QA EZ The Engincoring society For Advancing Mobili Eerfigrencing Mobiiy ~—- AEROSPACE INTERNATIONAL MATERIAL {a canmemeRh Biv Toren PATH SB ECIFIGATION ‘Sulbaite for racegniion as an Ararcan Nabonal Standard SAE | AMs-sTD-1595, Tesued 7998-08 Qualification of Aircraft, Missile and Aerospace Fusion Welders NOTICE This document has been taken directly from U.S. Miltary Specification MIL-STD-1595A and contains only minor editorial and format changes required to bring it into conformance with the publishing requirements of SAE technical standards. ‘The initial release of this document is intended to replace MIL-STD-1595A. Any part numbers established by the original specification remain unchanged. ‘The original Military Specification was adopted as an SAE standard under the provisions of the SAE Technical Standards Board (TSB) Rules and Regulations (TSB 001) pertaining to accelerated adoption of government specifications and standards. ‘TSB rules provide for (a) the publication of portions of Unrevised government specifications and standards without consensus voting at the SAE Committee level, and (b) the use of the existing government specification or standard format. Any material relating to qualified product lists has not been adopted by SAE. This material was part of the original military specification and Is reprinted here for historic reference only. ‘SAE Tectia landards Bord ues reso that “Ts eps pushed SAE anesthe lal of lchricl and enginaesing tence, The vs ‘ay. on spay end sutaty fr ony raricr ve ncloag my palen itingesn! rin htc, sho espesiiy a usa [SAE raves each eccal opt atest ey ve yar a whl eel be eae, eva, orcancele SAE nes yor wie comes ard ussesbns, Copy 1088 Sty Automate Egheas he ithe recone, Prt QUESTIONS RECARDNG THis DOCUMENT: 24 Tra 7154 Fx (29 rr60243 Foruace apoeuneNT ores (029 7764970 Pax (28) 760790 ‘SKEWED ADDRESS! Nipherseeorgze Engineering Society SAE For Advancing Mobility AEROSPACE INTERNATIONAL MATERIAL {Giconnomenn Gh WoradoPOTOH SPECIFICATION Sulyted for recogatien 28 an Amevican Natlonal Standard AMS-STD-1595 Qualification of Aircraft, Missile and Aerospace Fusion Welders NOTICE This document has been taken directly from U.S, Military Specification MIL-STD-1595A and contains only minor editorial and format changes required to bring it into conformance with the publishing requirements of SAE technical standards. The initial release of this document is intended to replace MIL-STD-1595A. Any part numbers established by the original specification remain unchanged. The original Military Specification was adopted as an SAE standard under the provisions of the SAE Technical Standards Board (TSB) Rules and Regulations (TSB 001) pertaining to accelerated adoption of government specifications and standards. TSB rules provide for (a) the publicetion of portions of unrevised government specifications and standards without consensus voting al the SAE Committee level, and (b} the use of the existing government specification or standard format. Any material relating to qualified product lists has not been adopted by SAE. This material was part of the original military specification and is reprinted here for historic reference only. ‘SAE Techical Standards Board Ruses poe tht “Thi topat ie pblehed by SAE fo sGverce to saa cl etn ad enginoeingslecos Those ol is evo eel ‘oun, ade sppiesbity and uty fr Sry partelar uso, neaudg eh ean eagorenteshg tarot tha cle responsi ata” ‘SAE rv och tecnica report at ct ovr fe yaaa whisk Et my be eae, rsd, or cnc, SAE nes your wren carmen end suggests ‘Capit 108 Saito tsmotve Engage. ‘Nine ese. Pastesin SA QUESTIONS REGARDING THISDOCUMENT: (724) 7727184 (729 7160243 FopLace abocuMeNT ORDER: fi2q reaar0 (2g 760709 ‘SAE WES ADDRESS" Iipuinenae orgAMS-STD-1595 Paragraph AMS-STD-1595 CONTENTS. SCOPE. Purpose... — . Welder and welding operator assignments Welder ae Welding operator REFERENCED DOCUMENT: Issues of documents. Other publications. DEFINITIONS... Welding terminology, As-welded.. ‘Automatic welding... Backing... Base metal Blank. Butt joint. Complete fusion Complete joint penetration. Defect Depth of fusion. Discontinuity... Filler MELA nnn Fusion 2008 sresneseei Heat-affected zone ... Manual welding. 7 ‘Semiautomatic are welding. Test weld..... sete Welder aaa Welding machine... : See eee eee 0 Welding operator. fe es 10 Symbols and termsAMS-STD-1595 Paragraph 4. 44 44d 4n2 42 43 44 45 45.4 46 464 4.6.2 47 AMS-STD-1595 CONTENTS - continued GENERAL REQUIREMENTS Qualification requirements ...n Welders . Welding operators Minimum requirements. Physical requirements Identification . Test records. Test record forms. Requalification.. Alternate requalification... DETAILED REQUIREMENTS ‘Welding process... Base metals.. Exception... Base metal thickness.. Welding position WeldetS «cc rnsnnrne Welding operators snss-sm Base metal form and weld type Welders .. Welding operators nm Other welding conditions. Welders .. Welding operators Test welds... ee Groove test weld in sheet, Fillet test weld in sheet Groove test weld in tube... Fillet test weld in tube ‘Special applications... Qualification limitations...AMS-STD-1595 Page Paragraph 5.7.5.2 58 58.1 5.82 5.8.3 5.84 585 59 594 5.9.2 5.10 5.104 5.10.2 5.10.3 11 5114 BA12 5.113 5114 5.12 5.124 51244 5121.2 5124.3 51214 5.122 5.12.24 51222 5.13 5.13.41 5.19.2 5.13.3 5.14 5.1441 51414 5AdA.2 5.14.1.3 5.14.2 5.14.21 5.14.2.2 AMS-STD-1595 CONTENTS - continued Acceptance critetia nna Inspection, examination, and bend esing requirements Visual inspection... Radiographic inspection .. Bend testing. Metallographic examination SUMMALY nnn Visual inspection procedure Weld length... Magnification Radiographic inspection procedure... Weld length...... Radiography standard Radiographer qualification Preparation of bend specimens. Groove welds in sheet. Groove welds in tub Fillet welds in sheet Fillet welds in tube. Bend testing procedure... Groove welds... Base metal thickness of more than 0.083 inch.. ‘Alternate method for base metal thickness of more than, Base metal thickness of equal to or less than 0.063 Inch, Bend radius... a Fillet welds. sensnees ST 37 37 46 46 Motallographic examination . Cutting Trimming... ross sections. Acceptance criteria... Visual inspection.. Groove welds... Fillet welds. Radiographic inspection Interpretation of indications Unacceptable indications..AMS-STD-1595 Paragraph 5.14.3 5.14.3.4 5.14.3.2 5.14.4 5144.4 5.14.4.2 5146.4.3, 5.14.4.4 10. 10.4 10.2 AMS-STD-1595 CONTENTS - continued Bend specimens Groove welds... Fillet welds: Metallogray Interpretation of defects... Fillet weld defects fi anes Base metal thickness of equal to or less than 0.063 inch... Base metal thickness more than 0.063 inch. GENERAL . Fusion welding process... Base metal groups... Base metal groups qualified by test weld... Welding position, base metal form, and weld type uid by tot wels Welding conditions qualified by test weld.. Base melals for which bend testing is not applicable. Required inspection, examination and bend testing of test weld Bend specimens for groove welds in sheet... eee Bend specimens for groove welds in tube. Bend specimen thickness and bend radius Maximum allowable weld reinforcement. Maximum linear indications ... Maximum allowable porosityFigure AMS-STD-1595 AMS-STD-1595 CONTENTS - continued FIGURES ‘Suggested test record form sun Groove weld in shest; positions 1G, 2G, 3G, 46. Fillet weld in sheet; positions 1F, 2F, 3F, 4F. Groove weld in tube; positions 1G, 26, 5G, 6G Fillet weld in tube; positions 1F, 2F, 4F, SF. Groove test weld in sheet nnn : Fillet test weld in sheet... Groove test weld in tube.. Fillet test weld in tube. Blank locations for bend specimens in groove-weided sheet. Blank locations for bend specimens in groove-welded sheet (continued) Bend specimens in groove-welded sheet... Bend specimens in groove-welded sheet (continued) a Blank locations for bend specimens in groove-welded tube. Bend specimens in groove-welded tube... a Bend specimens in groove-welded tube (continued). Blank location for bend specimens in filet welded sheet Blank location for bend specimens in fillet welded tube Wrap-around bend test fixture Ram-and-die bend test fixture... Slotted fillet wold... Blank locations for metallographic spe Blank locations for metallographic specimens in fillet-welded tube. ‘Alowable maximum total porosity area and maximum pore Allowable maximum total porosity area and maximum pore size (continued)... 