AWS D17.2/D17.2M:2019

An American National Standard

Specification for Resistance Welding for Aerospace Applications

AWS D17.2/D17.2M:2019

An American National Standard

Approved by the American National Standards Institute

February 27, 2018

Specification for Resistance Welding for Aerospace Applications

3rd Edition

Supersedes AWS D17.2/D17.2M:2013

Prepared by the American Welding Society (AWS) D17 Committee on Welding in the Aircraft and Aerospace Industry

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This specification provides the general resistance welding requirements for aerospace hardware. It includes, but is not limited to, resistance spot and resistance seam welding of aluminum, magnesium, iron, nickel, cobalt, and titanium-based alloys. There are requirements for machine and welding schedule qualification, production witness samples, and inspec- tion and acceptance criteria for aerospace hardware.

AWS D17.2/D17.2M:2019

AWS D17.2/D17.2M:2019

ISBN Print: 978-0-87171-952-2

ISBN PDF: 978-1-64322-020-8

© 2018 by American Welding Society

All rights reserved Printed in the United States of America

Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner.

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmen- tal bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS stand- ard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the proc- ess and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.

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In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or on behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. It is assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.

This standard may be superseded by new editions. This standard may also be corrected through publication of amend- ments or errata or supplemented by publication of addenda. Information on the latest editions of AWS standards including amendments, errata, and addenda is posted on the AWS web page (www.aws.org). Users should ensure that they have the latest edition, amendments, errata, and addenda.

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AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Standards Development Division, 8669 NW 36th Street, Suite 130, Miami, FL 33166 (see Annex F). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute profes- sional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These indi- viduals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS D17 Committee on Welding in the Aircraft and Aerospace Industry. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D17 Committee on Welding in the Aircraft and Aerospace Industry and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS D17 Committee on Welding in the Aircraft and Aerospace Industry to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 NW 36th Street, Suite 130, Miami, FL 33166.

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Personnel

AWS D17 Committee on Welding in the Aircraft and Aerospace Industries

G. Coleman, Chair The Boeing Company

S. H. Murray, Vice Chair NASA-Kennedy Space Center

1. Worley, Second Vice Chair General Electric Aviation

   1. Babinski, Secretary American Welding Society

      J. T. Amin Lockheed Martin Aeronautics Company (retired)

      R. Beil Northrop Grumman Corporation

      M. Bernasek C-SPEC

      M. Bernath Arconic

      C. Carl NASA Kennedy Space Center

      J. Carruth Lockheed Martin Missiles & Fire Control

      P. Daum Rolls-Royce Corporation

      R. Ding NASA-Marshall Space Flight Center

      H. Doucette SpaceX

      R. Durda The Nordam Group

      J. Fournier Pratt & Whitney Canada

      D. Lindland Pratt & Whitney

      1. Maust, III Raytheon Integrated Defense Systems

         1. Morris Raytheon Integrated Defense Systems

         2. Nordin Rolls-Royce Corporation

      G. Rolla California Welding Institute

      M. Sapp NAVAIR Fleet Readiness Center—East

      D. Sheldon voestalpine Roll Forming Corporation

      J. Thyssen Consultant

      G. Trepus Boeing Research and Technology

      
      

      Advisors to the AWS D17 Committee on Welding in the Aircraft and Aerospace Industries

      S. Dilcher Lockheed Martin Aeronautics Company

      R. Freeman TWI-The Welding Institute

      W. Guo Honeywell

      I. Harris Edison Welding Institute

      E. Helder GE Aircraft Engines (retired)

      B. Jackson NASA Safety Center

      1. Pearson, Jr. LTK Engineering Services

         1. Ponder Triumph Airborne Structures

            1. Sauer NAVAIR In-Service Support Center

               W. Schell The Boeing Company

            2. Senatore BG Inspections

      G. Stahle Navistar

      J. Vollmer Boeing Satellite Systems

      
      

      AWS D17.2/D17.2M:2019

      
      

      AWS D17.2/D17.2M:2019

      AWS D17D Subcommittee on Resistance Welding

      B. Worley, Chair General Electric Aviation

      P. Daum, Vice Chair Rolls-Royce Corporation

      1. Babinski, Secretary American Welding Society

S. Brown Exotic Metals Forming Company

R. Cohen WeldComputer Corporation

J. Fournier Pratt & Whitney Canada

D. Harris Exotic Metals Forming Company

I. Ibrahim Lynn Welding Company, Incorporated

L. Morris Raytheon Integrated Defense Systems

T. Nelson LTK Engineering Services

J. Pearson, Jr. LTK Engineering Services

M. Sapp NAVAIR Fleet Readiness Center—East

B. White, Jr. Janda Automation

Advisors to the AWS D17D Subcommittee on Resistance Welding

Roger Beil Northrop Grumman Corporation

W. Guo Honeywell

P. Lang Pratt & Whitney

D. Lindland Pratt & Whitney

G. Loy-Craft Oklahoma City Air Logistics Center

R. Maust, III Raytheon Integrated Defense Systems

L. Perkins United States Air Force

D. Ponder Triumph Airborne Structures

S. Potter SSP Consulting Services

J. Saenz Hydroform USA

W. Schell The Boeing Company

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J. Vollmer Boeing Satellite Systems

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Foreword

This foreword is not part of this standard, but is included for informational purposes only.

