PRC-0005 Rev.

Process Specification for the Manual Arc

Welding of Carbon Steel and Nickel Alloy
Hardware

Engineering Directorate

Structural Engineering Division

November 2012

National Aeronautics and

Space Administration

Lyndon B. Johnson Space Center

Houston, Texas

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 PRC-0005 Rev. G

Process Specification for the Manual Arc

Welding of Carbon Steel and Nickel Alloy
Hardware

Prepared by : Signature on file 10/10/12

Daniel J. Rybicki Date
Materials and Processes
Branch/ES4

Reviewed by : Signature on file 10/12/12

Lucie B. Johannes Date
Materials and Processes
Branch/ES4

Approved by: Signature on file 11/08/12

Rachel Kamenetzky, Chief Date
Materials and Processes
Branch/ES4

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 PRC-0005 Rev. G

REVISIONS
VERSION CHANGES DATE
Baseline Original version 6/1/95
A Revised version 10/29/97
B Formatting, changed process owner, rewrite numerous sections 07/07/99
for clarification, deleted requirement for WIR, deleted section 8.2
on audits, added section 8.3 on WPQ, deleted mil specs for NDE,
added PRCs for NDE.
C Comprehensive technical rewrite and reformat, exclude 9/7/00
applicability to pressurized hardware, clarify 3.0, add a ―D‖ class
weld in 3.1, expand design requirements, add reference to NASA-
SPEC-5004 and delete reference to inspection/NDE PRCs, delete
Table II, address use of metal cored filler wires in 6.1.2, clarify
6.1.4, specify requirement in 6.4, clarify 6.5 to include weld
―rework‖, expand section 7.0 to clarify, combine 7.2 and 7.3,
revise 8.0 to clarify compliance with AWS B2.1, revise all
acceptance criteria to clarify and simplify.
D Comprehensive rewrite to combine PRC-0005 and PRC-0006 and 01/28/04
make editorial changes. PRC-0006 will be cancelled with this
change. Include requirements for precision cleaned hardware (ref.
JPG 5332.1). Expand Class D definition and requirements.
E Add reference to good workmanship in section 7.1.4. 03/09/04
F Add reference to Class D welding in 3.0 for on-site JSC work 11/21/07
authorized by the JSC Engineering Directorate‘s manufacturing
operations. Add additional Class D stipulations in last paragraph
of 3.1. Added Reviewer signature block.
G Revised the definitions of flight and non-flight hardware in 2.0; 11/08/12
added NAS 410, NASA-STD-5009, PRC-5010, PRC-6503, PRC-
6505, PRC-6506, and PRC-6510 to 4.0; revised 6.5 to allow
mechanical repairs; revised 7.0 through 7.3 to add separate
inspection requirements for flight hardware and require NAS 410
certification for NDE personnel inspecting flight hardware; and
revised Appendix A in its entirety.

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 PRC-0005 Rev. G

1.0 SCOPE

This process specification provides the minimum requirements that govern the manual
arc welding of carbon steel and nickel alloy flight and non-flight hardware. Design,
procedural and quality assurance requirements are given. All work instructions and
Weld Procedure Specifications (WPS) used during welding shall satisfy the
requirements of this process specification.

2.0 APPLICABILITY

This process specification applies to manual (and semiautomatic) arc welding of carbon
steel and nickel alloy flight and non-flight hardware that is fabricated under the authority
of NASA/Johnson Space Center (JSC) by any of the following types of welding
processes:

a. Gas tungsten arc welding (GTAW).

b. Gas metal arc welding (GMAW).
c. Flux cored arc welding (FCAW).
d. Shielded metal arc welding (SMAW).
e. Plasma Arc Welding (PAW).

The term ―flight hardware‖ refers to any hardware acceptable for space flight use (Class
I), use in ground tests or training in a hazardous environment (Class II), use in water
immersion training (Class IIIW) and Ground Support Equipment (GSE). The term ―non-
flight hardware‖ refers to any hardware acceptable for use in non-hazardous training or
displays (Class III), Special Test Equipment/Devices (STE/D), use in facilities (buildings
and related accessories), mockup mission equipment and engineering prototype and
development hardware.

Future builds of hardware where the existing engineering documentation calls out
NASA/JSC PRC-0006 for welding shall utilize this specification. Existing hardware
fabricated to PRC-0006 requirements shall not be affected by this change. In addition,
existing engineering documentation that specifies welding per PRC-0007 shall be
accommodated by PRC-0005, Class D. Existing hardware fabricated to PRC-0007
requirements shall not be affected by this change.

3.0 USAGE
This process specification shall be invoked by including a note on the applicable
engineering drawing with the following general format which specifies the PRC and
weld class nomenclature:

WELD AND INSPECT PER NASA/JSC PRC-0005, CLASS X.

Regarding onsite JSC work for minor facilities repair and manufacture of shop aids that
is performed under the work authorization of the JSC Engineering Directorate's
manufacturing operations, welds shall be considered Class D, if they conform to the
Class D weld criteria and exclusions herein. Execution of these welds shall not require
the formality of an engineering drawing, and may be executed by verbal orders.
To minimize fabrication costs by avoiding over-inspection and unnecessary
rework/repair, individual welds, or components on a weldment shall be classified

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separate where possible. This can be accomplished by including a note on the

engineering drawing with the general format shown below which specifies only the PRC
nomenclature. The weld class shall then be indicated by either: 1) calling out the
specific weld class with the welding symbol at the individual weld joints or, 2) by using
specific flag notes with the welding symbol at the individual weld joints. Refer to Figure
3.0a and 3.0b below for examples of these methods.

WELD AND INSPECT PER NASA/JSC PRC-0005. WELD CLASSES SHALL BE AS

INDICATED AT WELD LOCATION CALLOUTS.