85 Complete and incomplete fusion in fillet welds. BTAMS-STD-1595, AMS-STD-1595 1. SCOPE: 4.1. Purpose: ‘This standard establishes the procedure for qualification of welders and welding operators engaged in the welding of aircraft, missiles, other aerospace equipment, and their parts and accessories by fusion welding processes. This standard is applicable to aircraft, missile, and aerospace ground support equipment or other welding, when included in the contracting documents or when invoked in the absence of a specified welder qualification docurnent. 4.2 Welder and welding operator assignments: 1.2.1 Welder: Welders may weld all joints by manual and semi-automatic welding for which they are qualified by producing acceptable test welds, as defined in Sections 4 and 5. In addition, welders ‘may weld all joints by machine and automatic welding within the same limitations as for the acquired welder qualification. 1.2.2 Welding operator: Welding operators may weld all joints by machine and automatic welding for they are qualified by producing acceptable test welds, as defined in Sections 4 and 5. . APPLICABLE DOCUMENTS: The following publications, of the issue in effect on the date of invitation for bids or request for proposal, form a part of this specification to the extent specified herein. 2.1. U.S. Government Publications: Available from DODSSP, Subscription Services Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094. MIL-STD-410 Nondestructive Testing Personnel Qualification and Certification MIL-STD-453 Inspection, Radiographic 22 ASTM Publications: Available from ASTM, 100 Barr Harbor, West Conshohocken, PA 19428-2959. ‘ASTM DS-56 Unified Numbering System for Metals and Alloys (Same as SAE HS1086) SAE Publications: Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE H81086_ Unified Numbering System for Metals and Alloys (Same as ASTM DS-56)AMS-STD-1595 AMS-STD-1595 2.4 AWS Publications: Available from American Welding Society, 550 N.W. LaJeune Road, Miami, FL 33126. “AWS A3.0 Welding Terms and Definitions “AWS B3.0 Welding Procedure and Performance Qualification AWS D1.1__— Structural Welding Code AWS D10.9 Qualification of Welding Procedures and Welders for Piping and Tubing 3, DEFINITIONS: 3.1 Welding terminology: ‘The welding terminology of ‘Welding Terms and Definitions" AWS A3.0, shall be used in the interpretation of this standard. Some of these items and additional terms are defined below. 3.1.1 As-welded: The condition of weld metal, welded joints, and weldments after welding but prior to any subsequent thermal, mechanical, or chemical treatments. 3.1.2 Automatic welding: Welding with equipment which performs the welding operation without adjustment of the controls of a welding operator. The equipment may or may not perform the loading and unloading of the work, 3.1.3 Backing: A material (base metal, weld metal, carbon, or granular material) placed at the root of a ‘weld joint for the purpose of supporting molten weld metal 3.1.4 Base metal: The metal to be welded, soldered, or cut. 3.4.5 Blank: Part of a test weld removed for the preparation of a bend test specimen or a metallographic specimen, 3.1.6 Butt joint: A joint between two members aligned approximately in the same plane. 3.1.7 Complete fusion: Fusion that has occurred over the entire base metal surfaces intended for welding and between all layers and weld beads. 3.1.8 Complete joint penetration: Joint penetration in which the weld metal completely fils the groove and is fused to the base metal throughout its total thickness. 3.1.9 Defect: A discontinuity or discontinuities which by nature or accumulated effect render a part or product unable to meet minimum applicable acceptance standards or specifications. This term designated rejectabilty. 3.1.40 Depth of fusion: The distance that fusion extends into the base metal or previous pass from the surface melted during welding,AMS-STD-1595 AMS-STD-1595 Discontinany= in the mechanical, metallurgical, or physical character discontinuity is not necessarily a defect. An interruption of the typical structure of a weldment, such as a lack of homogenely 8 of the material or weldment. A 3.1.12 Filler metal; The metal to be added in making a welded, brazed, or soldered joint. 3.1.13 Fusion zone: The areas of base metal melted as determined on the cross section of a weld, 3.1.14 Heat-affected zone: That portion of the base metal which has not been melted, but whose mechanical properties or microstructure have been altered by the heat of welding, brazing, soldering, or cutting, 3.1.15 Joint: The junction of members or the edges of members which are to be joined or have been joined. 3.1.18 Machine welding: Welding with equipment which performs the welding operation under the constant observation and control of a welding operator. The equipment may or may not perform the loading and unloading of the work, 3.1.17 Manual welding: A welding operation performed and controlled completely by hand, 3.1.18 Semiautomatic aro welding: Aro welding with equipment which controls only the filler metal feed. The advance of the welding is manually controlled, 3.1.19 Test weld: A joint made by a welder for purposes of welder qualification 3.1.20 Welder: One who performs a manual or semiautomatic welding operation. 3.1.21 Welder certification: Certification in writing that a welder has produced welds meeting prescribed standards. 3.1.22 Welding machine: Equipment used to perform the welding operation. For example, spot welding machine, arc welding machine, seam welding machine, etc. 3.1.23 Welding operator: One who operates machine or automatic welding equipment, 3.2 Symbols and terms: ‘a, Sheet refers to both sheet and plate, where appropriate. b. Tube refers to both tube and pipe, where appropriate. ¢. The lower case letter, t, indicates base metal thickness for either sheet or tube wall. d. Mathematical symbols used before numbers mean: less than more than equal to or less than equal to or more than. livia vwAMS-STD-1595, AMS-STD-1595 4. GENERAL REQUIREMENTS: 4.4. Qualification requirements: To achieve qualified status, welders and welding operators shall demonstrate their skill by producing acceptable test welds in accordance with 4.1.1. No test welds are required for those welds which will not be required in production welding, 4.1.1 Welders: The correlation between test welds and production welds shall be based on the following factors. .. Welding process (see 5.1). Base metal composition (see 5.2). . Base metal thickness (see 5.3). 1. Welding position (see 5.4). . Base metal form, sheet or tube (see 5.5). Type of weld, groove or filet (see 5.5). |. Other welding conditions (see 5.6). 