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!41L-STD-1595A3.DEFINITIONSThe welding terminology of “Welding Terms3.1 Welding terminology.and Definitions” AUS A3.0, shall be used in the interpretation ofthis standard, Some of these items and additional terms are definedbelow.3.1.1 As-welded.The condition of weld metal, welded joints, andweldments after welding but prior to any subsequent thermal , mechanical, or chemical treatments.3.1.2 Automatic weldinq. Welding with equipment which performs thewelding operation without adjustment of the controls of a weldingoperator. The equipment may or may not perform the loading and unloading of the work.A material (base metal, weld metal, carbon, or3.1.3 Backing.granular material) pl ced at the root of a weld joint for the purposeof supporting molten weld metal.3.1.4Base metal.The metal to be welded, soldered, or cut.3.1.5 Blank. Part of a test weld removed for the preparation ofa bend test specimen or a metal lographic specimen.3.1.6 Butt joint.in the same plane.‘“-JA joint between two members aligned approximately3.1.7 Complete fusion. Fusion that has occurred over the entirebase metal surfaces intended for welding and between all layers andweld beads.3.1.8 Complete joint penetration.Joint penetration in which theweld metal completely fills the groove and is fused to the base metalthroughout its total thickness.3.1.9 Defect. A discontinuity or discontinuities which by natureor accumulated effect render a part or product unable to meet miniThis termmum applicable acceptance standards or specifications.designates rejectability.3.1,10 Depth of fusion. The distance that fusion extends into thebase metal or previous pass from the surface melted during welding.3.1.11 Discontinuity.An interruption of the typical structure ofa weldment, such as a lack of homogeneity in the mechanical, metallurgical, or physical characteristics of the material or weldment.Adiscontinuity is not necessarily a defect.4—.

‘u”MIL-sTD-1595AThe metal to be added in making a welded,3.1,12Filler metal.brazed, or soldered joint.3,1.13Fusion zone. The areas of base metal melted as determinedon the cross section of a weld.3.1.14Heat-affected zone. That portion of the base metal whichhas not been melted, but whose mechanical properties or microstructurehave been altered by the heat of welding, brazing, soldering, orcutting.3.1.15Joint. The junction of members or the edges of members whichare to be joined or have been joined.3.1.16 Machine welding. Welding with equipment which performs thewelding operation under the constant observation and control Of a eldin9The equipment may or may not perform the loading and unoperator.loading of the work.3.1.17 Manual weldinq.completely by hand.A welding operation performed and controlledwtI chcon3.1.18 Semiautomatic arc welding.Arc welding with equip(lef-lttrols only the filler metal feed. The advance of the welding is manuallycontrolled.3.1.19 Test weld.fication.3.1.20Welder.A joint made by a welder for purposes of welder quali-One who performs a manual or semiautomatic welding operation.Certification3.1.21 Welder certification.produced welds meeting prescribed standards.in writing that a welder hasEquipment used to perform the welding operation.3.1.22 Weldinq machine.For example, spot welding machine, arc welding machine, seam weldingmachine, etc.3.1.23 Weldinq operator.equipment.3.2“’’G-’One who operates machine or automatic weldingSymbols and terms.d.Sheet refers to both sheet and plate, where appropriate.b.Tube refers to both tube and pipe, where appropriate.5---.

MI L-STD-1595Ac.The lower case letter, t, indicates base metal thickness foreither sheet or tube wall.d.Mathematicalsymbols used before numbers mean: less than more than equal to or less than equal to or more than.6

“-’---’MI L-sTD-1595A4,GENERAL REQUIREMENTSTo achieve qualified status, welders4.1 Qualification requirements.and welding operators shall demonstrate their skill by producingacceptable test welds in accordance with 4.1.1. No test welds arerequired for those welds which will not be required in productionwelding.4.1.1weldsThe correlation between test welds and productionWelders.shall be based on the following factors.a.b.c.d.e.f.9.L-’Welding process (see 5.1).Base metal composition (see 5.2).Base metal thickness (see 5.3).Welding position (see 5.4).Base metal form, sheet or tube (see 5.5).Type of weld, groove or fillet (see 5.5).Other welding conditions (see 5.6).The correlation between test welds and pro4.1.2. Welding operators.duction welds shall be based on only the first three factors given in4.1.1.The requirements of this standard are4.2. Minimum requirements.Other requirements may be added by the contractor, but mayminimum.not be substituted for the requirements of this standard.4.3 Physical requirements.The contractor shall establish reasonableand appropriate physical requirements for welders and welding operators.It will be accepted that those whose corrected vision in each eye forlong distance is better than 20/30 and for 16 inches distance permitsreading of Joeger No. 2 type will ordinarily satisfy vision needs forwelding.4.4Identification.other identificationThe contractor shall assign a unique number orto each welder or welding operator upon qualification.4.5 Test records. The contractor shall complete a test record containing the essential information required as evidence of the welder orwelding operator qualification.These records shall be retained forthe period of time specified in the contract or, if no retention time isspecified, the period of record retention shall be for the duration ofqualification.4.5.1Test record forms. Suggested test record forms are given inFigure 1 and in the following documents.7— .—.———— - — . —- — —.

