Gas Welding Procedures and Techniques

in Aircraft Welding

The material to be welded, the thickness of the metal, the type of joint, and the position of the weld dictates the procedure and technique to be used.

Figure 5-24. Hand position for light-gauge materials.

Figure 5-24. Hand position for light-gauge materials.

When light-gauge metal is welded, the torch is usually held with the hose draped over the wrist. [Figure 5-24] To weld heavy materials, the more common grip may provide better control of the torch. [Figure 5-25]

Figure 5-25. Hand position for heavy-gauge materials.

Figure 5-25. Hand position for heavy-gauge materials.

The torch should be held in the most comfortable position that allows the tip to be in line with the joint to be welded, and inclined between 30° and 60° from the perpendicular. This position preheats the edges just ahead of the molten puddle. The best angle depends on the type of weld, the amount of preheating required, and the thickness and type of metal. The thicker the metal, the more vertical the torch must be for proper heat penetration. The white cone of the flame should be held about 1⁄8-inch from the surface of the metal.

Welding can be performed by pointing the torch flame in the direction that the weld is progressing. This is referred to as forehand welding, and is the most commonly used method for lighter tubing and sheet metal. The filler rod is kept ahead of the tip in the direction the weld is going and is added to the puddle.

For welding thick metals or heavy plate, a technique called backhand welding can be used. In this method, the torch flame is pointed back toward the finished weld and the filler rod is added between the flame and the weld. This method provides a greater concentration of heat for welding thicker metals and would rarely be used in aircraft maintenance.


If the torch is held in the correct position, a small puddle of molten metal forms. The puddle should be centered in the joint and composed of equal parts of those pieces being welded. After the puddle appears, the tip should be moved in a semicircular arc or circular motion equally between the pieces to ensure an even distribution of heat.

Adding Filler Rod to the Puddle

As the metal melts and the puddle forms, filler rod is needed to replace the metal that flows out from around the joint. The rod is added to the puddle in the amount that provides for the completed fillet to be built up about one-fourth the thickness of the base metal. The filler rod selected should be compatible with the base metal being welded.

Correct Forming of a Weld

The form of the weld metal has considerable bearing upon the strength and fatigue resistance of a joint. The strength of an improperly made weld is usually less than the strength for which the joint was designed. Low-strength welds are generally the result of insufficient penetration; undercutting of the base metal at the toe of the weld; poor fusion of the weld metal with the base metal; trapped oxides, slag, or gas pockets in the weld; overlap of the weld metal on the base metal; too much or too little reinforcement; or overheating of the weld.

Characteristics of a Good Weld

A completed weld should have the following characteristics:

  1. The seam should be smooth, the bead ripples evenly spaced, and of a uniform thickness.
  2. The weld should be built up, slightly convex, thus providing extra thickness at the joint.
  3. The weld should taper off smoothly into the base metal.
  4. No oxide should be formed on the base metal close to the weld.
  5. The weld should show no signs of blowholes, porosity, or projecting globules.
  6. The base metal should show no signs of burns, pits, cracks, or distortion.

Although a clean, smooth weld is desirable, this characteristic does not necessarily mean that the weld is a good one; it may be dangerously weak inside. However, when a weld is rough, uneven, and pitted, it is almost always unsatisfactory inside. Welds should never be filed to give them a better appearance, since filing deprives the weld of part of its strength. Welds should never be filled with solder, brazing material, or filler of any sort.

When it is necessary to reweld a joint, all old weld material must be removed before the operation is begun. It must be remembered that reheating the area may cause the base metal to lose some of its strength and become brittle. This should not be confused with a postweld heat treatment that does not raise the metal to a high enough temperature to cause harm to the base material.