4.1.2 Welding operators: The correlation between test welds and production welds shall be based on only the first three factors given in 4.1.4 4.2. Minimum requirements: The requirements of this standard are minimum, Other requirements may be added by the contractor, but may not be substituted for the requirements of this standard, Physical requirements: The contractor shall establish reasonable and appropriate physical requirements for welders and welding operators. It will be accepted that those whose corrected vision in each eye for long distance is better than 20/30 and for 16 inches distance permits reading of Joeger No. 2 type will ordinarily satisfy vision needs for welding, Identification: ‘The contractor shall assign a unique number or other identification to each welder or welding ‘operator upon qualification, Test records: ‘The contractor shall complete a test record containing the essential information required as evidence of the welder or welding operator qualification. These records shall be retained for the period of time ‘specified in the contract or, if no retention time is specified, the period of record retention shall be for the duration of qualification.AMS-STD-1595 AMS-STD-1595 4.5.1 Test record forms: Suggested test record forms are given in Figure 1 and in the following documents. a. Structural Welding Code, AWS 01.1 b. Qualification of Welding Procedures and Welders for Piping and Tubing, AWS D10.9. Requalification: A welder or welding operator shall be requalified every five years to the same requirements as an original qualification. Requalification is also required when either of the following two conditions are present. ‘Awelder or welding operator has not welded with a given welding process for a period of three months; except that this period shall be extended to six months if the welder has welded with another process of Table |. There is a specific reason to question the ability of a welder or welding operator to meet the requirements for qualification in @ given welding process. Alternate requalification: As an alternate to the requirements of 4.6.1, requalification to the same requirements as an original qualification may be accomplished at two year intervals, in liou of the three month and six month restrictions, DETAILED REQUIREMENTS: Welding process: For welders and welding operators, a test weld made with a given welding process of Table | qualifies only that welding process. This standard does not apply to welding processes not included in Table |, Base metals: For welders and welding operators, a test weld made in a base metal included in one of the ten base metal groups of Table II qualifies only that base metal group, except as modified by 6.2.1 and .2.2 and as illustrated in Table Ill. The specific base metals included in each of the base metal groups of Table Ii, are given in the Appendix of this standard. Since the base metal groups are intended only for the purpose of qualification, some of the base metal ‘groups contain base metals whose composition does not conform to the nominal description of the base metal group.AMS-STD-1595, AMS-STD-1595 QUALIFICATION TEST RECORD Mane ra, 85 Joint welding procedure Woldor [] Welding operator (1 TEST WELD Base netal desoription Group No, Wolding process, Single weld [] Double weld ( ] Current aeTy BeTT Backing, yes (1 Not} vartical own f) Up 1 tration Complete { J] Partial [ j Position Divengton, inch Meet groove Gb) 20) sot) act) t. Tube groove «= GT] 201) SOT) ©. Dy. ® Sheet fillet AFT) art) aFL} Pt) « Mbe filet = ar (1) aPC) aPC) SRE] omy, « RESULTS viowat rail [1 Radlographic Fail (1 Bead Fait {j Matallographio rail 0) QUALIFIED Single wold [] Double wela [1 Backing with (] Without [ ] Penetration Complete (J Parttal [ ] ty dnoh 0. Dey inch Position Max. tin. ax, shost groove 1G 1 2001 360) 40) tube groove = IGE] 201) S601 eee a sheet fitet PE aR) oP 0) AP TD Sercerecerce? Tbe fidet PE) 2F (1 aPC) SPT ‘Tho above nanod Andlvidual 18 qualified 4n accordance with MII-BT0-1595A within the shove Limits for the welding process used for this tost veld. Date of toot wold signed by, Qualisier FIGURE 1. Suggested test record form. 12+AMS-STD-1595 AMS-STD-1595 TABLE |. Fusion welding processes. Oxyfuel welding Shielded metal arc welding (SHAW) Submerged arc welding (SAW) Gas tungsten arc welding (GTAW) Gas metal arc welding (GHAN) Flux cored arc welding (FCAW) Plasma are welding (PAW) Electron beam welding (EBH) TABLE Il, Base metal groups. Tontnal descriptton Carbon and iow alloy steels Alloy steels Stainless steels Precipitation hardening stainless stects Nickel and nickel-base alloys Precipitation hardening nickel-base alloys W ‘Aluminum and sTuminun-base alloys v Magnes tum-base alloys I Titanium and titaniun-base alloys vit Cobait-base alloys 5.21 Qualification in a base metal group with a *b" designator also qualifies for base metal numbers, with the same roman numeral designator and an “a” designator. See Table Ill.AMS-STD-1595 AMS-STD-1595 TABLE Ill, Base metal groups qualified by test weld Test weld quatified Ia I Ib Ta, Ib a Ta. IIb Ha, 11b Ila a IIIb IIa, T11b v Vv v v vr vr vit vit 5.2.2 For welders and welding operators, a separate qualification is required for each base metal not Included in the Appendix, except as modified in 6.2.2.1. 6.2.2.1 Exception: A base metal not included in the Appendix, with welding characteristics similar to a given base metal group of the Appendix, may be qualified with any base metal of the given base melal group. The preparing activity shall be notified by the organization qualifying a welder or welding operator under the provisions of this paragraph, with DD Form 1426 or a letter, of the two base metals involved and the chemical composition of the base metal not Included in the Appendix. 5.3 Base metal thickness: The qualification limits, with regard to base metal thickness (sheet thickness or tube wall thickness), are given below for welders and welding operators. These limits apply to both groove welds and fillet welds, 5.3.1 Atest weld with a base metal thickness of t shall qualify welds with a thickness range of 0.67t to 4t; except that, when the test weld thickness is equal to or greater than 1 inch, the qualification range is 0.67t to unlimited. 0! 7 6°? 5.3.2 Twotest welds, each with members of equal thickness, shall qualify welds with all intermediate thicknesses, in addition to the thickness qualifications of 5.3.1. Welding position: Welders: The welding positions qualified by a given test weld position, to be found at the left of Table IV, are denoted by an X in the table, The welding positions are illustrated in Figures 2 through 5. Welding operators: A test weld made in any welding position qualifies for all welding positions. -14-AMS-STD-1595 AMS-STD-1595 5.5 Base metal form and weld type: 5.5.1 Welders: The base metal forms and weld types qualified by a given test weld, to be found at the left of Table IV, are denoted by an X in the table, with the exceptions given below. §.5.1.1 Qualification for fillet welds in base metal equal to or less than 0.063 inch in thickness requires afillet test weld. Groove test welds do not qualify for fillet welds in this thickness range. 5.5.1.2 A tube test weld shall qualify only for tubes of an outside diameter equal to or greater than the outside diameter of the test weld 5.5.2 Welding operators; A test weld of any base metal form and of any weld type shall qualify for all base metal forms and all weld types. A tube test weld of any outside diameter shall qualify for tubes of any outside diameter. 5.6 Other welding conditions: In addition to the welding process, base metal composition, base metal thickness, welding position, base metal form and type of weld; other welding conditions which require a correlation between the test weld and the production welds are given in Table V. 5.8.1 Welders: The welding conditions qualified by the given test weld conditions, to be found at the left of Table V, are denoted by an Xn the table. ‘The current type restrictions apply only to the GTAW process. For all other processes, a tes! weld made with either ac or de current qualifies for welds made with elther current type. 5.8.2 Welding operators: The welding condition restrictions of Table V do not apply to the qualification of welding operators, 5.7 Test welds: One test weld shall be required for each combination of welding conditions, given in 4.1.1 and 4.1.2, being qualified. Test welds shall be made in accordance with a written joint welding procedure, Groove test weld in sheet: The test weld is a butt joint in sheet as described in Figure 6, -18-AMS-STD-1595 AMS-STD-1595 TABLE IV. Welding position, base metal form, and weld type qualified by test weld Test Held Qualifted position Sheet Tube Groove Fillet Groove Five 16 26 3G 4¢ | 1F 2F 3F AF | 16 26 56 6G | IF 2F 4F SF xe x xXx x x x x Fillet 1 U/ A groove test weld does not qualify for fillet welds in base metal equal to or less than 0,063 inch in thickness (see 6.5.1.1),AMS-STD-1595 AMS-STD-1595 ee flat position, The welding position used to weld from the upper aide of the Joints the face of the weld 1s approximately horizontal E 2G horizontal position. The position of welding im which, the axis of the veld lies in an approximately horizontal plane and the face of the weld lies in an approximately vertical plane. Vertical position, The position of welding in which the axio of the weld 4e approximately vertical, . ~~» everheed posttton. tho position in vi eektion fn woh velding 16 perfoimed fren the nde of the joint, ae iets FIGURE 2. Groove weid in sheet: positions 1G, 2G, 3G, and 4G. “17.AMS-STD-1595 AMS-STD-1595 fiat position, The welding position used to weld from the upper side of the joint; the face of the weld is approximately horizontal. iS horizontal position, The position in which welding 4e performed on the upper side of ‘an approximately horizontal surface and against an approximately vertical surface. It 3F T ~~ vortical position. The position of welding in videh the axio of the veld 1 approximately vertical. 