MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

NOTES
AIRCRAFT WELDING
GAV 1751

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AMENDMENTS
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TABLE OF CONTENTS

OBJECTIVES & LEARNING OUTCOMES

Page
5

Chapter 1 WELDING FUNDAMENTAL

1. Types of welding
1.1.Gas welding
1.2.Electric arc welding
1.2.1.1.
Shielded metal arc welding
1.2.1.2.
Gas metal arc welding
1.2.1.3.
Gas tungsten arc welding
1.3.Electric resistance welding
1.3.1.1.
Spot welding
1.3.1.2.
Seam welding
1.4.Brazing and soldering
1.4.1.1. Torch brazing of steel
1.4.1.2. Torch brazing of aluminum
1.4.1.3. Torch soldering

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2. Type of joints
2.1 Butt joints
2.2 Tee joints
2.3 Lap joints
2.4 Corner joints
2.5 Edges joints

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Chapter 2 Advanced welding and repairs

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1. Advanced welding
1.1.
Gas welding aluminum
1.2. TIG welding aluminum
1.3 TIG welding Magnesium
1.4
TIG welding titanium
1.5
TIG welding stainless steel

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Repair of aircraft structure by welding

Specific welded repairs
Dents at a cluster weld
Dents between clusters
Tube splicing with an inner sleeve reinforcement
Tube splicing with an outer sleeve reinforcement
Expansion and contraction
Landing gear and Engine mount repairs

Chapter 3 Basic Gas Welding and Cutting.

1. Basic gas welding

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1.1.1. Equipment
i) Gases
-Acetylene, oxygen, nitrogen, helium
ii) Pressure regulators
iii) Hoses
iv) Torches
v) Welding goggles
vi) Torch lighters
vii) Filler rods
viii) High frequency attachment
1.1.2.
Equipment set-up
1.1.3.
Gas welding procedures and techniques
1.1.4. Oxyacetylene cutting
1.1.5. Shutting down the equipments

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2. Safety precaution
2.1.1. Oil, greases and adhesive.
2.1.2. workshop safety.

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OBJECTIVE & LEARNING OUTCOMES

OBJECTIVES

To impart the applicable knowledge on aircraft Welding so that the understanding and compliance of
which shall contribute to good and safe practices in respect of aircraft maintenance operations.

LEARNING OUTCOMES

At the end of this lesson, the trainees will be able to:

1)
Understand the general foundation of aircraft welding technique and Repair on the
civil aircraft maintenance.
2)
Understand the safety precaution handling the welding equipments.
WHAT YOU WILL LEARN

1. WELDING FUNDAMENTAL
2. ADVANCED WELDING AND REPAIRS
3. BASIC GAS WELDING AND CUTTING.

WELDING FUNDAMENTAL
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Welding means a method of joining materials in which a portion of each piece is

melted and combined in its molten state.
Have 2 type aircraft welding :o Fusion welding
Join metal together when they are in molten state.
o Non fusion welding
Joining of metal by adhesion of one metal to another
General Evaluation of welds
o A good weld is uniform in width, even ripples and good penetration.
o How to ensure
by use correct type & size of filer rod
weld zone free from excessive oxidation
Oxidation
o Primary concern to welder
o Formed in weld zone of most metal alloy
o Cause by oxygen chemically react with heated surface of metal form metal
oxides example iron oxide and aluminum oxide
o Control formation differently in fusion welding: For GAS
generate CO2 which shield the welding zone from oxygen.
For electric arc
by using FLUX for coating electrodes
or gases flood the area around arc to shield from oxygen

