Visual Weld Inspection Guidelines Attachment A - Raytheon Quality Note HK

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1. PURPOSE:

This document establishes guidelines for visual weld inspection of fusion welded parts and clarifies specific guidelines for evaluation of discontinuities as stated in the controlling specifications AWS D17.1 and the WS33739 (base document only excluding appendices.) Specific guidelines for other specifications examples such as AWS D1.1 and AWS D1.2 are discussed in paragraph 4.11.

This Visual Weld Inspection Guidelines can be used as a best practice for a supplier's approved weld inspectors. Prior to use the supplier shall review drawing requirements to assure welding requirements align to these guidelines.

2. POLICY:

All weldments, including the weld and the adjacent base material, shall be visually inspected inch - by - inch in accordance with this guideline for conformance to drawing requirements.

3. DEFINITIONS:

Unless otherwise specified herein, welding terms shall be as defined in AWS A3.0, Standard Welding Terms and Definitions. Non-standard welding terms shall be as defined below.

Defect Area: All material within approximately one half inch of the edge of the correction.

Burn through: A nonstandard term used for excessive melt-through.

Discontinuity: For the purpose of this guideline, a discontinuity (as referenced in WS23719, MIS-47201 and G577917) shall be defined as only those specific discontinuities discussed in these guidelines.

Double fillet weld: A fillet weld in a T joint configuration with weld on both sides of the abutting member.

Effective weld length: The effective weld length shall be only that portion of weld that is full size and has proper fusion. (See paragraph 5.8)

Inclusion: For clarification, an inclusion, as defined in AWS A3.0, is entrapped foreign solid material, such as slag, flux, tungsten, or oxide.

Single fillet weld: A fillet weld in a T joint configuration with weld on one side of the abutting member only.

Incipient Melting: A condition, in the base material heat affected zone which may exist at or near the toe of the weld in which an inter-metallic phase of the base material is beginning to or is on the verge of melting; a textured or mottled surface results.

Arc Erosion: A nonstandard welding term that describes a condition caused by an arc impinging on the base material adjacent to be weld. The condition results in a surface roughening of the base material.

Linear Discontinuities: A discontinuity with a length that is substantially greater than its width and includes cracks, incomplete fusion, overlap, and incomplete penetration.

Design Configuration Verification: Verifying that the size, length and location of each weld on the part is as specified on the engineering drawing and that no unspecified welds have been added. 4. GENERAL REQUIREMENTS : Any units that fail to meet the requirements of this Guideline shall be rejected and documented.

4.1 Raytheon Quality Note (RQN) HK contains welding requirements not listed

on Raytheon's drawings. All suppliers and visual weld inspectors shall be approved in accordance with RQN HK.

4.2 All weldments shall be inspected inch-by-inch to the print requirements. Specifically, the size, length and location of each weld required by the print shall be verified on the part and no unspecified welds have been added.

Uniform bead appearance Non-uniform bead appearance

Poor workmanship requires more inspection time and increased chance of rejection

Excellent weld workmanship is easily inspected and accepted

4.3 Engineering Hotline 978-470-6300 - Suppliers can utilize Raytheon's Engineering Hotline as a central point of contact for all related welding issues, specifically questions related to the Technical Data Package (TDP) and visual weld inspection questions. A Raytheon Weld Subject Matter Expert (SME) will respond to your questions in a timely manner and provide technical support as needed. Raytheon Weld SMEs, Engineering, Supply Chain, and Quality staff use the hotline database to coordinate on all supplier issues and improve supplier performance.

4.4 Raytheon's approved weld inspector shall document weld inspection results using the Visual Weld Inspection Checklist, Figure 1. The Visual Weld Inspection Checklist is recommended as a best practice for supplier's approved weld inspectors.

4.5 The inspectors tool kit shall include, as a minimum, the following tools:

VISUAL WELD INSPECTORS TOOL KIT

TOOL TOOL REQUIREMENT RECOMMENDED Flashlight Xenon or Krypton bulb 2AA or 2AAA size batteries

Fillet Weld Gages Standard G.A.L. Fillet weld Gages

Undercut Gages Go, No-Go burr type Sizes -0.010, 0.015, 0.020,

0.025, 0.035, 0.050, 0.060 and 0.070

6 Scale 1/64 inch increments 12 Foot Tape Measure

Magnifying Lens 5x glass simple lens

10x glass simple lens

Metal Scribe Pin Gages 1/64, 1/32, 3/64, 1/16, 3/32

Dividers, Caliper, Micrometer

NOTE: For tool and gage selection, decimals and fractions can be interchanged for example a fillet weld size of 0.12 can be inspected with a 1/8-fillet weld gage.