7 TS vezhad postion, The position a vhtch welding 16 perforued from the underside of the Joint, FIGURE 3. Fillet weld in sheet: positions 1F, 2F, 3F, and 4F. 18+AMS-STD-1595 SAE AMS-STD-1595 horizontal rolled position. The position of ‘a pipe Joint in which the axis of the pipe a approximately horizontal, and welding 4g performed in the flat position by rotating the pipe. Joint in which welding is performed in the hordaontal position and the pipe is not sl rotated during welding. 1 vertical position, ‘the position of a pipe 2G iii horizontal fixed position, The position of a pipe Joint in which the axis of the pipe 4s approximately horizontal and the pape de not rotated during welding. Inclined position, The position of a pipe Joint in which the axis of the pipe 12 approximately at an angle of 45° to the horizontal and the pipe 1s not rotated during welding. FIGURE 4. Groove weld in tube: pos! TT —L_Ll -19-AMS-STD-1595 AMS-STD-15! -STD-1595 flat position. The welding position used to ‘weld from the upper side of the joint; the Face of the weld 4s approximately horizontal and the pipe is rotated during welding. horizontal position. The position in vnich = ‘Melding 48 performed on the upper side of IT we ppproxinately horizontal surface end we inet an approxiaately vertical surface garth pipe ie not rotated during welding, overhead position, The position in which ‘Gelding 4e perforned Fron the underside of GFT) f\ the joint and the pipe ie not rotated during welding. 5F il, sultipte poottion, The position in which the axis of the pipe 4e approxinately ‘ce forieontal and the pipe 10 not rotated \ during welding. FIGURE 6. Fillet weld in tube: positions 1F, 2F, 4F, and SF. =20-AMS-STD-1595 AMS-STD-1595 TABLE V. Welding conditions qualified by test weld. Qualified Current, Backing Groove weld type Complete Partial Test weld with | without Double | penetration | penetration | ac fac With backing x Without backing | x Single welded groove weld Double welded groove weld Complete penetration weld Partial penetration weld’ ac welding de welding U/ Applicable only to GTAW process (see 5.6.1),AMS-STD-1595 AMS-STD-1595 a aE t ut INCHES, , 0,063 2 30.063 3 FIGURE 6. Groove test weld in sheet, BASE METAL MINIMUM THICKNESS DIMENSIONSAMS-STD-1595 AMS-STD-1595 BASE METAL MINIMUM THICKNESS — DINENSTONS t won INCHES 0.063 4 5 2 30.068 4 BOB NOTE: Where the members differ in thickness more than 10 percent of the thicker, the cap sheet shall be the thicker, FIGURE 7, Fillet test weld in sheet.AMS-STD-1595 AMS-STD-1595 BASE NETAL MINTHUN WALL THICKNESS DIMENSIONS t L INCHES $0,063 30.063, FIGURE 8. Groove test weld in tube.AMS-STD-1595 AMS-STD-1595 MINIMUM 2.0 IN. MINIMUM, TYPICAL, 4 PLACES NOTE: Where the members differ in thickness equal to or more than 10 percent of the thicker member, the sheet shall be the thicker member, FIGURE 8. Fillet test weld in tube. -25-AMS-STD-1595 AMS-STD-1595 Fillet test weld in sheet: The test weld is a T-joint in sheet as described in Figure 7. Groove test weld in tube: The test weld is a butt joint in tube as described in Figure 8. Fillet test weld in tube: The test weld is a tube to sheet joint as described in Figure 9. ‘Special applications: When none of the test welds described above are applicable to a given production weld, a more limited welder or welding operator qualification may be achieved with a {est weld consisting of the given production weld or a test weld representative of the given production weld, Qualification limitations: The qualification is limited to the welding conditions of the test weld with regard to welding process, base metal composition, base metal thickness, welding position, base metal form, type of weld and the other welding conditions of 5. 5.7.6.2 Acceptance criteria: The required inspection, examination, bend testing, and acceptance criteria shall be consistent with 6.9 through 5.14, 5.8 Inspection, examination, and bend testing requirements: 5.8.1 Visual inspection: Visual inspection is required for all test welds and shall be completed with the test weld in the as-welded condition. 5.8.2. Radiographic inspection: Radiographic inspection is required for all groove welds, except that bend testing may be used as an alternate under the following conditions. The base metal is not included in Table VI. . The base metal is included in the Appendix. ;. The members of the test weld differ in thickness by less than 10 percent of the thicker member. For tube welds, the outside diameter is equal to or more than 2 inches or the wall thickness is equal to or more than 0.250 inch. Bend testing: Bend testing is required for all fillet welds with a base metal thickness of more than 0.063 inch, except that metallographic examination may be used as an alternate to bend testing. Bend testing of groove welds may be used as an alternate to radiographic inspection as described in 5.8.2,AMS-STD-1595 TABLE Vi. Base motals for which bend testing is not applicable. AMS-STD-1595 Base metal Unified ‘group nunber Common description la NA, 9Ni-4Co steel K92810 18Ni maraging steel Ib m Ma 63198 19-9 DL. 63199 19-9 DX R30155 NI55 30590 $590 $15500 15-5PH stainless steel 817400 17-4PH staintess steel $35000 AN350 PH stainless steel $35500 AN355 PH stainless steel $41800 Greek Ascoloy 342000 420 342200 422 345000 Custom 450 845500 Custom 455 Mb am 1b mn Vv 03560 356 492014 2014 Asz219 2219 v a WI E4620 Ti-6Al-25n-4Zr-2Ho Rg6210 Tt-6AT-20b-1Ta~INo 56260 Ti-6Al-2Sn-42r~640 56620 Ti-6A1-6V-25n 58640 T1-3A1-BV-6Cr-4Mo~42r Wa Ti-6A1-25n-22r-2r=2Ho NA a Ti-15V-3Cr-3Ho-38nAMS-STD-1595 AMS-STD-1595 Metallographic examination; Metallographic examination is required for all fillet welds with a base ‘metal thickness of equal to or less than 0.063 inch, Metallographic examination may be used as an alternate to bend testing for filet welds with a base metal thickness of more than 0.063 inch. 5.8.5 Summary: The required inspection, examination, and bend testing of test welds are summarized in Table Vil, 5.9 Visual inspection procedure: Visual inspection shall be completed with the test wold in the as- welded condition, 5.8.1 Weld length: The center 4-inch length of welds in sheet of equal to or less than 0.083 inch thickness, the center 6-inch length of welds in sheet of more than 0.063 inch thickness, and the entire weld in tubes shall be inspected. Magnification: Inspection shall be performed at a magnification of 3X for welds in base metal with a thickness of equal to or less than 0.063 inch and without magnification for more than 0.063 inch, 5.10 Radiographic inspection procedure: Radiographic inspection shall be completed with the test weld in the as-welded condition, except as modified by MIL-STD-453. 5.10.1 Weld length: The same length of weld as given in 5.9.1 shall be inspected. 5.10.2 Radiography standard: Radiography shall be performed in accordance with MIL-STD-453. 6.10.3 Radiographer qualification: Radiographors shall be qualified in accordance with MIL-STD-410. 