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MIL-STD-1895A
20 October 1986
SUPERSEDING
MIL-STD-1895(AT)
27 June 1984

MILITARY STANDARD

RADIOGRAPHIC REFERENCE STANDARDS AND RADIOGRAPHIC PROCEDURES

FOR PARTIAL-PENETRATION ALUMINUM WELDS

AMSC N/A AREA NDTI

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
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MIL-STD-1895A

DEPARTMENT OF DEFENSE
Washington, DC 20301

Radiographic Reference Standards and Radiographic Procedures

for Partial-Penetration Aluminum Welds

MIL-STD-1895A

1. This Military Standard is approved for use by all Departments and Agencies
of the Department of Defense.

2. Beneficial comments (recommendations, additions, deletions) and any

pertinent data which may be of use in improving this document should be addressed
to : US Army Tank-Automotive Command, ATTN: AMSTA-GDS, Warren, MI 48397-5000, by
using the self-addressed Standardization Document Improvement Proposal (DD Form
1426) appearing at the end of this document, or by letter.

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MIL-STD-1895A

FOREWORD

This document contains selected radiographs illustrating various types and

degrees of discontinuities occurring in partial-penetration aluminum welds. It
also contains instructional data concerning radiographic inspection of this type of
weldment.

It is intended that this document provide the following:

a. A weld discontinuity severity range for designers to select

standards for acceptance inspection.
b. Reference standards for acceptance personnel to evaluate the
quality of production weldments.
c. Guide lines for radiographers to effectively accomplish
radiographic examination of partial penetration welds.

The reference standards included in this document were prepared by the

U.S. Army Tank-Automotive Command under project authorization of the U.S.
Army Materials Technology Laboratory.

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MIL-STD-1895A

CONTENTS

Page(s)

Paragraph 1. SCOPE . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 1
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Classification . . . . . . . . . . . . . . . . . . . . . 1

2. REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . . . . 2
2.1 Government documents . . . . . . . . . . . . . . . . . 2
2.1.1 Specifications, standards and handbooks. . . . . . . . . 2
2.2 Other publications . . . . . . . . . . . . . . . . . . 2
2.3 Order of precedence . . . . . . . . . . . . . . . . . . 3

3. DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Partial penetration joint design . . . . . . . . . . 4
3.2 Radiation angle . . . . . . . . . . . . . . . . . . . . 4
3.3 Radiograph. . . . ... . . . . . . . . . . . . . . . . . 4
3.3.1 Radiographic inspection . . . . . . . . . . . . . . . 4
3.3.2 Discontinuity . . . . . . . . . . . . . . . . . . . . . . 4
3.3.2.1 Unfused area . . . . . . . . . . . . . . . . . . . . . . 4
3.3.3 Flaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Penetrameter/Image quality indicator . . . . . . . 4
3.5 Metallographic cross sections . . . . . . . . . . . . 4
3.6 Welding terms and definitions . . . . . . . . . . . . . . . 4
3.6.1 Gas metal arc welding (GMAW) . . . . . . . . . . . . . . 4
3.6.2 Gas tungsten arc welding (GTAW) . . . . . . . . . . . . . . . 5

4. GENERAL REQUIREMENTS .. . . . . . . . . . . . . . . . . . . . . 6
4.1 Radiographic location . . . . . . . . . . . . . . . . 6
4.1.1 Radiographic frequency . . . . . . . . . . . . . . . . 6
4.1.2 Radiation angle . . . . . . . . . . . . . . . . . . . . . 6
4*1.3 Penetrameter requirements . . . . . . . . . . . . . . 6
4,2 Acceptance standards . . . . . . . . . . . . . . . . . 6
4.3 Discontinuity types . . . . . . . . . . . . . . . . . . 6
4.4 Discontinuity grading . . . . . . . . . . . . . . . . 7

5. DETAILED REQUIREMENTS . . . . . . . . . . .. . . . . . . . . . . 8
5.1 Application of reference standards . . . . . . . . 8
50101 Determination of acceptability . . . . . . . . . . . 8
5.1.2 Quality level of radiographic sensitivity . . . . . . . . . . . . . 8
5.1.3 Rules 1 and 2. . . . .. . . . . . . . . . . . . . . . 8
5.1.4 Single discontinuity . . . . . . . . . . . . . . . . . . . . . . . 9
5.1.5 Multiple discontinuities. . . . . . . . . . . . . . . . . . . . . . 9
5.1.6 False indications . . . . . . . . . . . . . . . . . . . 9
5.2 Inspection records . . . . . . . . . . . . . . . . . . . 9

60 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Subject term (key word) listing . . . . . . . . . . . . . . 10

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CONTENTS - Continued.