M1l.-slL)-i595AQUALIFICATIONTEST RECORDNameId.Joint welding procedureWelderSS No.[ ]Welding operator[ ]TEST WELDBase metal descriptionWelding processCurrentVerticalGroup No.AC[)Down [ )Single weld[ ) Double weld[ ]BackingYes [ ] No[]PenetrationComplete [ ] Partial [ ) [1up [1PositionDimension, inchSheet grooveIG12G [ ]3G [ ]Tube grooveIG12G [ ]5G [ 1Sheet filletIF12F [ ]3F [ ]4F [ 1Tube filletlF12F [ ]4F [ ]5F [ 1t4G [ 1O. D.ttO. D.tTEST RESULTSVisualRadiographicBendMetallographicNA [ 1NA [ 1NA [ 1PasspassPassPass[[t[)11]Fail [ )Fail [ ]Fail [ ]Fail [ )QUALIFIEDBase HetaGroup i O.CurrentVerticalAC[]*[ISingle weld[ ] Double weld [With [ ] Wit}lout [BackingPenetrationComplete[ ] Partial[DC[]up{]t, inch?osit:cmMin.Sheet groovelG [ ]2G [ ]3G [ ]Tube groovelG [ ]2G [ ]5G [ 1Sheet filletlF [ ]2F [ ]3F[]4F [ )‘Ill& filletIF [ ]2F [ J4F[]SF [ 1Max .O. D.t inchMin.Max.4G [ 1The above named individual is qualified in accordance with F!IL-STD-1595A withinthe abovw limits for the welding process used for this test weld.Date of test weldSigned byQualifierFIGURE 1.Suggested test record form.8u

PIIL-sTD-1595A‘i ---’a.b.Structural Melding Code, AMS 01.1Qualification of Welding Procedures and Weldersand Tubjng, AWS D1O.9,for Piping4.6Requalification.A welder or welding operator shall be requalified every five years to the same requirements as an original qualifiRequalification is also required when either of the followingcation.two conditions are present.4.6.1 A welder or welding operator has not welded with a givenwelding process for a period of three months; except that this periodshall be extended to six months if the welder has welded with anotherprocess of Table I.4.6.2 There is a specific reason to question the ability of a welderor welding operator to meet the requirements for qualification in agiven welding process.As an alternate to the requirements4.7 Alternate requalification.of 4.6.1, requalification to the same requirements as an originalqualiflcatiori may be accomplished at two-year intervals, in lieu ofthe three month and six month restrictions.9

MIL-STD-1595A5.5,1 Ueldinq process.weld made with a giventhat weldinq process.processes n;t includedDETAILED REQUIREMEtlTSFor welders and welding operators, a testwelding process of Table I qualifies onlyThis standard does not apply to weldingin Table I.TABLE I.Fusion weldinq processes.Oxyfuel welding (OFW)Shielded metal arc welding (SMAW)Submerged arc welding (SAW)Gas tungsten arc welding (GTAW)Gasmeta arc welding (GPIAW)Flux cored arc welding (FCAW)Plasma arc welding (PAM)Electron beam welding (EBM)For welders and welding operators, a test weld5.2 Base metals.made in a base metal included in one of the ten base metal groups ofTable II qualifies only that base metal group, except as modified by5.2.1 and 5.2.2 and as illustrated in Table 111. The specific basemetals included in each of the base metal groups of Table 11, are givenSince the base metal group: arein the Appendix of this standard.intended only for the purpose of qualification, some of the base metalqroups contain base metals whose composition does not conform to theBase metal groups.TABLE II.IIIGroupNominal descriptionIaCarbon and low alloy steelsIbAlloy steelsIIaStainless steelsIIbPrecipitationIIIaNickel and nickel-base alloysIIIbPrecipitationIvAluminum and aluminum-basevMagnesium-baseVITitanium and titanium-baseVIICobalt-base alloyshardening stainless steelshardening nickel-basealloysalloysalloysalloys,10

