations shall conduct the vision test. The standard of acceptance for the visual examination shall be, natural or corrected, near distance acuity such that the individual is capable of reading one of the following: Jaeger J1 at 12 inches, Jaeger J2 at 16 inches, or the Snellen English at 12 inches. Other equivalent vision tests may be substituted providing a licensed optometrist verifies the equivalence. Far vision shall be 20/30 or better, natural or corrected in either eye. Welding procedure and welder performance qualifications shall be accomplished in accordance with AWS D1. (as applicable) or AWS B2.1 at the manufacturers option. Magnetic Particle Inspection ASTM E 1444 shall be used in lieu of ASTM E 709 (Ref. 6.14.4 of AWS D1.1). Dye Penetrant Inspection ASTM E 1417 shall be used in lieu of ASTM E 165 (Ref. 6.14.5 of AWS D1.1). Radiographic Testing ASTM E 1742 shall be used in lieu of the requirements in 6.16.1 of AWS D1.1. Visual Inspection Acceptance Criteria Delete (4) in table 6.1 of AWS D1.1

1.2

1.3

1.4

1.5 1.6 1.7 1.8 1.9

Specification No. WS 33739A Page 11 of 18 1.10 Statically Loaded Non-Tubular Structures AWS D1.1, Table 6.1 Section (7)(A) Visual Inspection Acceptance Criteria Statically Loaded Non-tubular Connections - Change the criteria to read continuous undercut shall not exceed 0.10T or 0.07 inches in depth, whichever is less. Selection of Inspection Methods - Selection and specification of weld inspection requirements shall be based on sound engineering judgement and is an integral part of the design process. The following are recommendations to aid in the selection of suitable weld inspections for structural welding of steel.

1.11

1.11.1 Visual Weld Inspection The Structural Welding Code for Steel, AWS D1.1, requires visual inspection of all welds. This is the minimum level of weld inspection required. Visual weld inspection only is usually adequate for most structural steel weldments. Typically, welds that are only visually inspected are: - Easy to weld alloys - Are ductile after welding - Are not heat treated after welding - Are not fatigue critical structures - Have low cyclic or dynamic loading - Carry only moderate stress - The consequences of a single failure are low 1.11.2 Magnetic Particle Inspection - In addition to visual inspection, magnetic particle inspection should be specified when a higher level of weld quality integrity is required. Magnetic particle inspection detects surface and close subsurface discontinuities such as cracks and voids. Welds in ferromagnetic steel alloys should always be magnetic particle inspected instead of using dye penetrant inspection. Typically, welds that are magnetic particle inspected are: - Alloys that can develop surface cracks during welding - May be heat-treated for strength or stress relief after welding - May have consequences if they fail - May not be ductile if welded improperly - Are not fatigue critical structures - Have only moderate cyclic or dynamic loading - Carry important structural loading

Specification No. WS 33739A Page 12 of 18 1.11.3 Radiographic Inspection - In some cases where a high level of weld quality and integrity are required radiographic (X-Ray) inspection is specified. Weldments that are inspected with radiographic inspection are always visually inspected and magnetic particle inspected as well. Fillet welds generally can not be radiographically inspected due to the weld geometry. Typically, welds that are radiographically inspected: - May be fatigue critical structures - May have severe consequences if they fail - May be loaded to high stress levels - May be more difficult to weld alloys - May be heat-treated to high strength levels - May have low ductility as welded or heat-treated - May be alloys that develop surface or subsurface cracks 1.11.4 Ultrasonic Inspection - Ultrasonic inspection is sometimes specified for the internal integrity of welds where the geometry of the weldment allows. Ultrasonic inspection is used in lieu of radiographic inspection. The specification of ultrasonic inspection should be done in concert with a nondestructive inspection expert.

Specification No. WS 33739A Page 13 of 18 APPENDIX 2 (The following appendix provides tailoring and modifications to AWS D1.2 and shall apply where D1.2 is a TDP requirement) 2.1 Visual Weld Inspector Responsibility The visual weld inspector responsibility is limited to post-weld inspection. Other pre-weld and process weld inspections are the responsibility of the fabricator or contractor. Visual Weld Inspectors - In addition to the requirements specified in AWS D17.1 paragraph 6.1.2 any request for deviations from AWS B5.2 requirements shall require approval from the Engineering Authority. Written Practice for certification of Visual Weld Inspectors - A written practice is required. The written practice shall specify the length of welding related experience (not to be less that 5 years) and the number of questions in a non-QC1 examination. There shall be at least 75 fundamental questions, 32 open book code questions and 32 practical questions. Time limits shall be specified for each section of the examination. The written practice shall specify that each section of the examination shall be graded separately. The minimum acceptable score for each section is 70% and that the arithmetic average of the 3 sections shall be at least 75%. Weld inspector requirements - The inspector shall be recertified at intervals not to exceed 4 years. The inspector shall also pass a vision test. Non-Destructive Equipment (NDE) and visual weld inspection personnel shall pass an annual eye examination. A technician trained in administering visual acuity examinations shall conduct the vision test. The standard of acceptance for the visual examination shall be, natural or corrected, near distance acuity such that the individual is capable of reading one of the following: Jaeger J1 at 12 inches, Jaeger J2 at 16 inches, or the Snellen English at 12 inches. Other equivalent vision tests may be substituted providing a licensed optometrist verifies the equivalence. Far vision shall be 20/30 or better, natural or corrected in either eye. Welding procedure and welder performance qualifications shall be accomplished in accordance with AWS D1. (as applicable) or AWS B2.1 at the manufacturers option. Weld Profiles The requirements in section 3.6 of AWS D1.2 shall not be used. Radiographic Inspection ASTM E 1742 shall be used in lieu of the requirements of AWS D1.2, paragraph 5.7.3. Penetrant Inspection ASTM E 1417 shall be used in lieu of ASTM E 165 (Ref. AWS D1.2, paragraph 5.7.5). Non-Tubular Statically Loaded Structures statically loaded structures, Section 7 of AWS D1.2, continuous undercut shall not exceed 0.10T or 0.07 inches in depth, whichever is less.

