The Engineering Society

For Advancing Mobility

Land Sea Air and Space,
AEROSPACE
I N T E R N A T I O N A L MATERIAL Issued APR 1981
400 Commonwealth Dnve. Warrendale. PA 15096-0001 &IFI g9a
SPEL., ~nTlON P?,ised JAN 1993

Superseding AMS 2680A

Submitted for recognition as an American National Standard

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Electron-Beam Welding
For Fatigue Critical Applications

1. SCOPE:

1. I Purpose:

This specification defines the procedures and requirements for joining metals and alloys using the
electron-beam welding process.

These procedures are used typically ior high-quality, electron-beam welding of aerospace
components, the failure of which could cause loss of the aerospace vehide or one of its major
components, loss of control, or significant injury to occupants of a manned aerospace veh~cle,but
usage is not limited to such applications.

1.2.1 The procedure covered by this speaification is recommended for square groove and square
scarf-butt joints for fatigue critical applications.:

2. APPLICABLE DOCUMENTS:

The following publications form a part of this specification to the extent specified herein. The latest
issue of SAE publications shall apply. The applicable issue of other publications shall be the issue In
effect on the date rf the purchase order.

!.I SAE Publications:

Available from SAE, Inc., 400 Commanwealth Drive, Warrendale, PA 15096-0001.

AMS 2630 llltrason~cInspection, Product Over 0.5 lnch (12.5 mm) Thick
AMS 2631 Ultrasonic Inspection, Titanium and Titanium .\lloy Bar and Billet
AMS 2632 Ultrasonic lnspection of Thin Materials, 0.5 lnch (13 mm) and Thinner
i?MS 26'35 Radiographic lnspection
AMS 2640 Magnetic Particle lnspection
AMS 2645 Fluorescent Penetrant Inspection
ARP1333 Nondesiruciive Testing of Electrun Beam Weiaea joinis in Tiian~um-BaseAlloys

a
SAE Technical Standards Board Rules provide that: 7his reporl is published by SAE to advance the gale of lechnical and engineeringsciences. The useof this wpcR is entirely
~lunlaly,and I s applicabllii ana sulabil'i for any pamcuhr use, including any patent Infringementarslng merefmrn. Is the sole respnslbllily of the user.'
A E reviews each technical repon at least e v w five Years al which lime it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.
Copyright 1996 Sociaty or Avtomplive Engineers, inc.
All rights reserved. Prided in U.S.A.
QUESTIONS REGARDING THIS ODCUMENT: (724) 772-7154 FAX: (724) 776-0243
TO PLACE A DOCUMENTORDER: (724) 7764970 FAX: (724) 776-0790
SAE WEB ADDRESS: http:llwmv.sae.org

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room 3NI38flOS33 ETLPPSZP98 XVJ 9P:90 ZOOZ/TE/LO
 AMS 268QB SAE AMS 26808 I

2.2 ASTM Publications: 5.72

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L\.

Available from ASTM, 1916 Race Street, Philadelphia, PA 19103-1187. 3 ~f'E4

ASTM E 8 Tension Testing of Metallic Materials
ASTM E 8M Tension Testing of Metallic Materials (Metric)

( 2.3 US. Government Publications: I

I Available from Standardization Documents Order Desk, Building 4D, 700 Robbins Avenue,
Philadelphia, PA 19111-5094.

MIL-STD-453
MIL-STD-1595
Inspection, Radiographic
Qualification of Aircraft, Missile, and Aerospace Fusion Welders
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MIL-STD-1949 Inspection, Magnetic Particle
MIL-STD-2073-1 DOD Materiel, Procedures for Development and Application of Packaging
Requirements
MIL-STD-6866 Inspection, Liquid Penetrant

I 2.4 ANSI Publications:

Available from American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018.
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ANSI 846.1 Surface Texture

2.5 AIA Publications:

Available from National Standards Association. Inc.. 4827 Rugby Avenue, Washington. DC 20014.

NAS 976 Electron Beam Welding Machine

3. TECHNICAL REQUIREMENTS:

3.1 Materials:

3.1.1 Parent Materials: Shall be as specified on the applicable part drawing.

3.1.2 Filler Materials: When required, filler metal shall be as specified on the part drawing.

3.1.3 Cleaning Materials: Cleaning materials, chemical solvents, or etching solutions shall be as
specified on the part drawing or in the certified welding procedure.

