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AWS 017.1/01 1M:2010
An American National Standard

Specification for Fusion Welding for Aerospace Applications

Table of Contents
Page No.
Personnel .................................................................................... v
Foreword ................................................................................... vii
List of Tables . ................................................................................ xi
List of Figures ................................................................................ xi
1. Scope and General Requirements ........................................................... I
1.1 Scope ............................................................................. 1
I .2 Classification ....................................................................... 1
1.3 Approval. .......................................................................... 2
1.4 Mandatory Provisions and Authority ..................................................... 2
1.5 Standard Units of Measure ............................................................. 2
1.6 Safety and Health .................................................................... 2
2. Normative References .................................................................... 2
2.1 Government Documents .............................................................. 2
2.2 Nongovernment Documents ........................................................... 3
3. Terms and Definitions .................................................................... 4
4. Design of Welded Connections ............................................................. 6
4.1 Scope ............................................................................. 6
4.2 Weldment Design Data ............................................................... 6
4.3 General Drawing Requirements ......................................................... 6
5. Welding Performance and Procedure Qualification ............................................ 7
5.1 General Description .................................................................. 7
5.2 General Requirements (Performance) .................................................... 7
5.3 Detailed Requirements (Performance) ................................................... 8
5.4 Welding Procedure Qualification (Procedure) ............................................. 22
6. Fabrication ............................................................................ 24
6.1 Scope ............................................................................ 24
6.2 Welding Consumables ............................................................... 24
6.3 Welding Equipment ................................................................. 27
6.4 Weld Settings ...................................................................... 27
6.5 Preweld Cleaning and Other Preparation ................................................. 27
6.6 Preweld Joint Preparation and Fit-up .................................................... 27
6.7 Preheating and Interpass Temperature Control ............................................ 28
6.8 Tack Welds ....................................................................... 28
6.9 Weld Start and Run-Off Tabs ......................................................... 28
6.10 Weld Shielding for GTAW, GMAW, and PAW ........................................... 28
6.11 Tungsten Electrodes ................................................................. 28
6.12 Filler Materials ..................................................................... 29
6.13 Interpass Cleaning .................................................................. 29
6.14 Welding and Weldments ............................................................. 29
6.15 Postweld Cleaning .................................................................. 31
6.16 Postweld Processing ................................................................. 31
6.17 Weld Identification Requirements ...................................................... 31
6.18 Acceptance Inspection ............................................................... 31
6.19 Rework ........................................................................... 31
6.20 Repair ............................................................................ 32
6.21 Record Requirements ................................................................ 32
7. Inspection ............................................................................. 32
7.1 Qualification of Inspection Personnel ................................................... 32
7.2 Vision Test. ....................................................................... 32
7.3 Visual Weld Inspection .............................................................. 32
7.4 Nondestructive Inspection ............................................................ 32
7.5 Acceptance Criteria ................................................................. 33
7.6 Inspection Records .................................................................. 37
8. Repair of Existing Stn.u::tures ............................................................. 37
8.1 Scope ............................................................................ 37
8.2 Design ........................................................................... 38
8.3 Welding Procedures ................................................................. 38
8.4 Welder and Welding Operator Qualification .............................................. 39
8.5 Welding Equipment ................................................................. 39
8.6 Weld Repair Inspection .............................................................. 39
8.7 Grounding ........................................................................ 39
8.8 Repair Documentation ............................................................... 39
9. Nonflight Hardware ..................................................................... 39
9.1 Scope ............................................................................ 39
9.2 Exceptions and Additional Requirements ................................................ 39
Annex A (Normative)- Guidelines for Design, Analysis, and Fabrication of Weld Joints ................... 45
Annex B (Normative)- Effective Throat ......................................................... 59
Annex C (Normative)- Bend Testing Criteria ..................................................... 61
Annex D (Informative)- Informative References ................................................... 69
Annex E (Informative)- Safe Practices ........................................................... 71
Annex F (Informative)- Guidelines for the Preparation of Technical Inquiries ............................ 75
Annex G (Informative)- Commentary ........................................................... 77

list of Tables
Page No.
Fusion Welding Processes ............................................................... 8
Samples of Alloys Contained in Material Groups l through VHI ................................ 10
Welding Position, Base Metal Form and Base Metal Qualified by Test Weld ...................... 12
Other Welding Conditions Qualified by Test Weld .......................................... l7
POR Test Requirements ............................................................... 24
Gas Requirements .................................................................... 26
Recommended Shielding Gases for Welding ............................................... 26
Preheat and Interpass Temperatures ...................................................... 29
Filler Metal for Welding Aluminum Alloys Using GMAW, GTAW, and PAW Processes ............ 29
Filler Metal for Welding Titanium Alloys Using GMA W, GTA W, and PAW Processes ............. 29
Filler Metal for Welding Stainless Steels and Heat Resistant Alloys Using GMA W, GTAW,
and PAW Processes ................................................................... 30
Acceptance Criteria (in [mm]) .......................................................... 33
Industrial Codes and Specifications Suggested for Welding Aerospace Nonftight Hardware .......... 40
Equivalent Fillet Weld Leg Size for Skewed T-Joints ........................................ 58
Base Metals for Which Bend Testing is Not Applicable ...................................... 62
Bend Specimen Thickness and Bend Radius (in) ............................................ 63
Bend Specimen Thickness and Bend Radius (mm) .......................................... 64
Bend Specimens for Groove Welds in Tube ................................................ 65