Page(s)

FIGURES

Figure(s) 1-3 Recommended radiation angle and film location

for typical partial-penetration joints . . . . . . . 11-13
4 Correct and incorrect radiographic procedure
for joint design (c) . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-6 Reference standards for fine scattered
porosity in aluminum welds . . . . . . . . . . . . . . . . . . . 15-16
7-8 Reference standards for coarse scattered
porosity in aluminum welds . . . . . . . . . . . . . . . . . . . 17-18
9-10 Reference standards for linear porosity in
aluminum welds . . . . . . . . . . . . . . . . . . . . . . . . 19-20
11 Reference ” standards for clustered porosity in
aluminum welds . . . . . . . . . . . . . . . . . . . . . . . . 21
12-13 Reference standards for gas cavities in
aluminum welds . . . . . . . . . . . . . . . . . . . . . . . . 22-23
14 Examples of incomplete penetration
correlated with weld cross-sections in
aluminum welds . . . . . . . . . . . . . . . . . . . . . . . 24
15 Examples of lack of fusion correlated with
weld cross–sections in aluminum welds . . . . . . . . . . . . 25

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MIL-STD-1895A

1. SCOPE

1.1 Scope. This standard provides standard reference radiographs and

recommended radiographic inspection procedures for partial penetration
weldments in aluminum plate, casting, or forging, 1/2 to 2 inches (12.70 to
50.80 millimeter) thick.

1.2 Classification.
— The reference radiographs comprised in this
standard are intended primarily for use on welds made with the gas in metal are
welding and gas tungsten arc welding processes and may be manual or machine
welded.

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MIL-STD-1895A

2. REFERENCED DOCUMENTS

2.1 Government documents.

2.1.1 Specifications, standards, and handbooks. Unless otherwise

specified, the following specifications, standards, and handbooks of the
issue listed in that issue of the Department of Defense Index of
Specifications and Standards (DoDISS) specified in the solicitation form a
part of this standard to the extent specified herein.

STANDARDS
MILITARY

MIL-STD-410 - Nondestructive Testing Personnel

Qualification and Certification.
MIL-STD-453 - Inspection, Radiographic.
MIL-STD-1946 - Welding of Aluminum Armor.

(Note: Negatives of radiographs illustrated in this standard can be

purchased through AMSTA-GDS. Requests should be addressed to US
Tank-Automotive Command, ATTN: AMSTA-GDS, Warren, MI 48397-5000.)

(Copies of specifications, standards, handbooks, drawings, and

publications required by manufacturers in connection with specific
acquisition functions should be obtained from the contracting activity or as
directed by the contracting officer.)

2.2 Other
— publications. The following documents form a part of this
standard to the extent specified herein. The issues of the documents which
are indicated as DoD adopted shall be the issue listed in the issue of the
DoDISS specified in the solicitation. The issues of documents which have not
been adopted shall be those in effect on the date of the cited DoDISS.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM E142 - Standard Method for Controlling Quality of

Radiographic Testing.
ASTM E340 - Standard Method for Macroetching Metals and
Alloys.

(Application for copies should be addressed to American Society for

Testing and Materials, 1916 Race Street, Philadelphia, PA, 19103.)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)/AMERICAN WELDING SOCIETY

(AWS)

ANSI/AWS A3.O - Standard Welding Terms and Definitions

Including Terms for Brazing, Soldering,
Thermal Spraying and Thermal Cutting.

(Copies of the above publications may be obtained from the American

Welding Society, Inc., 550 N. W. LeJeune Road, P.O. B OX 35104O, Miami,
Florida 33135.)

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MIL-STD-1895A

(Nongovernment standards are generally available for reference from

libraries. They are also distributed among nongovernment standards bodies
and using Federal agencies.)

2.3 Order of precedence. In the event of a conflict between the text of

this standard and the references cited herein, the text of this standard
shall take precedence.