5.11 Preparation of bend specimens: Blanks for bend specimens may be removed from the test weld by any means of culling, provided that any crack or heat affected zone caused by cutting is removed by mechanical means, 5.11.4 Groove welds in sheet: 2, Blanks for bend specimens shall be removed from test welds at the locations shown in Figure 10, b. The bend specimen type and dimensions for sheet are given in Table Vill. Each specimen type identified in Column 3 of Table Vill is illustrated in Figure 11.AMS-STD-1595 AMS-STD-1595, 3 = 3. e 5 i ie 3 & g 3 8 5 7 7 z “TGS UE poaniosop st uo}azodsus Suudeaborpes oa sazusoaye ue se p9sn aq Aes BUIISST pu9g SS, ER A pg Sm vraag socom t Rg a st fw u0y fw ey a a a uy voy 00H, 204 Aw uw Aw Ruy uw wwe uw uw uw uw uy uw e070, e200 e30°0 e90°05 55070. e005 e900 a0 a OL 8 s ¥ pouynbea| somouagoa susarzeds} sands Daydess o3pey Tena seouOHL aydeasoures= | Teie0 2509AMS-STD-1595 AMS-STD-1595 a, LONGITUDINAL BENDS DISCARD BEND BLANK WELD ecu CENTER BEND BLANK: DISCARD ————— | b, TRANSVERSE BENDS FIGURE 10. Blank locations for bend specimens in groove-welded sheet,AMS-STD-1595 AMS-STD-1595 g DISCARD CSTE en Aaland HELO ae ey DISCARD CENTER B DISCARD T a cc. SIDE BENDS NOTE: Discard pieces from b to be of equal width. Discard pteces from c to be of equal width. FIGURE 10. Blank locations for bend specimens in groove-welded sheet. Continued. -3t-AMS-STD-1595 AMS-STD-1595 TABLE VIIl. Bend specimens for groove welds in sheet. Base metal Bend test specimen Dimensfons, inch Thickness Type w t shown fn [= L inch No. Figel1 Min, |Max. [Min. | Min. | Max, 1 2 3 4 5 fe | 7 {8 £0,063 a Boa t [y | s | 1.00 [1.08 + > 0,083- Ail | Ted & TB-c | ost | t | 6 | 1.50 11,58 0.126 > o.125- zy | te-b& Tec [0.115 [0.198] 6 | 1.50 | 1.55 0.3: Others | Te-b&TB-c | O.9t | t | 6 | 1.50 | 1.55 > 0.375- 2/ | Tb & Tec | 0.115 [0.135] 6 | 1.50 | 1.55 0.750 or SB-d 0.115 | 0.138 | 6 t t Others | Te-b& TB-c | 0.350 | 0.400} 6 | 1.50 | 1.65 or SB-d 0.350 | 0,400 | 6 t [| t > 0.750 2 SB-d 0.115 }o.136] 6 | 37 | t Others SB-d 0.350 | 0.400 | 6 | yw iet J/ The weld face and root surfaces shall be dressed to produce smooth surfaces with a maximum weld metal thickness vartation of 10 percent. 2/ 96061 and A96063 of Base Metal Group IV. 3/ For base metal thicknesses of >0.750 to 1.50 inch, W is equal to t. For base metal thicknesses of >1.50 inch specimens may be cut into approximately equal strips between 0.75 and 1,50 inch wide for testing, or the specimens may be bent at full width, =32-AMS-STD-1595 AMS-STD-1595 TRANSVERSE BEND SLB LonerTuptnaL Beno SB ste Benn FIGURE 11. Bend specimens in groove-walded sheet. =33-AMS-STD-1595, AMS-STD-1595 Ko BEND eo ROOT BEND FACE. BEND NOTES:, - Longitudinal corners of 6b, 6c, and 6d specimens shat] be rounded to a radius not exceeding 10 percent of ‘the finished thickness, = Dashed lines indicate machined surfaces . = Where menbers of the test weld differ in thickness, the finished dimensions of the bend specimen shall be based on the thickness of the thicker menber. SIDE BEND FIGURE 11. Bend specimens in groove-welded sheet. Continued.AMS-STD-1595 AMS-STD-1595 FACE or ROOT BEND co SIDE BEND Oo FIGURE 12. Blank locations for bend specimens in groove-welded tube. -36-AMS-STD-1595 AMS-STD-1595 5.11.2 Groove welds in tube: ‘a. Blanks for bend specimens shall be removed from test welds at the locations shown in Figure 12. b. The bend specimen type and dimensions for tube are given in Table IX, Each specimen type Identified in Column 4 of Table IX is illustrated in Figure 13, 5.11.3 Fillet welds in sheet: Blanks for bend specimens shall be removed from the test weld at the location shown in Figure 14, 5.11.4 Fillet welds in tube: Blanks for bend specimens shall be removed from the test weld at the locations shown in Figure 15. 5.12 Bend testing procedure: Testing may be performed with the bend specimen either in the as-welded or any heat-treated condition, 5.12.1 Groove welds: §.12.1.1 Base metal thickness of more than 0.063 inch: Bend specimens shall be bent in the wrap- around bend test fixture illustrated in Figure 16. After clamping the bend specimen firmly in place, the roller (planetary cylinder) shall be advanced slowly through an arc of 180 degrees from its starting location directly below the fixed mandrel (cylinder with radius A). Root bend specimens shall be placed with the weld root out toward the roller and face bend specimens. shall be placed with the weld face out toward the roller. Alternate method for base metal thickness of more than 0.063 inch: Bend specimens shall be bent in the ram-and-die bend test fixture illustrated in Figure 17. After placing the bend specimen across the die shoulders, with the center of the weld at the center of the die opening for transverse bend and side bend specimens, the specimen shall be forced into the die cavity by applying a load to the ram until the curvature of the specimen will now allow a wire of 0.12 inch diameter to be inserted between the specimen and the die cavity. Root bend specimens shall be placed with the weld face against the ram and face bend specimens shall be placed with the weld root against the ram. Base metal thickness of equal to or less than 0.063 inch: Bend specimens with a base metal thickness of equal to or less than 0.069 inch shall be tested in a manner similar to that described in 5.12.1.1, except that the roller is not used. The free end of the bend specimen is gripped with pliers and slowly wrapped around the fixed mandrel, Specimens shall be placed with the weld face against the fixed mandrel,AMS-STD-1595 AMS-STD-1595 TABLE IX. Bend specimens for groove welds in tube. Tube Bend test specimen thickness t, inch Base metal umber Dimensions, inch Type. shown 4n t Ww Fig.13 [—Min. [ Max. | Hin, | Wax. 2 4 5 6 7 8 Radtographtc inspection Radiographic inspection Te-e & 8-7] 35 10, [0.800 | Bee & TB-F 2 {0.750 0.800 TB-e & TB-F 0.750 [0.800 or SBe-g t Te-e & T8-F| 37 | 3/ or SB-9 0 |0.400 s8-g {0.115 [0.135 stg —_|o.360 |0.400 Radtographtc inspection TB-e & TB-F]0.115 [0.135 [1.50 T-e & Tt] 27 | 27 (1.50 TB-e & TB-F or SB-g ‘TB-e & TB-F or SB-g SBeg SB-gAMS-STD-1595, AMS-STD-1595 Vy A96061 and A96063 of Base Metal Group IV. 2/ The maxinun ty is the thickness resulting from dressing of ‘the curved surface to a plane. The mintmun ty 1s 0.9 times the maximum. 3f The maximum ty 1s the thickness resulting from dressing the curved surface to @ plane, or 0.400 in., whichever is the lesser. In the finst case, the mintnun t 4s 0,9 tines the maximum, In ‘the second case, the minimun t) is 0.360 in. 4/ For wall thicknesses of> 0.750 to 1.50 tn., Mis equal to t. For wall thicknesses of >1.50 in., specimens may be cut into approxi- mately equal strips between 0.75 and 1.50 in. wide for testing, or the specimens may be bent at full width,AMS-STD-1595 AMS-STD-1595 NOTE: The thickness of the transverse root bend specimen is measured at the specimen edge, a, TRANSVERSE ROOT BEND NOTE: The thickness of the transverse root bend specimen ‘is measured at the specimen center. b, TRANSVERSE FACE BEND FIGURE 13. Bend specimens in groove-welded tube.AMS-STD-1595, AMS-STD-1595 c. SIDE BEND ROOT BEND NOTES: - Longitudinal corners of all specimens shall be rounded to a radius not to exceed 10 percent of the finished thickness. - Dashed lines indicate machined surfaces. - Where the members of the test weld differ in wall thickness, ‘the finished dimensions of the bend specinen shall be based on the thickness of the thicker ‘SIDE BEND member. : 4, BEND SPECIMEN SECTION DETAILS FIGURE 13. Bend specimens in groove-welded tube. ContinuedAMS-STD-1595 AMS-STD-1595 WELD CENTER FIGURE 14. Blank location for bend specimens in fillo-wolded sheet. oatAMS-STD-1595 AMS-STD-1595 B = BEND SPECIMEN BLANK a. For tubes <1.5 in. in b. For tubes 21.8 in, in outside diameter, 0D outside diameter, 0D op Ww INCHES 1.5 to 3.0 0.75 > 3.0 1.60 FIGURE 15. Blank location for bend specimens in filet-welded tube.AMS-STD-1595 AMS-STD-1595 A= Fty, where A is the bend radius “Fis the bend factor t, 1s the bend specimen thickness 20 ¥ 020 ~ 9 NOTES: 1, Dimensions not shown are the option of the designer. An essential con- sideration is to have adequate rigidity for the applied loads. For transverse weld bend specimens, the center of the weld shall be located within angle E. This clearance dimension shat] be a maximun of 0.06 inch plus 0.1 ty. This roller shal] be free to rotate about its cylindrical axis and shall have a minimum diameter of 0.75 