In the mid 1990s, the AWS D17 Committee on Welding in the Aircraft and Aerospace Industries decided it was necessary to form a subcommittee to write a resistance spot and seam welding specification.

This is the third edition of the D17.2/D17.2M specification. This specification is intended to replace the following documents:

MIL-W-6858D, Welding, Resistance: Spot and Seam, March 28, 1978 AMS-W-6858A, Welding, Resistance Spot and Seam, April 1, 2000

MIL-W-6858D or AMS-W-6858A, or both, take precedence over this specification only when they are cited by the con- tract documents.

A vertical line in the margin and underlined text in clauses, tables, or figures indicates an editorial or technical change from the 2013 edition.

Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS D17 Committee on Welding in the Aircraft and Aerospace Industries, American Welding Society, 8669 NW 36th Street, Suite 130, Miami, FL 33166.

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Table of Contents

Page No.

Personnel v

Foreword vii

List of Tables x

List of Figures x

1. General Requirements 1

   1. Scope 1

   2. Units of Measure 1

   3. Safety 1

2. Normative References 2

3. Terms and Definitions 2

4. Requirements 3

   1. Design Requirements 3

   2. Materials and Methods of Preparation 8

   3. Equipment Requirements 9

   4. Personnel 9

   5. Qualification of Welding Machines 9

   6. Welding Schedule Certification 10

   7. Production Verification Testing 17

   8. Acceptance Criteria 17

5. Quality Assurance Provisions 25

   1. Production Quality Control 25

   2. Production Witness Specimens 25

   3. Inspection of Production Parts 27

Annex A (Informative)—Form for Resistance Welding Data Sheet for Spot Welding 29

Annex B (Informative)—Form for Resistance Welding Data Sheet for Seam and Roll Spot Welding 31

Annex C (Informative)—Informative References 33

Annex D (Informative)—Recommendation for a Metallographic Method for the Examination of Weld

Penetration in Resistance Seam Welds 35

Annex E (Informative)—Commentary 39

Annex F (Informative)—Requesting an Official Interpretation on an AWS Standard 45

List of AWS Documents on Welding in the Aircraft and Aerospace Industries 47

AWS D17.2/D17.2M:2019

AWS D17.2/D17.2M:2019

List of Tables

Table Page No.

1. Shear Load Requirements for Spot Weld Sheet Specimens Group 1 Alloys—Aluminum and

   Magnesium Alloys 4

2. Shear Load Requirements for Spot Weld Sheet Specimens Group 2 Alloys—Steel, Nickel,

   and Cobalt Alloys 5

3. Shear Load Requirements for Spot Weld Sheet Specimens Group 3 Alloys—Titanium Alloys 6

4. Shear Load Requirements for Spot Welds in Foil 7

5. Machine Qualification Specimens and Examination Requirements 11

6. Welding Schedule Certification Specimen and Examination Requirements Spot Welds—Sheet 12

7. Welding Schedule Certification Specimen and Examination Requirements Spot Welds—Foil 12

8. Welding Schedule Certification Specimen and Examination Requirements Seam Welds—Sheet 12

9. Welding Schedule Certification Specimen and Examination Requirements Seam Welds—Foil 13

10. Limits for Visible Discontinuities in Production Parts or Lots 18

11. Nugget Size (All Groups) 20

12. Internal Metallographic Imperfections for Production Witness Samples or Sectioned Parts 22

13. Production Witness Welds, Test Lots 26

List of Figures

Figure Page No.

1. Spot Welds in Sheet 13

2. Close-Spaced Spot Welds in Sheet 14

3. Spot Welds in Foil for Class A Welds 14

4. Spot and Seam Welds in Foil, Peel Specimen for Class C Welds 15

5. Seam Welds in Sheet 15

6. Pressure Test of Seam Welds in Foil, for Class A Welds 16

7. Nomenclature for Metallographic Spot Weld Sections and Seam Weld Transverse Sections 18

8. Surface Indentation 19

9. Nomenclature Diagram of Spot and Seam Weld Radiographs 21

10. Minimum Penetration 22

    x

11. Shear Tests of Three or More Thicknesses 23

x