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3.2

3.2.1
Equipment:

Electron-Beam Welding Equipment: Shall be capable of producing welds meeting the

requirements of 3.6 and 3.7. Equipment conforming to NAS 976 is accepted as meeting this
requirement.
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 AMS 2680B SAE AM8 2680B

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3.2.2 Jigs and Fixtures: All holding fixtures shall be capable of maintaining the desired configuration and
tolerances during weiding, providin; bzck-i;p as required, and allowing required work space
between the work piece and the electron gun. Back-up material used to deflect or absorb residual
electron-beam energy shall be of the same alloy as the part being welded except that alternate
back-up materials may be used when approved by procedure certification as in 3.4.2. Tooling
within 6 inches (152 rnm) of the weld joint shall be made from nonmagnetic materials or be
degaussed to acceptable limits (See 3.2.3).

3.2.3 Degaussing: Ferromagnetic materials and tooling shall, prior to welding, be demagnetized to a
level established by procedure certification (3.4.2) which prevents electron beam deflections while
welding the joint.

3.3 Preparation:

Joint and surface preparation, prior to welding, shall be as follows and s.~allbe included as part of
the approved procedure certificntion:

3.3.1 Joint Preparation: Joints shall be prepared to conform to requirements specified on the part
drawing.

3.3.2 Edge Preparation: Edges shall be machined sqllare and parallel to ensure proper fit-up. Joints
shall have no rounded-off edges, but shall be deburred after machlnmg. Unless othewlse
specified, faying surfaces of joints shall have a surface texture not greater than 125 microinches
(3.2 pm), determined in accordance with ANSI 846.1. Wltness Ilnes, when specifled, shall be
applied in accordance with part drawing requirements (See ARP1333 for guidelines). Dry
machining is recommended for edge preparation of reactive metals.

3.3.3 Weld Start and Run-Off Tabs: Tabs, when used, shall be of the same alloy as the detail parts being
welded and shall be cleaned in the same manner as the parts. Tabs shall be integral with the part,
eithcr being machined in, or welded to, the part pieces prior to assembly.

3.3.4 Surface Preparation: Surfaces of parts to be welded shall be prepared using alkaline cleaners,
solvents (non-halogenated for titaniu~malloys), pickling, or combinations thereof as applicable to
the alloy being welded. Welding should commence within 40 hours after surface preparation,
unless otherwise permitted or restricted by purchaser.

3.3.4.1 Parts, after surface preparation, shall be handled in the joint a ea with clean, lint-free gloves and
shall be coverad or otherwise protected to prevent contamination except during set-up, welding,
and Inspection.

3.3.5 Joint Edges: Immediately prior to assembly for welding, joint edges may be additionally prepared,
depending on the alloy baing welded, by either alkaline cleaning, acid pickling, solvent cleaning
(non-halogenated for titanium alioys), wire brushing with a stainless steei brush and solvent
(non-halogenated for titanium alloys) cleaning, or, for aluminum alloys, scraping of joint faying
surfaces.
 AMS 26808 SAE AMS 26805

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3.3.6 Accessory Eq"pmen! Preparation: Jigs, fixtures, and measuring devices shall bd i r k of scare,
grease, protective coatings, oxides, dust, oil, and other foreign material detrimental to the welding
process.

3.3.6.1 Handle cleaned surfaces only with clean, lint-free gloves.

3.3.7 Pre-Weld Fit-Up: Gaps for productionwelding shall not exceed gap distance used for procedure
certification as in 3.4.2. For small diameter electron beams (high voltage guns), a suggested
maximum allowable gap is 0.001 lnah (0.03 mm). For larger diameter electron beams (low or
medium voltage guns), thesuggested maximum allowable gaps are 0.001 inch (0.03 mm) for
material thicknesses up to 0.020 inch (0.51 mm) and 0.005 inch (0.13 mm) for thicker material.

3.4 Procedure:

3.4.1 Qualification of Welding Operators: Electron-beam welding shall be performed by certified

operators qualified in accordance with procedures approved by purchaser.