CLASS B
WELD 3

FIGURE 3.0a FIGURE 3.0b

3.1 WELD CLASSIFICATION

Welds made using this specification shall be primarily classified in accordance with the
service conditions of the weldment. The "Class" governs the extent to which quality
assurance provisions are applied to the weld joint.

Alternatively, individual welds, welded connections, or entire weldments (for simplicity,

the terms weld, welded connection, and weldment will be used interchangably) may be
classified by relating the weld to the factor of safety used in the design. However, when
classifying welds in this manner, regardless of the factor of safety, adequate
consideration should be given to the severity of the service conditions (e.g., static
loading vs. dynamic loading, cyclic, vibration, fatigue, corrosive, extreme temp, etc.),
material characteristics (e.g., ductility, toughness, etc.), and the potential consequences
of weld failure.
Where conditions exist that make it difficult to choose between 2 weld classes, then the
more stringent of the 2 classes shall be applied.

Quality assurance provisions for all weld classes are detailed in Section 7.0. Weld
classes shall be chosen on the basis of the following definitions:

a. Class A (Flight or non-flight) — Applies to welds in critical load bearing

elements that are not fail-safe. Class A welds are typically used in
primary load bearing connections. Failure of a Class A weld in service
would be catastrophic and would result in the loss of life, system(s),
control, or major components. Alternatively, if it is determined from
appropriate engineering analyses that a weld has a Factor of Safety
(FSuts) vs ultimate tensile strength of the calculated minimum weld throat
cross section of 2.0, it shall be designated as a Class A weld.

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b. Class B (Flight or non-flight) — Applies to welds in load bearing elements

that are fail-safe. Class B welds are typically used in secondary load
bearing (i.e., shared load) connections. Failure of a Class B weld in
service would reduce the overall efficiency of the system, but the loss of
the system(s) or endangerment to personnel would not be expected.
Alternatively, if it is determined from appropriate engineering analyses that
a weld will have a FSuts of 2.0 and 3.5, it may be designated as a Class
B weld.

c. Class C (Flight or non-flight) — Applies to welds that are in minor load

bearing elements that are fully contained where failure in service would
have minor or no affect on the efficiency of a system and endangerment
to personnel would not occur. Class C welds are typically used in
secondary or tertiary load bearing (i.e., shared load) connections.
Alternatively, if it is determined from appropriate engineering analyses that
a weld will have a FSuts of 3.5 and 5.0, it may be designated as a Class
C weld.
d. Class D (Non-flight hardware only) — Applies to welds that are in noncritical
elements and where failure would have no affect on the efficiency of a
system and endangerment to personnel would not occur. Class D welds are
typically used in connections where any expected load transfer at the weld
would be negligible. Alternatively, if it is determined from appropriate
engineering analyses that a weld will have a FS uts of 5.0, it may be
designated as a Class D weld. In any case, Class D shall not be specified for
welds used for making connections onto critical or primary load path
elements (e.g., lift points, etc.) or elements directly related to personnel
supporting activities, regardless of the loading condition/direction.

In addition to the above definitions, the following requirements shall also apply to weld
classifications:

If any weld intersects or overlaps another weld of a higher classification,

then the lower classed weld shall be automatically upgraded to the higher
of the 2 weld classes and subjected to the appropriate quality assurance
provisions.
If any weld falls within ½‖ of any higher classed weld, then it shall be
automatically upgraded to the higher of the 2 weld classes and subjected
to the appropriate quality assurance provisions.
Class D welds are only intended for on-site (JSC) fabrication operations.
All welds that are specified as Class D on weldments that are
subcontracted off-site shall be recognized as Class C and shall be subject
to all applicable Class C requirements specified herein. Class D welds
shall only apply to welds made on common ―structural‖ low carbon steels
or 300 series CRES steels. HSLA, quenched & tempered steels, and
―alloy‖ (e.g., chromium-molybdenum) steels shall not be considered for
Class D welding. In addition, welds joining 2 or more dissimilar base
metals shall not be allowable under Class D provisions.

3.2 WORK INSTRUCTIONS

Work instructions shall be generated for implementing this process specification. The
work instructions shall contain sufficient detail to ensure that the manufacturing process
produces consistent, repeatable results that comply with this specification. At JSC,
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these work instructions are approved as Detailed Process Instructions (DPIs) that
describe in a detailed, step-by-step format the required procedures, equipment, and
materials to be used for conducting a given process. If this manufacturing process is to
be performed by an outside vendor, work instruction development shall be the
responsibility of the vendor.

3.3 DESIGN REQUIREMENTS

a. The design of welded joints (including weld sizes) shall utilize adequate
engineering analysis methods (e.g., stress analysis, fracture
mechanics/fracture control, etc.) to ensure that the resultant connection
strength is capable of successfully transferring the maximum load expected
to pass between the interconnecting members and meet the required
factors of safety and design margins.

b. All engineering drawings shall depict welded joints using the applicable
symbols described in AWS A2.4.
c. The engineering drawing shall specify any additional or alternate testing or
inspection requirements. Where spot, intermittent, or other special
inspection requirements are specified that deviate from those stated herein,
it shall be detailed on the drawing as a note or by using the applicable
symbology described in AWS A2.4. For Class A welds, alternate or
reduced NDE requirements shall not be allowed.

d. Class A welds are expected to be welds requiring full strength of the weld
joint therefore, these welds shall be a groove design and full penetration
wherever possible. The ability to successfully perform radiographic
examination on these weld joints shall be considered during design.

e. Class A welds which will be subjected to unusual or extreme service

conditions (e.g., severe dynamic loading, cyclic, vibration, impact, corrosive,
fatigue, extreme temp, etc.), shall be welded using a WPS qualified in
accordance with AWS B2.1 ―Special Test Weldments.‖ This requirement
shall be noted on the engineering drawing.

f. Unless otherwise specified on the engineering drawing or WPS, welded

hardware will be delivered in the ―as welded‖ condition. If required, any
heat treatment processing required shall be detailed on the engineering
drawing and shall include notation that will reference NASA/JSC PRC-2001
or PRC-2003 as applicable.

g. Intermittent welding (skip welds) shall not be specified for Class A welds.

h. Intermittent welds shall not be specified for groove welds (square or

prepared groove design) unless the unwelded portions of the joint are
adequately supported to prevent one member from coming out of plane with
the adjoining member.