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3. DEFINITIONS

3.1 Partial penetration joint design. The term “partial-penetration

joint” as used in this standard is defined as a weld joint containing an
intentionally unfused area in the central portion of the joint. Examples of
typical partial-penetration joint designs are shown in figures 1, 2, and 3.

3.2 Radiation angle. This term refers to the angle from any given plane
to the central beam of radiation as shown in figure 4.

3.3 Radiograph. A visible image on an X-ray sensitive recording medium

produced by the penetration of radiation through the materials being tested
as defined in MIL-STD-453.

3.3.1 Radiographic inspection. The use of X-rays or gamma rays to

detect discontinuties in material by presenting their images on a recording
medium suitable for interpretation by qualified personnel.

3.3.2 Discontinuity. As defined in ANSI/AWS A3.0, a discontinuity is an

interruption of the typical structure of a weldment, such as a lack of
homogeneity in the mechanical, metallurgical or physical characteristics of
the material or weldment. A discontinuity is not necessarily a defect-.

3.3.2.1 Unfused area. In partial penetration weldments the

intentionally unfused area does not constitute a discontinuity, flaw or
defect (see 3.1).

3.3.3 Flaw. As defined in ANSI/AWS A3.0, a flaw is a near synonym for

discontinuity, but with an undesirable connotation.

3.4 Penetrameter/Image Quality Indicator. A strip of metal the same

composition as that of the metal being tested, representing a percentage of
object thickness and provided with a combination of steps, holes, and/or
slots. Its image on a radiograph is used to determine the radiographic
quality level. It is not intended for use in judging the size nor for
establishing acceptance limits of discontinuities. Examples of penetrameters
are shown in figures 5, 7, 9, 11 and 12.

3.5 Metallographic cross sections. Cross sections through the welds as

shown in figures 4 through 15 which are cut perpendicular to the direction of
welding, polished and etched as specified in ASTM E-340. These samples show
internal discontinuity, depth of weld penetration, weld size, and other
characteristics of the weldment.

3.6 Welding terms and definitions. Welding symbols, terms and

definitions shall be as specified in ANSI/AWS A3.O.

3.6.1 Gas metal arc weldin g (GMAW). An arc welding process that
produces coalescence of metals by heating them with an arc between a
continous filler metal electrode and the workplaces. Shielding is obtained
entirely from an externally supplied gas.

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3.6.2 Gas tungsten arc weldin g (GTAW). An arc welding process that
produces coalescence of metals by heating them with an arc between a tungsten
electrode (nonconsumable) and the workplaces. Shielding is obtained from a
gas. Pressure may or may not be used, and filler metal may or may not be
used.

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MIL-STD-1895A

4. GENERAL REQUIREMENTS

4.1 Radiographic location. Weldments shall be radiographically

inspected in the location specified on the applicable radiographic position
chart drawing, component drawing, specification, or contract requirement.
Radiographic inspection shall meet the requirements of MIL-STD-410 and
MIL-STD-453.

4.1.1 Radiographic frequency. Establishment of radiographic frequency

of spot checking of weldments shall be accomplished in accordance with
MIL-STD-453 and MIL-STD-1946. A quality assurance plan approved by the
procuring activity shall be used.

4.1.2 Radiation angle. Radiographic inspection of partial-penetration

welds requires special consideration of joint design when selecting the
radiation angle. The angle employed shall insure adequate coverage of the
weld with minimum interference from the normally unfused area. Generally
this can be achieved by directing the X-ray beam such that any possible
incomplete penetration at both roots would be separated on the film by at
least 1/8 inch (3.18 millimeter). Figure 4 illustrates the radiographic
results of a correct and incorrect radiation angle. If a radiographic
position chart is not available the recommended procedures shown on figures
1, 2, and 3 shall be used as a guide.

4.1.3 Penetrameter requirements. Each penetrameter shall be produced

with three holes, one of which shall be of a diameter equal to twice the
penetrameter thickness (2T). Penetrameters shall conform to the requirements
of ASTM E142 and MIL-STD-453.

4.2 Acceptance standards. Designation of acceptance standards for each

type of discontinuity illustrated in the reference standards shall be made by
the procurement or design agency and shall be indicated on the applicable
radiographic position chart, drawing, or contract requirement.