““4’MI L-ST D-I 595A5.2.1 Qualification in a base metal group with a “b” designatoralso qualifies for base metal numbers with the same reman numeraldesignator and an “a” designator,See Table 111.TABLE III.Base metal groups qualified bytest weld.Test weldlaIbIIaIIbIIIaIIIbIvvVIVII.“u”5.2.2For welders and welding operators, a separate qualificationexceptis required for each base metal not included In the AppendIx,as modified in 5.2.2.1.A base metal not included in the Appendix, with5.2.2.1Exception.welding characteristics similar to a given base metal group of themetal of the gi”ven base metalAppendix, may be qualified with any baseThe preparing activity shall be notified by the organizationgroup.qualifying a welder or welding operator under the provisions of thisparagraph, with DD Form 1426 or a letter, of the two base metalsinvolved and the chemical composition of the base metal not includedin the Appendix.The qualification limits, with regard to5.3 Base metal thickness.(sheetthickness or tube wall thickness), arebase metal thicknessThese l’imits aPP Y togiven below for welders and welding operators.both groove welds and fillet welds.thickness of t shall qualify welds5.3.1 A test weld with a base metalwith a thickness range of 0.67t to 4t; except that, when ethe.test weldthickness is equal to or greater than 1 inch, the quallflcat on rangeis 0.67t to unlimited.5,3.2 Two test welds, each with members of equal thickness, shallin addition to thequalify welds with all intermediate thicknesses,thickness qualifications of 5.3.1.11

MIL-STD-1595A5.4Weldinq position.The welding positions qualified by a given test weld5.4.1 Welders.position, to be found at the left of Table IV, are denoted by an X inthe table. The welding positions are illustrated in Figures 2 through 5.A test weld made in any welding position5.4.2 Weldinq operators.qualifies for all welding positions.5.5Base metal form and weldtvDe.The base metal forms and weld types qualified by a5.5,1 Welders.given test weld, to be found at the left of Table IV, are denoted byan X in the table, with the exceptions given below.5.5.1.1Qualification for fillet welds in base metal equal to or lessinch in thickness requires a fillet test weld. Groove testwelds do not qualify for fillet welds in this thickness range.than0.0635,5.1.2A tube test weld shall qualify only for tubes of an outsidediameter.equal to or greater than the outside diameter of the test weld.A test weld of any base metal form and of any5.5.2Weldinq operators.weld type shall qualify for all base metal forms and all weld types. Ar :{ ? of any outside diameter jh ll qudlify for(,ubesof anytube .e &outside diameter.5.6 Other welding conditions.In addition to the welding process, basemetal composition, base metal thickness, welding position, base metalform and type of weld; other welding conditions which require a correlation between the test weld and the production welds are given inTable V.5.6.1Welders.weld conditions,X in the table.The weldingto be foundThe currentconditionsqualified by the given testat the left of Table V, are denoted by anapply only to the GTAWtype restrictionsprocess.For all other processes, a test weld made with either ac ordc current qualifies for welds made with either current type.The welding conditionrestrictions5.6.2 Welding operators.do not apply to the qualification of welding operators.of Table V5,7Test welds. One test weld shall be required for each combinationTestof welding conditions, given in 4.1.1 and 4,1,2, being qualified.welds shall be made in accordance with a written joint welding procedure.Groove test weld in sheet.as described in Figure 6.5.7.1The test weld is a butt joint in sheet12‘ ’

MIL-STD-I 595AWeldinq position, base metal form, andweld type qualified by test weld.TABLE Iv.{*TestWeldIIQualified positionIco-!ITubeSheetTFillet /GrooveFilletL/GrooveOFI-1OrmMeldtype“2EIG 2G 3G 4G1F2F3F4FIG 2G 5G6GIF %.---’”TubeGroovexxxxxxxFilletxxxx xxxxxxXxxxLI / A groove test weld does not qualify for fillet welds in base metalequal to or less than 0.063 inch in thickness (see 5.5.1.1).135Fx

MIL-STD-1595AThe weldingflat tionof theusedjoint;approximatelyhorizontal position. Thetothehorizontalpositionofin which the axis of the weld liesapproximatelyhorizontalplaneandof theweldliesin an approximatelyvertical plane,weldin . ,in antheface/3G/verticalwhichposition.Thepositionthe axis of the weldisof .weldingof theFIGURE 2,Grooveis perfomedjoint.weldThe positionin whichfromthe undersidein sheet:positions lG, 2G, 3G, and 4G.

MI L-ST D-1595A/.The weldingS i’tion.f rom theupperside IFfaceofhorizontal.theweldisposition n.The positionin whichweldingis performedon theuppersideofhorizontalsurfaceandan approximatelyagainstan approximately vertical surface.2F‘k-’ ”3rTheverticalposition.in sweldwelding\u\ove rheadweldingofFIGURE 3.positionfrominthewhichundersidethe joint.Fillet weld in sheet:15-1.LTheposition.is performedpositions IF, 2F, 3F, and 4F.