3.4.1 .I Personnel performing welding in accordance with this specification shall be qualified under the
cognizance and supervision of the designated welding activity and approved by the cognizant
quality control activity. Qualified personnel shall be assigned a stamp with a number or symbol
that shall be used to identify all weldments made by such personnel.

3.4.1.2 An operator undergoing qualification testing may weld a certification plate in accordance with
3.4.2 according to a pre-establishedschedule as part of the test. If the operator successfully
qualifies, the weld procedure shall be considered certified. All parameters used for welding the
certification plate shall be recorded in the weld procedure, Table I.

3.4.1.3 Operators certified in accordance with MIL-STD-1595 shall be considered qualified to weld in
accordance with this specification.

3.4.2 Procedure Certification: Prior to prodwtion, a separate weld schedule shall be established for
each joint and alloy or alloy combination to be welded. The schedule shall be prepared for each
penetrationweld joint confwuration, and for each cosmetic pass configuration, if required,
according to Table 1 as a minimum requirement. Where minimum tensile strength requirements
are specified as a requirement of the weld, the following procedures shall apply:

3.4.2.1 For a full penetration weld joint, a test plate conforming to Figure 1 shall be welded in accordance
with the prepared weld procedure and submitted to the cognizant quality control activity for
tensile testing. Where the test plate of Figure 1 is not an appropriate representationof the parts
to be welded, as in the case of forgings, castings, tubing, or other geometric considerations, the
procedure shall be established on actual or simulated parts as agreed upon by purchaser and
vendor.

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AMS 26808 SAE AMS 26808

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U.CI.L.2
~n For the cosmet~cpass configuration, a test plate conforming iu Figure 2 shall be welded in
accordance with the prepared weld procedure and submitted for metallurg~calexammation in
accordance with 3.6.2.2. The cosmetic pass configuration shall be made as a
bead-on-previously-depositedfull-penetration weld. The cosmetic pass configuration test
sample may also be taken from a simulated or actual part as specified by purchaser.

3.4.2.3 Upon acceptance of the test piece(s) (either Figure 1, actual part, or simulated part) fcr either a
full-penetration or (Figure 2 ) a cosmetic-pass weld, the cognizant quality control activity shall
certify the weld procedure and forward copies to other cognizant agencies.

3.4.2.4 Test Plate Preparation and Testing: The weld schedule certification test piece (either Figure 1,
actual part, or simulated part) shall be of the same material and condition and shall be prepared
and cleaned in the same manner as the production part. Welding shall be performed using the
same welding position and joint configuration (thickness and angle) representative of that used
on the production part. The welding operator's ID number shall be marked on each test piece
welded for certification. Testing shall be accomplished in accordance with 3.6 and 3.7.

3.4.2.5 TackinglLocking Passes: A tacking pass may be used to restrict relative motion in the weld
assembly prior to the first full penetration pass. Wald schedule certification of a tacking pass is
not required provided all evidence of the tack welding is obliterated by the actual weld through
fusion.

3.4.2.5.1 A tacking pass, other than a full-penetration pass, made with a power density setting
substantially reduced frorn the certif~edsettings, may be used over any portion of the weld joint
up to and including the full length of the weld.

3.4.2.5.2 A full-penetration tacking pass using certified parameters may be utilized but shall not exceed
10% of the weld joint length. This locking pass shall terminate in the starting or stopping tabs,
when applicable.

3.4.2.6 Cosmetic Pass: Cosmehc passes for the purpose of correcting unacceptable underfill conditions
may be applied at any time after completion of the initial full-penetration pass. Cosmetic passes,
if used, shall be certified in accordance with 3.4.2.2.

3.4.3 Procedure Recertification: Recertification of weld schedules shall be required for failed test welds
and when any change is made to the following parameters:

3.4.3.1 When a change is made in base rn~etaicomposition or a change is made in thickness in excess of
tlO% (not applicable to cosmetic-pass-weld configuration).

3.4.3.2 When a change is made in joint design (not applicable to cosmetic-pass-weld configuration), but
not necessarily after changes in iength ot diameter of joint.

3.4.3.3 When the welding position (relationship between fhe gun angle and the w ,rk angle) is changed
in excess of 10 degrees.

ETLPPSZP98 XVJ 8P:90 ZOOZ/TE/LO

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AMS 26808 SAE AMS 26808

3.4.3.4 When a change is made In any one of the machine settrngs, Items 12 and 14 through 20, or In the
energy input, item 23 of Table 1.