4.3 Discontinuity types. With the exception of cracks, the common

discontinuities experienced in partial-penetration aluminum weldments are
shown in the reference standards forming part of this document. These
discontinuities are described below and shown in figures 5 through 13. All
cracks shall be rejected; any deviation from this procedure will require
approval from the Government procuring activity.

a. Scattered porosity (fine and coarse). This discontinuity

consists of scattered voids formed by gases failing to escape
during weld metal solidification. On the radiograph these
discontinuities are dark round or elongated spots of varying
size and density. The average size of fine porosity is
1/32 inch (0.79 millimeter) in diameter and that of coarse
porosity is 1/16 inch (1.59 millimeter) in diameter.

b. Clustered porosity. Clustered porosity appears the same as

scattered porosity except that the pores are concentrated in
one area, generally at the start of a bead or an interrupted
arc.

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MIL-STD-1895A

c. Linear porosity. The type most common in partial-penetration

welds results from expanding gases generated in the normally
unfused area. The cavities are linearly distributed at the
root of the weld deposit and generally range from 1/32 inch
(0.79 millimeter) in diameter to 1/16 inch (1.59 millimeter)
in diameter.

d. Gas cavities. This discontinuity generally results from

inadequate shielding gas or severe contamination of the gas.
It appears the same as scattered porosity except the average
cavity size is approximately 1/8 inch (3.18 millimeter) in
diameter.

e. Incomplete (inadequate) penetration. In partial-penetration

welds this discontinuity consists of a linear root void in
excess of the unfused area normally present in this type of
joint. It appears on the radiograph as a straight dark line
at either root or at both roots. When present at both roots
the two images should be separated if properly radiographer.

f. Lack of fusion. Lack of fusion is failure of the weld metal

to fuse completely with the base metal or with the preceding
bead. Lack of fusion between the weld metal and base metal is
most common in aluminum welds and is generally associated with
incomplete penetration near the root of the weld. Examples of
this are illustrated in figures 14 and 15. This discontinuity
is very difficult to detect radiographically due to its
hair-line condition and interference from the incomplete
penetration void.

4.4 Discontinuity grading. Discontinuity severity grading of the

refecence standards was selected to extend from standard 1, which represents
a high-quality weld, to that of standard 5, which is indicative of poor
workmanship and is usually rejected in commercial practice.

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MIL-STD-1895A

5. DETAILED REQUIREMENTS

5.1 Application of reference standards.

5.1.1 Determination of acceptability. Acceptability of production welds

shall be determined by directly comparing the production radiograph with the
designated reference standard for each type of discontinuity. In general the
extent of discontinuity exhibited in the designated standard will be
Permitted
. throughout the length of any particular weld joint provided that
the discontinuity content in any weld length equal to that of the reference
standard does not exceed that shown in the standard. Exceptions to this are
required for incomplete penetration and lack of fusion since acceptability of
these discontinuities is based on material thickness. The examples shown in
figures 14 and 15 are for illustration purposes only; the evaluation is
described in 5.1.2.

5.1.2 Quality level of radiographic sensitivity. Figures 5, 7, 9, 11

and 12 illustrate the radiographic image quality level of 2-lT. MIL-STD-453
defines the formula as follows:

Quality level inspection 1

Penetrameter designation 2-lT

Maximum penetrameter thickness 2%

expressed as a percentage of
material thickness, T.

Minimum penetrameter hole 1T

diameter expressed as a multiple
of thickness of penetrameter.

Equivalent penetrameter 1.4%

sensitivity express as a
percentage of the specimen
thickness in which a 2T hole
would be clearly visible under
the same radiographic conditions.

5.1.3 Rules 1 and 2. Incomplete penetration and lack of fusion shall be

judged by image width–and length. Unless otherwise specified by the
Government procuring activity, the following rules shall apply:

Rule 1. The average image width of any incomplete

penetration line shall not exceed l/16 inch.

Rule 2. The greatest accumulated length of all incomplete

penetration lines in any weld length of 8T, where T
equals the average plate thickness, shall not exceed
the following:

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MIL-STD–1895A

IT for standard 1
2T for standard 2
4T for standard 3
6T for standard 4
8T for standard 5

5.1.4 Single discontinuity. When the production radiograph shows but

one type of discontinuity which is equal to or less severe than the
designated acceptance standard specified for that type of discontinuity, the
weld shall be considered radiographically acceptable. If the radiograph
shows a discontinuity of greater severity than specified, then the weld shall
be rejected, unless repair is permitted.