4.6 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.

4.6.1 Magnification, when used, shall be done using only approved

lenses as included in the inspectors tool kit. 4.6.2 Initial use of magnification shall be with 5x. 4.6.3 When acceptability or rejectability cannot be established with 5x

magnification, use 10x magnification and consult supervision if required.

4.7 Visual weld inspections shall be conducted under proper lighting

conditions.

4.7.1 All weld areas shall be illuminated with an approved flashlight as included in the inspectors tool kit.

4.7.2 Welds that will be covered or obstructed by subsequent operations shall be inspected prior to the subsequent operations.

4.8 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.

4.9 The initial angle of viewing for each weld shall be approximately 90 +/- 45 to the weld face. Other viewing angles may be used to closely scrutinize specific discontinuities.

4.10 For direct visual inspection, eye to work piece distance shall not exceed 24 inches.

4.10.1 When mirrors are used, the total distance of the eye to the mirror

plus the distance of the mirror to the work piece shall not exceed 24 inches.

4.11 The following are examples of specific guidelines for other specifications examples such as AWS D1.1 and AWS D1.2 are discussed

4.11.1 Overlap: AWS D9.1 - No criteria for overlap required 4.11.2 Craters: AWS D1.2 - Craters are not allowed for, Cyclically Loaded

Structures. Unfilled craters allowed for fillets welds in statically loaded structures

4.11.3 Spatter: AWS D1.1 - May remain in some cases tightly adhered 4.11.4 Inclusions: Criteria vary per varies specifications. 4.11.5 Porosity: Criteria vary per varies specifications.

5. DETECTION & EVALUATION OF SPECIFIC DISCONTINUITIES:

5.1 CRACKS: None permitted.

5.1.1 Heat Area Zone (HAZ) is defined as a surface condition on the base material adjacent to the toes of a weld that exhibits a mottled or textured condition with fine linear discontinuities.

5.2 INCOMPLETE FUSION: None permitted

Incomplete fusion can

become exposed after

finishing or grinding

operations

Crack in Heat Affected Zone adjacent to weld toe

If shadows disappear under different lighting angles, the discontinuity is acceptable

Crater cracks can propagate

5.3 INCOMPLETE PENETRATION: When required by the welding symbol, full penetration groove welds welded from one side shall show complete joint penetration as evidenced by the absence of a joint line at the root of the weld. Full penetration groove welds are required when the groove weld symbol appears by itself without additional weld size or depth of bevel requirements or the depth of bevel equals material thickness or if CJP appears in the tail of the welding symbol.

5.4 MELT-THROUGH: 5.4.1 For outside corner fillet welds without a melt-through symbol in the

welding symbol, complete joint penetration must be obtained as evidenced by any of the following; melting of the original edges, penetration of filler metal into the root, a wavy uneven surface at the root, heat deformation when viewed from the back side of the weld. 5.4.2 Where the welding symbol requires full penetration by evidence of

a melt-through symbol, complete joint must be obtained as evidenced by any of the following; melting of the original edges, penetration of filler metal into the root, a wavy uneven surface at the root, heat deformation when viewed from the back side of the weld.

5.5 OVERLAP : Overlap shall be detected using the 90 oblique lighting technique. Hold the flashlight at approximately 90 to the toe of the weld being examined. If overlap is present at the toe of the weld, a shadow will be cast under the overlap area.

5.5.1 All overlap shall be rejected.

Shadows Reveal Overlap

Use a strong light at 90 degrees at the toe of the weld to detect

overlap

Acceptable

Evidence of melt through must be seen in the joint

No evidence of melt through original joint lines still visible

Rejectable

5.5.2 Convexity is acceptable

5.6 ARC STRIKES : Arc strikes outside the area of deposited weld metal shall be rejected.

5.7 FILLET WELDS : 5.7.1 When the size of the fillet weld is stated on the engineering

drawing, the minimum fillet weld size shall be as shown in the welding symbol.

5.7.2 When the fillet weld size is not stated on the print, the minimum

fillet weld size shall be as stated below and shall be verified using the appropriate gage:

Lighting

Viewing

Convexity is acceptable, overlap is not

Can cause cracks None permitted outside the weld zone

MINIMUM FILLET WELD SIZE (1) WHEN NOT SPECIFIED ON THE DRAWING, IN INCHES (CUSTOM FILLET GAGE) BASE MATERIAL

THICKNESS (inches) SINGLE SIDE FILLET (2) DOUBLE SIDE FILLET (3)

0.010 to 0.060 0.09 0.060 0.061 to 0.090 0.156 0.090 0.091 to 0.0156 0.220 .0156 0.157 to 0.1875 0.0.3125 0.1875 0.188 to 0.220 0.375 0.220 0.221 to 0.250 0.375 0.250 0.251 to 0.3125 0.500 0.3125 0.313 to 0.375 0.625 0.375 0.376 to 0.4375 0.750 0.4375 0.438 to 0.500 0.750 0.500 0.501 to 0.625 1.00 0.625 0.626 to 0.750 1.250 0.750 0.752 to 0.875 1.31 0.875 0.876 to 1.00 1.50 1.0

(1) Weld size is determined by the thinner member.

