S9074-AQ-GIB-010/248 Rev 1
4-5.4 FIRST ARTICLE TEST EVALUATION FOR AUTOMATIC ROBOTIC WELDING. Each weld pass in a first article test assembly shall be visually examined to ensure intended bead placement, profile, and fusion, and that intended fit-up tolerances are maintained throughout welding of the part; for multipass fillet welds, only the first three passes must be inspected this way. First article test assembly welds shall also be evaluated as follows: a. Butt welds shall be inspected by VT and by RT or UT per 4-5.1.1 and 4-5.1.2 upon completion. b. Other full penetration welds shall be inspected by VT per 4-5.1.1 and by RT (if suitable or, if not, UT) per 5- 4.1.2 upon completion. If the weld is not amenable to RT or UT, MT/PT per 4-5.4.d below shall be applied on the root layer, back-gouged surface (if applicable), and each subsequent 1/4-inch thickness of the deposited weld and completed weld surface. c. Plug/slot welds shall be examined per 4-5.4.a above. d. Multipass fillet welds shall require MT/PT of the root layer per 4-5.1.2 to ensure absence of linear and non-linear indications in excess of MIL-STD-2035, class I. VT and MT/PT of the completed weld shall be per 4-5.1.1 and 4-5.1.2. e. Partial penetration groove welds shall be inspected per 4-5.4.d above. f. Socket welds shall be inspected per 4-5.4.d above and also receive macro inspection per 4-5.2.6. Repair of defects shall be per 4-2.9. The same welding procedure to be used for production repairs shall be used for repair of the first article test weld and shall also be recorded on the report of 4-6.1.2. If the first cycle of repair fails, then two additional first article test specimens shall be welded and tested in accordance with the requirements of this document, and any further defects shall require three additional such tests for each defect. 4-6 DATA ACCUMULATION AND REPORTING FOR PROCEDURE QUALIFICATION. This section specifies the requirements for procedure qualification data reporting to obtain approval of a welding procedure qualification test report. 4-6.1 TEST REPORT. The welding procedure qualification test report shall include the following items in sufficient detail to ensure compliance with the requirements of this document:
a. Welder/welding operator (name and badge number). b. Bend radius.
c. Essential elements of the welding procedure, as specified in table 7-5, or for stud welding, as specified in 4- 4.4. For each essential element, the actual value(s) used for qualification welding shall be recorded. Where heat input is a required essential element, it shall be reported for each pass. Where bead width applies, see 4- 4.1.14. d. Destructive test results. e. Nondestructive test results and acceptance criteria. f. The repair data required in 4-2.9, if applicable. g. The test report number, revision, and date. h. The qualifyi ng activity’s name. i. For filler materials not listed in table 7-2 that are intended for production welding, lot conformance testing requirements per 4-2.3.2. When HAZ Charpy V-notch (CVN) testing is performed, photomacrographs of CVN-HAZ specimens per figure 7-24 shall be submitted with the test report. A sample welding procedure qualification test report with a form for data accumulation is provided for guidance in figure 7-11. The report shall contain a certification statement in accordance with 4-2.2. See 4-4.10 for additional reporting of distance and temperatures.
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