2.2

2.3

2.4

2.5 2.6 2.7 2.8 2.8

Specification No. WS 33739A Page 14 of 18 2.10 2.11 2.12 Figure 7.1 in AWS D1.2 is not applicable. Undercut for tubular structures, class 2, shall be in accordance with Table 8.1 of AWS D1.2. Selection of Inspection Methods - Selection and specification of weld inspection requirements shall be based on sound engineering judgement and is an integral part of the design process. The following are recommendations to aid in the selection of suitable weld inspections for structural welding of aluminum.

2.12.1 Visual Weld Inspection The Structural Welding Code for Aluminum, AWS D1.2, requires visual inspection of all welds. This is the minimum level of weld inspection required. Visual weld inspection only is usually adequate for most structural aluminum weldments. Typically, welds that are visually inspected only are: - Easy to weld alloys - Are ductile after welding - Are not heat treated after welding - Are not fatigue critical structures - Have low cyclic or dynamic loading - Carry only moderate stress - The consequences of a single failure are low 2.12.2 Dye Penetrant Inspection - In addition to visual inspection, dye penetrant inspection should be specified when a higher level of weld quality integrity is required. Dye penetrant inspection only reveals discontinuities open to the surface such as cracks and voids. Typically, welds that are dye penetrant inspected are: - Alloys that can develop surface cracks during welding - May be stress relief heat-treated after welding - May have consequences if they fail - May not be ductile if welded improperly - Are not fatigue critical structures - Have only moderate cyclic or dynamic loading - Carry important structural loading

Specification No. WS 33739A Page 15 of 18 2.12.3 Radiographic Inspection - In some cases where a high level of weld quality and integrity are required radiographic (X-Ray) inspection is specified. Weldments that are inspected with radiographic inspection are always visually inspected and dye penetrant inspected as well. Fillet welds generally can not be radiographically inspected due to the weld geometry. Typically, welds that are radiographically inspected: - May be fatigue critical structures - May have severe consequences if they fail - May be loaded to high stress levels - May be more difficult to weld alloys - May be heat-treated for strength or stress relief after welding - May have low ductility as welded or heat-treated - May be alloys that develop surface or subsurface cracks 2.12.4 Ultrasonic Inspection - Ultrasonic inspection is sometimes specified for the internal integrity of welds where the geometry of the weldment allows. Ultrasonic inspection is used in lieu of radiographic inspection. The specification of ultrasonic inspection should be done in concert with a nondestructive inspection expert.

Specification No. WS 33739A Page 16 of 18 APPENDIX 3 (The following appendix provides tailoring and modifications to AWS D1.6 and shall apply where D1.6 is a TDP requirement) 3.1 Visual Weld Inspector Responsibility The visual weld inspector responsibility is limited to post-weld inspection. Other pre-weld and process weld inspections are the responsibility of the fabricator or contractor. Visual Weld Inspectors - In addition to the requirements specified in AWS D17.1 paragraph 6.1.2, any request for deviations from AWS B5.2 requirements shall require approval from the Engineering Authority. Written Practice for certification of Visual Weld Inspectors - A written practice is required. The written practice shall specify the length of welding related experience (not to be less that 5 years) and the number of questions in a non-QC1 examination. There shall be at least 75 fundamental questions, 32 open book code questions and 32 practical questions. Time limits shall be specified for each section of the examination. The written practice shall specify that each section of the examination shall be graded separately. The minimum acceptable score for each section is 70% and that the arithmetic average of the 3 sections shall be at least 75%. Weld inspector requirements - The inspector shall be recertified at intervals not to exceed 4 years. The inspector shall also pass a vision test. Non-Destructive Equipment (NDE) and visual weld inspection personnel shall pass an annual eye examination. A technician trained in administering visual acuity examinations shall conduct the vision test. The standard of acceptance for the visual examination shall be, natural or corrected, near distance acuity such that the individual is capable of reading one of the following: Jaeger J1 at 12 inches, Jaeger J2 at 16 inches, or the Snellen English at 12 inches. Other equivalent vision tests may be substituted providing a licensed optometrist verifies the equivalence. Far vision shall be 20/30 or better, natural or corrected in either eye. Welding procedure and welder performance qualifications shall be accomplished in accordance with AWS D1. (as applicable) or AWS B2.1 at the manufacturers option. The requirements of Figure 5.2 in AWS D1.6 (1999) do not apply.

