Visual Weld Inspection Guidelines Attachment A - Raytheon ...

1 Visual weld Inspection Guidelines Attachment A - Raytheon Quality Note HK 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 and the WS33739 (base document only excluding appendices.) Specific Guidelines for other specifications examples such as AWS and AWS are discussed in paragraph 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.

2 3. DEFINITIONS: Unless otherwise specified herein, welding terms shall be as defined in AWS , 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 ) Inclusion: For clarification, an inclusion, as defined in AWS , is entrapped foreign solid material, such as slag, flux, tungsten, or oxide.

3 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 4. GENERAL REQUIREMENTS: Any units that fail to meet the requirements of this Guideline shall be rejected and documented. 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. 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 appearanceNon-uniform bead appearancePoor workmanship requires more Inspection time and increased chance of rejectionExcellent weld workmanship is easily inspected and accepted 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.

5 A Raytheon weld Subject Matter Expert (SME) will respond to your questions in a timely manner and provide technical support as needed. Raytheon weld SME s, Engineering, Supply Chain, and Quality staff use the hotline database to coordinate on all supplier issues and improve supplier performance. 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. 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 2 AAA size batteries fillet weld Gages Standard fillet weld Gages Undercut Gages Go, No-Go burr type Sizes , , , , , , and 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 can be inspected with a 1/8- fillet weld gage.

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. Magnification, when used, shall be done using only approved lenses as included in the inspector s tool kit. Initial use of magnification shall be with 5x. When acceptability or rejectability cannot be established with 5x magnification, use 10x magnification and consult supervision if required. Visual weld inspections shall be conducted under proper lighting conditions. All weld areas shall be illuminated with an approved flashlight as included in the inspectors tool kit. Welds that will be covered or obstructed by subsequent operations shall be inspected prior to the subsequent operations. 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.

7 This includes all straightening operations. 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. For direct Visual Inspection , eye to work piece distance shall not exceed 24 inches. 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. The following are examples of specific Guidelines for other specifications examples such as AWS and AWS are discussed Overlap: AWS - No criteria for overlap required Craters: AWS - Craters are not allowed for, Cyclically Loaded Structures. Unfilled craters allowed for fillets welds in statically loaded structures Spatter: AWS - May remain in some cases tightly adhered Inclusions: Criteria vary per varies specifications.

8 Porosity: Criteria vary per varies specifications. 5. DETECTION & EVALUATION OF SPECIFIC DISCONTINUITIES: CRACKS: None permitted. 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. INCOMPLETE FUSION: None permitted Incomplete fusion can become exposed after finishing or grinding operationsCrack in Heat Affected Zone adjacent to weld toeIf shadows disappear under different lighting angles, the discontinuity is acceptableCrater cracks can propagate 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.

9 MELT-THROUGH: 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 . 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 . 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.

10 All overlap shall be rejected. Shadows Reveal OverlapUse a strong light at 90 degrees at the toe of the weld to detect overlapAcceptableEvidence of melt through must be seen in the jointNo evidence of melt through original joint lines still visibleRejectable Convexity is acceptable ARC STRIKES: Arc strikes outside the area of deposited weld metal shall be rejected. fillet WELDS: 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. 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: LightingViewingConvexity is acceptable, overlap is not Can cause cracks None permitted outside the weld zoneMINIMUM 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) to to to.