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4.0 REFERENCES

The standards listed below shall be considered a part of this specification to the extent
specified herein. Unless otherwise indicated, the revision that is in effect on the date of
invitation for bids or the date of request for proposals shall apply.

a. Aerospace Industries Association of America (AIA) National Aerospace

Standards (NAS)

NAS 410 NAS Certification & Qualification of Nondestructive Test Personnel

b. American Society of Nondestructive Testing (ASNT)

SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing

c. American Welding Society (AWS) Standards

ANSI/AWS A2.4 Standard Symbols for Welding, Brazing and Nondestructive Testing

ANSI/AWS A3.0 Standard Welding Terms and Definitions

ANSI/AWS A5.X – A5.XX Specifications for Welding Electrodes, Rods, and Filler
Metals (Applicable to Specific Alloy and Process as
governed by this PRC)

ANSI/AWS B2.1 Standard for Welding Procedure and Performance Qualification

ANSI/AWS D1.1 Structural Welding Code - Steel

ANSI/AWS D1.6 Structural Welding Code - Stainless Steel

ANSIAWS QC-1 Standard for AWS Certification of Welding Inspectors

d. Compressed Gas Association, Inc.

G-11.1 Argon, Commodity Specification for

e. Federal Documents

BB-C-101 Carbon Dioxide (CO2) : Technical and U.S.P.

BB-H-1168 Helium Federal Specification

BB-O-925 Oxygen, Technical, Gas and Liquid

f. Military Documents

MIL-A-18455 Argon, Technical

MIL-P-27407 Propellant Pressurizing Agent, Helium

MIL-P-27201 Military Specification, Propellant, Hydrogen

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g. NASA/JSC Documents

JPG 5322.1 Contamination Control Requirements Manual

PRC-0008 Process Specification for the Qualification of Manual Arc Welders

PRC-2001 Process Specification for the Heat Treatment of Steel Alloys

PRC-2003 Process Specification for the Heat Treatment of Nickel Alloys

PRC-5010 Process Specification for Pickling, Etching and Descaling of Metals

PRC-6503 Process Specification for Radiographic Inspection

PRC-6505 Process Specification for Magnetic Particle Inspection

PRC-6506 Process Specification for Liquid Penetrant Inspection

PRC-6510 Process Specification for Ultrasonic Inspection of Welds

SOP-004.5 Control of Weld Filler Materials, Electrodes, and Fluxing Materials

SOP-007.1 Preparation and Revision of Process Specifications

TI-0000-04 Training Instruction for the Welding Processes

h. NASA Headquarters

NASA-SPEC-5004 Welding of Aerospace Ground Support Equipment and Related

Nonconventional Facilities

NASA-STD-5009 Nondestructive Evaluation Requirements for Fracture Critical

Metallic Components

5.0 MATERIAL REQUIREMENTS

All materials (base and filler materials as applicable) used in the welding of hardware
per this specification, shall meet the requirements of an applicable JSC material
specification unless otherwise specified. If a JSC material specification is not available,
then an applicable commercial specification or a manufacturer's specification shall be
used.

5.1 SHIELDING GASES

Allowable shielding gases (including purge gases) are listed in Table I. Gases
purchased to alternate specifications shall be allowed provided they meet the minimum
requirements of the specifications listed herein. Mixtures of these gases are allowed
and the nominal mixture used for the qualification welding shall be that used for
production and shall be listed on the WPS. Shielding and purging gas mixtures shall be
subject to the qualification variable requirements listed in AWS B2.1. In addition:

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a. Hydrogen gas in any concentration, may not be used for welding any alloys
known to be susceptible to hydrogen related problems (e.g., alloy steels, Q&T
steels, martensitic stainless steels, etc.).

b. Nitrogen shall not be used for shielding or purging in any welding operation
governed under this specification.

c. All gases used for shielding or purging shall have a dewpoint of -40°F (minus
40 °C) or better.

5.2 FILLER METALS AND ELECTRODES

All filler metals shall meet the requirements of the applicable AWS filler metal
specification relative to the specific alloy and process being used. Filler metals shall be
selected from Tables II, III, and IV. If designated in BOLD TYPE, this shall be the first
choice for filler metal. Otherwise, selection shall be based on specific base metal
combinations, service environment, etc.). Tubular sleeve and filler insert materials shall
have compositions similar to those indicated in Tables II, III, and IV. In addition, the
following shall apply:

a) For dissimilar metal welds joining carbon steel to low alloy steel, or between
two different low alloy steels, filler metal with strength levels matching the
lower strength material shall be used. For dissimilar metal joints involving
stainless and corrosion resistant steels, nickel alloys, and/or other materials,
filler metal selection shall be based on that stated herein and approved by the
NASA/JSC M&P organization prior to use.

b) All filler metals shall be used in accordance with a qualified WPS.

c) Filler metal configurations which cannot be procured to an AWS or other

applicable filler metal specification shall meet an applicable NASA/JSC or
other industry material specification and shall be approved by the NASA/JSC
M&P organization prior to use.

d) Non consumable tungsten and tungsten alloy electrodes for GTAW and PAW
shall conform to the applicable AWS specification.
e) Filler metals shall be listed on the engineering drawing.