3.4.3.4.1 The use of the beam-deflectionswitch, item 19 of Table 1, need not be considered when used
for the purpose of scanning or beam alignment.

3.4.3.5 When the weld machine, weld gun, or filament shape are different from that used to certify the
welding procedure.

I 3.4.4

3.4.4.1
Production Welding: Production patits shall be welded in accordance with the parameters
established in the weld procedure certification of 3.4.2.

Welding Environment: Electron-beam welding shall be performed in a vacuum at a partial

pressure not higher than 1x 10-4 millimeters of mercury. Venting of the chamber after welding
shall not occur less than 2 minutes after completion of welding, unless otherwise established in
the weld procedure certification.

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3.4.5

3.4.6
Marking and Identification: Each weld shall be traceable to the date of welding and identiable to
the welding operator, and shall be recorded, unless waived by purchaser.

Rework: A rework shall be a full or partial electron-beam penetration weld accomplished

subsequent to the full-penetration weld. Rework of imperfections, such as cosmetic passes for
correction of underfill or bead appearance improvement, as well as full-penetration passes for
correction of a missed joint, and other defects may be accomplished by electron-beam welding in
accordance with a certified welding schedule. Restarting the electron beam affer an arc-out shall
not be classified as a rework but the reason, location, and method shall be recorded. Only one
reweld is permitted.

I 3.5 Post Treatment:

I 3.5.1 Machining: ?Jachiningof face surface, root surface, or both skA! be as specified by Ine applicable
part drawing, the certified weld schedule, or both. Cosmetic blending is permitted, but shall not

I 3.5.2
decrease base metal thickness, and shall not decrease weld thickness by more than 10%of weld
minimum depth of penetration.

Heat Treatment: Weldments requiring heat treatment shall be processed in accordance with part
drawing requirements.
 AMS 26808 SAE AMS 26808

3.6 Properties:

Specimens taken from test plates, actual parts, or simulated parts produced for procedure
certification as in 3.4.2.1 and 3.4.2.2 shall conform to the following requirements;

3.6.1 Tensile Strength: When required, specimens shall conform to 2nd be tested in accordance with
ASTM E 8 or ASTM E 8M. The weld is acceptable when failure occurs at a stress equal to or
greater than the minimum tensile strength specified by purchaser. Specimens failing at the bond
line of the weld or in the weld metal are acceptable only when examination of the fracture surface
at 15X magnification reveals it to be free of defects.

3.6.2 Metaliurgical Examination for Soundness, Bead Shape, and Weld Width:

3.6.2.1 Ma~ro-sectionsof the weld shall conform to the requirements of 3.7. Sections shall be taken
trnnsverse to the weld direction and shall be examined at 3 to 10X magnification. Minimum weld
bead width shall be established and recorded and witness llne acceptance criteria for scarf joints
shall also be noted for full penetration welds.

3.6.2.2 Micro-sections of cosmetic welds, examined at not less than 100X magnification, shall meet the
acceptance criteria of 3.7. Sections shall be taken parallel to and transverse to the weld
direction.

3.6.3 Special Properties: When special test: are required to establish nondestructive acceptance criteria
as in 3.7.2, the tests and specimens shall be established as agreed upon by purchaser and vendor,
and shall apply to both weld certification test pieces and parts.

3.7 Quality:

Electron-beam welds shall conform to the following requirements, unless otherwise specified (See
8.2 for defect definitions): I I I

3.7.1 Visual Inspection: All weldme~its,examined at 3X magnification or greater, shall meet the following:

3.7.1 1 Color: The weld bead and adjacent parent metal shall have a color similar to that of the unwelded
parent material. In the case of titanium, this color shall have a bright silver or light straw-colored
appearance; blue-gray or gray discoloration or the presence of loose scale is not acceptabfe.
Discolorationdue to vapor depositrion is xczptable. Cosmetic passes shall not be used to
change color.

3.7.1.2 Penetration: Joints shall have complete penetration unless a partial penetration weld is specified.
011special designs, however, complete penetration may be achieved by post-weld machining.

