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11 PPUURRPPOOSSEE && AAPPPPLLIICCAATTIIOONN 1.1 This procedure establishes the minimum requirements for

qualification, certification, and re-certification of personnel who perform welding operations at MTI.

1.2 This procedure applies to all personnel involved in the management and performance of welding. This includes personnel assigned and utilized in training, qualification, and certification as well as those actually performing welding operations.

1.3 This procedure meets, as a minimum, the requirements of AWS D17.1:2001, Specification for Fusion Welding for Aerospace Applications

2 RESPONSIBILITIES

2.1 The Quality Director 2.1.1 Approves all welding personnel 2.1.2 Issues welding stamps

2.2 The Operations Director 2.2.1 Approves all welding personnel 2.2.2 Recommends welding personnel to the Quality Director for

issuance of welding stamps 2.3 The Production Manager

2.3.1 Coordinates welding personnel qualification and certification.

3 PROCEDURE 3.1 Physical Requirements

3.1.1 Vision Requirements 3.1.1.1 Welders shall have vision acuity of 20/30 or better in

either eye, and shall be able to read the Jaeger No. 2 Eye Chart at 16in. Natural or corrected vision may be used to achieve eye test requirements.

3.1.1.2 Vision shall be tested al least every two years. 3.2 Qualification Requirements

3.2.1 Welders shall demonstrate their skill by producing acceptable test welds per the requirements of paragraph 3.3. Test welds are not required for those welds that will not be required in production welding.

3.2.2 The correlation factors between test welds and production welds shall be based on the following essential variables

3.2.2.1 Welding process 3.2.2.2 Base metal composition group 3.2.2.3 Base metal thickness 3.2.2.4 Welding position 3.2.2.5 Base metal form, sheet or tube 3.2.2.6 Type of weld, groove or fillet 3.2.2.7 Other welding conditions

3.3 Certification 3.3.1 Initial Certification

3.3.1.1 Successful completion of welder qualification tests shall be valid justification for issuance of certification for a period of two years from the date qualification test results are received.

3.3.2 Extended Certification 3.3.2.1 Qualification of a process may be extended indefinitely

provided an auditable record is maintained from the date of initial qualification that verifies the welder has used the process within a six month period to weld applications normally welded by the certified individual.

3.3.3 Disqualification 3.3.3.1 Revocation of welder certification shall result under any

of the following conditions. 3.3.3.1.1 The welder has not performed the qualification

tests successfully within the previous two years and a record has not been maintained as required in paragraph 3.3.2.

3.3.3.1.2 The record required by paragraph 3.3.2 has not been maintained.

3.3.3.1.3 The physical requirements of paragraph 3.1 are not maintained

3.3.3.1.4 There is a specific reason to question the ability of the welder to meet the requirements for qualification

3.4 Test Records

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3.4.1 Weld Qualification Test Record MQ-04-42-01-01 will be used to document each test weld and will be maintained in the employee’s training record.

3.5 Testing Requirements 3.5.1 Welding Process

3.5.1.1 A test weld made with a given process of Table 1 qualifies only that welding process.

Table 1

Fusion Welding Process Process Abbreviation Oxyfuel welding (OFW) Shielded metal arc welding (SMAW) Gas tungsten arc welding (GTAW) Gas metal arc welding (GMAW) Flux cored arc welding (FCAW) Plasma arc welding (PAW)

3.5.2 Base Metals

3.5.2.1 A test weld made in a base metal included in one of the base metal groups of Table 4.2, AWS D17 qualifies only that metal group.

3.5.3 Base Metal Thickness 3.5.3.1 A test weld with a base metal thickness of t shall qualify

welds with a thickness range of 0.67t to 4t, except when the test weld thickness is equal to or greater than 1in., the qualification range is 0.67t to unlimited.

3.5.3.2 Qualification for sheet or tube fillet welds in material 0.063” thickness (sheet or tube wall) or less requires a fillet weld test. A groove weld test cannot be used to qualify fillet welds in this thickness range.

3.5.4 Welding Position 3.5.4.1 The welding positions qualified by a given test weld

position, in Table 2, are denoted by an “X” in the table. The welding positions are designated, identified, and illustrated in Figures 1-4.