inch. The minimum roller width shall be W plus 0.25 inch. This fixed mandrel may or may not be free to rotate about its cylindrical axis and shall have a minfmum width of H plus 0.25 inch. FIGURE 16. Wrap-around bend test fixture.AMS-STD-1595 AMS-STD-1595 A= Fty, where A ts the bend radius F fs the bend factor t, 1s the bend specimen thickness NOTES: / Dimensions not shown are the option of tha designer, An essential consideration 1s to have adequate rigidity for the applied loads, 2/ The length of the ram shall be suffictent to reach the bottom of the die cavity. The ram shall be fitted with an appropriate base and provision shall be made for attachnent to the testing machine, 3 The minimum width of the die cavity.and the ram shall be equal to W plus 0.25 in. A The maximum radius of the die cavity shat! be equal to A plus 1.1t, plus 0,06 in. The minimum depth shall be 2 in. The die shall be fitted with an appropriate base and provision shall be made for maintaining the ram centered in the die cavity, 5/ This dimension shall be twice the radius of the.die cavity. S/ Either hardened and greased shoulders or hardened rollers, free to rotate, shall be Used, The minimum radius shat be Sty or 0.75 in., whtehever ts ess. FIGURE 17. Ram-and-die bend test fixture. 4gAMS-STD-1595, AMS-STD-1595 5.12.14 Bend radius: The bend radius (A) to be used with a given bend specimen thickness and a given base metal may be found in Table X. Other ranges of bend specimen thickness and bend radius may be used, provided that the bend factor does not exceed the range of F to 1.1F. (See equation of Figure 16.) 5.12.2 Fillet welds: 5.12.2.1 Loading: The stem of the bend specimen shall be loaded parallel to the cap sheet, so that the root of the weld is in tension. The load shall be slowly increased until the specimen fractures in the weld. $.12.2.2 Weld fracture: Where it is necessary to ensure fracture in the weld, the weld face shall be grooved as shown in Figure 18. For fillet welds in tube, the groove shall be cut before the bend specimen blanks are removed from the test weld. 5.13 Metallographic examination: Blanks for metallographic specimens shall be removed from test welds in accordance with Figures 19 and 20. 6.13.1 Cutting: Removal from the test weld may be by any means of cutting, provided that any crack or heat affected zone caused by culting is removed by mechanical means, 5.13.2 Trimming: Extraneous metal may be trimmed from the blanks, either before or after removal from the test weld, to obtain a metallographic specimen of convenient size, provided that the entire weld and heat affected zone at the designated cross section remains in the metallographic specimen. 5.13.3 Cross sections: Each of the cut weld cross sections, designated in Figures 19 and 20, of the metallographic specimens shall be smoothed by fine abrasive or file and etched with a suitable reagent to clearly reveal the weld macrostructure for examination at a magnification of 5X, 5.14 Acceptance criteria: 6.14.1 Visual inspection: 5.14.1.1 Groove welds: Groove welds in sheet or tube which have any of the following defects are unacceptable: a. Any type of crack. b, Incomplete joint penetration. ©. Underfil, 48 =AMS-STD-1595 AMS-STD-1595 = 5 4 £ & 5 é x 4 Fe 2 = Unified number 50250 50400 50550 52400 ast 0.395, 496061 596063, 8 54520 54810 56320 56400 Fe 133/ F bend Radius 2 ‘a a in inches. AJ the body of the tabla containe the bend epacinen thickness (¢1) -2/ Tha tolerance on bend radius A 4 40.001 én, or 41%, whichever te the larger. LB) ¥'= Bond factor 46AMS-STD-1595 AMS-STD-1595 NOTES: @ shall be a maximum of 0.5 t or 0.25 inch, whichever is tess, P shall be no less than 0.6 t, FIGURE 18. Slotted fillet weld. |AMS-STD-1595, AMS-STD-1595 WELD CENTER 0.50 0,75 FIGURE 19, Blank locations for metallographic specimens in fillet-welded sheet, | Rael FIGURE 20. Blank locations for metallographic specimens in fillet-welded tube. 48.AMS-STD-1595 AMS-STD-1595 5.14.1.1 (Continued): d. Overlap. €. For test welds with a base metal thickness of more than 0.063 inch, undercut at any location in excess of 0.05 t or 0.032 inch, whichever is the lesser. f, Mismatch at any location in excess of 10 percent of the base metal thickness or 0.12 inch, whichever is the lesser, except that a mismatch up to 25 percent is allowed for a base metal thickness of equal to oF fess than 0.083 inch. 9. Reinforcement of the weld face or the weld root in excess of that shown in Table XI. 6.14,1.2 Fillet welds: Fillet wolds in sheet or tube which have elther of the following defects are unacceptable: a. Any type of crack, b. Overlap. 5.14.1.3 Base metal thickness of more than 0.063 inch: Fillet welds in sheet or tube with a base metal thickness of more than 0.063 Inch, which have any of the following defects, are unacceptable: ‘a. Undercut at any location in excess of 0.1 tor 0.063 inch, whichever is the lesser. b, Fusion evident at any sheet or tube surface opposite the weld bead. ¢. For base metal thickness equal to or less than 1 inch, a leg size less than t. For a base metal thickness of more than 1 inch, the minimum leg size shall be 1 inch. Where the members of the test weld differ in thickness, the minimum leg size shall be based on the thinner member. 4d. For base metal thickness equal to or less than 1 Inch, a leg size in excess of 3 t, or t plus 0.26 inch, whichever is the lesser. For a base metal thickness more than 1 inch, the maximum leg size shall be 4.25 inch. Where the members of the test weld differ in thickness, the maximum leg size shall be based on the thinner member. ©. Aralio of the leg of larger size to the leg of smaller size greater than 1.5 at any location. {Fora convex weld, at any location a convexity in excess of 0.1 times the average leg size at that location. g. Fora concave weld, a theoretical throat size of less than 0.6 t at any location. Where the members of the test weld differ in thickness, the minimum theoretical throat size shall be based on the thinner member. -49-AMS-STD-1595 AMS-STD-1595 TABLE XI. Maximum allowable weld reinforcement, Maximum allowable weld reinforcement 1/ Root. Base metal Base ‘thickness Any metal Any t, in, Tocation group location < 9,083 0,020 inch +t | Iv and V 0.030 inch + t or 0.960 tnch or 0.070 inch oe . Tay Ib, Tay 1b, | 0,020 inch + t Ifa, inp, "vt, "| or 0,050 inch and Vil 0.8 t . | Wand y t or 0,25 inch or 0.25 inch Jay Ib, Ila, Ii, 0.8 t Ula, Erb, VI, or 0,25 inch and VIT —! U/ The applicable maximum is the smaller’of the two values given in the body of the table.AMS-STD-1595, AMS-STD-1595 5.14.2 Radiographic inspection: 5.14.21 Interpretation of indications: . A linear indication is defined as one whose maximum dimension is more than three timos its minimum dimension, b. Non-linear indications with major and minor dimensions shall be evaluated as an equivalent circle with estimated average diameter. This estimated diameter shall be the size used in determining the acceptability of the indication, and the area corresponding to this estimated diameter shall be used in calculating the area of an indication. . Tungsten inclusions shall be counted as porosity. d. Ina test weld with a base metal thickness of equal to or less than 0.063 inch, a disregard all indications of less than 0,002 inch size. In a test weld with a base metal thickness of more ‘than 0.063 inch, disregard all indications of less than 0.005 Inch or 0.02 t size, whichever is greater. 5.14.2.2 Unacceptable indications: Test welds, whose radiograph of the inspected length shows any of the following indications, are unacceptable: a. Any type of crack. b. Incomplete joint penetration, except as indicated in 5.14.2.2c. c, Internal linear indications in excess of those show! Table Xi. d. Porosity in excess of that shown in Table XII. Examples of the allowable maximum total porosity area and the maximum pore size are shown in Figure 21. TABLE XII. Maximum linear indications. Indication Tength’/ Base metal thickness, inch Linear indication = 0,068 > 0,063 Length of any indication 2t or 0.38 inch’ Accumulated length in any 2t t or 0.38 inch?