WELDING WORKBOOK

Datasheet 303

Fusion Welding for Aerospace Applications

Due to the criticality of many aerospace weldments, the identification, storage, and use of all welding consumables (including wires, rods, inserts, fluxes, gases, etc.) require proper controls. It is important to store fluxes and covered electrodes in a clean, dry environment or in sealed containers. To prevent moisture accumulation, employ heating as necessary. Low-hydrogen shielded metal arc welding (SMAW) and flux cored arc welding (FCAW) electrodes should be handled and stored according to the manufacturers recommendations or according to AWS A5.1, A5.5, A5.20, or A5.29, as appropriate. Proper identification and storage of consumables will have a positive contribution to the quality of the product. Filler materials, when used in the welding process, must be specified by the Engineering Authority. Tables 13 list the filler materials normally used in welding aerospace base metals. Unless the Engineering Authority allows the use of the table in the selection of fill material, it is only to be used as a guide by the fabricator. The fabricator is responsible for verifying the correct application of any filler material through the Welding Procedure Specification/Procedure Qualification Record cycle. Welding fluxes are to be labeled and segregated by type and/or by their particular application. To prevent moisture pickup, store fluxes in sealed containers or keep them in a suitably clean and dry environment. Clean, unfused flux may be reused after reconditioning according to the manufacturers recommendations. Consumables used in welding are to be identified using an established standard or specification or by a standard specified in the procurement specification. If the identification marking is destroyed or missing, dont use the consumable. When specified on the engineering drawing or a contract document, traceability of the consumables must be maintained throughout the welding process.

Table 1 Filler Metal for Welding Aluminum Alloys Using GMAW, GTAW, and PAW Processes(a) Base Metal 1100 3003 2219 A5.10 5052 6013 6061 Filler Material Specification ER1100 or ER4043 ER1100 or ER4043 ER2319 ER5356 or ER4043 ER4043 ER4043 or ER5356 Filler Material AWS A5.10 AWS A5.10 AMS 4191 or AWS AWS A5.10 AWS A5.10 AWS A5.10

Table 3 Filler Metal for Welding Corrosion-Resistant Steels and Heat-Resistant Alloys Using GMAW, GTAW, and PAW Processes(a) Base Metal 304L and 316L 321 and 347 A286 21-6-9 PH 13-8Mo PH 15-7Mo PH 15-5 Filler Material ER308L ER321 or ER347 A286 ER219 WPH 13-8Mo ELC WPH 15-7Mo-VM 15-5PH or ER630 WPH 17-4 or ER630 PH17-7 WPH 15-7Mo-VM ERNiCrFe-5 Inconel 625 Hastelloy W or ERNiMo-3 Inconel 718 ERNiCrFe-7 Filler Material Specification AWS A5.9 AWS A5.9 AMS 5804 or AMS 5805 AWS A5.9 AMS 5840 AMS 5812 AMS 5826 or AWS A5.9 AMS 5825 or AWS A5.9 AMS 5824 AMS 5812 AWS 5.14 AMS 5837 AMS 5786 or AWS A5.14 AMS 5832 AWS A5.14

(a) Refer to C5.12 in the Commentary and 5.12 in the main body of the AWS D17.1 specification.

Table 2 Filler Metal for Welding Titanium Alloys Using GMAW, GTAW, and PAW Processes(a) Base Metal Commercially Pure Titanium 3Al-2.5V Ti 5Al-2.5Sn-Ti 6Al-4V or 6Al-4VELI Filler Material CP ERTi-4 ERTi-3Al-2.5V 5Al-2.5Sn ERTi-5Al-2.5Sn 6-4 ERTi-6Al-4V Filler Material Specification AMS 4951 AWS A5.16 AWS A5.16 AMS 4953 AWS A5.16 AMS 4956 AWS A5.16

PH 17-4 PH 17-7 Inconel 600 Inconel 625

Inconel 718 Inconel X750

(a) Refer to C5.12 in the Commentary and 5.12 in the main body of the AWS D17.1 specification.

(a) Refer to C5.12 in the Commentary and 5.12 in the main body of the AWS D17.1 specification.

Excerpted from AWS D17.1: 2001, Specification for Fusion Welding for Aerospace Applications. 54 FEBRUARY 2009