FUSION WELDING
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The three principal methods of fusion welding are gas, electric arc, and electrical
resistance.
Gas Welding
Oxygen support combustion.
Acetylene/hydrogen is considered fuel gases.
Temperature range from 5,600 to 6,300 F
Most done on ranges about 0.027 to 0.050 thickness of metal
Electric Arc.
1.Shielded Metal Arc Welding (SMAW)
known as stick welding
useful fabricating tools or shop equipments
Uses a consumable electrode clamped in the jaws of a hand held jaw.
Mainly for low carbon/low alloy steels
Electrode coated with flux is to creates an inert gas that helps to floats out
the impurities and form air tight seal over the weld ( slag )
The slag must chipped away
Using low voltage/high current AC/DC.
The temperature is approximately 100000F
2. Gas Metal Welding ( GMAW )
Formally called MIG (Metal Inert gas )
Used for primarily in large volume production work
Advantages over stick are no slag.
Uncoated filler rod as an electrode that is fed through a handle, when trigger is
depressed with inert gas flow out to protect the weld from oxidation forms.
The consumable electrode of the same material as the base metal being used
normally.
Inert gas used such as argon / helium / carbon dioxide.

Gas Tungsten Arc Welding ( GTAW )

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Commonly called TIG ( tungsten Inert Gas) or trademarks as Heliarc /

Heliweld.
Can be using either AC or DC current.
For using DC current there have 2 method for TIG
Straight polarity.
Reverse polarity.
Filler rod is fed into molten metal that cause by the arc between electrode and
the work.
Inert gas flows around the weld to prevent the formation of oxide in the puddle.
TIG/GTAW normally preferred over oxyacetylene as can stabilize the
temperature of the welded area/heat concentrate at the weld area only.
Temperature range as high as 11,000 F
Tungsten electrodes must select according to the size and type of metal to be
welded.
Basically have 3 type of electrode used
Pure tungsten
Less expensive and consumed so fast than other
Zirconium tungsten
Last longer and provides more stable arc.
Thorium tungsten
Produce cleaner weld and arc easiest to start.
Diameters of electrodes that are use used for A/C weld are 0.040 inch, 1/16 inch
and 3/32 inch but when choose the right size must follow the manufacturer
manual for particular equipment used.
Electric Resistant Welding
Three basic items required are current, pressure and dwell time.
Thin sheet metals especially stainless steel.
1. Spot welding.
Use two cooper electrodes held in jaws and the work clamp between them.
Current flow through electrode and metal
Resistance of metal is higher than electrode than the metal melts and welding
itself.
2. Seam Welding
A metal is rolled between two copper wheels as the electrode.
Normally used on fuel tank to provide continues air tight
Lap weld is a welded seam in which two pieces of metal overlap and are welded
together.
NON_FUSION WELDING
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BRAZING and SOLDERING

Adhesion using non-ferrous material filler by capillary attraction
A joint achieved at a much lower temperature than fusion welding.
Not permitted to weld over brazed/solder joint
Used widely in electrical connectors, fuel and hydraulic fittings and many other
low stress application
Brazing
Form of metal joining in which an iron free metal is used as cohesive material
Filler material melts above 8000F but below base metal to be joined
Have 2 operation
Braze welding
Joined same manner as fusion expect filler not fuse into the base
metal.
Seldom used in A/C structure.
Used to join dissimilar metal that cannot joined by fusion
Brazing
Once melted, flow between close fitting metal surfaces by capillary
action
Brazing flux has a caustic base it washes away oxides and
impurities on surface.
Torch brazing of steel
Mechanically clean dirt/rust.
Pre heat with a mild flame until a dull red.
Head rod tip about 2 until dark/purple and dip into borax-type flux.
Use a neutral flame and heat the base metal to a cherry red.
Remove flux by immersing for 30 minutes in a lye solution.
B. Torch brazing of aluminum/magnesium
Completely clean and no oxides
Mix flux and apply to surface
Use soft neutral flame.
Apply filler rod as soon as the flux begins to melt.
Remove flux with an acid wash then rinse with a lot of hot water.

