tips for Aerospace Test Joints 1G, 2G, 3G AWS D17.1

Roy shows us some tips for passing a weld test with thin material with arc shots, explanations, etc.

6G 2 inch sched 80 ER309L Root pass with argon purge
This welding test as also known as the ua41 and this video demonstrates the root pass with argon purge and 309 filler using the dip keyhole technique.
a 1/8 gap with a 3/32 filler was useed

6G 2 inch schedule 80 ua-41 pipe welding test with 309 filler for root along with argon purge.
1/8" gap and 3/32 filler rod for root using keyhole dip technique.
both freehand and cup walking techniques are used.

This is A practice weld using 304L stainless steel in .063" thickness.
usually other alloys like 17-7ph, 15-7ph, are used for this test but the same techniques apply across the board

AWS D17.1 is the specification for aerospace fusion welding.

It is common for 1G tests to be done in aerospace welding certification because shops often have positions and manipulators that can pretty much get every weld in the flat position.

But sometimes employers require a 2G and or a 3G tes...

Video shows a 1G AEROSPACE PRACTICE TEST USING COLD ROLLED STEEL 038" at 48 AMPS.
Also compares using pulse settings to straight current.
If you are thinking about an aerospace welding job, edge beads are a great way to practice for a lot of the common tasks in aerospace tig welding.
And as far ...

AWS D17.1 specification is for Aerospace welding certification.
This is a 3g position using .063" 6061 aluminum.
Filing the sheared edge smooth and wipe with acetone prior to welding.

38 amps full pedal without pulse using .045" CP filler wire
pulse settings ...
100PPS
40% PULSE PEAK
25% BACKGROUND
MAIN AMPS SET TO 100 AMPS USING FOOT PEDAL

The monster coupon is a fairly common test given because it qualifies for a greater range of diameters and thickness. This video shows some techniques for the root.

The monster coupon is a fairly common test given because it qualifies for a greater range of diameters and thickness. This video shows some techniques for the stick fill and cap and body positioning tips.

A laser cut aluminum star provides lots of different angles and opportunity to learn things like hand position

There is a lot to talk about.
things like tungsten electrodes..type and size ( i like 2% lanthanated for everything and 3/32 takes care of most of my daily welding)
shielding gases ...argon is best to start but if you begin to specialize in thicker aluminum, it might make sense to use a blend of ...

The current waveforms are advanced square wave, soft square wave, sine wave, and triangle wave.
They all have slightly different looks, sounds and characteristics.
Some waveforms are supposed to be better for thin metals, others for thicker metals.
There is another advanced feature on a very few...

Questions about AC balance, AC frequency, tungsten electrodes, shielding gases, techniques for feeding wire, how to keep a tight arc without dipping in the puddle, and a lot more.
While I figure out the best way to answer as many questions as possible, I have to start by answering just a few of t...

You’ve probably read how aluminum needs to be really cleaned thoroughly before welding.
A lot of aluminum can be tig welded without doing a whole lot of cleaning it really depends on the application.
For general fabrication, often times a wipe with acetone or alcohol will do the trick if the me...

Aerospace tig welding tests almost always involve a fixture like the one shown in this video. Little details like how you place the chill bars can make a big difference.
Even though it would be rare to weld plain 304 stainless for aerospace, the tips still apply.
Typical test material for th...

This Video gives tips for TIG welding a 1G flat butt joint and how to watch the puddle sink to make sure you are getting penetration,
A tee joint fillet weld test in 11 ga thickness usually requires penetration into the root but not all the way thru the back side