3.7.1.3 Incomplete Fusion. lncomplete fusion of full penetration joints, insufficient penetration of partial
penetration welds, and missed joints are not acceptable. Not less than 0.010 inch (0.25 I I ~of)
parent metal from each side of the joint shall be in-cludedin the welded area (See ~ ~ ~ 1 for 3 3 3
 AMS 2680B SAE AMS 2680B

3.7.1.4 Cracks: Not acceptable in the wcid-heat affected zone or adjacent parent metal except where
microiissuring is speciiically ;;e;mitted by the engineering drawing (See 3.7.2.1).

3.7.1.5 Voids and Pores: Voids and pores open to the surface are not acceptable unless they are
subsequently to be removed by machining or blending.

3.7.1.6 Underfill and Concave Root Surface: The cumulative depths of underfill on face and root
surfaces shall not exceed the post-weld machining allowances specified on the part drawing.
The allowable underfill for each surface not machined after welding shall be 10% of the joint
thickness or as specified on the drawing.

3.7.1.7 Undercut and Root Notches: Where permissible, shall not exceed engineering drawing
tolerances. When not specifically noted, undercut or root notches shall not exceed 10% of
material thickness total and shall be blended to have not less than 0.06 inch (1.5 mm) root
radius.

3.7.1.8 Mismatch: For plate over 0.250 inch (6.35 mm) in nominal thickness, mismatch shall not exceed
10% of the joint thickness or 0.030 inch (0.76 mm), whichever is less. For sheet and plate over
0.150 inch (3.81 mm) and up to 0.250 inch (6.35 rnm) in nominal thickness, mismatch shall not
exceed 10% or 0.020 inch (0.51 mm), whichever is less. For sheet and plate up to 0.150 inch
(3.81 mm) in nominal thickness, mismatch shall not exceed 10% or 0.010 inch (0.25 mm).
whichever is less.

3.7.1.9 Overlaps: Not acceptable.

3.7.1.10 Peaking: Distortion, usually in sheet metal in thin configurations,which causes the weld,
measured from each weld toe or edge, to move out of the plane of the parent metal by more than
30% of the parent metal thickness, is unacceptable.

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3.7.1.11 Witness Unes: When specified on the part drawing, witness lines shall be applied to the face and
root sides of the wdd joint (See ARP1333 for procedure).

1.7.1.11.1 Face Side: Joint interface (seam) as established by witness lines shall fall within the central
one-third of the weld beam. If the face side witness line examination indicates that the joint
interface does not fall within the central one-third of the weld bead, the witness line data shall
be evaluated for acceptance by the cognizant electron-bearn weld activity to ensure
compliance with 3.7.1.3.

1.7.1 .I
1.2 Root Side: Joint interface (seam), as established by witness lines, shall fall at least one-half
space within the weld bead width. In addition, the difference between unmelted witness line
spaces on each side of the weld bead shall be one space or less. Weld bead locations which
show a difference of more than one space (0.030 inch (0.76 mm) displacement) shall be
evaluated for acceptance to ensure compliance with 3.7.1.3.

.7.1.11.3 Witness line joint interface locations on the weld face shall be evaluated and accepted before
any cosmetic passes are made.
 AMS 2680B SAE AMS 26808

3.7.1.11.4 For scarf joints, the requirements of 3.7.1.11.1 and 3.7.1.11.2 shall apply, unless otherwise
specified Witness line acceptance criteria for all scarf joints shall be as specified on the
I pertinent electron-beam certification (EBC).

3.7.1.12 Welder's Identification: Each indivlidual weld shall be positively identifiable or traceable to the
weld operator who made that weld, !Isrng the stamp or symbol provlded in 3.4.1 .I. The method
for applying the welder's identification shall be as specified on the part drawing or by purchaser.
The method selected should ensure that the ldentlfrcatlon cannot be lost or obliterated during
subsequent processing.

3.7.2 Radiographic Inspection: All welds shall be radiographically inspected in accordance with
AMS 2635 or MIL-STD-453 to determine conformance to the following acceptance standards. In
addition, radiographic inspection shall be used as the referee technique for identifying, locating,
and determining the sizz of indications disclosed by ultrasonic inspection as in 3.7.3.