/ Tfhch weld Tength Average length t 0.5 t or 0.18 inch2/ V/ ‘here the menbers of the test weld differ in thickness, t is the thickness of the thicker member, 2/ The applicable maximum is the smaller of the two values, -51-AMS-STD-1595 AMS-STD-1595 TABLE Xill. Maximum allowable porosity. Porosity size, area, or amount Base meta? thickness 1/ Porosity < 0.063 2/ > 0.063 3/ Any pore 0.6 t 0.4 t or 0,18 inch 4/ Pores of > 0.3 t 8 pores NA Pores of> 0.2 t or NA 12 pores >0.12 inch 4/ Total porosity area 0,10 € Inch® | 0.10 Inch Cluster porosity area 0.04 t inch’ 0.025 inch? in any 1/2 inch of weld Tength | Attoned porostty erea 5/ [0.02 € inch” | 0,018 ¢ inch Wihere the members of the test weld differ in thickness, t 1s the thickness of the thicker menber. ‘These values apply to a 4 inch weld length. For groove welds in tube, the values shall be adjusted in proportion to the tube circunference. These Values apply to a 6 inch wald length. For groove welds in ‘tube, the values shall be adjusted in proportion to the tube circumference. The applicable maximum is the lesser of the two values. Aligned porosity is defined as a group of more than 3 pores within 142 neh of weld Tengths and which-may be intersected by a straight ne,AMS-STD-1595 AMS-STD-1595 Base metal thickness: 0.032 inch Represents 1 inch of weld length at 6X magnification b. Base metal thickness: 0,063 inch Represents 2 inches of weld length at 3X magnification c. Base metal thickness: 0.125 inch Represents 2 inches of weld length at 3X magnification d, Base metal thickness: 0.260 inch Represents 6 inches of weld length at no magnification FIGURE 21. Allowable maximum total porosity area and ‘maximum pore size, =53-AMS-STD-1595 AMS-STD-1595 Base metal thickness: 0.50 inch Represents 6 inches of weld length at no magnification Base metal thickness: ~ 1.00 inch Represents 6 inches of weld length at no magnification Base metal thickness: 2.00 Inches Represents 6 inches of weld length at no magnification Base metal thickness: 4.00 inches Represents 6 inches of weld length at.no magnification FIGURE 21. Allowable maximum total porosity area and maximum pore size, Continued.AMS-STD-1595 AMS-STD-1595, 5.14.3 5143.4 5.14.4 5.14.44 Bend specimens: Groove welds: Groove welds bend specimens having open defects exceeding t or 0.12 inch, whichever is the lesser, on the convex surface are not acceptable. Cracks occurring on the comers shall not be considered, unless it is evident that they result from weld defects. Fillet welds: Fillet weld bend specimens which exhibit less than complete fusion to the root of the joint are not acceptable. The left-hand fillet of Figure 22 illustrates this condition prior to bending. ‘The right-hand fillet illustrates minimum acceptable root fusion. Metallographic examination: Interpretation of defects: a. Alinear defect is defined as one whose maximum dimension is more than three times its minimum dimension. Non-linear defects with major and minor dimensions shall be evaluated as of an equivalent estimated average circle. The estimated diameter shall be the size used in determining the ‘acceptability of the defect, and the area corresponding to this estimated diameter shall be sed in calculating the area of a defect. ‘Tungsten inclusions shall be counted as porosity. In a test weld with base metal thickness of equal to or less than 0.063 inch, disregard all defects of less than 0.002 inch size. In a test weld with a base metal thickness of more than 0.063 inch, disregard all defects of Jess than 0,005 inch or 0.02 t size, whichever is greater. 5.14.4.2 Fillet weld defects: Fillet welds which have any of the following defects are unacceptable: A crack which intersects the weld face. ). Acrack at the weld root which exceeds 0.2 times the actual throat size or 0.12 inch, whichever is the lesser. . Incomplete fusion at the weld face. |. Overlap. Undercut at any cross section in excess of 0.1 t or 0.063 inch, whichever is the lesser.AMS-STD-1595 AMS-STD-1595 INCOMPLETE COMPLETE FUSION FUSION FIGURE 22. Complete and incomplete fusion in fillet welds.AMS-STD-1595 AMS-STD-1595 5.14.4.2 (Continued): {. For base metal thickness of equal to or loss than 1.00 inch, a leg size less than t. For a base metal thickness of more than 1.00 inch, the minimum leg size shall be more than 1 inch. Where members of the test weld differ in thickness, the minimum leg size shall be based on the thinner member. g. Aratio of the leg of larger size to the leg of smaller size greater than 1.5 at any cross section. h, Fora convex weld, at any cross section a convexity in excess of 0.1 times the average of the two leg sizes, i. Fora concave weld, an actual throat sizo of less than 0.5 t at any cross section. Where the members of the test weld differ in thickness, the minimum actual throat shall be based on the thinner member. i. Any linear defect in excess of 0.3 times the actual throat size or 0.12 inch, whichever is the lesser. k. A total porosity area, on any cross section, greater than 0.05 times the area of the weld metal. 5.14.4.3 Base metal thickness of equal to or less than 0.063 inch: Fillet welds in sheet or tube with a base metal thickness of equal to or less than 0,063 inch, which have any of the following, defects, are unacceptable: a. Weld metal at a sheet or tube surface opposite the weld bead and extending more than t beyond the sheet or tube surface; at any cross section, b. Aleg size larger than 6 t or t plus 0.18 inch, whichever is the lesser. Where members of the test weld differ in thickness the maximum leg size shall be based on the thinner member, ©. Incomplete fusion, at either weld leg, as shown in Figure 22, with a dimension b in excess of 0.3 times the actual throat size. 4G. An individual pore size in excess of 0.6 t, where tis the thickness of the thicker member of the test weld. 5.14.4.4 Base metal thickness more than 0.063 inch: Fillet welds in sheet or tube with a base metal thickness of more than 0.063 inch, which have any of the following defects, are unacceptable: a. Fusion evident at any sheet or tube surface opposite the weld bead. b. Aleg size larger than 3 t or t plus 0.25 inch, whichever is the lesser. Where members of the test weld differ in thickness, the maximum leg size shall be based on the thinner member. . Less than complete fusion to the root of the joint, as illustrated in Figure 22. d. An individual pore size in excess of 0.4 t or 0.18 inch, whichever is the lesser. Where the members of the test weld differ in thickness, t shall be based on the thickness of the thicker member. PREPARED UNDER THE JURISDICTION OF AMS COMMITTEE “8” -87-AMS-STD-1595 AMS-STD-1595 APPENDIX SPECIFIC BASE METALS OF BASE METAL GROUPS 10, GENERAL: 10.1 Scope: The classification of metals by base metal groups for welder and welding operator qualification is given in this Appendix. The base metals are identified by the Unified Number of the Unified Numbering System for Metels and Alloys and by the common description, 10.2 This Appendix is a mandatory part of this Standard. Base Metal Group Ia. Carbon and Alloy Steels Unified Unified Number Common Desert pton Nunber Common. Description 10050 Carbon steel 15220 Carbon steel 10060 Carbon steel 15240 Carbon steel @10080 Carbon steel 15270 Carbon steel 10090 Carbon steel 302502 Carbon steel @10100 Carbon steel 302503 Carbon steel @i0110 Carbon steet 302504 Carbon steel 810120 Carbon steel 302505 Carbon steel g10130 Carbon steel 302506 Low alloy steel @10150 Carbon steel 903002 Carbon steel G10160 Carbon steel 903003 Carbon steel 10170 Carbon steel 903004 © Carbon steel G10180 Carbon steel 903011 Carbon steel 10190 Carbon steel 011522 Low alloy steel 810200 Carbon steel 11549 Low alloy steel | 10210 Carbon steel 12072 Low alloy steel 610220 Carbon steel 12080 Carbon_stee? @10230 Carbon steel u12082 Low alloy steel 10260 Carbon steel 912092 Carbon steel 10260 ‘bon steel 912522 Low alloy steel 410290 Carbon steel 312524 Low alloy steel @10300 Carbon steel 313005 Low alloy stee? @10330 Carbon steel 013047 Low alloy steel 10340 Carbon steal 921890 Low alloy steel 10350 Carbon steel 322000 Low alloy steel 410370 Carbon steel 922091 Low alloy steel 10380 Carbon