Torch Soldering
Filler material melts below 8000F and also below base metal to be joined.
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A) Soft Soldering
Is a metal joining procedure melts at the lowest temperature using soft
flame.
Solder pulled in by capillary action.
Produces a relative weak joint but useful for air tight without much pull
or vibration.
Flux type used is recommended for the metal.
Uniform heating to the joint to a red color and put the solder onto until
melts.
The solder rod using mixture of TIN and LEAD.
Identification (filler/solder rod )
Two number in percentage.
1st two amount of tin%
Last two amount of lead %
Example : 40-60 solder heated to 4600F to flow.
50-50 solder heated to 4200F to flow ( most commonly used)
63-37 solders the lowest temperature. to heated
B) Hard soldering/ silver solder
Under brazing group of joining process
Filler material melts above 8000F.
Produces high strength than other brazing processes
Neutral/slight carburizing flame ( soft not harsh ) and inner cone from work
using oxyacetylene.
Apply solder onto when indicate the flow of flux ( mixture of water/flux )
Flux used to chemically clean the base metal of oxide film.
The produce that the flux is applied to both materials to be joined and heated
with torch until flux makes a clear liquid then touch the rod to the edges of the
joint and capillary action will draw the molten metal into the joint.
Soldering copper / soldering iron
Used Electrical or heat
Bit made of copper.
Use for seam soldering and electrical wire repair.
For electrical connections, you must use solder with non-corrosive flux.

The five basic types of weld joints are : Butt joints

Tee joints
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Lap joints
Corner joints
Edges joints

Butt joints
Used to join metal forms such as sheet, bar, plate, tube and pipe.
In a/c application, generally are not used for joining tubing because they are too
weak for a/c structure.
A typical butt weld should penetrate 100% of thickness of the base metal.
Tee joint
Quite common in aircraft work, particularly in tubular structure
The plain tee joint is suitable for most aircraft metal thickness.
Thicker metal require the vertical member to be either single or double beveled
to permit the heat to penetrate deeply enough.
Lap joints
Seldom used in a/c structures when welding with gas, but commonly used spot
welding.
Single lap has very little resistance to bending and will not withstand shearing
stresses.
Double lap joints are stronger, but require twice the welding of the simpler,
more efficient.
Corner joints.
When two pieces of metal are brought together so their edges forms a corner of
a box or rectangle.
Used where load stresses is not significant.
Edges joints
Where load stresses are not significant, edge joints may be used to joint two
pieces of sheet metal.
To form, bend the edges of one or both part upward, place the two ends parallel
to each other and weld along outside of the seam form by two edges

Advanced welding and repairs

Gas welding aluminum.
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Most aluminum welding done with SMAW but there are times when aluminum
is welded with either acetylene or hydrogen gas.
Preferred hydrogen gas because of its cleaner flame and less risk of oxidizing
the joint
Prepared the metal by cleaning the with aluminum brush.
Heat the metal and apply flux to the pieces and rod that will joined
Use light blue welding goggle.
Flame should be neutral or slightly carburizing to reduce possibility of the metal
oxidized during welding.
Proper form bead will be uniform in width, height, and bright shinny surface.
If oxidized, have powdery white appearance and rough surface.

TIG welding aluminum

The ability using AC to keep the oxides off the heated metal
Clean with stainless steel brush to removed oxides ten uses MEK or other
recommended solvent.
Use electrodes specified by manufacturer.
Starts arc with High Frequency Signal (superimposed stabilization) without
touching the electrode to the work.
When looks frosty, then lift just a little and be ready to add filler rod.
TIG welding magnesium
AC high frequency to blast oxides
Clean with stainless steel/MEK.
Filler rod as same as material

TIG welding titanium

Weld in atmosphere where no oxygen/nitrogen contacts with hot metal.
Minor impurities in metal can cause brittle.
Use large nozzle/ trailing shield to keep air away
Used thoriated tungsten electrode and straight polarity DC current

TIG welding stainless steel

Exhaust residue to be remove by abrasive blasting.
Using straight polarity DC
Filler rod recommended by material manufacturer.