list of Figures
Page No.
Suggested Test Record Form ............................................................ 9
Groove Weld in Sheet: Positions lG, 2G, 3G, and 4G ........................................ 13
Fillet Weld in Sheet: Position IF, 2F, 3F, and 4F ............................................ 14
Groove Weld in Tube Positions lG, 2G, 5G, and 6G ......................................... 15
Fillet Weld in Tube: Positions IF, 2F, 4F, and SF ........................................... 16
Groove Test Weld in Sheet ............................................................. 17
Fillet Test Weld in Sheet. .............................................................. 18
Groove Test Weld in Tube ............................................................. 19
Fillet Test Weld in Tube ............................................................... 19
Blank Locations for Metallographic Specimens in Fillet-Welded Sheet .......................... 20
Blank Locations for Metallographic Specimens in Fillet-Welded Tube ........................... 20
Incomplete Fusion at Root in Fillet Welds When Thickness of Both Members is
Greater Than 0.063 in [1.6 mm] ........................................................ 21
Incomplete Fusion at Root in Fillet Welds When Thickness of Any Member is Less Than
or Equal to 0.063 in [1.6 mm] ........................................................... 21
Welding Procedure Specification (WPS) Form ............................................. 23
Procerlure Qualification Record (PQR) Form ............................................... 25
Joint Preparation in Joint Members of Unequal Thickness ..................................... 28
Acceptable and Unacceptable Weld Profiles ............................................... 36
Mismatch Between Joint Members After Welding ........................................... 37
Square Groove Butt Joints .............................................................. 46

Single-Bevel-Groove Weld Joints ........................................................ 47
Single-V-Groove Weld Joints ........................................................... 48
Single-J-Groove Weld Joints ........................................................... 49
Single-U-Groove Weld Joints ........................................................... 50
Double-Bevel-Groove Weld Joints ....................................................... 51
Double-V-Groove Weld Joints .......................................................... 52
Double-J-Groove Weld Joints ........................................................... 53
Double-U-Groove Weld Joints .......................................................... 54
Two- and Three-Piece T-Weld Joints- Melt-through Welds ................................... 55
Flanged Joints ....................................................................... 55
Flanged Edge Joints (Nonstandard) ...................................................... 56
Fillet Weld Details ................................................................... 57
Effective Throat. ..................................................................... 59
Bend Specimens in Groove Welded Tube ................................................. 67

Specification for Fusion Welding of
Aerospace Applications
1. Scope and General Requirements
1.1 Scope. This specification contains requirements for fusion welding of aerospace hardware. It is to be used in
conjunction with the Engineering Authority's design handbooks or their accepted data. When conformance to this
specification is stipulated in contract documents, all provisions of this specification shall be complied with, except
for those provisions that the Engineering Authority or contract documents specifically exempt, or those optional
provisions that shall be applied when specified by the contract documents.
The following is a summary of the specification Clauses:
Clause I. Scope and General Requirements: basic information on the scope and provisions of this specification.
Clause 2. Normative References: a listing of the documents that are required for the application of this specification.
Clause 3. Terms and Definitions: a list of technical terms and definitions of particular importance to this specification.
Clause 4. Design of Welded Connections: requirements and guidance information for the design of welded connections.
Clause 5. Welding Performance and Procedure Qualification: qualification requirements for welders, welding operators
and welding procedures.
Clause 6. Fabrication: requirements for preparation, assembly and workmanship when welding aerospace hardware.
Clause 7. Inspection: criteria for inspector qualification, responsibilities of inspectors, acceptance of production welds,
and standard requirements for performing visual inspection and nondestructive examination (NDE).
Clause 8. Repair of Existing Structures: requirements for repair of existing aerospace hardware.
Clause 9. Welding ofNonfli.ght Hardware: requirements for welding nonflight hardware.
1.1.1 Flight Hardware. The fundamental premise of this specification is to provide general requirements for currently
recognized aerospace fusion welding processes and materials. However, this specification provides for the application
of new materials, new welding processes, or acceptance criteria for production welds differing from those defined in
this specification. These new applications shall be documented by the proposer and approved by the Engineering
Authority.
1.1.1.1 Aircraft, Rotorcraft, and Engines Subject to FAA Regulation. When applying welding in the design,
construction and repair of aircraft, rotorcraft or engines subject to FAA Regulation, the Engineering Authority must
perform the appropriate design analyses and impose process control measures that will ensure compliance with the
applicable requirements of the Code of Federal Regulations, Title 14.
1.1.2 Nonflight Hardware. Nonflight hardware, tooling, ground support equipment and related nonconventional
aerospace facilities shall be designed and welded in accordance with the requirements of Clause 9.
1.2 Classification. All welds produced in accordance with this specification shall be classified on the engineering
drawings. Weld classifications shall be as follows: Class A, Class B, or Class C. These classifications refer to the level of
inspection required and to the acceptance criteria. Alternate acceptance criteria and inspection methods may be applied
if specified on the engineering drawing. The Engineering Authority shall also determine the weld procedure qualification
requirements (see Annex G-Commentary).