stee? 031550 Low alloy steel 10390 Carbon steel 042045 Alloy steel 210400 Carbon steel 382090 Alloy steelAMS-STD-1595 unitted ‘umber Ko1200 orzo KorS01 01502 Ko1504 Ka1s05 01601 Ko1700 Ko1701 Ko1800 Korso) koraoz KoTe05 Kore0s Ko1807 Ko1808, 02000 Ko2001 02003, Koz004 02005, Koz007 02003 02100 Kozi01 02102 ooi04 02200 02201 xozz02 02203 02300, 02400 Kozol Koz4oz 02403 Koz4o¢ 02500 02600 Ko2s01 02602 o2803 2604 02505 02505 02600 02601 Base Metal Group 1a, Carbon and Alloy Steels (continued) AMS-STD-1595 unified Sonnon Description Number Connon Deseription Carbon steel 02700 carbon steel Carbon ste! 02701 Carton steel Carbon stcel 02702 Carbon steel Carbon steel Carbon steel Carbon Carbon Carbon Carbon erbon Carbon Carbon Carbon Carbon Carbon Carbon Carton Carton Low alloy steel Carton see! Carton steel Carbon steo! Carbon steel Carbon Carbon 02703 Carbon steel K0270§ Carbon steel 02705 Carbon steel K02707 Carbon stee! 02800 Carbon steel 02801 Carbon steel 02802 Carbon steel 02003 Carbon steal KO2808 Carbon 7900 Carbon 02000 Carton 3002 Carbon 03003 Carton Kos008 Carton 03005 Carbon 03006 Cerbon 03007 Carbon 03003 Carton 03009 Carbon KO3010 Caron KO3OIT Carbon 03012 Carbon KO3013 Carbon 3100 Carbon Koso Carbon Kosio2 Carbon Ko3103 Carbon 03200 Carbon 03300 Carbon KO3501 Carbon 03502 Carbon 03503 Carbon 03504 Carbon 03505 Carbon 03505 Carbon KO3607 Carbon Kosoo Carbon stee? Kot700 Carbon steel KOSOO) Carbon stee! 05200 Carbon steel KO7SCI Carbon ste K11224 Low alloy steol KU1267 Cow alloy steel KIM422 Low alloy steel -59-AMS-STD-1595, AMS-STD-1595 Base Metal Group Ia, Carbon and Alloy Steels (continued) Untied Untfied Number Coron Description Nunber — Contion Desertptifon 111430 Carbon steel K12021 Low alloy st KIT501 Carbon steel £12022 Low alloy ste KII5I0 Carbon steel K12023 Low alloy KIISIT Low alloy steel K12032 Low alloy stee? K11622 Low alloy steel 412039 Low alloy steel K11823 Low alloy steel K12080 Low alloy steel KI1526 Low alloy steel K12042 Low alloy steel KIIE35.— Low alloy steal K12043. Low alloy steel £11538 Low alloy steel K12044 Low alloy stee? KI160 Low alloy steel K12085 Low alloy stee? KIIBAL Low alloy stes K12047 Low alloy steel KI1547 Low alloy steel K12054 Low alloy steel KITE52 Low alloy steel K12122 Low al Toy steel KI1562 Low alloy steel K12143_— Low alloy steel KI1564 Low alloy steal K12202 Low alloy steel KI1567 Low alloy steel K12203— Low alloy steel KI1572 Low alloy ste K12211 Low alloy steel KI1676 Low alloy ste K12320 Low alloy steel K11673 Low alloy steel K12520 Low alloy steel] K11691— Low alloy stea? K12521 Low alloy steel! K11897 Low alloy steel K12524 Low alloy steel KIT625 Low alloy steel K12528 Low alloy st K11630 Low alloy ste K12539 Low alloy stes KI1646 Low alloy ste K12642 Low alloy steel K11662 Low alloy steel K12564 Low alloy steel K11682 Low alloy steel K12609 Low alloy stee? K11603 Low alloy steel 12700 Low alToy ste: K11596 Low alloy steel! K12765 Alloy steel KUI742 Low alloy steel K12766 Alloy steel KI1757 Low alloy steel 12822 Low alloy stee? K11789 Low alloy stool K13502 Low alloy steel K11803 Low alloy steel 20622 Low altoy steel K11820 Low alloy steel K20787 Low alloy steel Ki1047 Low alloy steel K21609 Low alloy steel 111886 Low alloy steel K21690 Low alloy steel X11072 Low alloy stee! K2160¢ Low alloy stool 12000 Low alloy steel K21650 Low alloy steal 12003 Low alloy stee! K21709_— Low al Toy steel K12010 Low alloy steel K21903 Low alloy steel K12020 Low alloy steel K22036 Low alloy steel -60-AMS-STD-1595, Base Metal Group Ia. Carbon and Alloy Steels (continued) Unt fied Number K22036 22103 22375 K31509 K31545 1718 K31918 32018 K32025 Ka1245 K41545 ka1583 Connon Description Low alloy steel Low alloy steel Low alloy steel Low alloy steel Low alloy steel Low alloy steel! Low alloy steel Low alloy steel Low alloy steel Alloy steel Alloy steel Alloy steel Base Metal Group Ib. Alloy Steels Uni fied Number. 41300 641360 641400 643400 686300 Connon Description 4130 4136 4140 4340 8630 -61- Unified Number Kq254a K51255, K51545 K61595, K71340 81340 81590 9094) k92810 93601 NA Unified Number 24728 Kag3i5 720811 AMS-STD-1595 Common Description Alloy Alloy Alloy Alloy Alloy Alloy Alloy Alloy steel steel steel steel steel steel steel steel VBNi maraging steel Alloy steel SNI-4C0 steel Common Description D6AC 3008 HITAMS-STD-1595 Unt fied Number 991160 991161 991540 392600 392600 992710 992800 992900 993400 993402 994202 995180 kogi98 63199 64299 R30158 30590 $16500 16800 $17400 20100 20200 20910 S21600 21603 21900 821904 $24000 830100 $30200 $30215 30400 $30403 $30409 $30461 330482 330800 $30800 $3080 30908 31000 Base Metal Group Ila, Stainloss Steels Conon Description Stainless steel Stainless steel Stainless steel Stataless Stainless Stainless Stainless Stainless Stainless Stainless Stainless Stainless 19-9 DL 199 OX 29-9 N16 $590 16-5 Pit stainless steel Stainless steol i7=4 PH stainless steel 201 202 Staimloss stool 216 2161. 2n6-9 21-6-9 Le Stainless steel 301 302 3028 304 3041 3041 04H Stainless steel 305 308 309. 3088 310 Unt fied Nunber $31008 831500 831600 831603 $31609 831651 $31700 $31703 $32100 $3209 $3290 833100 '$34700 '$38709 334800 524809 $3500 35600 38100 40300 $4000 40300 41000 $4108 Sa1040 841460 alae 347800 42000 42200 42900 43000 $43035 844300 344400 544600 344625 346000 345500 WA Connon Description 310s Stainless steel 316 316L 316H 316K 317 307L 321 321H 329 Stainless steet 347 347K 348, 34H ANS5O PH stainless steel ANGB5 PH stainless steel Stainless steel 403, 405 409 410. 4105 Stainless stool Stainless steel Stainless steel Grock Ascoloy 420, 422 429 430 Stainless steel 403, Stainless steel 46. Statnless stool Custom 450 Custom 455 16-26-6 AMS-STD-1595AMS-STD-1595 AMS-STD-1595 Base Metal Group IIb. Precipitation Hardening Stainless Steels Unified Unified Number Conon Description Number Conon Description 66286 A286 stainless steel $15700 PH 15-7Ho stainless steel 66545 W545, $17700 _-17-7PR stainless steel $13800 PH 13-8Mo stainless steel Alloys Base Netal Group Ila, Nickel and Nickel-Base Unified Unified Number Common Description Nunber Common Description N02200 Nickel 200 No330 —RA330 No2201 Nickel 201 NoBB00 ——Incoloy 800 04400 Mone? 400 NOBB10 —-Incoloy B00H No6002 —Hasteloy x NOBB25 —Incoloy 825. NO6007 ~Hasteloy G NOB904—Fe-Ni-Cr alloy NO6455 —-Hasteloy C4. N10001 —Hasteloy 8 NO6600 —‘Incone}’ 600 N10002_ Hasteloy C NO6625 Inconel 625 N10003° Hasteloy N NO6975 —Hasteloy G2 10276 Hasteloy 276 N08020 Carpenter Cb3 10665 Hasteloy B2 No8320 Haynes 20 Hod Base Netal Group I11b. Precipitation Hardening Nickel-Base Alloys Unified Unified Number, Common Deser4ptfon Number Conon Description 05500 Monel K500 NO7750 Inconel X750 NO6601 Inconel 601 NO9706 Inconel 706 NO7001 —Maspaloy 09901 Tncoloy 901 No7041 Rene 41 NA Rene 77 No7252 M252 NA Rene 80 WO7500 —Udimet_ 500 NA Udinet. 700 NO7718 Inconel 718 -63-AMS-STD-1595 AMS-STD-1595 Base Metal Group IV. Aluminum and Alumtnum-Base Alloys Unified Unt fied Number Common Description Numbe Common Description 03560 356 980865086 A91060 1060 A96154 5154 Ag100 1100 952645254 Agz014 2014 95454 5454 92219 2219 A95456 5456 93003 © 3003 AQ5652 6652. 493004 ©3004 ‘96061 6061 A96052 5052 96063 6063 A96083 6083. Base Motal Group V. Hagnestum-Base Alloys Unt fied Unified Number” Common Description Number Conon Description 10100 ANTOOA 13210 HMRIA, M1131 AZ31B M13310,—HKSIA 11610 AZGTA 13312 HNSIA 11800 AZBOR 13320 HZ32A MITSIO — AZOTA Maa) LATA 11920 AzSZA mi6620 © ZH62A 12330 EZ33A 18220 QE22A Base Metal Group VI. Titanium and Titantum-Base Alloys Unified Unified Humber Conon Description Nunber Common _Deseription R50250 Titantun R56260 —T1-6A1~2Sn-4Z7-64o R60400 = Titantum 56320 TH 5 50550 = Titanium 56400 R2400 © Titantum 56620 R64520TH-5AT-2.65n 58640 64620 T1-6A1~2Sn-47r-2H0 NA TI-6A1-2Sn-2Zr-2Cr-2Mo 54810 T1-GA1~Ho-1V NA THe168 R56210 —TH-6AT~2Cb-1Ta~1Mo 64AMS-STD-1595 Base Netal Group VII. Cobalt-Base Alloys Unified Number. 230006 30021 30023 30027 30030 Connon Description Stellite 6 Stellite 21 Stellite 23 Stellite 27 Stellite 30 Unified Number 30031 30188 30605, 30816 AMS-STD-1595 Common Description Stellite 31 Hs188 L605 3816