(2) Single side welds are welds made from only one side of the joint.

(3) Double side welds are welds made on both sides of the joint.

(4) Gages identified with fractional sizes may be used to inspect welds sized in decimal for instance; use a 1/8 fillet weld gage for a 0.12 weld callout and use a 3/8 fillet weld gage for a 0.38 weld callout.

5.7.3 Fillet Weld Maximum Size - Where there is no print requirement for maximum fillet weld size the following shall apply. The minimum fillet weld size is established either by the print (takes precedence) or from the table in para. 5.7.2, in either case the minimum fillet weld size shall be used to establish the maximum permissible weld size from the table below and is applicable to all classes.

Fillet Weld Size Maximum fillet weld size, based on minimum fillet weld size from print or paragraph 5.7.2

Fillet Weld Size (X) Class A Class B Class C

Fillet less than or equal to 0.063 in. 3 X 3 X 3 X

greater than 0.063 but less than or equal to 0.157 in.

2 X 2 X 2 X

greater than 0.157 but less than or equal to 0.250 in.

2 X 2 X 2 X

Fillet greater than 0.250 in. 1 X 1 X 1 X

5.7.4 Concave Fillet Weld

5.7.5 Convex Fillet Weld

5.8 INTERMITTENT FILLET WELDS : When inspecting intermittent fillet welds, the following sequence shall be used:

5.8.1 Determine the effective length of each weld by discounting the portions of the

start and stop area at both ends of the weld that are not full size or that show evidence of roll over, a condition where the end of the weld is not tied into 1 or both members.

NOTE: The ends of intermittent fillet welds on aluminum may have evidence of roll over. This is due to weld metal build-up resulting from a rosebud technique used to eliminate weld craters. This portion of the weld will not be included in the measurement to verify weld length and therefore is not a rejectable indication.

Disregard weld start and stop areas that are not full sized or completely

fused.

The welding symbol delineates the minimum effective weld length and the maximum pitch dimension

5.8.2 When roll over/incomplete fusion at the end of the fillets welds is observed, the inspector shall use a 1/64 diameter pin gage to measure the length of roll over/incomplete fusion at the ends of the weld. This portion of the weld shall not be included when determining the effective length of the weld.

5.8.2.1 The maximum length of incomplete fusion at the ends of the welds shall be .125.

5.8.3 Set the dividers at the length dimension required for each weld. Verify that each of the individual welds have an effective length of at least the dimension set on the dividers.

5.8.4 Mark the approximate center of each of the individual welds.

5.8.5 Set the dividers at the pitch dimension required by the welding symbol. Verify that the center-to-center distance between the center marks each of the intermittent welds does not exceed the dimension on the dividers.

5.9 WELD BEAD WIDTH : The maximum weld bead width shall be as shown below:

WELD PROCESS MAXIMUM WIDTH GMAW, GTAW, FCAW SAW .625 maximum

SMAW 2 times the core diameter

5.10 WELD REINFORCEMENT: (Excludes fillet welds) Weld reinforcement shall fair smoothly with itself and the base material. The maximum weld reinforcement shall be as stated below for manual welds, machine welds refer to WS33739:

MAXIMUM WELD REINFORCEMENT CLASS

MATERIAL THICKNESS (T) MAXIMUM ALLOWABLE

Up to .125" thick 1T

For .126" to .510" thick 1/3T or 0.100" whichever is

greater A

.510" and thicker 0.170" maximum

B or C No Stated Requirement No Stated Requirement

5.11 DISCONTINUITIES: The discontinuities to be examined are only those listed in Figure 1. Two or more adjacent surface discontinuities shall be treated as one when the space between them is less than the dimension of the smallest discontinuity.

5.11.1 POROSITY: Inspect per Paragraph 4.6 Porosity shall be measured using the pin gages provided in the inspectors tool kit. Magnification may be used as an aid for accurate measurement of the porosity and porosity spacing.