Table I. Allowable Shielding Gases

GAS DESCRIPTION SPECIFICATION
Argon Gas MIL-A-18455
Argon Type II, Grade B (Liquefied) CGA G-11.1
Carbon Dioxide Grade B BB-C-101
Helium Type I, Grade A MIL-P-27407
Hydrogen Gas MIL-P-27201
Oxygen Type I BB-O-925

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Table II. Approved Filler Metals for Welding Carbon and Low Alloy Steel
MATERIAL SMAW GTAW / GMAW FCAW
GROUP and PAW
A5.1: E60XX, E70XX or A5.28: E70S-2, E70S-3, ER70S-6 A5.22: E70T-1, E70T-5
(a)
M-1 A5.5: E70XX-A1
A5.5: A5.28: (b)
M-3 E70XX-A1 ER80S / E80C-D2
A-5.5: A5.28: ER80S,E80C-B2, (b)
M-4 E80XX-B2 ER80S / E80C-B2L
M-5 A5.5: A5.28: ER90S, E80C-B3, (b)
E90XX-B3 ER90S / E90C-B3L
(3% Cr max)
Notes:
(a) A5.5, E70XX-A1 shall be used for materials with maximum specified carbon greater than 0.30%.
(b) Filler metal to be used for joining must be compositionally compatible with base metal. Primary consideration shall
be given to mechanical properties, corrosion resistance, and weldability, as applicable for the specific application.

Table III. Approved Filler Metals for Welding Nickel Alloys

BASE METAL SMAW GTAW / GMAW / PAW
(AWS A5.11) (AWS A5.14)
Nickel 200 ENi-1 ERNi-1
Nickel 201
Monel 400 ENiCu-7 ERNiCu-7
Monel K500 -- ERNiCu-7
Inconel 600 ENiCrFe-1, ENiCrFe-3 ERNiCrFe-5, ERNiCr-3
Inconel 601 ENiCrFe-3, ENiCrMo-3 ERNiCr-3, ERNiCrMo-3
Inconel 625 ENiCrMo-3 ERNiCrMo-3
Inconel 718 -- ERNiFeCr-2
Inconel X750
Incoloy 800 ENiCrFe-2, ENiCrCoMo-1 ERNiCr-3, ERNiCrCoMo-1
Incoloy 800HT ENiCrFe-2 ERNiCr-3
Incoloy 825 -- ERNiFeCr-1

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Table IV. Approved Filler Metals for Welding Austenitic Stainless Steel
AWS M-8 321
Base 304 347
Metal: 308 304L 309 310 316 316L 348
301 308 308 308 308 308 308 308
308L 308L 308L 308L 308L 308L 308L
302 309 309 316 316
304 309L 309L 316L 316L
308 310
304L 308 308L 308 308 308 308L 308L
308L 308L 308L 308L 316L 347
309 309 316 309L
309L 309L 316L
310
309 309 309 309 309 309
309L 309L 309L 309L 309L
310 316 316 347
316L 316L
310 310 316 316 308
316L 316L 308L
310 310 310
316 316 316 308
316L 316L 308L
316
316L
316L 309L 309L
316L 316L
321 309L
321
347 347
348

5.2.1 Control and Storage

Welding electrodes shall be stored in a clean, dry, and controlled area that provides
protection from contamination, physical damage, and commingling of alloys. Any form
of electrodes or weld filler metal which is damaged, dirty, exhibits oxidation/corrosion or
has been contaminated with water, oil, grease or any form of hydrocarbons shall not be
used and shall be disposed of in accordance with an appropriate disposal procedure.
For JSC operations, welding electrodes and filler materials shall be controlled in
accordance with SOP-004.5. Outside vendors shall provide control and storage
according to the applicable material specification or manufacturer's recommendation,
whichever is more rigid.

6.0 PROCESS REQUIREMENTS

All weldments shall be fabricated according to the requirements of this process

specification and shall be performed using Welding Procedure Specifications (WPS)
that have been qualified in accordance with the requirements of Section 8.1 except for
that as detailed below.

Class D welds may be performed without the use of a specific qualified WPS within the
following restrictions:
a) all other provisions of this specification are met,

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b) the filler metal/electrodes used shall be within the same F-Number group of
fillers as those used for the other higher classed welds in the same weldment
or as approved by the responsible M&P Engineering organization where the
only welds in the weldment design are Class D,

c) the filler metal shall be compositionally compatible with the base metal(s),
and

d) welding shall be conducted within the recommendations of the specific filler

metal manufacturer.

6.1 WELDING PRECISION CLEANED HARDWARE (including tube preparation

for welding)

Whenever precision-cleaned hardware must be maintained clean during welding into an

assembly, the welding operation shall be performed in a dedicated Class 100,000
Clean Work Area. This may require temporary tents over the weld area and/or local
monitors located in the area of welding to ensure the Class 100,000 environment is
being met. Portable particle counters shall be located as close as possible to the work
area, so as to monitor local contaminants during tube preparation and welding. Tools
used in weld preparation and welding (such as cutter, weld head, files) shall be visibly
cleaned per JPG 5322.1 and maintained clean (e.g. bagged when not in use).

For hardware that cannot be subsequently precision-cleaned, a proven method for

protecting against system contamination during tube preparation and welding shall be
implemented. One such method is the use of a physical barrier, such as plugs. The
installation and removal of plugs shall be tracked by a reliable method and
independently verified. Prior to plug removal, the exposed internal surfaces of the tube
shall be cleaned using a swab wetted with an approved solvent, and positive
backpressure shall be maintained as the plug is removed.