3.5.5 Base Metal Form and Weld Type 3.5.5.1 The base metal forms and weld types qualified by a

given test weld, to be found at the left of Table 3, are denoted by an “X” in the table.

3.5.6 Other Welding Conditions 3.5.6.1 In addition to the welding process, base metal

composition, base metal thickness, welding position, base metal form, and type of weld other welding conditions are listed in Table 2.

Table 2

Other Welding Conditions Qualified by Test Weld Qualified Backing Groove Weld Current

Type(1)

Test Weld With Without Single Double Complete Penetration

Partial Penetration

AC DC

With Backing X Without Backing X X Single Welded Groove Weld X X

Double Welded Groove Weld X

Complete Penetration Weld X X

Partial Penetration Weld X

AC Welding X DC Welding X Note: (1) Applicable only to GTAW

3.5.7 Test Welds

3.5.7.1 One test weld shall be required for each combination of welding conditions.

3.5.7.2 Groove test weld in sheet per Figure 5. 3.5.7.3 Fillet test weld in sheet per Figure 6. 3.5.7.4 Groove test weld in tube per Figure 7. 3.5.7.5 Fillet test weld in tube per Figure 8.

3.5.8 Inspection and Examination Requirements 3.5.8.1 Visual

3.5.8.1.1 Test welds will be inspected and accepted or rejected in accordance with MQ-04-42-02-00, the criteria for Class A welds, except 1/2in. discard may be taken at the ends of groove and fillet weld coupons in sheet or plate.

3.5.8.1.2 Shall be accomplished in the as welded condition. 3.5.8.2 Metallographic Examination

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3.5.8.2.1 Metallographic examination shall be used in place of radiographic examination for fillet welds.

3.5.8.2.2 Blanks shall be removed in accordance with Figures 9 and 10 for fillet welds in sheet or tube.

3.5.8.2.3 When the base metal thickness is ≤.063”, sections of specimen marked “M” shall be allowed lack of root fusion not to exceed .1 times the actual throat (see Figure 11A).

3.5.8.2.4 All fillet test welds >.063” shall exhibit complete root fusion on both cross section surfaces of specimen marked “M” (see Figure 11B).

3.5.8.2.5 All other acceptance criteria for MQ-04-42-02-00, Class A welds apply.

4 REVISION HISTORY –– AAuutthhoorreedd bbyy TTrraavviiss MMcciillnnaayy,, aapppprroovveedd 44

DDeecceemmbbeerr 22000066.. 4.1 Added reference to inspection procedure MQ-04-42-02-00.

Authored by Travis Mcilnay, approved 9 December 2006.

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9-Dec 2006 Document Custodian Date

9-Dec 2006 Quality Director Date

9-Dec 2006 President or Vice President Date

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Table 3 Welding Position, Base Metal Form, and Base Metal Qualified by Test Weld(3)

Qualified Position Sheet Tube

Figure 1

Test Weld

Groove Fillet(1) Groove(2) Fillet(1)

Form Weld Type P

ositi

on

1G 2G 3G 4G 1F 2F 3F 4F 1G 2G 5G 6G 1F 2F 4F 5F

1G X X X X X 2G X X X X X X X 3G X X X X X X X Sheet Groove

4G X X X X X X X 1 F X X 2F X X X X 3F X X X X Sheet Fillet

4F X X X X X X 1G X X X X X X 2G X X X X X X X X 5G X X X X X X X X X X X Tube Groove

6G X X X X X X X X X X X X X X X X 1 F X X 2F X X X X 4F X X X X X X Tube Fillet

5F X X X X X X X X Notes:

(1) A groove weld does not qualify for fillet wilds in base metal ≤0.063” thickness (2) A sheet test weld qualifies for tube weld 1” in OD or greater. (3) Welding position, base metal form, and base metal qualified by test weld. Use of heat sinks or backing is optional.

However, qualification using heat sinks or backing does not qualify for welding without heat sinks or backing.

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Figure 2 Figure 3 Figure 4

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Figure 5

Figure 6

Figure 7

Figure 8

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Figure 10

Figure 11B

Figure 9

Figure 11A