5.11.1.1 The maximum individual size for porosity shall be as shown in the chart below:

MAXIMUM ALLOWABLE POROSITY (inches) MATERIAL THICKNESS

CLASS A CLASS B CLASS C

Up to .059 None None None .060 to .090 1/64 1/64 1/32 .091 to .125 1/64 1/32 3/64 .126 to .312 1/32 3/64 1/16

.313 or greater 1/32 1/16 3/32

Measure size using pin gage

5.11.1.2 Minimum spacing between any two holes of porosity and the maximum accumulated length of the area of porosity shall be as follows:

CONDITION CLASS A CLASS B CLASS C

Minimum Spacing

8 times the size of the larger adjacent

indication where cumulative pore

diameters exceeds the requirements for

maximum individual pore size (paragraph 5.11.1.1), exclusive of the space between the

pores.

4 times the size of the larger adjacent indication where cumulative pore diameters exceeds the

requirements for maximum individual pore size (paragraph 5.11.1.1),

exclusive of the space between the pores.

2 times the size of the larger adjacent indication where cumulative pore diameters exceeds the

requirements for maximum individual pore size (paragraph 5.11.1.1),

exclusive of the space between the pores.

Maximum accumulated length in 3 inches of weld

1 T or 0.12 inch whichever is less

1.33 T or .24 inch whichever is less

2 T or .36 inch whichever is less

Where T is the thickness of the thinner member being joined.

5.11.2 INCLUSIONS: Inspect per Paragraph 4.6. Inclusions shall be measured using a 6 scale or the pin gages provided in inspectors tool kit. Magnification may be used to obtain an accurate measurement of the inclusion.

Measure using pin gages to determine size

5.11.2.1 The maximum individual size for inclusions shall be as follows:

MAXIMUM ALLOWABLE INCLUSIONS (inches) MATERIAL THICKNESS

CLASS A CLASS B CLASS C

Up to .059 None None None .060 to .090 1/64 1/32 1/16 .091 to .125 1/32 3/64 3/32 .126 to .312 3/64 1/16 1/8

.313 or greater 1/16 3/32 1/8

5.11.2.2 Cleanliness: Oxides and oxide films must be removed prior to coating (chromate, plating, paint, etc.)

5.11.3 UNDERCUT: Undercut shall be detected using oblique lighting technique. Align the flashlight and beam of light in line with the member of material being examined for undercut. If undercut is present, a shadow will be cast in the area of undercut.

5.11.3.1 The maximum amount of allowable undercut shall be measured using the appropriate undercut gage in a Go, No-Go assessment.

5.11.3.2 Where undercut is detected it shall be evaluated for acceptance in the following order:

5.11.3.2.1 All undercut, regardless of length, shall be

acceptable if it does not exceed the maximum depth requirements of Chart A.

SHADOW REVEALS UNDERCUT

Use a strong light along surface to create potential undercut shadows on

the toe of the weld

If light is visible under the gage, then the undercut depth is less than the gage size

5.11.3.2.2 Where the undercut exceeds the maximum depth limits of Chart A, the following evaluations must be performed:

5.11.3.2.2.1 The maximum depth of any undercut shall not exceed the requirements of Chart B. 5.11.3.2.2.2 The accumulated length of undercut that exceeds Chart A but does not exceed Chart B shall be acceptable if it does not exceed the length requirements of Chart C.

CHART A

MAXIMUM ALLOWABLE DEPTH OF UNDERCUT REGARDLESS OF LENGTH (Undercut Gage Sizes)

MATERIAL THICKNESS

(inches) CLASS A CLASS B CLASS C .060 to .089 NONE NONE NONE .090 to .124 NONE NONE NONE .125 to .186 NONE NONE (0.010) .187 to .218 NONE NONE (0.015) .219 to .249 NONE NONE (.020) .250 to .311 NONE NONE (.025) .312 to .374 NONE NONE (.025) .375 to .499 NONE NONE (.035) .500 AND GREATER

NONE NONE (.050)

CHART B

UNDERCUT INDIVIDUAL DEFECT MAXIMIUM DEPTH (Unde rcut Gage Sizes)

MATERIAL THICKNESS

(inches) CLASS A CLASS B CLASS C .060 to .089 NONE NONE (0.010) .090 to .124 NONE NONE (0.015) .125 to .186 NONE (0.010) (.025)

.187 to .218 (0.010) (0.015) (.035)

.219 to .249 (0.015) (.020) (.035)

.250 to .311 (0.015) (.025) (.050)

.312 to .374 (.020) (.025) (.060)

.375 to .499 (.025) (.035) (.070) .500 AND GREATER

(.025) (.050) (.070)

CHART C

MAXIMIUM ACCUMULATED LENGTH IN ANY 3 INCH OF WELD - EXCEEDING DEPTH REQUIREMNTS OF PARAGRAPH CHART A

CLASS A: .20 inch CLASS B: .60 inch CLASS C: .1.00 inch

The shadow indicates

underfilled areas

5.11.4 UNDERFILL : (Plug, Slot and Groove Welds Only) A condition in which the weld face or root surface is below the adjacent surface of the base metal. Underfill is always rejectable.