Tube cutters shall use a sharp blade, changed frequently. Cutting shall be performed
with minimal cutter pressure to aid in preventing particle generation. Vacuum shall be
used during tube facing operations to remove particulate. Whenever possible, facing
operations shall be performed away from the weld assembly area, to reduce particulate
contamination of the welding work area. Tube facing shall be performed without the
use of cutting oils, other fluids, lubricants or coolants. Abrasives, including sandpaper
or abrasive pads, shall not be used inside tubes or when unprotected internal surfaces
are exposed. After each tube preparation, and prior to welding, a high-velocity gas
purge shall be performed. The purge gas velocity shall be the maximum attainable
using a 90-psig source. The purge gas used during facing and welding shall meet the
hydrocarbon and particulate requirements for the system under assembly. The purge
gas shall be supplied in accordance with Section 5.1.

6.2 PROCESS-SPECIFIC REQUIREMENTS

Applicable to all processes, weld joints that are specified for intermittent welding shall
have the ends of the parts, or departure from a straight weld line (e.g., square corner,
etc.), welded regardless of the interval of the weld.

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6.2.1 Gas Tungsten Arc Welding

Additional filler metal shall be used with the GTAW process unless it can be
demonstrated by weld qualification that weld cracking and other undesirable
metallurgical conditions will not exist in the finished weld made without filler metal
(autogenous weld). This method of welding shall be specified on an approved WPS.

6.2.2 Gas Metal Arc Welding

This process shall be recognized to include both solid and metal cored wires.

The GMAW short circuiting transfer mode shall not be used for welding of flight
hardware nor to join materials of greater than ¼‖ thickness unless specifically qualified
and documented in a WPS. Thickness limitations for this process mode shall be as
specified by AWS B2.1. The process can be used to deposit the root and additional
passes in the root region of butt joints exceeding that specifically qualified for, up to a
deposited weld metal thickness as allowed by the WPS. The GMAW short circuiting
transfer mode shall not be used to make Class A welds.

6.2.3 Flux Cored Arc Welding

This process shall be recognized to include both self shielding and dual shielding filler
metals.

6.2.4 Shielded Metal Arc Welding

Base metals known to be susceptible to hydrogen related problems shall utilize only low
hydrogen coated electrodes with this process.

6.2.5 Plasma Arc Welding

Additional filler metal shall be used with the PAW process unless it can be
demonstrated by weld qualification that weld cracking and other undesirable
metallurgical conditions will not exist in the finished weld made without filler metal
(autogenous weld). This method of welding shall be specified on an approved WPS.

6.3 PREHEATING

Preheat shall not exceed the temperature specified in the applicable WPS. In weld
joints between different base metal types and/or thicknesses, the higher of the preheat
requirements of the joint members shall apply.

6.3.1 Interpass Temperature

In weld joints between different base metal types and/or thicknesses, the higher of the
interpass temperature requirements of the joint members shall apply. Minimum
interpass temperature during welding shall be the same as the preheat temperature
specified in the WPS and shall be maintained by the application of concurrent heat as
necessary. The maximum interpass temperature for welding quenched & tempered
steels shall be at least 50o F below the nominal tempering temperature.

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6.4 POST-WELD HEAT TREATMENT (PWHT)

Postweld heat treatment, when required by the engineering drawing or WPS, shall be
performed after completion of all welding in accordance with NASA/JSC PRC-2001 or
PRC-2003, as applicable. Vibratory techniques shall not be used in place of thermal
treatments. All postweld inspections shall be applied immediately following all post
weld heat treatment activities with the exception of ASTM A514, A517, and A709
Grades 100 and 100W. Inspection of welds made on these alloys shall not occur less
than 48 hours after welding.

6.5 WELD REPAIRS AND WELDED REPAIRS TO BASE METAL

All weld rework and welded repairs shall be performed using the WPS used for the
original weld, a specific qualified WPS for that repair, or as approved by the responsible
M&P engineering organization. Rework and repairs shall meet all of the requirements
of the original drawing and any additional requirements documented in the WPS. Weld
rework and repair does not include the correction of dimensional or other deficiencies of
the groove/bevel preparation of weld joints by ―buttering‖ or build up provided the area
corrected by welding is fully consumed in the final weld. Also, the following
requirements shall apply in the weld repair activity:

a. Mechanical Repairs. Defects shall be repaired by grinding, chipping, sanding,

or machining the weld metal to the extent needed to completely remove the
defects. For groove welds, the reinforcement shall not be machined past
flush to the base metal. For fillet welds, the final machined weld profile shall
meet the applicable profile and size requirements. In both cases, the repair
shall be blended smoothly into the unrepaired weld metal. All repairs shall be
subjected to the same visual, surface and subsurface inspections as the
unrepaired weld. Repairs requiring liquid penetrant inspection shall be etched
in accordance with PRC-5010 prior to inspection.

b. Weld Repairs. Defects shall be repaired by grinding, chipping, sanding, thermal

gouging or machining the weld metal to the extent needed to completely remove
the defects. Except on low carbon steels, thermal gouging and cutting performed
with carbon based electrodes shall require the excavated cavity be finished by
grinding to sound metal. The final repair cavity shall be of a configuration suitable
for welding. Prior to welding, the excavation shall be subjected to the same
visual, surface and subsurface inspections as the unrepaired weld. Excavations
requiring liquid penetrant inspection shall be etched in accordance with PRC-
5010 prior to inspection. Weld repairs shall be documented by the use of a
weldment map or other record with sufficient detail to ensure identification of the
weldment, identification of repair location(s), and type of defect. Repair welds
shall be subjected to the same visual, surface and subsurface inspections as the
unrepaired weld.

No more than two weld attempts shall be made to successfully repair a

rejected flaw. If a second attempt is unsuccessful, a discrepancy report
requiring review and dispositioning by the responsible Material Review Board
(MRB) shall be generated. The level of documentation of repair welds shall,

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at a minimum, be consistent with that required for the original production

weld.

c. Straightening. Welds or adjacent base metal which have been deformed by

the welding operation may be straightened. All straightening operations shall
take place at temperatures not to exceed the determined critical temperature
for that alloy. All straightening operations shall be performed prior to any final
inspection.

d. Base Metal Repairs. Repairs to base metal anomalies shall be brought to the
attention of the NASA/JSC M&P organization for consideration of cause, prior
to repair activities.