3.7.2.1 Cracks: The presence of cracks, as a result of welding, in the weld-heat-affected zone or
adjacent parent metal are not acceptable. Should microfissuring be accoptablefn any specific
alloy (e.g. precipitation hardenable nickel alloys), acceptance criteria shall be specified by
purchaser.

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3.7.2.2 Porosity, Voids, and Inclusions: Weld discontinuities, such as porosity, voids, and inclusions
(metallic and nonmetallic). within the weld metal or immediately adjacent in the parent metal shall
be restricted and sized as follows:

3.7.2.2.1 The size of internal porosity, cavities, voids, and inclusions shall be determined by its largest
dimension.

I 3.7.2.2.2

3.7.2.2.3
Inclusions (metallic or nonmetallic) shall be treated the same as porosity.

1nterconnectr:d porosity, inclusions, and cavities (voids) shall be considered as one sinqle pore
for sizing purposes.

1 3.7.2.2.4 Pores and voids identified with the welding operat~onare acceptable provlded they do not
exceed the limits of 3.7.2.3.

I 3.7.2.3

3.7.2.3.1
Internal Discontinuity Limits:

Maximum Poro Diameter: Two or more adjacent discontinuities, other than aligned (3.7.2.3.3).
shall be treated as a single discontinuity (excluding the space between them) when the spacing
between them is less than three times the greatest dimension of the smaller adjacent
discontinuity. The allowable limits for various parent metal thicknesszs are established in
Table 2, Column B(2). for aluminum alloys, and In Table 2, Column B(1), for all other materials
covered by this specification.

J 3.7.2.3.2 Maximum Defect Area: Shall he the sum of the areas of the pores totally within a 1.0-inch
(25-mm) length of weld not to exceed the limits of Table 2, Column C(2), for aluminum alloys,
and Table 2, Column C(l), for all other materials.
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 AMS 2680B SAE AMS 26808

3.7.2.3.2.1
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Pores under 0.010 inch (0.25 mm) shall not be considered in calculating total defect area for
thicknesses 0.25 inch (6.4 mm) or ove:.

3.7.2.3.3 Maximum Aligned Defect Area: Shall be any group of five or more individual pores within a
1.0-inch (25.mrn) length of weld whose images can be intersected by a straight line (regardless
of orientation within the weld) and the distance between adjacent discontinuities within the
group being considered is less 6han four times the longest dimension of the smaller adjacent
discontinuity. The limits of aligned defects are established in Table 2, Column C(4), for
aluminum alloys, and in Table 2, Column C(3), for all other materials (See 3.1 .I).

3.7.3 Ultrasonic Inspection: When specified by purchaser, all welds, including weld certification tests.
shall be ultrasonically inspected in accordance with AMS 2630, AMS 2632 or, for titanium and
titanium alloys, AMS 2631. Acceptance criteria shall be as specified in 3.7.2.1 and 3.7.2.2.

3.7.3.1 Discontinuities or isolated ultrasomic responses, which by a reanalysis of witness line data and
reinspection are shown not to be missed joints, shall be acceptable. Discontinuities which
cannot be confirmed by radiograhpic inspection as in 3.7.2 in the area of the ultrasonic indication
shall be referred to the cognizant engineering activity for disposition.

3.7.4 Fluorescent Penetrant Inspection: All welds, including weld certification tests. of nonmagnetic
materials shall be fluorescent penetrant inspected in accordance with AMS 2645 or MIL-STD-6866
to locate imperfections open to the surface. No defects are permissible except as permitted by
3.7.1.5, unless otherwise authorized by the cognizant engineering activity.

3.7.5 Magnetic Particle Inspection: All welds, including weld certification tests, of magnetic materials
shall be magnetic particle inspected in accordlncs with AMS 2640 or MIL-STD-1949. No defects
are permissible unless otherwise authorized by the cognizant engineering activity.

4. QUALITY ASSURANCE PROVISIONS:

4.1 Responsibility for Ins~cticn:

The welding vendor shall be responsible for performing all required tests. Purchaser reserves the
right to sample and to perform any confirmatory testing deemed necessary to ensure that welded
assemblies confom to the requirements of this specification.

