MIL-R-45774 Radiographic Inspection, Soundness Requirements For Fusion Welds In Aluminum And Magnesium Missile ComponentsThis specification covers the methods for defining soundness and freedom from defects of manual or automatic shielded inert gas arc welds in aluminum and magnesium as determined by radiographic inspection.

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MIL-R-45774A (MI)

records shall be made available for examination by the procuring activity for the period specified in the contract.

4.3 Sampling. Unless otherwise specified by the procuring activity, longitudinal and circumferential butt welds or fillet welds in missile components shall be radiographed 100 percent.

4.4 Test criteria.

4.4.1 Rule 1. Imperfect fusion or incomplete penetration shall be rejectable under standards III and IV (see table III) when the greatest summation end-to-end (see figure 2) of all defect lines is greater than a length of T/3 in any weld length of 6T.

4.4.2 Rule 2. Imperfect fusion or incomplete penetration shall be rejectable under standard V welds (see table III) when the greatest summation end-to-end (see figure 2) of all defect lines is greater than a length of 3T/4 in any weld length of 6T.

4.4.3 Rule 3. Linear porosity shall be classified as a condition in which there are images of two or more connected voids or a series of inline voids distributed in a line parallel to the longitudinal axis (in some cases, transverse to the longitudinal axis). The acceptable maximum average diameter and closest distance of approach of the individual images in linear porosity shall be as indicated in table III. Cases where fine linear porosity is aligned in a series with a length not greater than 0.25 inch and in which greater than 50 percent (%) of the length if occupied by voids, regardless of the size of the individual voids, shall be unacceptable.

4.4.3.1 Scattered porosity. Scattered porosity shall be cause for rejection if it is greater than the amount indicated on the reference radiograph for the specific recommended standard (see table II). Isolated voids greater than 0.05T of the parent metal for standards II, III, IV and V shall be cause for rejection.

4.4.4 Rule 4. All longitudinal cracks shall be unacceptable. Greatest occurrence of these cracks are at weld junctions. Transverse cracks are unacceptable, except to the extent indicated in table I, where the crack does not extend completely across the weld. Crater cracks shall be unacceptable for standards I, II, and III (see table III), and classified as borderline for standards IV and V (see table III), depending upon the severity of the crack and the requirements of the weldments.