7.0 PROCESS VERIFICATION

Process verification shall consist of the inspections described in sections 7.1 to 7.3. In
addition, the manufacturer shall assure that fabrication activities are carried out in a
manner that meets the requirements of this process specification.

7.1 REQUIRED INSPECTIONS

Unless otherwise specified, all welds in a structure shall be subjected to the required
inspections for the applicable weld class or classes. Unconsumed temporary or tack
welds shall be subjected to the level of inspection required by the highest weld class
specified in the design documentation.

7.1.1 Class A

Class A welds require visual, surface and subsurface inspections. Surface inspections
shall be accomplished using liquid penetrant or magnetic particle methods. Subsurface
inspections shall be accomplished using the radiographic method. In cases where the
weld configuration renders adequate radiographic inspection impractical, an alternate
inspection method shall be utilized as approved by the NASA/JSC M&P engineering
organization. When liquid penetrant or magnetic particle methods are selected and
approved as an alternate to radiographic inspection of multi-pass welds, inspections
shall be performed on every pass. When ultrasonic inspection is selected and approved
as an alternate to radiographic inspection, the ultrasonic inspection shall be performed
as specified in section 7.2.6.
7.1.2 Class B

Class B welds require visual and surface inspections. Surface inspections shall be
accomplished using the liquid penetrant or magnetic particle methods.

7.1.3 Class C

Class C welds only require visual inspection.

7.1.4 Class D

Class D welds only require inspection to verify the weld type, nominal size, length and
location and to verify that the welds exhibit good workmanship practices. Good
workmanship shall be defined as the presence of a uniform appearance and overall
clean weld zones absent of spatter, arc strikes, tool marks and other obvious
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discontinuities. Where a size is not specified, the nominal weld size shall be per best
shop practice and at the discretion of the manufacturing organization with the intent to
utilize single pass welds wherever possible so as to avoid over-welding. A CWI is not
required for this inspection. This level of inspection may serve as a means of ―in
process‖ or ―self verification‖ where design and/or manufacturing protocols permit.

7.2 INSPECTION METHODS AND ACCEPTANCE CRITERIA

7.2.1 General

Inspections shall be performed in accordance with a written procedure by personnel

certified in accordance with section 7.3.

7.2.2 Visual

Welds shall be visually inspected for conformance to the drawing requirements and
acceptance shall be in accordance with the applicable Class A, B or C acceptance
criteria in Appendix A.

7.2.3 Liquid Penetrant

a) Non-Flight Hardware: Liquid penetrant inspections shall be performed per

PRC-6506. Unless otherwise specified, a fluorescent (Type I) Sensitivity
Level 3 or 4 penetrant shall be used for Class A welds and a visible (Type II)
penetrant shall be used for Class B welds. Acceptance shall be in
accordance with the applicable Class A or B acceptance criteria in Appendix
A.

b) Flight Hardware: Liquid penetrant inspections shall be performed per PRC-

6506. Unless otherwise specified, a fluorescent (Type I) Sensitivity Level 3 or
4 penetrant shall be used. Acceptance shall be in accordance with the
applicable Class A or B acceptance criteria in Appendix A.

7.2.4 Magnetic Particle

a) Non-Flight Hardware: Magnetic particle inspections shall be performed per

PRC-6505. Unless otherwise specified, the wet fluorescent continuous
method shall be used for Class A welds and the dry continuous method may
be used for Class B welds. Acceptance shall be in accordance with the
applicable Class A or B acceptance criteria in Appendix A.

b) Flight Hardware: Magnetic particle inspections shall be performed per PRC-

6505. Unless otherwise specified, the wet fluorescent continuous method
shall be used. Acceptance shall be in accordance with the applicable Class A
or B acceptance criteria in Appendix A.

7.2.5 Radiographic

a) Non-Flight Hardware: Radiographic inspections shall be performed per PRC-

6503. Acceptance shall be in accordance with the applicable Class A
acceptance criteria in Appendix A. Gamma radiation sources shall not be
used unless approved by the NASA/JSC M&P engineering organization.

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Approval of gamma radiation sources shall be based on demonstration of

radiographic sensitivity equivalent to that obtainable with an X-ray source.

b) Flight Hardware: Radiographic inspections shall be performed per PRC-6503.

Acceptance shall be in accordance with the applicable Class A acceptance
criteria in Appendix A.

7.2.6 Ultrasonic

a) Non-Flight Hardware: Unless otherwise specified, ultrasonic inspections and

acceptance shall be performed per PRC-6510, Class A.

b) Flight Hardware: Ultrasonic inspections and acceptance shall be performed

per PRC-6510, Class A.

7.3 CERTIFICATION AND QUALIFICATION OF INSPECTION PERSONNEL

7.3.1 Visual Inspection

Personnel performing visual inspections of Class A, B and C welds shall be American

Welding Society (AWS) Certified Welding Inspectors (CWI). The CWI certification must
be current.

7.3.2 Nondestructive Inspection

Personnel performing acceptance inspections of flight hardware (Class I, II, IIIW and
GSE) shall be qualified and certified, at a minimum, to Level 2 in accordance with NAS
410. Personnel performing acceptance inspections requiring Special NDE shall also be
qualified and certified for Special NDE in accordance with NASA-STD-5009.

Personnel performing acceptance inspections of non-flight hardware (Class III, STE/D,

mockup, and facility hardware) shall be qualified and certified in accordance with either
NAS 410 or SNT-TC-1A. Personnel making accept/reject decisions shall, at a minimum,
be certified to Level 2. Level 3 personnel making accept/reject decisions shall have
successfully completed a hands-on practical examination equivalent to the examination
required for Level 2. Level 1 personnel may perform acceptance inspections under the
direct supervision of a Level 2 but shall not make accept/reject decisions.
Formal qualification and certification is not required for personnel performing
engineering evaluation inspections.