5.1.5 Multiple discontinuities.

a. When the production radiograph shows two or more types of

discontinuities to an extent equal to the designated
acceptance standard for each type of discontinuity, then the
weld shall be rejected, unless repair is permitted.

b. When the production radiograph shows one predominant type of

discontinuity to be equal to the designated acceptance
standard and all other types to be less severe than the
designated standard, then the weld shall be considered
radiographically acceptable.

5.1.6 False indications. At times, radiographic films may indicate weld

discontinuities when actually the film is defective. If doubt exists as to
whether the discontinuity is in the weld or is a film imperfection, then the
weld shall be radiographed again.

5.2 Inspection records. Radiographic reports and films shall be made

available to the procuring activity in accordance with MIL-STD-453.

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MIL-STD-1895A

6. NOTES

6.1 Intended use. This standard provides radiographic reference

standards and procedures for partial penetration arc welding of aluminum.

6.2 Subject term (key word) listinq.

Aluminum Welding
Fusion Welding
Inspection
Partial Penetration Welds
Radiation Angles
Radiographic
Reference Standards

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MIL–STD-1895A

FIGURE 1. Recommended radiation angle and film location

for ty pical partial- penetration joints.

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FIGURE 2. Recommended radiation angle and film location

for typ ical partial-p enetration joints.

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FIGURE 3. Recommended radiation angle and film location

for typical partial-penetration joints.

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Figure 4:
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MIL-STD–1895A

STD. 1 (APPROX. 6 PORES PER, SQ. IN)

STD. 2 (APPROX. 12 PORES PER SQ. IN)

FIGURE 5: Reference standards for fine

scattered porosity in aluminum welds.

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MIL-STD-1895A

STD. 3 APPROX. 25 PORES/SQ. IN.

STD. 4 APPROX. 50 PORES/SQ. IN.

STD. 5 APPROX. 100 PORES/SQ. IN.

FIGURE 6: Reference standards for fine

scattered porosity in aluminum welds.

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MIL–STD-1895A

2-1T RADIOGRAPHIC SENSITIVITY

CROSS SECTION OF COARSE

SCATTERED POROSITY. ALL
PLATES ARE JOINT A, RADIO-
GRAPHED AS ILLUSTRATED.

STD. 1 (APPROX. 2 PORES PER SQ. IN.

STD. 2 (APPROX. 4 PORES PER. SQ. IN.)

REFERENCE STANDARDS FOR COARSE

SCATTERED POROSITY - ALUMINUM WELDS
FIGURE 7: Reference standards for coarse
scattered porosity in aluminum welds.

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STD. 3 (APPROX. 8 PORES PER. SQ. IN.)

STD. 4 (APPROX. 16 PORES PER. SQ. IN.)

STD. 5 (APPROX. 32 PORES PER. SQ. IN.)

FIGURE 8: Reference standards, for coarse
scattered porosity in aluminum welds.

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MIL–STD–1895A

2-1T RADIOGRAPHIC SENSITIVITY

CROSS SECTION OF LINEAR

POROSITY. ALL PLATES ARE
JOINT A, RADIOGRAPH D AS
ILLUSTRATED.

STD. 1

STD. 2

FIGURE 9: Reference standards for linear

porosity in aluminum welds.

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STD. 3

STD. 4

STD. 5

FIGURE 10: Reference standards for linear

porosity in aluminum welds.

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2-1T RADIOGRAPHIC SENSITIVITY

CROSS SECTION VIEW

STD. 1

STD. 2

STD. 3

FIGURE 11: Reference standards for clustered

porosity in aluminum welds.

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MlL–STD--l895A

2-1T RADIOGRAPHIC SENSITIVITY

CROSS SECTION OF A
LARGE GAS CAVITY. MOST
PLATES ARE JOINT A, RADIO-
GRAPHED AS ILLUSTRATED.

STD. 1

STD. 2

FIGURE 12: Reference standards for gas

cavities in aluminum welds.

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STD. 3

STD. 4

STD. 5

FIGURE 13: Reference standards for gas

cavities in aluminum welds.

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Figure 14:
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Figure 15:
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Custodian: Preparing activity:

Army - AT Army - AT
Air Force - 20
(Project NDTI-0123)

Review Activities:
Army - AR, AV

*U.S. GOVERNMENT PRINTING 0FFICE: 1986/1224/70013 26

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