Aerospace Welding Certification

Lesson 1 • Regulatory and Quality Framework Basics

Introduces aerospace welding quality management systems, traceability requirements, and documentation standards. Students understand how compliance underpins every weld produced.

Lesson 2 • Aerospace Materials Identification

Covers identification of aluminium alloys, titanium, stainless steel, and nickel superalloys used in aerospace. Material selection directly impacts process and filler choices covered later.

Lesson 3 • Welding Hazards and Personal Protection

Identifies physical, chemical, and radiological hazards specific to aerospace welding environments. Proper PPE selection and usage are demonstrated and assessed.

Lesson 4 • Shop Safety and Housekeeping Standards

Establishes safe workspace organisation, equipment inspection routines, and emergency response procedures. Reinforces a zero-tolerance safety culture foundational to aerospace quality.

Lesson 1 • Process Qualification and Procedure Specs

Explains welding procedure specification development, essential variables, and process qualification testing. Students understand how approved procedures govern every production weld.

Lesson 2 • Gas Metal Arc Welding in Aerospace

Examines GMAW transfer modes, wire feed systems, and shielding gas blends suited to aerospace structural components. Limitations versus GTAW are critically analysed.

Lesson 3 • Plasma Arc Welding Fundamentals

Introduces PAW torch design, plasma gas flow, and keyhole versus melt-in modes for thin aerospace skins. Students distinguish PAW advantages for precision and penetration control.

Lesson 4 • Resistance and Solid-State Welding Methods

Covers spot, seam, and friction stir welding as used in aerospace sheet metal and panel assemblies. Process selection criteria based on joint geometry and material are established.

Lesson 1 • Fit-Up, Tacking, and Distortion Control

Establishes fit-up measurement methods, tack weld placement strategies, and pre-weld fixturing to minimise distortion. Distortion control is critical for aerospace dimensional tolerances.

Lesson 2 • Groove Weld Geometry and Preparation

Covers groove angle, root opening, root face, and land dimensions for full and partial penetration welds. Correct geometry ensures fusion and meets radiographic acceptance criteria.

Lesson 3 • Joint Types and Configuration Selection

Analyses butt, T, lap, corner, and edge joints relative to load paths and access constraints in aerospace structures. Configuration choice directly affects weld quality and inspection access.

Lesson 4 • Engineering Drawing Interpretation

Teaches weld symbols, drawing views, and tolerance notation as used on aerospace fabrication drawings. Accurate drawing reading prevents costly joint preparation errors.

Lesson 1 • Welding Aluminium Alloys with GTAW

Focuses on AC GTAW of 2xxx, 6xxx, and 7xxx aluminium alloys including oxide removal, filler selection, and heat input management. Aluminium's thermal conductivity demands specific technique adjustments.

Lesson 2 • Welding Stainless and Nickel Alloys

Covers sensitisation prevention, interpass temperature control, and filler compatibility for austenitic stainless and nickel superalloys. These alloys are common in engine and exhaust components.

Lesson 3 • Multi-Position GTAW Practise

Develops flat, horizontal, vertical, and overhead GTAW technique through structured repetition on coupons. Position proficiency is required for welder performance qualification testing.

Lesson 4 • Welding Titanium with GTAW

Addresses contamination prevention, trailing shield design, and inert gas coverage for titanium GTAW. Colour-based contamination assessment is practised as a real-time quality check.

Lesson 1 • Incomplete Fusion and Penetration Defects

Examines lack of fusion, incomplete joint penetration, and cold lap causes tied to technique and parameter errors. These planar defects are the most structurally critical in aerospace.

Lesson 2 • Root Cause Analysis and Corrective Action

Applies structured root cause analysis tools to weld defect scenarios and generates corrective action documentation. Systematic problem-solving prevents recurrence in production environments.

Lesson 3 • Porosity Causes and Prevention

Analyses gas, surface, and subsurface porosity mechanisms in aerospace alloys and their relationship to shielding, cleanliness, and moisture. Prevention strategies are tied to specific alloy behaviours.

Lesson 4 • Cracking Mechanisms and Mitigation

Covers hot cracking, cold cracking, and stress corrosion cracking relevant to aerospace weld joints. Mitigation through preheat, filler selection, and post-weld treatment is detailed.

Lesson 1 • Liquid Penetrant Inspection

Covers penetrant families, dwell times, developer application, and indication interpretation for surface-breaking discontinuities. LPI is widely used on non-ferromagnetic aerospace alloys.

Lesson 2 • Visual Inspection Techniques and Tools

Establishes systematic visual inspection methodology, lighting requirements, and measurement tool usage for weld surface evaluation. Visual inspection is the first and most frequent quality gate.

Lesson 3 • Radiographic Testing of Welds

Explains X-ray and gamma-ray source selection, film placement, density requirements, and image interpretation for internal discontinuities. RT is the primary volumetric method for aerospace welds.

Lesson 4 • Ultrasonic Testing Fundamentals

Introduces pulse-echo and phased array UT for weld inspection, including calibration, scanning patterns, and flaw sizing. UT complements RT for thick-section aerospace components.

Lesson 1 • Post-Repair Inspection and Verification

Applies the full NDT sequence to repaired areas and compares results against original acceptance criteria. Re-inspection scope must equal or exceed the original inspection requirement.

Lesson 2 • Repair Documentation and Traceability

Generates complete repair records linking defect origin, removal, re-weld parameters, and re-inspection results. Traceability chains are audited during customer and regulatory reviews.

Lesson 3 • Repair Authorisation and Planning

Establishes the engineering disposition and repair order process before any material removal begins. Unauthorised repairs are a major nonconformance in aerospace quality systems.

Lesson 4 • Re-welding and Parameter Adjustment

Addresses parameter modifications required when re-welding previously heat-affected zones and thin-section repairs. Welding heat input management prevents additional distortion and metallurgical damage.

Lesson 1 • Written Examination Preparation

Reviews knowledge domains tested in certification written exams including processes, metallurgy, and inspection. Structured review and practise testing build exam confidence and retention.

Lesson 2 • Certification Maintenance and Records

Establishes ongoing qualification maintenance through continuity records, renewal testing, and employer documentation systems. Lapsed certifications create production stoppages and audit findings.

Lesson 3 • Performance Qualification Test Execution

Guides students through coupon preparation, welding under observed conditions, and submission for destructive and NDT evaluation. Test execution mirrors production conditions to ensure validity.

Lesson 4 • Destructive Testing Interpretation

Covers bend test, tensile test, and macro-etch evaluation of qualification coupons against acceptance criteria. Students interpret results and identify pass/fail determinations independently.