8.0 PROCESS DOCUMENTATION REQUIREMENTS

The WPS, PQR, and WPQ shall be prepared and retained as a permanent record and
made available upon request to the NASA/JSC M&P organization for review. One copy
of the WPS shall be maintained in the vicinity of the welding station and shall be readily
accessible by the welding, inspection, supervision, and engineering personnel.

8.1 WELDING PROCEDURE SPECIFICATION

A Welding Procedure Specification (WPS) is a qualified written working procedure used
in production that must be developed before beginning production for each unique weld

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type to be produced. Qualification support documentation in the form of a Procedure

Qualification Record (PQR) shall be qualified by appropriate testing and maintained on
file to show proof of process/procedure capability for using the WPS. The WPS shall
be traceable by means of serialized nomenclature and shall show traceability to the
applicable PQR(s). The WPS used for production welding shall meet the requirements
of AWS B2.1 and shall be certified by the responsible M&P organization at the
operating facility, prior to use in production. If a qualified WPS does not exist prior to
welding of production parts, one shall be qualified according to AWS B2.1 ―Standard
Test Weldments‖, at a minimum.

8.2 PROCEDURE QUALIFICATION RECORD

A Procedure Qualification Record (PQR) is documentation to support the WPS to show

proof of process/procedure capability. A PQR shall be unique and traceable, by means
of serialized nomenclature. The PQR shall be process-specific and specific to a unique
weld type. The PQR shall meet the requirements of AWS B2.1 and shall be certified by
the responsible M&P organization at the operating facility.

8.3 WELDER PERFORMANCE QUALIFICATION

A Welder Performance Qualification (WPQ) is documentation showing that a welder

has been tested in accordance with the governing specification and shown competent
to produce a sound weld for a specific welding process/base metal/filler metal/position
combination. NASA/JSC PRC-0008 is the governing document for personnel
performance qualifications required by this specification.

9.0 TRAINING AND CERTIFICATION OF PERSONNEL

9.1 TRAINING

At JSC, if welder training is considered necessary prior to qualification/requalification of

existing JSC welding personnel or for the initial qualification of new hires, it shall be
conducted in accordance with TI-0000-04. For an outside JSC vendor, welder training
(when necessary) should consist of practice using the facility welding equipment and a
specific WPS to demonstrate proficiency, under the supervision of a qualified/certified
welder. Specific development of an appropriate training program shall be the
responsibility of the vendor.

9.2 WELDER QUALIFICATION

Welding shall be performed by a welder qualified and certified in accordance with

NASA/JSC PRC-0008. Sufficiently detailed records shall be maintained to demonstrate
continuity of performance qualification on a semi-annual (6 month) basis.

10.0 DEVIATIONS AND WAIVERS

Any deviations or waivers regarding the use of this process specification shall be
requested in writing. This request shall be directed to the NASA/JSC M&P organization
with the appropriate justification and rationale. A written response will be provided upon
such a request.

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 PRC-0005 Rev. G

Appendix A

WELD ACCEPTANCE CRITERIA

A1.0 GENERAL
If any of the acceptance criteria given below conflict with the engineering drawing
requirements, then the stricter criteria shall apply. The symbol ‗T‘ shall equal the
nominal base metal thickness of the thinnest component in the welded connection. The
weld length shall be the distance from end to end of the weld deposit or to a sharp
change in weld direction where the angle of change in any direction is greater than 30°
with a radius of less than 1/2‖. Unless otherwise stated, the criteria in this Appendix
shall apply to all weld classes except Class D. Acceptance criteria for Class D welds
are detailed in Section 7.1 of this specification. Alternate and/or additional acceptance
criteria, when applicable, shall be specified in the design documentation.

Visual inspection of welds in all steels may begin immediately after the completed welds
have cooled to ambient temperature. Acceptance criteria for ASTM A 514, A 517 and A
709 Grade 100 and 100 W steels shall be based on visual inspection performed not
less than 48 hours after completion of the weld.
Table A1.0. Acceptance Criteria

ITEM DISCONTINUITY TYPE Class A Class B Class C

1.0 CRACKS IN THE WELD None allowed None allowed None allowed
OR BASE METAL
2.0 OVERLAP (COLDLAP) None allowed None allowed None allowed
3.0 INCOMPLETE FUSION None allowed None allowed None allowed
4.0 INCOMPLETE None allowed None allowed None allowed
(1)
PENETRATION
5.0 POROSITY – SURFACE(2)
5.1 Maximum Individual 0.25T or 0.030‖ whichever is 0.33T or 0.060‖ whichever is 0.50T or 0.090‖ whichever is
Size(3 & 4) less less less
5.2 Minimum Spacing 8x the size of the larger 4x the size of the larger 2x the size of the larger
adjacent pore adjacent pore adjacent pore
5.3 Maximum Accumulated 1T or 0.12‖ whichever is less 1.33T or 0.24‖ whichever is 2T or 0.36‖ whichever is less
Length in any 3‖ of less
Weld(5)
6.0 POROSITY –
SUBSURFACE(2)
6.1 Maximum Individual 0.33T or 0.060‖ whichever is 0.50T or 0.090‖ whichever is Not Applicable
Size(3 & 4) less less
6.2 Minimum Spacing 4x the size of the larger 2x the size of the larger Not Applicable
adjacent pore adjacent pore
6.3 Maximum Accumulated 1.33T or 0.24‖ whichever is 2T or 0.36‖ whichever is less Not Applicable
Length in any 3‖ of less
Weld(5)
7.0 INCLUSIONS(2)
7.1 Maximum Individual 0.33T or 0.060‖ whichever is 0.50T or 0.090‖ whichever is Not Applicable
Size(3 & 4) less less
7.2 Minimum Spacing 4x the size of the larger 2x the size of the larger Not Applicable
adjacent inclusion adjacent inclusion
7.3 Maximum Accumulated 1.33T or 0.24‖ whichever is 2T or 0.36‖ whichever is less Not Applicable
Length in any 3‖ of less
Weld(5)
8.0 UNDERCUT

