This specification classifies fusion welds according to structural integrity requirements and establishes inspection methods and acceptance standards for welded tubular assemblies used in aerospace applications.

Welding Processes:

The requirements specified herein apply to fusion welding by one of the following processes:

a. Shield metal arc welding (SMAW)

b. Gas tungsten arc welding (GTAW)

c. Gas metal arc welding (GMAW)

d. Plasma arc welding (PAW)

e. Flux cored arc welding (FCAW)

f. Submerged arc welding (SAW)

Classification:

Each weld shall be classified according to structural integrity requirements and the weld classification and inspection level shall be noted on the engineering drawing. Welds shall be classified as follows:

a. Class A: Welds which are fracture or fatigue critical or welds the single failure of which would cause significant danger to operation personnel or would result in an operational penalty. This includes, but is not limited to, loss of major components, loss of control, unintentional release, inability to release armament stores, or failure of weapon installation components.

b. Class B: A welded joint whose failure would reduce the overall reliability of the equipment or system or preclude the intended functioning or use of equipment.

c. Class C: All welds not classified as Class A or Class B.

Inspection Level:

Each weld shall be assigned a level of nondestructive inspection consistent with design requirements. Nondestructive inspection requirements shall be as follows:

a. Level I: Radiographic, fluorescent penetrant and visual or radiographic, magnetic particle, and visual inspection of all welds on each weldment for conformance to standards specified herein

b. Level II: Fluorescent penetrant or magnetic particle and visual inspection of all welds in each weldment for conformance to standards specified herein

c. Level III: Radiographic, fluorescent penetrant and visual or radiographic, magnetic particle, and visual inspection of welds to an AQL of 1.0 per MIL-STD-105 for conformance to the requirements specified herein. A unit of product shall be a weld of 4 inches in length or increments thereof

d. Level IV: Visual inspection only of all welds of each weldment for conformance to standards specified herein

e. Level V: No inspection required

Assignment of Inspection Level:

Assignment of inspection level by weld class shall be in accordance with Table 1.