4.2 Classification of Tests:

4.2.1 Acceptance Tests: Tests for quality (3.7) are acceptance tests and shall be performed on each
weld.

4.2.2 Preproduction Tests: Tests for weld procedure certification (3.4.2) and properties (3.6 and 3.7) are
preproduction tests and shall be periorrned on the first-article shipment of a welded part to a
purchaser, when a change in processing requires reapproval of the welded part as in 4.4.2, and
when purchaser deems confirmatory testing to be required.
 AMS 26808 SAE AMS 26808

4.2.2.1 For direct U.S. Milita~fprocureme%, suusiantiating tesi d:s a:d, xhen requested,
preproduction test material shall be submitted to the cognizant agency as directed by the
procuring activity, contracting officer, or request for procurement.

4.3 Sampling and Testing:

Shall be in accordance with the following; a lot shall be all parts or assemblies of the same alloy(s) of
one configuration processed st one iime in sequence and presented for vendor's inspection at one
time:

4.3.1 For Acceptance Tests: Ail production weldments.

4.3.2 For Preproduction Tests: Not less than three welds for procedure certification (3.4.2)
representative of each joint in the part or assembly using production facilities or facilities
representative of those to be used in production. When preproduction test welds are made on
actual hardware, the number and location of test specimens shall be as designated by purchaser.

4 Approval:

1.4.1 Purchaser shall approve the vendor's facilities, inspection methods, and process controls before
production parts are supplied and these shall be available for purchaser's inspection during the
period of production part manufacture.

1.4.2 When specified, sample parts and the welding procedure shall be approved by purchaser before
welded parts for production use are supplied. If necessary to make any change in procedures or
methods of inspection, the welding processor shall submit for reapproval details of proposed
changes and, when requested, sample welded parts.

1.5 Reports:

The vendor of welded parts shall furni~shwith each ::hipment a report showing the results of tests on
each lot to determine conformance to the acceptance test requirements and stat~ngthat the parts
have been processed in accordance with the certified welding procedure by ce~tifiedwelding
operators. This report shall include the purchase order number, AMS 2G80A, part or assembly
number, and quantity.

i. PREPARATION FOR DELIVERY:

i.1 Identification:

Welded parts shall be identified as specified on the part drawing or as agreed upon by purchaser and
vendor.
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AMS 2680B SAE AMS 26808
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I 5.2 Prctective Trectment:

When required, welded parts shall be given a suitable protective treatment as specified in the
purchase order or by the part drawing.

( 5.3 Packaging:

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5.3.1 Welded parts shall be handled and packaged to ensure that the required physical characteristics of
the parts are preserved.

5.3.2 Packages of parts shall be prepared for shipment in accordance with, commercial practice and in
compliance with applicable rules and regulations pertaining to the handl~ng,packaging, and
transportation of the parts to ensure carrier acceptance and safe delivery.

I1 5.3.3 For direct U.S. Military procurement, packaging shall be in accordance with MIL-STD-2073-1,
Commercial Level, unless Level A is specified in the request for procurement.

6. ACKNOWLEDGMENT:

1 A vendor shall mention this specification number and its revision letter in all quotations and when
acknowledging purchase orders.

7. REJECTIONS:

Parts nat welded in accordance with this specifrration, or with modificatiocs authorized by purchaser,
will be subject to rejection.

8. NOTES:

8.1 The change bar ( I) located in the [sf! margin is for the convenience of the x e r in Issating areas
where technical revisions, not editorial changes, have been made to the previous issue of this
specification. An (R) symbol to the left of the document title indicates a complete revision cf the
specification.

8.2 Defect Definitions:

Shall conform to standard definitions as shown in AWS A3.0.

8.3 Dimensions in inchlpound units are primary; dimensions in SI units are shown as the approximate
equivalents of the primary units and are presented only for information.
AMS 26808 SAE AMS 26808

,r.",
- u,,ect
A:- U S . Military procurement, purchase documents should s p e d y not less than the following.

Title, number, and date of this specification

Part or assembly number of parts to be welded
Quantity of parts to be welded
Level A packaging, if required (See 5.3.3).

Processes meeting the requirements of this specification have been classified under Federal
Standardtzat~onArea Symbol "THJM".