3.2

3.3

3.4

3.5 3.6

Specification No. WS 33739A Page 17 of 18 3.7 Dye Penetrant or Magnetic Particle Inspection - In addition to visual inspection, magnetic particle inspection or dye penetrant inspection should be specified when a higher level of weld quality integrity is required. Dye penetrant inspection only detects discontinuities open to the surface such as cracks and voids. Magnetic particle inspection detects surface and close subsurface discontinuities such as cracks and voids. Magnetic particle inspection is preferred for any of the ferromagnetic alloys and is not appropriate for nonmagnetic or paramagnetic alloys. Reference ASTM E1444 for a listing of nonmagnetic and magnetic alloys. Dye penetrant inspection is selected when alloys are nonmagnetic or paramagnetic. Typically, welds that are inspected via dye penetrant or magnetic particle inspections are: - Alloys that can develop surface cracks during welding - May be stress relief heat-treated after welding - May have consequences if they fail - May not be ductile is welded improperly - Are not fatigue critical structures - Have only moderate cyclic or dynamic loading - Carry important structural loading Penetrant inspection shall be in accordance with ASTM E 1417 Type 1. Magnetic particle inspection shall be conducted in accordance with ASTM E 1444 and shall be the continuous wet fluorescent method unless approved in writing in advance by the engineering authority. The acceptance criteria shall be applicable sections of the visual weld inspection criteria. 3.8 Radiographic Inspection - In some cases where a high level of weld quality and integrity are required radiographic (x-ray) inspection is specified. Weldments that are inspected with radiographic inspection are always visually inspected and dye penetrant inspected as well. Fillet welds generally can not be radiographically inspected due to the weld geometry. Typically, welds that are radiographically inspected: - May be fatigue critical structures - May have severe consequences if they fail - May be loaded to high stress levels - May be more difficult to weld alloys - May be heat-treated for strength or stress relief after welding - May have low ductility as welded or heat-treated - May be alloys that develop surface or subsurface cracks Radiographic inspection shall be conducted in accordance with ASTM E 1742. The engineering authority must specify the acceptance criteria. 3.9 Ultrasonic Inspection - Ultrasonic inspection is sometimes specified for the internal integrity of welds where the geometry of the weldment allows. Ultrasonic inspection is used in lieu of radiographic inspection. The specification of ultrasonic inspection should be done in concert with a nondestructive inspection expert.

Specification No. WS 33739A Page 18 of 18 APPENDIX 4 (The following appendix provides tailoring and modifications to AWS D9.1 and shall apply where D9.1 is a TDP requirement) 4.1 Visual Weld Inspector Responsibility The visual weld inspector responsibility is limited to post-weld inspection. Other pre-weld and process weld inspections are the responsibility of the fabricator or contractor. Visual Weld Inspectors - In addition to the requirements specified in AWS D17.1 paragraph 6.1.2, any request for deviations from AWS B5.2 requirements shall require approval from the Engineering Authority. Written Practice for certification of Visual Weld Inspectors - A written practice is required. The written practice shall specify the length of welding related experience (not to be less that 5 years) and the number of questions in a non-QC1 examination. There shall be at least 75 fundamental questions, 32 open book code questions and 32 practical questions. Time limits shall be specified for each section of the examination. The written practice shall specify that each section of the examination shall be graded separately. The minimum acceptable score for each section is 70% and that the arithmetic average of the 3 sections shall be at least 75%. Weld inspector requirements - The inspector shall be recertified at intervals not to exceed 4 years. The inspector shall also pass a vision test. Non-Destructive Equipment (NDE) and visual weld inspection personnel shall pass an annual eye examination. A technician trained in administering visual acuity examinations shall conduct the vision test. The standard of acceptance for the visual examination shall be, natural or corrected, near distance acuity such that the individual is capable of reading one of the following: Jaeger J1 at 12 inches, Jaeger J2 at 16 inches, or the Snellen English at 12 inches. Other equivalent vision tests may be substituted providing a licensed optometrist verifies the equivalence. Far vision shall be 20/30 or better, natural or corrected in either eye. Convexity of Fillet Welds There are no restrictions on convexity provided that the weld size has been achieved for both the leg and throat of the weld (Reference 6.4 of AWS D9.1-90) Porosity Porosity less than 0.1T shall be disregarded (Reference 6.5.2 and 11.4 of AWS D9.1-90)

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