MIL-STD-1595AIlGhorizontal rolled position. The position ofI,.whichthe axis of the pipehorizontal,and weldingin the flatpositionbypipe.a pipejointinis approximatelyis performedrotatingtheII[!-.verticalposition.The positionof a pipejointin whichweldingis performedin thehorizontalpositionand thepipeis xed position.pipejointinis approximatelyis notrotatedThe positionwhichtheaxisof thehorizontaland �—— 1.(—I-/\IThe positionof a pipeinclinedposition.gipeisjointin whichthe axisof theapproximatelyat an angleof 45to thehorizontaland thepipeis notrotatedduringwelding.FIGURE 4.Groove weld in tube:16— ------3m–positions IG, 2G, 5G, and 6G.

FIIL-STD-1595A“vThe sideof thejoint;thefaceof the weldis approximatelyhorizontaland thepipeis rotatedduringwelding.The positionin whichhorizontalposition.weldingis performedon theuppersideofan approximatelyhorizontalsurfaceandagainstan nd thepipeis notoverheadL/’position.Thewelding is performedthe jointand thepipeduringpositionfromtheisnotin whichundersideof2F,IIiII \*IL4Frotatedi/.I[\iwelding.T5FThe positionin whichposition.of the pipeis approximatelyhorizontaland thepipeis notrotatedduringwelding.multiplethe axisFIGURE 5.Fillet weld in tube:17positionsIF, 2F, 4F, and 5F.

MIL-STD-1595ATA[!LE v.Welding conditionsqualifiedby test weld.QualiJiedWithTest weldidith ationPartialPenetrationacxxweldxxweld.—xac weldingdc welding /ICompletepenetrationxDouble we’ dedgroove we dCompletepenetrationDouble—xSingle weldedgroove we dCurrenttype /Groove weldBac ingApplicable only to GTAW process (see 5.6.1).18\/dc

MIL-STD-1595A‘-u.I---’’’’T” BASE METALTHICKNESSMINIMUMDINENSJONSWLtINCHESso. 063L 0.0632358t‘. .-”FIGURE6.Groovetestweldin sheet.19——--,. -----——,,. ,.-,

MIL-STD-1595A‘;-ft--BASE METALTHICKNESSMINIMUMDIMENSIONSWtLt{INCHES 0.063 0.063L452483Ii“-%/” “THI81INOTE :\/here the members differ in thickness morethan 10 percent of the thicker, the capsheet shall be the th cker.FIGURE7.Fillet20testweld in sheet.

“.-iMIL-STD-1595Ai-’L.J”&0?-----p---- @ t‘l!.: tBASE METALWALL THIC}(IIES51tINCIIES23FIGURE 8.Groove test weld in tube.21

.-—--e-MIL-STD-1595A—t3.0 IN.MINIMUM2.0 IN. MINIMUM, TYPICAL, 4 PLACEStNOTE :the members differ in thicknessequal to or more than 10 percent of thethicker member, the sheet shall be thethicker member.WhereFIGURE 9.—-.---—-aFillet test weld in tube.

MIL-STD-1595A5,7.2 Fillet test weld in sheet.sheet as described in Figure 7,5.7.3tubeGroove test weld in tube.as described in Figure 8.5.7.4jointFillet test weld in tube.as describedin FigureThe test weld is a T-joint inThe test weld is a butt joint inThe test weldis a tubeto sheet9.5.7.5 Special applications.When none of the test welds describedabove are applicable to a given production weld, a more limited welderor welding operator qualification may be achieved with a test weldconsisting of the given production weld or a test weld representativeof the givenproductionweld.The qualification is limited to the5.7.5.1 Qualification limitations.weldina conditions of the test weld with regard to welding process,base m tal composition, base metal thickness, welding position, basemetal form, type of weld and the other welding conditions of 5.6.The requiredinspection,examination,5.7.5.2 Acceptance criteria.bend testing, and acceptance criteria shall be consistent with 5.9through5.85.14.Inspection,examination,and bend testifvrequirements.5.8.1 Visual inspection.Visual inspection is required for all testwelds and shall be completed with the test weld in the as-weldedcondition.5.8.2Radiographicins

flIL-sTD-1595A 2. REFERENCED DOCUMENTS 2.1 Issues of documents. The following documents of the issue in effect on the date of invitation for bids or request for pro-posal, form a part of this standard to the extent specified herein. STANDARDS MILITARY MIL-STD-41O - Nondestructive Testing Personnel Qualification and Certification