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Type of metal / design / repair refer to MFG. service manual or structural repair
manual.
Dent at cluster weld
Reinforced with a patch over the dent
Same thickness and material
Extend 1 diameter of the tube beyond the damaged
Dents between clusters
Welding a sleeve over the damage area
Stop drill any crack
Same wall thickness and material ( the ID same as OD of the damage tube )
Scarfed with 30 degree, split the tube, butt and lap weld.
Dent not deeper than 1/10 of tube diameter and less tube circumference with
no crack or sharp edge may be patch repair.

Inner sleeve tube splicing

Cut tube 30 angle and remove damage.
Prepare replacement same diameter /wall thickness
Prepare sleeve same original tube/ 5 x D long centered ever scarf cut. With 1/8
gap between end
Rosette weld / lap joint

BASIC GAS WELDING

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Equipments

WELDING GASES
Acetylene
Flammable /colorless/ distinctive odor
Produces yellow smoky flame / transparent blue when added to oxygen.
Acetylene become unstable at 15 PSI( dangerous ) and will explode at 30
PSI
Commonly stored in steel cylinder (bottle) and protected from exploding
during a shop flame by a plug (safety fuse plug) in the bottom of the tank
that melts if outside/inside temperature exceed 2120F and lets the gas
escape.
Cylinder colored red/ maroon.
Amount of acetylene in cylinder determined by the weight.
Accept value for acetylene line pressure is 5 PSI. (normal 4 to 8 PSI )
Cautions:
Never open cylinder valve more than to turn and never remove the wrench
( bottle key from cylinder )
Never use all the gas to prevent loss of acetone and the filler practically 50 PSI
Never move cylinder without protective cap.
Oxygen
Colorless/ odorless/ tasteless about 21 % in atmosphere
Cannot used as aviation breathing oxygen.
Stored in green seamless steel cylinder at 2000 PSI or above
Oxygen bottle is protected from exploding (due to pressure built up) by safety
disc in the top valve.
Beeswax is approved lubrication on threads and oxygen fittings.
Cautions:
Never use/ contact petroleum base product, which can generate sufficient
heat to ignite.
When moving away always install steel protective cap
Cylinder valve should open fully.

Hydrogen
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Highly flammable/ colorless

Normally used for gases welding aluminum/ magnesium.
Using hydrogen instead of acetylene that will produce cleaner flame to
minimize oxidation
Heat temperature lower than acetylene
Argon/ Helium
Colorless/ odorless about less 1% in atmosphere
As inert gas (shielding gas) to envelope the welding area that prevent oxidation
to form
Equipment
Pressure regulator
Two stage type.
The first stage with high pressure gauge is to drop cylinder pressure to a
constant of intermediate pressure.
The second stage with low pressure gauge is to give specific value needed
for welding ( working / operating pressure
Acetylene
Has a left hand threads ( anti clockwise )
The high pressure between 400 -500 PSI normally and the low pressure 30 50
PSI
Working 4 8 PSI ( practically 5 PSI )
Oxygen
Has right hand thread ( clockwise )
High pressure up to 3000 PSI with low pressure up to 400 PSI
Working pressure up to 10 PSI
Hoses
Mostly synthetic rubber with inner two layers of rubber impregnated fabric and
outer cover of abrasion resistance vulganized rubber
Acetylene
Left hand thread with groove in hex sided fitting
Red/maroon color
Oxygen
Green color hose
Right hand thread fitting
Torches
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Two valve for adjusting the flow of oxygen/acetylene through mixing chamber
to the tip.
Interchangeable tip nozzle (orifice) made of hard copper/ alloy.
The size of the torchs tip opening determines amount of heat applied to the
work / the thickness of the metal.
Two type of oxyacetylene torches :Equal pressure torch
Injector torch
Equal pressure type
Use when the acetylene supplied from steel cylinder.
Independently controlled to suite the flame requirement for aircraft weld
Oxyacetylene normally fed at same pressure (1- 5 PSI) depend on metal
thickness.
Injector type
Is used with an acetylene generator
Venturi effect caused by oxygen flows that pull the acetylene
Torch lighters
To light a welding torch used flint/ steel type approved striker
For stationery welding equipment may used a pilot flame.
Cautions: Never use matches or cigarette lighter especially butane lighter even though
keep inside pocket while welding
Welding goggles
The clear cover is to protect lens ( filters )
The lens used to protect eyes from heat/ultra violet / infrared rays that produce
by the welding flame.
Blue lens for welding aluminum
Green/ brown lens for welding steel