Key Words: ,

EB %elding, fatique critical application

PREPARED UNDER THE JURISDICTION OF AMS COMMITTEE "8"

I
AMS 26808 SAE AMS 26808

"

\
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TABLE 1 Mmimum Parameters To Be Recorded in Welding Procedure
I. Applicable Electron-Beam Certification (EBC)Number
2. Parent Metal
3. P a r d Metal Thickness
4. Pre-Weld Cleaning Procedure, Applicable Gleanlng Specification, or both
5. Surface Preparation at Weld Joint
6 Filler Metal Type, Specification, or both
7. Automatically Fed Filler Metal Diameter
8. Filler Wire Feed Speed (210%)
9. Operator and ID Stamp
10. Welding Speed, incheslminute (mmls) (f5%)
11. Sketch of Set-Up Including All Angles (53.5 degree)
72. Distance of Gun to Work ( W 8 inch (23.2 mm))
13. Beam Current (+5%)
14. High Voltage (&%)
15. Focusing Current (&5%)
18. Vacuum Level
17. Welding Schedule
18. TackingILocking Passes
-
19. Beam Deflection OnIOff . .rype or Shape-----: Amplitude---- Frequency
20. Cathode l o Anode Spacer
21. Witnessing Inspector's Name ~ n Stamp
d
22. Quality Control Certification
23. Maximum Residual Magnetism, gauss
24. Weld Machine Identification
25. Weld Gun ldentificatm
26. Filament Type
 Plan Area o f Inuge. Plan Area of Imge, P l a n Area of Image. Plan Urea of Inage.
f l n r l v e l d f l a ~ l mPore D l l n r t e r Hart-, Pore Olamier Square Inches x 10.000 Square Inches 1 10.000 Square Inches x 10.000 Square Inches r 10,000
Thlckress (3.7.2.3.11 l3.7.2.3.11 rota1 O l r ~ o n t l n u l l i e s Total D l r e m t l n u l t l e s hllgned n i r i o n t t n u l t i e s r l l g n e d Dlrcontlnultles
Inch Inch inch [3.?.2.3.2) 13.1.2.3.2) 13.1.7.3.31 13.7.2.3.31

8-1 8-2 C-1 C-2 C-3 C-I

70
dl F m fable 2. C o l m C;l;, th. ae~pt.bIe arm of t o b l d l f ~ ~ t l l ~ l t il net sl t s n l m l r 125, because the calculated area war 10, the weld
I s a ~ ~ e p t a b lfrm
= the s t m d p l n t of tat.1 d l r r o n t l n u < t l e l
el SO 111gmd that they cwld 08 Intersectmd by r r t r d 8 t 1 i w (3 12.3 3). the r l l m a h l r I l n l t f o r
i f , h M w e r . tkC d l s m n t l l l ~ l t l ~~a l m
th. L l t a n l ~ n c x ~ n prl al d ( C d m CO)) I s M while th. s.lcu1at.d m a war 70 and the rc;d * w i d n o t be ars=ptrblr.
AMS 26808 SAE 4MS 2680B

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TABLE 28 Internal Discontinuity Limits, SI Units
AMS 26808 SAE AMS 26808

TABLE 3A - Effective Areas of Discontinuities, InchlPound Units

Discontinuity Diameter Plan Area of Image
Inch Square Inches x 10,000
Up to 0.010, excl 1
0.010 to 0.021, excl 2
0.021 to 0.031, excl 6
0.031 to 0.041, excl 10
0.041 to 0.050, excl 20
0.050 to 0.063. excl 31

TABLE 30 - Effective Areas of Discontinuities, SI Units

Discontinuity Diameter Plan Area of Image
Millimeters mm2x 100
Up to 0.25, excl 6.4
0.25 to 0.53, excl 12.9
0.53 to 0.79, excl 38.7
0.79 to 1.04,excl 64.5
1.04 to 1.27, excl 129.0
1.27 to 1.60, excl 200.0
AMS 26808 SAE AMS 26806

Tensile speclfien shall be mashlned Plush t o remove

weld retnforcentent and penetration.

Dimensions are i n inches (millimeters)

FIGURE 1 - Weld Test Specimen

AMS 26808 SAE AMS 2680B

Cut ut Section A-A for

pardel micm of weld
centerline.

Cut out Section B-B for

transverse micm of weld
centerline.
Cosmetic pass deposited on top
of w e l d c.enter.ine

Dimensions are i n inches (millimeters).

FIGURE 2 - Cosmetic Pass Weld Test Specimen