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 PRC-0005 Rev. G

ITEM DISCONTINUITY TYPE Class A Class B Class C

8.1 Full Length of Weld, 0.002‖ 0.015T or 0.002‖, whichever is 0.025T or 0.002‖, whichever is
Maximum Depth greater greater
8.2 Maximum Individual 0.07T or 0.03‖, whichever is 0.10T or 0.05‖, whichever is 0.20T or 0.07‖, whichever is
Defect less less less
8.3 Maximum Accumulated 0.20‖ 0.60‖ 1.00‖
Length in any 3‖ of
Weld(5)
9.0 FACE OR ROOT
UNDERFILL – GROOVE
WELDS
9.1 Full Length of Weld, 0.005‖ 0.015T or 0.005‖, whichever is 0.025T or 0.005‖, whichever is
Maximum Depth greater greater
9.2 Maximum Individual 0.07T or 0.03‖, whichever is 0.07T or 0.03‖, whichever is 0.07T or 0.03‖, whichever is
Defect less less less
9.3 Maximum Accumulated 0.20‖ 0.60‖ 1.00‖
Length in any 3‖ of
Weld(5)
10.0 CRATERS
10.1 Maximum Depth 0.20T or 0.03‖, whichever is 0.20T or 0.05‖, whichever is 0.20T or 0.05‖, whichever is
less less less
10.2 Maximum Length 1T 1T 2T
11.0 ARC STRIKES AND Unacceptable Unacceptable Unacceptable
GOUGE MARKS
12.0 WELD REINFORCEMENT
-MANUAL WELDS
12.1 Material < 0.125‖ 1T maximum No stated requirement No stated requirement
12.2 Material 0.125‖ to 0.510‖ 1T or 0.100‖ maximum, No stated requirement No stated requirement
whichever is greater
12.3 Material > 0.510‖ 0.170‖ maximum No stated requirement No stated requirement
13.0 PEAKING 3 degrees max 5 degrees max No stated requirement
14.0 MISMATCH BETWEEN T/10 or 1/8‖, whichever is less T/5 or 3/16‖, whichever is less No stated requirement
MEMBERS AFTER
WELDING
15.0 FILLET WELDS
15.1 Weld Profiles See Fig. A2.0 See Fig. A2.0 See Fig. A2.0
15.2 Weld Size (Size Stated As shown by welding symbol As shown by welding symbol As shown by welding symbol
on Drawing)
15.3 Minimum Weld Size 1.5T 1.5T 1.5T
(Size Not Stated on
Drawing) – Single Side
Fillet
15.4 Minimum Weld Size 1.0T 1.0T 1.0T
(Size Not Stated on
Drawing) – Double Side
Fillet
15.5 Maximum Weld Size –
Size Stated on Drawing
15.6 Material ≤ 0.090‖ 2.0x 2.0x 2.0x
15.7 Material 0.091‖ – 1.5x 1.5x 1.5x
0.156‖
15.8 Material 0.157‖ – 1.25x 1.25x 1.25x
0.750‖
15.9 Material 0.751‖ 1.1x 1.1x 1.1x
16.0 DISCOLORATION
16.1 Stainless Steel, Nickel
and Cobalt Alloys
16.2 All oxidation colors Acceptable Acceptable Acceptable
except for black
16.3 Black Reject Reject Reject
16.4 STEEL
16.5 All oxidation colors Acceptable Acceptable Acceptable
except for black

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ITEM DISCONTINUITY TYPE Class A Class B Class C

16.6 Black Reject Reject Reject
17.0 LOOSE OXIDATION AND Reject Reject Reject
SCALE
(1) Applicable to groove welds only.
(2) For all discontinuities approaching a free edge (See Figure A1.0), the closest edge of the discontinuity shall have clearance from the free edge
3X the largest of its dimensions or 2X the nominal weld throat, whichever is greater.
(3) Adjacent rounded discontinuities separated by 1X the length of the longer discontinuity shall be considered a single discontinuity.
(4) Adjacent elongated discontinuities separated by 3X the diameter of the larger discontinuity, shall be considered a single discontinuity.
(5) For weld lengths less than 3‖, the total sum of indications shall be an equivalent proportion of the weld length.

C = Clearance spacing between closest edge of discontinuity and free edge

FIGURE A1.0 – DISCONTINUITY APPROACHING A FREE EDGE

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 PRC-0005 Rev. G

(1) Desirable Fillet Welds (2) Acceptable Fillet Welds

Note: Convexity of a weld or individual surface bead with dimension Width shall not exceed the value of the following table.

Width of Weld Face or Individual Surface Bead Maximum Convexity Allowed

Width ≤ 5/16” 1/16”
Width > 5/16” to Width < 1.00” 1/8”
Width ≥ 1.00” 3/16”

Insufficient Excessive Excessive Overlap Insufficient Leg Incomplete

Throat Convexity Undercut Fusion

(3) Unacceptable Fillet Weld Profiles

(4) Acceptable Groove Weld Profiles in Butt Welds Note: Reinforcement shall not exceed 1/8”.

Excessive Convexity Insufficient Throat Excessive Undercut Overlap

(5) Unacceptable Groove Weld Profiles in Butt Joints

Figure A2.0 – ACCEPTABLE AND UNACCEPTABLE WELD PROFILES

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