Filler rods
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Classified as ferrous/non-ferrous rods that use to add reinforcement to the weld

area (beads) and to pull heat away from the molten puddles
Rod diameters (size) depend on metal thickness as stated in the appropriate
aircraft service/welding manual.
Type material as per recommended by manufacturer manual
Welding magnesium should use same base metal/material filler rod.
Copper-coated filler rod used to prevent rust.
Flux coated to prevent formation of oxidation
Material compatibility is the most important when selecting welding rod.
Gloves
An important part of the welder personal safety equipment
Prevent sparks and weld splatters from burning your hand and arms.
Equipment Set-up
Remove the protective cap on up right cylinder.
Instantly open cylinder valves to blow any foreign matter and wipe clean after
close.
Connect pressure regulators and tighten enough to prevent leakage.
Connect the red/maroon hose to acetylene pressure regulator and the
green/black hose to oxygen pressure regulator.
Caution: Do not force or over tighten. May damage the thread, which made of
brass
Open cylinder valves to check the contents in each cylinder while pressure
regulator adjusting screw in off position. Fully open for oxygen and to turn
for acetylene.
Blows out the hoses to the torch and leak check with 20-PSI shows on the
oxygen working pressure gage and 5 PSI on the acetylene pressure gage

Gas welding procedures and techniques

Flame adjustment
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Hold away the torch and open the acetylene valve about 1/6 turn and light
the torch, adjust the valve until the smoke clear and the flame yellowish
color.
Open oxygen valve until bluish white, bright inner cone surrounded by
outer flame (envelope).
Heat obtain from a proper amount is 56000F
Neutral flame
Oxygen /acetylene burn together with same volume supply
Outer cone cover the intermediate cone with rounded inner cone.
Reducing / carburizing flame
Excess acetylene
Outer cone ( envelope ), intermediate (feather), inner cone
Oxidizing flame
Excess flame
Two cones with sharps- pointed inner cone
Torch motions
Semicircular
Crescent
Circular
The welder should keeps the motion of the torch as uniform as possible in order
to make smooth, even spaced ripples.
Ripples small wavelike marks left on the surface of the completed weld by the
action of the torch and welding rod
Welding technique
Forehand welding
The torch flame is pointed in the direction the weld is progressing (flame
pointed towards the unwelded portion and the filler rod is fed in from the
front of the torch or flame. Also known as forward welding
Backhand welding
The flame directed back towards the finished weld, away from direction
the weld is progressing, the filler fed from the back of the torch or flame.
Known backward welding

Oxyacetylene cutting
Neutral flame on preheat orifice to heat metal to cherry red.
Cut made referred as a kerf.
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Cutting torch has an extra oxygen valve used to adjust oxygen jet blast
for actual cutting through orifice at the center torch tip.
Shutting down the equipments
General procedures
Close the acetylene and oxygen needle valve on torch
Close the acetylene and oxygen cylinder valve.
Open the acetylene valve on the torch to drain the acetylene hose
and regulator. This removes pressure on the regulators working
pressure gauges
Turn the acetylene-regulator adjusting screw to the left to relieve
pressure on the diaphragm and close the torch acetylene valve.
Do the same step to the oxygen torch, hose regulator, and cylinder.
Hang up the torch and hose properly to prevent hose and torch
damage.
Safety precaution
Oil, greases, and adhesive
Workshop safety

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