5.11.5 CONCAVITY: Concavity on the weld face of fillet welds shall be acceptable if the minimum throat dimension of the required fillet weld size is verified using the appropriate fillet weld gage.

5.11.6 CRATERS: Craters shall be visually examined for compliance to the criteria of 5.11.6.1 for depth and 5.11.6.2 for length.

5.11.6.1 If the depth of a crater appears excessive, the condition

shall be evaluated by comparison with undercut gages identified in brackets. The following chart lists the maximum crater depth and appropriate gage to be used for determining acceptance.

MAXIMUM ALLOWABLE DEPTH OF CRATER (Undercut Gage Siz es) MATERIAL

THICKNESS, T (inches)

CLASS A CLASS B CLASS C

.050 to .075 0.01" 0.01" 0.01"

.076 to .100 0.015" 0.015" 0.015"

.101 to .125 0.020" 0.020" 0.020"

.126 to .175 0.025" 0.025" 0.025"

.176 to .249 0.025" 0.035" 0.035"

.250 and GREATER 0.025" 0.050" 0.050"

5.11.6.2 The maximum length of any crater is:

CLASS A: 1 T CLASS B: 1 T CLASS C: 2 T

PROPERLY FILLED CRATER UNFILLED, DIMPLED CRATER

May be unacceptable depending upon fill

requirements

T is the thickness of the thinner member. If the length of any crater appears excessive, the condition shall be evaluated by comparison to a pin gage of T diameter or 6" scale.

5.12 Spatter is the metal particles expelled during fusion welding that do not form a part of the weld.

Some tightly adhering spatter is allowed.

Form #126 02/10 Ref. VI 8002, RQN HK

VISUAL WELD INSPECTION CHECKLIST Part Number:

PO (RSV only)) or ID Number (Inc Insp.):

Supplier (RSV only):

Weld Inspector:

REQUIRES INCH BY INCH WELD INSPECTION TO DRAWING REQUIREMENTS BY RAYTHEON

APPROVED WELD INSPECTORS PER VI 8002 & RQN HK. CHECKLIST SHALL BE USED FOR

RAYTHEON INCOMING INSPECTION AND SOURCE INSPECTION (RSV) - IN-PROCESS & FINAL

WELD INSPECTIONS. RECOMMENDED AS A BEST PRACTICE TOOL FOR SUPPLIERS.

Inspection Date:

IMPERFECTION CONDITION ACCEPT CRITERIA Accept(x) Reject(x)

DESIGN CONFIGURATION ALL

Criteria unique to drawing weld specification See

Para. 3, Design Configuration Verification

CRACKS ALL Non Permitted See Para. 5.1

INCOMPLETE FUSION ALL

Non Permitted See Para. 5.2

INCOMPLETE PENETRATION AND

MELT-THROUGH ALL See Para. 5.3 and Para. 5.4

OVERLAP ALL See Para. 5.5 ARC STRIKES ALL See Para. 5.6

FILLET WELD SIZE ALL FILLET WELDS

Criteria unique to drawing weld specification See

Para. 5.7 INTERMITTENT FILLET WELDS

ALL INTERMITTENT FILLET WELDS

Verify size, length and spacing See Para. 5.8

WELD BEAD WIDTH ALL See Para. 5.9 WELD REINFORCEMENT ALL See Para. 5.10

DISCONTINUITIES (As listed below) In any 1 inch of weld

No more than 5 See Para. 5.11

POROSITY Individual size See Para. 5.11.1 INCLUSIONS ALL See Para. 5.11.2

For full length weld maximum depth See Para. 5.11.3 Individual defect maximum depth See Para. 5.11.3 UNDERCUT

Accumulated length in any 3 inches of weld

maximum See Para. 5.11.3 UNDERFILL ALL See Para. 5.11.4

CONCAVITY (FILLET WELDS) ALL

Acceptable if the minimum weld throat is verified See

Para. 5.11.5 CRATERS ALL See Para. 5.11.6

Comments:

VISUAL WELD INSPECTION CHECKLIST

NOTE: Raytheon's weld inspector shall use this checklist and insure that all the criteria listed below have been verified on the parts being inspected. This checklist is recommended as a

documentation best practice for supplier's weld inspectors.

Design configuration - need to add